KIA Niro: Sub High Voltage Battery - Removal

Kia Niro - First generation - (DE) (2017-2022) - Service and Repair Manual / Service Highlight / Power Relay Assembly (PRA) / Sub High Voltage Battery - Removal

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 read and follow the "High Voltage Shut-off Procedures" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

Turn ignition switch OFF and disconnect the negative (-) battery terminal.
Shut off the high voltage circuit.

(Refer to Hybrid Control System - "High Voltage Shut-off Procedures")
Remove the sub high voltage battery rear cover (A) after loosening the mounting bolts.

High Voltage Battery Rear Cover mounting bolt : 7.8 - 11.8 N*m (0.8 - 1.2 kgf*m, 5.8 - 8.7 lb*ft)

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

High Voltage Battery Cover mounting bolt : 7.8 - 11.8 N*m (0.8 - 1.2 kgf*m, 5.8 - 8.7 lb*ft)

Disconnect the BMS connector (A).
Remove the BMS ECU after loosening the mounting nuts (B).

BMS ECU mounting nut : 7.8 - 11.8 N*m (0.8 - 1.2 kgf*m, 5.8 - 8.7 lb*ft)

Installation

Installation

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 read and follow the "High Voltage Shut-off Procedures" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

Install the BMS ECU in the reverse order of removal.

Safety Plug Description and operation

Description Safety Plug is installed on the rear side of the high voltage battery and it can mechanically shut the high voltage circuit off when servicing the high voltage system. (i.e. High Voltage Battery, Power Relay Assembly, HPCU, BMS ECU

The Power Relay Assembly

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

High Voltage Battery Cooling

Component Location Cooling Fan #1 Cooling Fan #2 Main High Voltage Battery Cooling Duct (Inlet) Main High Voltage Battery Cooling Duct (Outlet) Sub High Voltage Battery Cooling Duct (Inlet) Sub High Voltage Battery Cooling Duct (Ou

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Piston and Connecting Rod Repair procedures

Disassembly 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

Cylinder Head

Inspect for flatness. Using a precision straight edge and feeler gauge, measure the contacting surface of the cylinder block and check the manifolds for warpage. If the flatness is greater than maximum, replace the cylinder head. Fla