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Removal and Installation
 
 
dangerPHEV vehicles have high voltage batteries, so incorrect handling may cause electric shock and electric leakage. Work correctly, according to the work procedure, when performing inspection and maintenance.
warning
  • Before inspecting or servicing high-voltage wiring harnesses and components, be sure to disconnect the service plug and inter lock connector to cut off the high-voltage circuit.
  • Keep the removed service plug in your pocket, or place it in a toolbox or other receptacle, while you are working, to make sure nobody else can mistakenly connect it while you are working.
  • Always wear insulative protector while working on high-voltage systems.
  • When working with high-voltages, clearly decide who is in charge, and make sure nobody else touches the vehicle. Also, whenever you are not working on them, cover the high-voltage parts with an electricity-resistant cover sheet etc. so that nobody else can touch them.
  • Refer to PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE.
caution
  • When the vehicle is in the READY state, with the service plug detached, faults can occur in the vehicle. Therefore, do not put the vehicle in READY state other than when instructed by the workshop manual to do so.
  • Work with safety in mind, and do not attempt anything risky.
  • Do not start work before the exhaust system and engine coolant have cooled down.
  • Use the specified support points when lifting. Refer to LIFTING, JACKING SUPPORT LOCATION.
 
 
REMOVAL
 
 
1. Shut off the high-voltage circuit. Refer to PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE.
2. Check the voltage of the high-voltage circuit. Refer to PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE.
3. Drain the EV coolant. Refer to EV COOLANT CHANGE.
4. Drain the rear transaxle fluid. Refer to TRANSAXLE FLUID CHANGE.
5. Widen hose clip at the front side of the rear motor, and disconnect the EV radiator piping hose H . Refer to WATER HOSE/WATER PIPE REMOVAL AND INSTALLATION.
6. Widen hose clip at the rear right side of the rear motor, and disconnect the EV radiator piping hose X . Refer to WATER HOSE/WATER PIPE REMOVAL AND INSTALLATION.
7. Remove main muffler. Refer to EXHAUST PIPE AND MAIN MUFFLER REMOVAL AND INSTALLATION.
8. Remove rear stabilizer. Refer to Removal and Installation.
9. Remove drive shaft. Refer to Removal and Installation.
10. Remove rear axle housing. Refer to Removal and Installation.
11. Remove the cable protector and service lid from the rear motor.
12. Remove the drive battery rear cable (REMCU) and body wiring harness (rear motor side) mounting bolts from the rear motor.
13. Disconnect the drive battery rear cable (REMCU) and body wiring harness from the rear motor.
14. Set jack rear suspension member.
caution
  • Check the stable condition when using a jack.
  • Never damage rear suspension member with a jack.
15. Remove rear suspension member stay.
16. Remove rear suspension member mounting bolts.
17. Slowly lower jack, remove rear suspension member with rear lower link, rear suspension arm and rear motor/rear transaxle assembly.
cautionOperate while checking that jack supporting status is stable.
18. Remove the following parts.
19. Perform inspection after removal. Refer to Inspection.
 
 
INSTALLATION
Note the following, and install in the reverse order of the removal.
  • Perform final tightening of fixing parts at the vehicle installation position (rubber bushing), under unladen conditions with tires on level ground.
  • Perform inspection after installation. Refer to Inspection.