More under-side disassembly and visibility

Front under-covers removed There are two separate pieces to the aero plastic under-covers in the front.  The forward one had been off for some time, but now I wanted a good look at the underside of everything forward of the battery pack.  To effect this I raised the front end about as far as I could with my existing scissor-jacks and stands, although maybe I should have hauled out the old red ramps to try for this...  The "oil change carpet" underneath allowed for a bit more comfort while crawling around under there.  Both covers attach using a mix of nuts, bolts, and those annoying little plastic expandy-pins with the plungers.

There's a nice general view underneath the Kona in this video from Edmunds.

Having the forward under-cover off allowed snaking my hand up through the front to disconnect the little alarm-beeper that makes noise when the car gets locked or unlocked electronically.  It's the little green object near the right in the shot of the VESS box between the lights and bumper frame.  It was still a bit hard to get at with the nose of the car still on, as there's a lot of other stuff in the way.  It's totally invisible and inaccesible from above.

View under front: motor/transaxle, pack connections Now I could see all of the motor, suspension, and battery connections in all their shiny new glory.  The under-covers would protect all this from road-slop to some extent, but how well remained to be seen.  The front of the powertrain was visible with just the foward cover off, as it was when I did an exhibit over the National Drive Electric weekend I had brought the carpet along, and laid it right in front of the car with a sign taped down saying "MOTOR" and an arrow pointing underneath.  Those who were willing to kneel down were encouraged to do so and have a look at this TINY LITTLE thing that could produce 200 horsepower!  The motor itself is only the ribbed left half here, bolted up to the final drive.  The extra round can on the right is the electric A/C compressor.

With the rear cover off I could get to the battery stuff on the front of the pack too.


Battery topology and fact sheet Having a look inside the battery pack would involve dropping the entire thing out of the car, which requires all kinds of heavy-duty lifting equipment, so that wasn't about to happen here.  [Although people *have* accomplished such things in a driveway at home with a handful of jacks and blocks.] I found some nice bits of documentation on it in Techinfo, though, and printed up a nice architecture and fact sheet to display while at the NDEW events.  I added a quick summary of how the capacity is built up, to give a viewer a better idea of just what goes into these things.  There's a much more in-depth technical look at battery innards in an Electricrevs article from late 2018 when Kona sales were starting to ramp up; recommended reading for anyone who likes geeking out on such topics.  A key thing to note in that is not all versions include the heater hardware.

Big battery connector For yucks I pulled out the main battery connection for a look.  It has a big double-locking ejector to help get it in and out of there.  This is supposed to be good for over 400 amps, maybe not continuously but you'd certainly have generous moments of that in spirited driving.  Do the math: 150 kilowatts at, say, 350 volts after some high-discharge battery sag -- 429 amps at peak.

Besides the obvious cooling lines and control harness, the little black square blocked-off plate half-hidden behind the orange hose is where an additional cable for the battery coolant PTC heater wiring would come back out of the pack in the Canadian version of the car.  It's flatly ridiculous that Konas without that and "winter mode" were sold into the New England region.  I believe that Hyundai wised up for the 2020 model year and includes the heater and associated support for all subsequent US releases.


Battery box with PTC heater connection Here's what the same area looks like in models with the battery heater, according to a small shot in disassembly instructions from Techinfo.  The smaller orange wire runs to a module inserted in the cooling lines to the pack, and the relays to energize it are in the pack itself.

  After examining all this stuff I put both covers back on, because I had seen everything I needed to under here for the moment and did want to try and keep it all a little cleaner and more protected.

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