KIA Niro: Hybrid Power Control Unit (HPCU)/ 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 shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shutoff Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.

Hybrid Power Control Unit (HPCU)

1. Shut off the high voltage circuit.

   (Refer to Hybrid Control System - "High Voltage Shutoff Procedure")

2. Remove the air cleaner assembly and air duct.

   (Refer to Engine Mechanical System - "Air Cleaner")

3. Remove the ECM & TCM bracket assembly.

   (Refer to Engine Control/Fuel System - "Engine Control Module")

4. Drain the coolant of hybrid motor cooling system.

   (Refer to Hybrid Motor Cooling System - "Coolant")

5. Disconnect the motor power cable connector (A) and HSG power cable connector (B) after loosening the mounting bolts.

6. Disconnect the power cable (A) and inverter power cable (B) from the HPCU.

Warning

Remove the inverter power cale in the follwing order.

7. Disconnect the HCU & inverter (MCU) connector (A).

8. Disconnect the coolant outlet hose & pipe after loosening the mounting bolt (A).

9. Disconnect the coolant inlet hose quick-connector (A).

10. Remove the LDC power outlet cable mounting bolt (A) and ground cable bolt (B).

11. Remove the HPCU (A) after loosening the mounting bolts.

Hybrid Power Control Unit (HPCU) Tray

1. Remove the hybrid power control unit.

   (Refer to Hybrid Control System - "Hybrid Power Control Unit (HPCU)")

2. Remove the hybrid power control unit tray (A) after loosening the mounting bolts.

Hybrid Power Control Unit (HPCU) tray mounting bolt : 21.6 - 23.5 N*m (2.2 - 2.4 kgf*m, 15.9 - 17.4 lb*ft)

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.

1. Install the HPCU in the reverse order of removal.
2. Refill the hybrid motor cooling system coolant and perform air bleeding by using the KDS.

   (Refer to Hybrid Motor Cooling System - "Coolant")

Warning

Perform HCU Variant Coding and Engine Clutch / Motor Resolver learning after replacing the HPCU.

HCU Variant Coding

1. Turn the ignition switch OFF.
2. Connect the KDS to Data Link Connector (DLC).

   Turn the ignition switch ON.

3. Select "Vehicle, Model year, Engine, System".
4. Select "Vehicle S/W Management".
5. Select "HCU Variant Coding".

Engine clutch/motor resolver adaptation

1. Turn the ignition switch OFF.
2. Connect the KDS to Data Link Connector (DLC).

   Turn the ignition switch ON.

3. Select "Vehicle, Model year, Engine, System".
4. Select "Vehicle S/W Management".
5. Select "Engine clutch/motor resolver adaptation.".

HCU Terminal And Input/Output Signal

Terminal Function

Connector (C133-S)

Input/Output signal

Connector (C133-S)

Circuit Diagram

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.

1. Refer to "HPCU".

Warning

The HCU is integrated into the HPCU that can't be disassembled. So refer to "HPCU" for the removal or installation procedure of the HCU.

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.

1. Refer to "HPCU".

Warning

The HCU is integrated into the HPCU that can't be disassembled. So refer to "HPCU" for the removal or installation procedure of the HCU.

Specification

• Type : ON/OFF Switch

Description

The Brake Switch is installed on the brake pedal and linked with the HCU and stop lamp. It sensors
the status of the brake pedal (Release, Push) and transmits the signal to the HCU.

Circuit Diagram

Harness Connector

Removal

1. Refer to Brake System - "Brake System".

Installation

1. Refer to Brake System - "Brake System".

Inspection

1. Refer to Brake System - "Brake System".

Adjustment

1. Refer to Brake System - "Brake System".

Specification

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