Kia Niro: Power Cable / Repair procedures

Removal
  

Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.

Engine Room Fuse & Relay Box, HPCU ↔ Auxiliary 12V Battery & High Voltage Battery System Assembly

1.

Shut off the high voltage circuit.

(Refer to Hybrid Control System - “High Voltage Shutoff Procedure”)

2.

Remove the air cleaner assembly.

(Refer to Engine Mechanical System - "Air Cleaner")

3.

Disconnect the power cable (A) from the HPCU.

  

Remove the inverter power cable in the follwing order.

4.

Remove the positive (+) cable (A) after loosening the mounting nut.

Auxiliary 12V battery (+) cable mounting nut [Engine room fuse & relay box] :

10.8 - 13.7 N·m (1.1 - 1.4 kgf·m, 8.0 - 10.1 lb·ft)

5.

Remove the high voltage battery rear cover.

(Refer to High Voltage Battery System - "Case")

6.

Remove the high voltage battery inlet cooling duct.

(Refer to High Voltage Battery Cooling System - "Cooling Duct")

7.

Disconnect the power cable connector (-) (A) and power cable connector (+) (B).

8.

Disconnect the auxiliary 12V battery positive (+) cable after loosening the mounting nut (C).

9.

Disconnect the ground cable (D) after loosening the mounting bolt.

Ground cable mounting bolt (M6) [Trunk chassis ground] :

10.8 - 13.7 N·m (1.1 - 1.4 kgf·m, 8.0 - 10.1 lb·ft)

10.

Lift the vehicle.

11.

Remove the front sub frame.

(Refer to Suspension System - "Sub Frame")

12.

Remove the side under cover (A) after loosening the mounting bolts and nuts.

13.

Remove the power cable (B) after loosening the mounting nuts (A).

Power cable mounting nut :

10.8 - 13.7 N·m (1.1 - 1.4 kgf·m, 8.0 - 10.1 lb·ft)

HPCU ↔ HSG & Electric A/C compressor

1.

Shut off the high voltage circuit.

(Refer to Hybrid Control System - “High Voltage Shutoff Procedure”)

2.

Remove the air cleaner assembly.

(Refer to Engine Mechanical System - "Air Cleaner")

3.

Remove the HPCU protector (A) after loosening the mounting bolts

4.

Disconnect the power cable connector (A) from the HPCU.

5.

Lift the vehicle.

6.

Remove the engine room under cover.

(Refer to Engine Mechanical System - "Engine Room Under Cover")

7.

Disconnect the power cable (A) from the electric A/C compressor.

8.

Disconnect the power cable (A) from the HSG.

9.

Remove the power cable (A).

Installation
  

Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.

1.

Install in the reverse order of removal.

Components and components location
Components 1. Power Cable [Engine Room Fuse & Relay Box, HPCU ↔ Auxiliary 12V Battery & High Voltage Battery System Assembly] 2. Power Cable [HP ...

Engine Mechanical System
...

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