KIA Niro: Battery Pack Assembly Repair procedures

Kia Niro - First generation - (DE) (2017-2022) - Service and Repair Manual / Hybrid Control System / High Voltage Battery System / Battery Pack Assembly Repair procedures

Warning

  • 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 high voltage battery front cover (A).

  1. Disconnect the OBC relay connector (A) and PRA connector (B).

  1. Remove the high voltage cable cover (A).

  1. Disconnect the battery current sensor connector (A).
  2. Disconnect the high voltage power cable (+) terminal (A) and (-) terminal (B) after loosening the mounting nuts.

  1. Remove the power relay assembly (A) after loosening the mounting bolts and nuts.

  1. Disconnect the inlet temperature sensor connector (A) and then remove the inlet temperature sensor (B).

  1. Disconnect the cell monitoring unit connector (A).
  2. Remove the cell monitoring unit (CMU) (B) after loosening the mounting nuts and screw.

  1. Remove the high voltage cable (B) after loosening the ground bolts (A).

  1. Remove the battery temperature sensor (A).

  1. Remove the air duct (A).

  1. Remove the bus bar (A) after loosening the mounting nuts.

  1. Remove the cell monitoring unit bracket (A) after loosening the mounting nuts.

  1. Remove the battery module mounting nuts.

  1. Remove the main battery pack support bar (A).

  1. Remove the sub high voltage battery module (A) from the battery plate.

Sub Battery Pack Assembly

Sub Battery Pack Assembly

  1. Remove the high voltage battery cover (A) after loosening the bolts.

  1. Disconnect the BMS connector (A).
  2. Remove the BMS after loosening the bolts (B).

  1. Remove the BMS wiring harness (A).

  1. Remove the outlet duct (A).

  1. Remove the watertight case (A) after loosening the bolts.

  1. Disconnect the cell monitoring unit connector (A).
  2. Remove the cell monitoring unit (B) after loosening the screw.

  1. Remove the high voltage cable (B) after loosening the nuts (A).

  1. Remove the cell monitoring unit bracket (A) after loosening the nuts.

  1. Remove the main fuse assembly (A) after loosening the nuts.

  1. Remove the battery temperature sensor (A).

  1. Remove the air duct (A).

  1. Remove the sub battery pack support bar (A).

  1. Remove the sub high voltage battery module (A) from the battery plate.

Adjustment

Adjustment

    READ NEXT:

     High Voltage Battery Module Balancing & Voltage Measurement

    After removing the defective module from the HV battery pack make carefully a visual check and then put back it into the safety disposal box. Warning The cell quantity varies per module number. Check before conducting procedure.

     Power Relay Assembly (PRA)

    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 the battery pack assembly and controls the high voltage power c

     Main High Voltage Battery Case

    SEE MORE:

     Power/Charge gauge

    The Power/Charge Gauge shows the energy consumption rate of the vehicle and the charge/discharge status of the regenerative brakes. Power: It shows the energy consumption rate of the vehicle when driving uphill or accelerating. The mor

     Ignition Coil Repair procedures | Spark Plug Repair procedures

    Removal Turn ignition switch OFF and disconnect the battery negative (-) terminal. Remove the engine cover. Disconnect the ignition coil connector (A). Remove the ignition coil (A) after loosening the mounting bolt. I

    Categories

    2022-2025 © - www.infoniro.com | Policy