Drive Motor/Generator: Service and Repair

REAR TRACTION MOTOR

Components:

REMOVAL
1. OBSERVE PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE SERVICE PLUG GRIP
4. REMOVE ENGINE ROOM SIDE COVER LH
5. REMOVE INVERTER BRACKET NO.5
6. REMOVE POWER STEERING ECU ASSEMBLY

7. SEPARATE INVERTER RESERVE TANK SUB-ASSEMBLY
a. Remove the 2 bolts and inverter reserve tank sub-assembly.

8. REMOVE POWER STEERING ECU BRACKET
9. REMOVE INVERTER COVER
10. VERIFY THAT VOLTAGE OF W/CONVERTER INVERTER ASSEMBLY IS 0V
11. INSTALL INVERTER COVER
12. DRAIN HYBRID TRANSAXLE FLUID
13. REMOVE REAR WHEELS
14. REMOVE EXHAUST PIPE ASSEMBLY
15. REMOVE REAR AXLE SHAFT LH NUT
16. REMOVE REAR AXLE SHAFT RH NUT

HINT: Removal procedure of the RH side is the same as that of the LH side.

17. DISCONNECT HEIGHT CONTROL SENSOR (W/Discharge Headlight)
18. SEPARATE REAR STRUT ROD ASSEMBLY

a. Support the rear axle carrier with a wooden block placed between the jack and axle carrier.

b. Remove the bolt, nut and strut rod assembly rear.

NOTICE: Hold the nut to turn the bolt.

19. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.1 LH
a. Remove the bolt and nut, and separate the rear suspension arm assembly No.1.

NOTICE: Hold the nut to turn the bolt.

20. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.1 RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

21. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.2 LH
a. Remove the bolt and nut, and separate the rear suspension arm assembly No.2.

NOTICE: Hold the nut to turn the bolt.

22. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.2 RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

23. REMOVE REAR DRIVE SHAFT ASSEMBLY LH
24. REMOVE REAR DRIVE SHAFT ASSEMBLY RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

25. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.3
a. Remove the 2 nuts, and separate the parking brake cable assembly No.3.

26. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.2

HINT: Removal procedure of the RH side is the same as that of the LH side.

27. SEPARATE NO.3 WIRE FRAME

NOTICE: Wear insulating gloves.

a. Disconnect the 2 connectors and clamp.

b. Remove the 2 nuts, and separate the ground cable.

c. Remove the nut, and separate the wire harness clamp.

d. Wear the insulated gloves. Remove the 2 nuts, and separate the frame wire No.3 from the rear traction motor.

28. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY

a. Support the rear suspension member with a jack.

HINT: Remove the rear suspension member together with the rear traction motor.

b. Remove the 2 bolts and 4 nuts, and separate the rear suspension member.

NOTICE: When removing the bolts and nuts on the rear side, be sure to hold the bolt.

29. REMOVE REAR TRACTION W/TRANSAXLE MOTOR ASSEMBLY
a. Remove the 4 bolts, rear traction w/transaxle motor assembly.

30. REMOVE FRONT DIFFERENTIAL SUPPORT ASSEMBLY
a. Remove the 2 bolts and front differential support assembly.

31. REMOVE EXTENSION WIRE ASSEMBLY

a. Remove the 3 bolts and extension wire assembly

b. Remove the bolt, nut, ground cable, and wire harness clamp bracket.

c. Remove the bolt and wire harness clamp bracket.

INSTALLATION
1. INSTALL EXTENSION WIRE ASSEMBLY

a. Install the wire harness clamp bracket with the bolt to the rear traction w/transaxle motor.
Torque: 5.5 Nm (56 kgf-cm, 49 inch lbs.)

b. Install the wire harness clamp bracket and ground wire to the rear traction w/transaxle motor with the bolt and nut.
Torque: 5.5 Nm (56 kgf-cm, 49 inch lbs.)

c. Install the extension wire with the 3 bolts to the rear traction w/transaxle motor.

CAUTION: Be sure to securely insert the extension wire assembly in to the rear traction motor.

Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

2. INSTALL FRONT DIFFERENTIAL SUPPORT ASSEMBLY
a. Install the front differential support assembly with the 2 bolts to the rear traction w/transaxle motor.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)

3. INSTALL REAR TRACTION W/TRANSAXLE MOTOR ASSEMBLY
a. Place the lower stopper, differential support assembly FR w/rear traction motor, and upper stopper in this order. Install them to the rear suspension member with the 4 bolts.
Torque: Bolt A 95 Nm (969 kgf-cm, 70 ft. lbs.)
Bolt B 103 Nm (1,050 kgf-cm, 76 ft. lbs.)

4. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY

a. Slowly jack up the vehicle and install the rear suspension member w/rear traction motor to the vehicle.

b. Install the rear suspension member to the vehicle with the 2 bolts and 4 nuts.
Torque: Nut A 115 Nm (1,173 kgf-cm, 85 ft. lbs.)
Nut B 181 Nm (1,846 kgf-cm, 134 ft. lbs.)

NOTICE: When tightening the bolts B and nuts on the rear side, be sure to hold the bolt B and turn the nut.

5. CONNECT NO.3 WIRE FRAME

a. Wear insulated gloves. Install the frame wire No.3 to the rear traction motor with the 2 nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)

b. Install the wire harness clamp to the vehicle with the nut.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)

c. Install the ground cable to the rear traction motor with the nut.
Torque: 5.5 Nm (56 kgf-cm, 49 inch lbs.)

d. Connect the 2 connectors and clamp to the rear traction motor.

6. CONNECT PARKING BRAKE CABLE ASSEMBLY NO.3
a. Install the parking brake No.3 cable assembly with the 2 nuts.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)

7. CONNECT PARKING BRAKE CABLE ASSEMBLY NO.2

HINT: Install the RH side by following the same procedures as for the LH side.

8. INSTALL REAR DRIVE SHAFT ASSEMBLY LH
9. INSTALL REAR DRIVE SHAFT ASSEMBLY RH

HINT: Install the RH side by following the same procedures as for the LH side.

10. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2 LH

a. Jack up the rear axle carrier, placing a wooden block to avoid damage.

b. Temporarily tighten the rear suspension arm assembly No.2 with the bolt and nut.

HINT: Insert the bolt from the rear side of the vehicle and lightly tighten the bolt.

11. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2 RH

HINT: Install the RH side by following the same procedures as for the LH side.

12. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1
a. Temporarily tighten the rear suspension arm assembly No.1 with the bolt and nut.

HINT: Insert the bolt from the front side of the vehicle and lightly tighten the bolt.

13. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 RH

HINT: Install the RH side by following the same procedures as for the LH side.

14. TEMPORARILY TIGHTEN REAR STRUT ROD ASSEMBLY
a. Temporarily tighten the strut rod assembly rear with the bolt and nut.

HINT: Insert the bolt from the inside of the vehicle and lightly tighten the bolt.

15. STABILIZE SUSPENSION

16. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2
a. Fully tighten the bolt.
Torque: 112 Nm (1,140 kgf-cm, 83 ft. lbs.)

NOTICE: Turn the bolt while holding the nut.

17. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2 RH

HINT: Install the RH side by following the same procedures as for the LH side.

18. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1
a. Fully tighten the bolt.
Torque: 112 Nm (1,140 kgf-cm, 83 ft. lbs.)

NOTICE: Turn the bolt while holding the nut.

19. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 RH

HINT: Install the RH side by following the same procedures as for the LH side.

20. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY
a. Fully tighten the bolt.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)

NOTICE: Turn the bolt while holding the nut.

21. CONNECT HEIGHT CONTROL SENSOR (W/Discharge Headlight)
22. INSTALL REAR AXLE SHAFT LH NUT
23. INSTALL REAR AXLE SHAFT RH NUT

HINT: Install the RH side by following the same procedures as for the LH side.

24. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
25. INSTALL EXHAUST PIPE ASSEMBLY
26. INSTALL POWER STEERING ECU BRACKET
27. CONNECT INVERTER RESERVE TANK SUBASSEMBLY
28. INSTALL POWER STEERING ECU ASSEMBLY
29. INSTALL INVERTER BRACKET NO.5
30. INSTALL REAR WHEELS
31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
32. ADD AND INSPECT HYBRID TRANSAXLE FLUID

33. CHECK HIGH VOLTAGE CABLE CONNECTION

NOTICE: Be sure to wear insulated gloves and protective goggles.

a. Make sure that the frame wire No.3 is securely installed with the nuts.

NOTICE:
^ Do not install the frame wire No.3 at an angle.
^ Be sure to tighten the nuts securely.

34. INSTALL SERVICE PLUG GRIP
35. INSTALL ENGINE ROOM SIDE COVER LH
36. INSPECT EXHAUST GAS LEAK
37. HEADLIGHT AIM ONLY
38. PERFORM INITIALIZATION