MOUNT DISASSEMBLY/ASSEMBLY

id301000100200

No.1 mount

1.  Remove front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

2.  Remove the gusset. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

3.  Remove floor under cover No.1. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

4.  Remove using the procedure shown in the figure.

5.  Install in the reverse order of removal.

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1	No.1 mount bracket (See No.1 Mount Removal Note.) (See No.1 Mount Installation Note.)
2	No.1 mount rubber (See No.1 Mount Installation Note.)

No.1 Mount Removal Note

1.  Support the electric motor on a jack.

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Note

•  If the stud bolts will be replaced, remove the stud bolts before removing the No. 1 mount bracket.

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No.1 Mount Installation Note

1.  Temporarily tighten the bolts shown in the figure.

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2.  Tighten the bolts shown in the figure.

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3.  Tighten the stud bolts.

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4.  Temporarily tighten the nuts shown in the figure.

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5.  Tighten the nuts shown in the figure.

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6.  Tighten the bolt shown in the figure.

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No.3 mount

Replacement part

Caution

•  Slots are used for the No.3 mount installation holes. If the No.3 mount deviates from its original position when it is installed, noise and vibration may increase. When installing the No.3 mount, align it with the alignment marks that were made at the time of removal, and install it in its original position.

Warning

<<High voltage>>

•  If the necessary measures are not taken before servicing an electric vehicle, it could cause electrical shock and result in serious injury or, in the worst case, death. Before servicing the electric vehicle, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and implement the necessary measures. (See HIGH VOLTAGE SERVICE CAUTIONS.)

High Voltage Part Inspection And Removal/Installation Notes

Warning

<<High voltage>>

•  If necessary measures such as wearing the correct protective gear are not taken when inspecting or removing/installing the high voltage parts, it could cause electrical shock and result in serious injury or, in the worst case, death.

•  Before inspecting or removing/installing the high voltage parts, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and [High Voltage Part Inspection and Removal/Installation Notes] of the high voltage system service cautions and implement the necessary measures and preparations. (See HIGH VOLTAGE SERVICE CAUTIONS.) (See HIGH VOLTAGE SYSTEM SERVICE CAUTIONS.)

1.  Verify that the READY indicator on the instrument cluster is not illuminated.

•  If the READY indicator is turned on, switch the main power OFF.

2.  Disconnect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)

3.  Partially peel back the cover.

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4.  Remove the service hole cover.

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5.  Wear insulating gloves and remove the service plug using the following procedure.

Warning

<<High voltage>>

•  Touching the terminal on the vehicle side can result in serious injury or death from electric shock. For this reason, after removing the service plug, cover the vehicle-side terminals with insulating tape so that they cannot be touched.

•  Do not touch high voltage parts for 10 min after removing service plug. Electric charges may be stored on the condenser for 10 min after the service plug is removed, and touching high voltage parts during that time can result in serious injury or death from electric shock.

•  Service plugs must be removed by workers inspecting/removing/installing high voltage parts. Keep the removed service plug on your person until inspection/removal/installation of the high voltage parts is completed to prevent other workers from accidentally installing the service plug.

Caution

<<High voltage>>

•  After removing the service plug, cover the vehicle side terminals with insulating tape to prevent foreign matter from adhering to them.

•  When you are keeping the service plug on your person, cover the service plug terminals with insulating tape to prevent damage to them.

•  Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, the vehicle may malfunction.

(1)  Slide the lock in the direction of the arrow shown in the figure. (Do not pull out completely)

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(2)  Raise the lever.

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(3)  Press the area indicated by arrow (1) shown in the figure, release the tabs, and then raise the lever until it is perpendicular.

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(4)  Hold the lever and pull the service plug straight up.

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6.  After removing the service plug, leave it for 10 min.

7.  Wear insulating gloves and measure the voltage at the high voltage cable connection (junction box No.3 side) using the following procedure.

(1)  Remove the seal cover. (See SEAL COVER REMOVAL/INSTALLATION.)

Caution

<<High voltage>>

•  Be careful not to allow foreign matter or water droplets to enter the junction box No.3. Since the junction box No.3 has a high voltage circuit, there is a risk of malfunction if foreign matter or water drops enter it.

•  Remove the terminal cover by pulling it straight up. The terminal cover is fitted with an interlock switch. This interlock switch may be damaged if the terminal cover is removed while being tilted.

•  Do not touch the moisture-proof seal on the terminal cover. If the seal is touched or damaged, replace the terminal cover.

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(2)  Remove the terminal cover.

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(3)  Measure the voltage at the high voltage cable connection.

Note

•  Use a voltmeter with a measurement range of 450 V DC or more.

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―  Verify that the voltmeter indicates 0 V and go to the next step.

•  Verify that the waterproof rubber on the terminal cover is securely installed.

•  Be careful not to damage the interlock, and install it securely.

(4)  Install the terminal cover.

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8.  Remove the coolant reserve tank with the hose still connected to it, and secure it using rope or other means so that it does not interfere with work. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION.)

