Kia Niro: Hybrid Motor Assembly / Hybrid Drive Motor Assembly Repair procedures
1. |
Using mΩ tester, measure the line-to-line resistance.
Item
|
Inspection area
|
Specification
|
Remarks
|
Phase-to-phase resistance
|
Pins U - V
|
36.0 mΩ ± 5 %
|
Deviation in phase-to-phase resistance at room temperature 68°F
(20°C): 5%
|
Pins V - W
|
Pins W - U
|
|
2. |
Inspect the temperature sensor resistance.
Item
|
Inspection area
|
Specification
|
Remarks
|
Resistance (Temperature sensor)
|
Pins 4 - 8
|
10.92 - 13.44 kΩ
|
At room temperature 68°F (20°C)
|
|
3. |
Inspect the resolver sensor resistance.
Item
|
Inspection area
|
Specification
|
Remarks
|
Resistance
(Resolver sensor)
|
Pins 1 - 5
|
11.7 Ω ± 10 %
|
At room temperature 68°F (20°C)
|
Pins 2 - 6
|
34.5 Ω ± 10 %
|
Pins 3 - 7
|
29.5 Ω ± 10 %
|
|
4. |
Inspect the insulation resistance.
Item
|
Inspection area
|
Specification
|
Remarks
|
Insulation
(housing, cover)
|
Motor
|
Pin U - GND
Pin V - GND
Pin W - GND
|
10 MΩ↑
|
DC 540 V, 1 minute
|
2.5 mA↓
|
AC 1600 V, 1 minute
|
Resolver sensor
|
Pin 1 - GND
Pin 2 - GND
Pin 3 - GND
|
10 MΩ↑
|
DC 500 V, 1 minute
|
Temperature sensor
|
Pin 4 - GND
|
10 MΩ↑
|
|
1. |
Remove the hybrid drive motor & dual clutch transmission assembly from
the vehicle.
(Refer to DCT System - "DCT")
|
2. |
Remove the engine clutch actuator (A).
Tightening torque :
21.6 - 26.5 N·m (2.2 - 2.7 kgf·m, 15.9 - 19.5 lb·ft)
|
|
3. |
Remove the concentric slave cylinder.
(Refer to Clutch System - "Concentric Slave Cylinder Assembly")
|
4. |
Remove the hybrid drive motor (A) by loosening the bolts.
Tightening torque :
42.2 - 53.9 N·m (4.3 - 5.5 kgf·m, 31.1 - 39.8 lb·ft)
|
|
1. |
Install in the reverse order of removal.
1) |
Check the pilot bearing (B) and motor side connector
(A) on the side of engine for any dents, damages and deformations
before installing the DCT.
|
2) |
Align the motor side connector spline (A) with the dual
clutch spline (B).
|
3) |
Insert the input shaft (A) into the pilot bearing (B)
and then assemble the DCT to the bushing on the motor side.
|
4) |
After mounting the DCT to the engine by pushing the DCT,
tighten the mounting bolts making sure that there is no
gap (less than 2 mm) between the clutch housing and the
engine block.
(If the bolt is tightened while there is a gap, then
the spline of motor side connector or clutch will be damaged
or broken.)
|
|
|
2. |
Perform the procedure below after installing.
(1) |
Refill the hybrid motor cooling system with coolant and then
perform the air bleeding using the KDS/GDS.
(Refer to Hybrid Motor System - "Coolant")
|
(2) |
Perform learning of the engine clutch inspection line and initialization
of diagnostic information using the GDS/KDS.
|
(3) |
Refill the engine clutch reservoir with brake fluid and then
perform the air bleeding using the KDS/GDS.
|
(4) |
Perform the engine clutch / motor resolver adaptation using the
KDS/GDS.
|
(5) |
Stabilize the engine clutch hardware transfer torque using the
GDS/KDS.
|
|
Specification
Item
Specification
Type
PMSM
(Interior Permanent Magnet Synchronous Motor)
Max. output
...
Components
1. Hybrid starter generator (HSG)
2. HSG bracket
...