POWER DRIVE UNIT REMOVAL AND INSTALLATION

REMOVAL AND INSTALLATION

danger

When servicing the high-voltage system parts, always wear the protective equipment or armour and always shut off the high-voltage by removing the service plug (Refer to PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE

caution

When the power drive unit is replaced, perform the vehicle specification writing (Refer to VEHICLE SPECIFICATION WRITING

Pre-removal Operation

EV coolant draining (Refer to EV COOLING SYSTEM - On-vehicle Service , Coolant Change EV COOLANT CHANGE).
Air cleaner duct (Refer to INTAKE AND EXHASUT - Air cleaner AIR CLEANER REMOVAL AND INSTALLATION).
Engine control module (ECM) (Refer to MULTIPORT FUEL INJECTION (MFI) - Engine Control Module (ECM) ENGINE CONTROL MODULE (ECM) REMOVAL AND INSTALLATION).
EV radiator condenser tank (Refer to EV COOLING SYSTEM - EV Radiator Condenser Tank EV RADIATOR/EV RADIATOR CONDENSER TANK REMOVAL AND INSTALLATION).

Post-installation Operation

EV radiator condenser tank (Refer to EV COOLING SYSTEM - EV Radiator Condenser Tank EV RADIATOR/EV RADIATOR CONDENSER TANK REMOVAL AND INSTALLATION).
Engine control module (ECM) (Refer to MULTIPORT FUEL INJECTION (MFI) - Engine Control Module (ECM) ENGINE CONTROL MODULE (ECM) REMOVAL AND INSTALLATION).
Air cleaner duct (Refer to INTAKE AND EXHASUT - Air cleaner AIR CLEANER REMOVAL AND INSTALLATION).
EV coolant draining (Refer to EV COOLING SYSTEM - On-vehicle Service , Coolant Change EV COOLANT CHANGE).

			Removal steps
		1.	Power drive unit cover
		2.	Service lid
		3.	Ground cable
		4.	Generator cable connection
		5.	Front motor cable connection
		6.	Drive battery front cable connection
		7.	A/C compressor cable connection
		•	EV radiator piping hose A connection
		•	EV coolant temperature sensor harness connection
		•	EV radiator piping hose C connection
		8.	Power drive unit bracket stay
		9.	Power drive unit bracket
		10.	Power drive unit connector protector
		11.	Power drive unit
		12.	Power drive unit harness bracket A
		13.	Power drive unit harness bracket B
		14.	Power drive unit harness bracket C
		15.	Power drive unit rear bracket
		16.	EV coolant temperature sensor
		17.	O-ring

REMOVAL SERVICE POINT

<<A>> FRONT MOTOR CABLE, GENERATOR CABLE, DRIVE BATTERY FRONT CABLE, AND A/C COMPRESSOR CABLE DISCONNECTION

1. Remove the 10 inner cable mounting bolts.

2. Remove the 8 outer cable mounting bolts.

3. Pull out the cables from the power drive unit.

<<B>> RADIATOR PIPING HOSE DISCONNECTION

Put a mating mark before removal as shown in the figure in order to assemble the hose and hose clips to the original positions.

INSTALLATION SERVICE POINT

>>A<< RADIATOR PIPING HOSE CONNECTION

1. Insert the hose to each pipe up to the convex portion.

2. Align the mating marks on the hose and hose clips and install the hose without twisting the hose.

>>B<< A/C COMPRESSOR CABLE AND DRIVE BATTERY CABLE CONNECTION

1. Connect A/C compressor cable and drive battery front cable into the power drive unit.

2. Install the outer cable mounting bolts and inner cable mounting bolts in this order and tighten them to the specified torque.

Tightening torque: 8.0 ± 1.2 N·m

>>C<< GENERATOR CABLE AND FRONT MOTOR CABLE CONNECTION

1. Connect generator cable and front motor cable into the power drive unit.

2. Install the outer cable mounting bolts and inner cable mounting bolts in this order and tighten them to the specified torque.

Tightening torque: 8.0 ± 1.0 N·m

>>D<< SERVICE LID INSTALLATION

caution

When reusing the service lid, check that the sealing surface on the service lid is free of damage (scratch or cracks) and install it.