9.  Remove the DC-DC converter with the hose and wiring harness still connected to it, and secure it using rope or other means so that it does not interfere with work. (See DC-DC CONVERTER REMOVAL/INSTALLATION.)

10.  Disconnect the high voltage cable (junction box No.3 side). (See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)

•  After disconnecting the high voltage cable, wrap the terminal part with insulating tape to insulate it.

11.  Remove junction box No.3. (See JUNCTION BOX No.3 REMOVAL/INSTALLATION.)

12.  Remove front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

13.  Remove the clips, then remove the insulator shown in the figure.

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14.  Use a commercially available table lifter to support the electric motor.

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15.  Remove the nuts shown in the figure and remove the accumulator together with the bracket. (See ACCUMULATOR REMOVAL/INSTALLATION.)

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16.  Remove the bolt shown in the figure and remove the heat pump unit No.2 bracket. (See HEAT PUMP CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].)

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17.  Disconnect the connector shown in the figure.

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18.  Detach the wiring harness clip shown in the figure.

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19.  Remove using the procedure shown in the figure.

20.  Install in the reverse order of removal.

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1	Bolt
2	Nut (See No.3 Mount Removal Note.) (See No.3 Mount Installation Note.)
3	Stud bolt (See No.3 Mount Installation Note.)
4	Bolt (See No.3 Mount Removal Note.) (See No.3 Mount Installation Note.)
5	No.3 mount (See No.3 Mount Removal Note.) (See No.3 Mount Installation Note.)

Caution

•  Before connecting the service plug, check the tightness of the high voltage terminals and the connection status of the connectors.

21.  Wear insulating gloves and install the service plug using the following procedure.

(1)  Insert the service plug as far as it will go.

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(2)  Depress the lever completely.

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(3)  Slide the lock in the direction of the arrow shown in the figure until the hook is engaged.

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22.  Install the service hole cover.

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23.  Close the cover.

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24.  Connect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)

No.3 Mount Removal Note

1.  Place alignment marks at the positions shown in the figure so that they can be assembled to the same positions as before removal.

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Note

•  Use paint to apply alignment marks so that the No.3 mounts on the body side are outlined, and the positions of the nuts on the No.3 mount side are outlined.

No.3 Mount Installation Note

Note

•  If a No.3 mount will be replaced with a new part, make alignment marks on the new part in the same locations as the old part.

1.  Tighten the electric motor stud bolts.

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2.  Align the alignment marks on the body side with the No.3 mount, and temporarily tighten the bolts shown in the figure.

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3.  Temporarily tighten the nuts shown in the figure while aligning the alignment marks of the No.3 mount with the nuts.

•  If the alignment marks have deviated, align them by slightly moving the electric drive system assembly, then temporarily tighten the nuts.

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4.  Tighten the No.3 mount installation bolts and nuts in the order shown in the figure.

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5.  Remove the table lifter or garage jack.

No.4 mount

Replacement part

Caution

•  Slots are used for the No.4 mount installation holes. If the No.4 mount deviates from its original position when it is installed, noise and vibration may increase. When installing the No.4 mount, align it with the alignment marks that were made at the time of removal, and install it in its original position.

1.  Remove the lead-acid battery and battery tray. (See LEAD-ACID BATTERY REMOVAL/INSTALLATION.)

2.  Remove front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

3.  Remove the clips, then remove the insulator shown in the figure.

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4.  Use a commercially available table lifter to support the electric motor.

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5.  Remove using the procedure shown in the figure.

6.  Install in the reverse order of removal.

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1	Nut (See No.4 Mount Removal Note.) (See No.4 Mount Installation Note.)
2	Bolts
3	Bolts (See No.4 Mount Removal Note.) (See No.4 Mount Installation Note.)
4	No.4 mount (See No.4 Mount Removal Note.) (See No.4 Mount Installation Note.)

No.4 Mount Removal Note

1.  Place alignment marks at the positions shown in the figure so that they can be assembled to the same positions as before removal.

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Note

•  Use paint and make alignment marks so that the No.4 mounts on the body side are outlined, and the positions of the nuts on the No.4 mount side are outlined.

2.  Remove the No.4 mounts.

No.4 Mount Installation Note

Note

•  If a No.4 mount will be replaced with a new part, make alignment marks on the new part in the same locations as the old part.

•  When the No.4 mount nuts were loosened, there is the possibility that the support bracket stud bolts became loose. Therefore tighten the stud bolts.

1.  Tighten the support bracket stud bolts.

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2.  Align the alignment marks on the body side with the No.4 mount, and temporarily tighten the bolts shown in the figure.

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3.  Temporarily tighten the nuts shown in the figure while aligning the alignment marks of the No.4 mount with the nuts.

•  If the alignment marks have deviated, align them by slightly moving the support bracket, then temporarily tighten the nuts.

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4.  Tighten the No.4 mount installation bolts and nuts in the order shown in the figure.

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5.  Remove the table lifter or garage jack.