GROUP
ELE

MODEL
2017MY
Niro (DE HEV)

NUMBER
135

DATE
October 2017

TECHNICAL SERVICE BULLETIN
SUBJECT:

SERVICE ACTION: INSPECTION AND/OR
REPLACEMENT OF HYBRID DRIVE MOTOR (SA304)

This bulletin provides the procedure to inspect and, if necessary, replace the hybrid drive motor
on some Niro (DE HEV) vehicles produced from January 1, 2017 through July 10, 2017, which
may exhibit a hybrid drive motor warning light malfunction and concerns with the EV mode
driving. To correct this concern, follow the procedure as outlined in this bulletin. Before
conducting this procedure, verify that the vehicle is included in the affected vehicle production
date range and in the attached VIN list.

 NOTICE
A Service Action is a repair program without customer notification that is performed
during the warranty period. Any dealer requesting to perform this repair outside the
warranty period will require DPSM approval.
Repair status for a VIN is provided on WebDCS (Service → Warranty Coverage →
Warranty Coverage Inquiry → Campaign Information). Not completed Recall / Service
Action reports are available on WebDCS (Consumer Affairs → Not Completed Recall
→ Recall VIN → Select Report), which includes a list of affected vehicles.
This issue number is SA304.
File Under:
Circulate To:

X General Manager


X Service Advisors


X Technicians


X Service Manager


X Parts Manager


X Body Shop Manager  Fleet Repair


Page 2 of 9
SUBJECT:

SERVICE ACTION: INSPECTION AND/OR
REPLACEMENT OF HYBRID DRIVE MOTOR (SA304)

Motor Inspection Procedure:
1.

Drain the Hybrid motor coolant by
referring to the “Hybrid motor system →
Hybrid motor cooling system → Coolant
→ Repairing procedure” chapter in the
applicable workshop manual. Hybrid
motor coolant drain is located on the
front side of the radiator (A).

A

WARNING
Do not loosen the radiator drain
plug or open the radiator cap
when the engine is hot.
2.

Remove the inlet hose by releasing the
hybrid drive motor inlet hose clamp (B).
Do not allow coolant onto the engine
clutch actuator assembly, as this may
damage the actuator (C).
Leave a shallow drain pan in place on
the floor to continue to catch additional
coolant that will drain out in step 6.

WARNING
Remove inlet hose carefully to
avoid being burned by hot fluid.

TSB: ELE135/SA304 Niro (DE HEV) October 2017

B

C

Page 3 of 9
SUBJECT:

3.

SERVICE ACTION: INSPECTION AND/OR
REPLACEMENT OF HYBRID DRIVE MOTOR (SA304)

Lower the vehicle and remove the air
cleaner (D).

D

4.

Remove the hybrid starter generator
(HSG) temperature sensor connector
(E).

E

5.

Release and move the HSG inlet hose
clamp (F) and remove the HSG hose.

F

TSB: ELE135/SA304 Niro (DE HEV) October 2017

Page 4 of 9
SUBJECT:

6.

SERVICE ACTION: INSPECTION AND/OR
REPLACEMENT OF HYBRID DRIVE MOTOR (SA304)

Drain the remaining traction motor
coolant completely, by using an air gun
as shown, into the drain pan left under
the vehicle from step 2.

 NOTICE
Be careful and avoid getting
coolant on adjacent parts when
using the air gun.

7.

8.

Connect the Pressure Test Adapter Hose
(G) to the HSG inlet pipe.

G
g
g
g
g
g
g
g
g
g

Raise the vehicle on a lift and connect
the Capped Test Adapter Hose (H) to the
hybrid drive motor inlet pipe.

H
G

TSB: ELE135/SA304 Niro (DE HEV) October 2017

Page 5 of 9
SUBJECT:

9.

SERVICE ACTION: INSPECTION AND/OR
REPLACEMENT OF HYBRID DRIVE MOTOR (SA304)

Lower the vehicle and set up the air bleeding
tool to confirm no leaks, and then perform
the 3-bar air leak test as follows:

 NOTICE
Click the link below for a short
video on setup details and
operating the air bleeding tool.
Air Bleeding Tool Video

1. Close the valve (I), place the cap
on the outlet hose (K), and install
the air hose.
2. Open the valve (I).
3. Pull the pressure valve adjuster
outwards (J) and adjust the
pressure to 3 bars and push back
in.
4. Close the valve (I) and remove the
air hose. Pressure should remain
at three (3) bars (confirm air
bleeding tool is not leaking). If
OK, proceed to step 7, if NG, then
fix the leak before proceeding.
5. Open the valve (I) slowly and
remove the pressure.
6. Close the valve (I).
7. Remove the cap (K) and install
the air hose.
8. Install the output hose end into
HSG inlet adaptor.
9. Attach the air hose and open the
valve (I) and ensure 3 bars
pressure.
10. Close valve (I), remove air hose
and test for leaks.
- Keep the pressure valve
closed and monitor for one (1)
minute and check to ensure the
pressure remains at three (3)
bars.

