Kia Niro: High Voltage Battery Control System / Safety Plug 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.

Switch "OFF" the ignition and disconnect the negative (-) terminal of the auxiliary 12V battery.

2.

Remove the safety plug cover (A).

3.

Unfasten the hook (A) in the direction of arrow.

4.

Unfasten the lever (A) in the direction of arrow.

5.

Remove the safety plug (A).

Inspection
  

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.

Remove the safety plug.

(Refer to "Removal")

2.

Visually check the safety plug and conduct electrical test.

- Check the interlock switch (A) and high voltage terminal (B).

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 Safety Plug in the reverse order of removal.

Safety Plug Schematic diagrams
Circuit Diagram Harness Connector [Interlock] ...

Main Fuse Specifications
Specification Item Specification Rated Voltage (V) 450 Fuse Rated Current (A) 125 In ...

Other information:

Toyota Corolla 2019-2022 Owners Manual: Safety Connect
Safety Connect is a subscription- based telematics service that uses Global Positioning System (GPS) data and embedded cellular technology to provide safety and security features to subscribers. Safety Connect is supported by Toyota’s designated response center, which operates 24 hours per day, ...

Kia Niro 2017 (DE HEV) Service Manual: Hybrid Power Control Unit (HPCU) Components and components location
Components 1. Hybrid Control Unit(HCU) [HPCU] 2. Inverter [HPCU] 3. Low Voltage DC/DC Converter (LDC) [HPCU] 4. High voltage connector (↔ High voltage battery system assembly) 5. High voltage connector (↔ Hybrid drive motor assembly) 6. H ...

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