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The 2023 Kia Niro EV may not be an all-new electric platform, but it’s a fascinating example of how repurposing internal combustion engine (ICE) architectures can yield a cost-effective, mass-market electric vehicle. In this Munro hoist review, the team digs into the undercarriage, battery, suspension, and thermal management systems — revealing both the clever engineering choices and compromises that come with this approach.
A Familiar K-Frame with a Twist
From the outset, the Niro’s subframe (or K-frame) shows its ICE heritage. This structural piece houses the electric drive module (EDM), including the motor and gearbox. Instead of starting from scratch, Kia adapted an existing K-frame design, welding on an additional structural member to meet the Insurance Institute for Highway Safety’s (IIHS) small overlap rigid barrier (SORB) crash requirements.
This carryover strategy reduces tooling and validation costs. The pre-existing design has already undergone durability and crash testing, so Kia’s engineers could focus validation on the welded extensions rather than an entirely new cradle.
Transverse Powertrain Mounting
The EDM mounts like a transverse ICE powertrain. Two mounts secure it to the side rails, and a torque reaction strut counters drivetrain rotation under load. In contrast, longitudinal EV setups place mounts and supports lower and farther aft to handle different torque vectors and transmission housings.
Smarter Thermal Management Layout
Compared to earlier Niro iterations, Kia has significantly improved the thermal system layout. A plate heat exchanger links the EDM’s gear oil loop to the ethylene glycol system, while a compact chiller interfaces between glycol and refrigerant (likely R134yf). Components are mounted higher and closer together, reducing line length and complexity.
Quick-connect fittings simplify assembly, though some hoses still use constant-tension clamps instead of fully integrated nylon lines like PA12. Interestingly, the system mixes EPDM rubber and PA12 selectively — a possible sign of OEMs trialing lighter, kink-resistant nylon alternatives. However, the team noted at least one kinked EPDM line, possibly violating minimum bend radius guidelines.
Offset Drivetrain and Suspension Choices
Unlike Rivian’s centered motor layout, the Niro’s gearbox is offset to the left, requiring a short transfer shaft to the right CV axle. This packaging choice limits suspension travel compared to more inboard designs but is cost-efficient for this segment.
Front suspension features forged aluminum knuckles and lightweight internal-torque fasteners — a weight-saving measure especially valuable in unsprung components. Brakes use a floating two-piston caliper for more uniform clamping force than a single-piston design, improving pedal feel and rotor wear.
Battery Pack Design and Energy Density
The Niro’s 64.8 kWh battery pack, built by Webasto, uses an aluminum bottom plate that appears to integrate coolant channels for cell thermal management. One-way security fasteners secure the lower shell, discouraging tampering.
The pack achieves just under 70 Wh/lb gravimetric density — better than Tesla’s 4680 structural pack (around 64.5 Wh/lb), though the Niro’s pack omits the DC-DC converter. Harness protection is mixed: the high-voltage cabling is well-shielded, but a low-voltage harness remains somewhat exposed near the leading edge.
Removable underside panels improve serviceability by allowing access to contactors and fuses. However, Munro advises against through-holes in pack bottoms because they create potential leak paths. In addition, these openings disrupt smooth airflow, reducing aerodynamic efficiency compared to a fully sealed belly pan.
Evidence of ICE Platform Repurposing
A telltale sign of the Niro’s roots is the large, unused cavity under the rear seat — space once reserved for a fuel tank and exhaust. Heavy steel stanchions reach up to secure the pack to the body, adding unnecessary mass in an EV-only platform. While not ideal for weight or packaging efficiency, these carryover elements help Kia control costs and speed production.
Rear Suspension: Simple but Effective
The rear setup uses a stamped steel isolated cradle with a twist blade stabilizer bar. Three suspension links are stamped steel, while only the knuckle is cast aluminum. This design is among the lowest-cost independent suspensions available. Switching to a twist beam would reduce costs further but would intrude into the battery space.
Mass dampers are bolted to the lower control arms, suggesting late-stage tuning to counter specific vibration frequencies. While such add-ons add cost and weight, they can be necessary to meet noise, vibration, and harshness (NVH) targets.
Manufacturing Discipline
Compared to vehicles like Rivian’s R1T — which displayed extensive paint markings for quality verification — the Niro has minimal visual inspection marks. This indicates Kia’s manufacturing processes are consistent enough to require fewer manual checks, a sign of mature production control.
The Bigger Picture: Who This EV is For
The Niro EV isn’t designed for off-road adventures or high-performance driving. It’s a practical, well-built commuter car offering around 250 miles of range at a competitive price. Its engineering reflects a clear mission: deliver a reliable, cost-effective EV using proven components and manufacturing techniques.
For buyers prioritizing affordability, efficiency, and build quality over cutting-edge performance, the 2023 Kia Niro EV is a smart choice. For engineers, it’s a case study in how to adapt ICE platforms for EV use without compromising too much on efficiency or functionality.
2023 Kia Niro hoist Review Takeaways
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Repurposing Works — With Limits: Leveraging existing ICE platforms saves cost and time but sacrifices some packaging efficiency.
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Thermal System Routing Matters: Compact layouts reduce material costs, improve efficiency, and minimize potential failure points.
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Suspension Choices Shape Ride and Cost: Forged knuckles and multi-piston calipers add refinement, even in cost-conscious builds.
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Battery Serviceability Is a Tradeoff: Easy access to components can conflict with sealing and aerodynamic goals.
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Mature Manufacturing Shows: Minimal inspection marks point to stable, repeatable assembly processes.
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