TSB: ELE135/SA304 Niro (DE HEV) October 2017

Page 6 of 9
SUBJECT:

SERVICE ACTION: INSPECTION AND/OR
REPLACEMENT OF HYBRID DRIVE MOTOR (SA304)

10. If the traction motor assembly tests OK,
then reassemble all the parts in the
reverse order, go to step 11. If test result
is NG, then go to traction motor
replacement procedure below.
11. Refill the coolant and operate the Electric
Water Pump (EWP) using KDS by
referring to “Hybrid motor system →
Hybrid motor cooling system → Coolant
→ repairing procedure” section in the
applicable workshop manual.

 NOTICE
Fill the coolant system with the
recovered coolant. If needed for
top-off, add 50/50 coolant or a
mixture appropriate for the area.
12. Verify proper vehicle operation and make
sure no coolant leaks are present.
Traction Motor Replacement Procedure

DANGER
When performing this procedure, follow all EV battery safety procedures found in the
Service Materials → Service Info → EV Battery System → General Safety Information
and Caution” chapter in the Shop Manual, and wear all required Personal Protection
Equipment (PPE).
1.

Replace the Hybrid drive motor by
referring to “Hybrid motor system →
Hybrid motor assembly → Hybrid drive
motor assembly → repairing procedure”
section in the applicable workshop
manual.

CAUTION
When
removing/installing
the
traction motor/DCT assembly, the
DCT clutch actuators/connectors
can be damaged from interference
with the LH frame rail. Avoid
damage by carefully guiding the
components past the rail during
removal/installation.

TSB: ELE135/SA304 Niro (DE HEV) October 2017

L

Page 7 of 9
SUBJECT:

SERVICE ACTION: INSPECTION AND/OR
REPLACEMENT OF HYBRID DRIVE MOTOR (SA304)

NOTE:
When
mating
the
traction
motor/DCT assembly to the engine
assembly, it may be necessary to rotate the
crank pulley bolt to align the traction motor
input splines with the engine’s clutch.

2.

Perform these four (4) KDS calibrations in
specific order as indicated below:

3.

Clear DTCs and confirm normal operation
and check that the hybrid coolant level is
still OK. Confirm that no DTC reoccurred.

TSB: ELE135/SA304 Niro (DE HEV) October 2017

Page 8 of 9
SUBJECT:

SERVICE ACTION: INSPECTION AND/OR
REPLACEMENT OF HYBRID DRIVE MOTOR (SA304)

AFFECTED VEHICLE RANGE:
Model

Production Date Range

Niro (DE HEV)

01/01/2017 through 07/10/2017

REQUIRED TOOLS:
Part Number

Part Name

09580 3D100

Air Bleeding Tool

Figure

Comments

Located in the Kia Tool
Cabinet Drawer 7

Auto-shipped to Dealer
Leak Test
Adapter Hose

1K373 G5100QQ

For replacement, contact
Snap-on Business
Solutions at
(888) 542-1011

REQUIRED PARTS:
Model

Part Name

DE HEV

Hybrid Drive
Motor

Part Number
Previous

New

36500-2BDC0

36500 2BDC0QQK

TSB: ELE135/SA304 Niro (DE HEV) October 2017

Figure

Page 9 of 9

SERVICE ACTION: INSPECTION AND/OR
REPLACEMENT OF HYBRID DRIVE MOTOR (SA304)

SUBJECT:

WARRANTY INFORMATION:
N Code: N99 C Code: C99
Model

DE
HEV

Claim
Type

V

Causal
P/N

Qty.

Repair
Description

Labor Op
Code

Op
Time

Replacement
P/N

Qty.

0

(SA304)
Inspect Drive
Motor for Leaks

170071R0

0.9
M/H

N/A

0

0

(SA304)
Inspect Drive
Motor for Leaks
and Replace Drive
Motor

170071R1

5.1
M/H

36500
2BDC0QQK

1

36500
2BDC0

NOTE: Use sublet code X1 with a maximum amount of $17.00 reimbursement for topping
off coolant.

 NOTICE
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers
should reference SA304 when accessing the WebDCS system.

TSB: ELE135/SA304 Niro (DE HEV) October 2017