ELECTRIC DRIVING SYSTEM COMPONENT REMOVAL/INSTALLATION

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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.)

Warning

•  The EV system is hot immediately after driving and charging, and can cause severe burns. Turn off the EV system and wait until it is cool before performing the servicing.

•  If the cooling system cap is removed while the EV system is hot, hot coolant may be ejected, causing severe burns or injury. Perform the removal of the cooling system cap when the EV system is cool.

•  When removing the cooling system cap, cover the cooling system cap with a clean cloth and remove it slowly.

•  The cooling fan may suddenly start operating regardless of the main power switch position. Keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent injury, or damage to the cooling fan. When servicing the cooling fan or parts near the cooling fan, ensure the following.

―  Do not perform normal charging or quick charging

―  Do not select high voltage battery cooling on center display after EV system stops

―  Do not open/close doors frequently with main power switched OFF

―  Access connected vehicle maintenance mode (MyMazda App connected vehicle)

―  Cancel climate control timer

―  Operate center display and turn off battery heater operation

Electric Driving System Component Removal/Installation Preparation

1.  Place the vehicle onto an auto lift and prepare it so it can be lifted up.

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

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

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

4.  Partially peel back the cover.

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5.  Remove the service hole cover.

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

8.  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 terminal cover waterproof rubber is securely installed.

•  Install securely, being careful not to damage the interlock.

(4)  Install the terminal cover.

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Coolant draining procedure

Replacement part

1.  Remove the cooling system cap.

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

3.  Remove the clips and remove the insulator shown in the figure.

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4.  Remove the drain plugs shown in the figure and drain the coolant.

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5.  Remove the breather hose clip of the transaxle from the water hose and set the breather hose aside.

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6.  Place a clean cloth around the plug shown in the figure so that coolant does not flow out onto places such as the motor case.

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7.  Remove the plug.

8.  Remove the water hose (onboard charger side) shown in the figure from the water pipe (on deceleration mechanism).

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9.  Install the plug.

10.  Install the drain plugs.

Electric Driving System Component Removal

1.  Remove the joint cover. (See INTERMEDIATE SHAFT REMOVAL/INSTALLATION.)

2.  Disconnect the Intermediate shaft (lower side) from the steering gear and linkage. (See INTERMEDIATE SHAFT REMOVAL/INSTALLATION.)

3.  Drain the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [A71M].)

4.  Remove the wheel and tire. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

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

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

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

8.  Remove the guard component. (See GUARD COMPONENT REMOVAL/INSTALLATION.)

9.  Disconnect the front stabilizer control link. (See FRONT STABILIZER REMOVAL.)(See FRONT STABILIZER INSTALLATION.)

10.  Disconnect the tie-rod end from the steering knuckle. (See TIE-ROD END REMOVAL/INSTALLATION.)

11.  Disconnect the front lower arm ball joint from the steering knuckle. (See FRONT LOWER ARM REMOVAL/INSTALLATION.)

12.  Remove the front deflector. (See DEFLECTOR REMOVAL/INSTALLATION.)

13.  Remove the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

14.  Remove the front crossmember component. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

15.  Disconnect the left and right drive shafts from the transaxle and secure them using wire or rope so that they do not interfere with the work. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

Note

•   If the transaxle is tiled with the drive shaft connected, the drive shaft joint could be damaged.

16.  Remove the electric water pump. (See ELECTRIC WATER PUMP REMOVAL/INSTALLATION.)

17.  Cover and tie the connection hole of the water pipe (on deceleration mechanism) with a plastic bag so that coolant does not leak.

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18.  Remove the water hose (motor side) from the motor.

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19.  Disconnect the lower radiator hose from the motor.

Note

•  Secure the lower radiator hose to the side of the radiator so that the coolant inside it does not flow out.

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20.  Remove the coolant temperature sensor. (See COOLANT TEMPERATURE SENSOR REMOVAL/INSTALLATION.)

21.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION.)

22.  Remove the DC-DC converter. (See DC-DC CONVERTER REMOVAL/INSTALLATION.)

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

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

25.  Remove the A/C compressor with the A/C hoses and the pipes connected, and secure it using wire or rope so that it does not interfere with the work. (See ELECTRIC COMPRESSOR REMOVAL/INSTALLATION.)

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26.  Remove the bolts shown in the figure and set the brackets aside.

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27.  Remove the water hose (water pipe (on deceleration mechanism) from inverter).

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28.  Cover and tie the connection hole of the water pipe (on deceleration mechanism) with a plastic bag so that coolant does not leak.

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29.  Suspend the water pipe using rope.

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

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31.  Remove the support bracket. (See SUPPORT BRACKET REMOVAL/INSTALLATION [A71M].)

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

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33.  Remove the No.3 mount and remove the electric drive system assembly. (See MOUNT DISASSEMBLY/ASSEMBLY.)

Electric Driving System Component Installation

1.  Replace the transaxle oil seals (LH/RH). (See OIL SEAL (DIFFERENTIAL) REPLACEMENT [A71M].)

2.  Install in the reverse order of removal.

Note

•  Secure the water hose (onboard charger side) near the DC-DC converter without connecting the water pipe (on deceleration mechanism).

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Coolant Replenishment Procedure

1.  Remove the coolant reserve tank installation nuts.

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2.  Remove the coolant reserve tank outlet hose from the DC-DC converter.

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3.  Tilt and secure the coolant reserve tank so that the coolant reserve tank outlet hose is pointed upward.

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4.  Using a commercially-available bottle (volume: approx. 0.5 L), slowly add coolant to the coolant reserve tank.

Note

•  To prevent air infiltration, add approx. 0.5 L for 1 min.

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5.  Stop adding coolant if it begins accumulating in the coolant reserve tank.

6.  Install the coolant reserve tank outlet hose.

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Note

•  Because coolant will overflow from the outlet hose, install the coolant reserve tank lower than the DC-DC converter.

7.  Install the coolant reserve tank installation nuts.

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8.  Using a commercially-available bottle (volume: approx. 0.5 L), add coolant to the water pipe (on deceleration mechanism).

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9.  Using a commercially-available bottle (volume: approx. 0.5 L), add coolant to the water hose (onboard charger side).

Note

•  Because coolant may overflow from the water hose when installing it, lower the water hose to the side of the inverter and add coolant.

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10.  Install the water hose (onboard charger side).

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11.  Using a commercially-available bottle (volume: approx. 0.5 L), add coolant to the F line on the coolant reserve tank.

Note

•  To prevent air infiltration, add approx. 0.5 L for 1 min.

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12.  After adding coolant to the F line on the coolant reserve tank, add an additional 0.26 L.

13.  Install the cooling system cap.

Electric Driving System Component Post-Installation

Caution

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

1.  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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2.  Install the service hole cover.

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3.  Close the cover.

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

Air Bleeding Procedure

1.   Implement [Air Bleeding Procedure] for the coolant replacement. (See COOLANT REPLACEMENT.)

2.  Inspect to confirm that there is no coolant leakage at any part. (See COOLANT LEAKAGE INSPECTION.)

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

4.  Lower the vehicle to the ground and adjust the coolant amount to the F line on the coolant reserve tank.

5.  Install the seal cover. (See SEAL COVER REMOVAL/INSTALLATION.)