KIA Niro: High Voltage Battery System / Repair Procedures

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

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.

Main Battery Pack Assembly

Shut off the high voltage circuit.

(Refer to Hybrid Control System - "High Voltage Shut-off Procedures")
Remove the rear seat cushion.

(Refer to Body - "Rear Seat Assembly")
Remove the rear door scuff trim.

(Refer to Body - "Door Scuff Trim")
Remove the inlet cooling duct.

(Refer to High Voltage Battery Cooling System - "Cooling Duct")
Open the high voltage battery cushion (A) in the direction of an arrow.

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

Remove the outlet cooling duct.
(Refer to High Voltage Battery Cooling System - "Cooling Duct")
Remove the cooling fan #1.
(Refer to High Voltage Battery Cooling System - "Cooling Fan")
Disconnect the inverter power connector (+) (A), inverter power connector (-} (B), OBC power connector (+) (C), OBC power connector (-) (D), BMS extension connector (E).

Remove the luggage side trim (RH).

(Refer to Bady - " Luggage Side Trim")
Disconnect the high voltage cable connector (A) and BMS wiring harness connector (B) connected the sub high voltage battery.

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

Remove the main high voltage battery assembly (A) after loosening the mounting bolts.

Sub Battery Pack Assembly

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

Battery Pack Assembly Repair procedures

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.

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Special features

Hybrid vehicles sound different than gasoline engine vehicles. When the hybrid system operates, you may hear a sound from the hybrid battery system behind the rear seat. If you apply the accelerator pedal rapidly, you may hear an unconventional