Kia Niro: High Voltage Battery System / Power Relay Assembly (PRA) Repair procedures

Kia Niro 2017 (DE HEV) Service Manual / Hybrid Control System / High Voltage Battery System / Power Relay Assembly (PRA) 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.

1.	Shut off the high voltage circuit. (Refer to Hybrid Control System - “High Voltage Shutoff Procedure”)

2.	Remove the rear seat cushion. (Refer to Body - "Rear Seat Assembly")

3.	Remove the rear door scuff trim. (Refer to Body - "Door Scuff Trim")

4.	Remove the cooling duct. (Refer to High Voltage Battery Cooling System - "Cooling Duct")

Remove the upper frame (A) after loosening the mounting bolts and nuts.

High voltage battery system assembly upper frame mounting bolt :

19.6 - 29.4 N·m (2.0 - 3.0 kgf·m, 14.5 - 21.7 lb·ft)

High voltage battery system assembly upper frame mounting nut (M8) :

19.6 - 29.4 N·m (2.0 - 3.0 kgf·m, 14.5 - 21.7 lb·ft)

High voltage battery system assembly upper frame mounting nut (M6) :

7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Remove the high voltage battery rear cover (A) after loosening the mounting bolts and nuts.

High voltage battery rear cover mounting bolt / nut :

7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

7.	Disconnect the high voltage power cable [+] (A) and high voltage cable [-] (B) after loosening the mounting bolts.

8.	Disconnect the BMS ECU extension connector (A), battery current sensor connector (B), inverter power connector [-] (C), inverter power connector [+] (D), and PRA connector (E).

Remove the power relay connector after loosening the mounting nuts (A).

Power relay assembly mounting nut :

7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

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 the power relay assembly in the reverse order of removal.

Power Relay Assembly (PRA) Description and operation

Description The Power Relay Assembly (PRA) consists of the positive and negative main relays, pre-charge relay, pre-charge resistor and battery current sensor. It is located inside th ...

Case Repair procedures

Removal • Be sure to read and follow the “General Safety Information and Caution” ...

Other information:

Kia Niro (DE HEV) Owners Manual: To resume cruise control set speed
If any method other than the CRUISE button was used to cancel cruising speed and the system is still activated, the cruising speed will automatically resume when you move the lever up (to RES+). If you move the lever up (to RES+), the speed will resume to the recently set speed. When the sp ...

Kia Niro 2017 (DE HEV) Service Manual: Description and operation
Description The HCU (Hybrid Control Unit) controls whole hybrid systems and is connected with each control modules (ECM, TCM, MCU, BMS ECU etc.) by CAN interface. In addition this system uses the brake switch signals for controlling the hybrid system. & ...