Kia Niro: Hybrid Motor Assembly / Hybrid Starter Generator(HSG) Repair procedures

Inspection

Inspect the resistance line to line using mΩ tester.

Inspect the temperature sensor resistance.

Item	Pin	Specification	Remarks
Resistance (Temperature sensor)	4 - 9	121.6 - 133.14 kΩ	At room temperature 68°F(20°C)

Inspect the resolver sensor resistance.

Inspect the insulation resistance.

Item	Inspection area		Specification	Remarks
Insulation resistance (Housing, Cover)	Motor	Pin U - GND Pin V - GND Pin W - GND	GND	DC 540 V, 1 min
	Motor	Pin U - GND Pin V - GND Pin W - GND	5 mA↓	AC 1600V, 1 min
	Resolver sensor	Pin 1 - GND Pin 2 - GND Pin 3 - GND	10 MΩ↑	DC 500 V, 1 min
	Temperature sensor	Pin 4 - GND	10 MΩ↑	DC 500 V, 1 min

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 circuit according to the “High Voltage Shut-off Procedures” before doing any work related with the high voltage system to avoid serious electrical injuries.

1.	Shut off the high voltage circuit. ( Refer to Hybrid Motor System - "High Voltage Shut-off Procedure")

2.	Drain the coolant of hybrid cooling system. (Refer to Hybrid Motor Cooling System - "Coolant")

3.	Remove the air cleaner assembly. (Refer to Engine Mechanical System - "Air Cleaner")

4.	Remove the drive belt. (Refer to Engine Mechanical System - "Drive Belt")

5.	Remove the drive belt tensioner. (Refer to Engine Mechanical System - "Drive Belt Tensioner")

6.	Remove the idler. (Refer to Engine Mechanical System - "Idler")

7.	Disconnect the HSG connector (A).

8.	Separate the cooler hose (A) from the HSG.

9.	Remove the intake manifold (Refer to Engine Mechanical System - "Intake Manifold")

10.

Loosen the HSG mounting nut (A) and bolt (B).

Tightening torque :

44.1 - 49.0 N·m (4.5 - 5.0 kgf·m, 32.5 - 36.2 lb·ft)

11.

Remove the HSG after removing the HSG bracket (A).

Tightening torque :

55.9 - 60.8 N·m (5.7 - 6.2 kgf·m, 41.2 - 44.8 lb·ft)

Installation

Install in the reverse order of removal.

•	Be careful not to damage other hose by when tightening the clamp.

•	Install the clamp in the specified direction to prevent interference with surrounding components.

Perform the procedure below after installing.

(1)	Refill the hybrid cooling system with coolant and bleed air from the hybrid cooling system using GDS. (Refer to Hybrid Motor Cooling System - "Coolant")

(2)	Perform the engine clutch / motor resolver adaptation using the KDS/GDS.

Specification Item Specification Type PMSM (Interior Permanent Magnet Synchronous Motor) Max. output ...

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