HYBRID VEHICLE TRANSAXLE REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the FCV transaxle with motor assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedure Effects/Inoperative when not Performed Link
Front wheel alignment adjustment

  1. Clear zero point calibration data

  2. Perform yaw rate and acceleration sensor zero point calibration

 VSC malfunctioning

Click here

Adjust lane departure warning camera Lane departure alert system does not operate correctly

Click here

CAUTION:


  • B000ZMO

    This vehicle has contains high voltage circuits standardized with orange colored wiring and connectors, so follow the instructions in this manual to perform the procedures correctly.

    Click here

  • If the correct procedures are not followed according to the instructions in this manual, there is a danger of electric shock from the high voltage circuits.


  • A01MG1JC01
    *a Heavy object exceeding the capacity of the transmission jack

    Because the FCV transaxle with motor assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.

  • If work is not performed according to the procedures described in the repair manual, there is a danger that the transmission jack could drop and components could fall down.


  • B006JFB

    Be sure to wear insulating gloves when working on high voltage wiring or components.

  • If work is performed without wearing insulating gloves, there is a danger of electric shock.

Note

When the vehicle is parked with the power switch off, if the FC control ECU judges that the FC stack temperature will go below 0°C (32°F), it activates the FC air compressor, hydrogen pump and FC cooling water pump for a maximum of 180 seconds and drains water from the FC stack assembly. When performing inspection or repairs with the power switch off (not on (IG) or on (READY)), disconnect the cable from the negative (-) auxiliary battery terminal before performing work.

PROCEDURE


  1. CAUTIONS FOR HIGH VOLTAGE SYSTEM COMPONENTS

    Click here

  2. CAUTIONS FOR INTAKE SYSTEM COMPONENTS

    Click here

  3. REMOVE NO. 1 MOTOR UNDER COVER

    Click here

  4. REMOVE NO. 2 MOTOR UNDER COVER

    Click here

  5. REMOVE REAR MOTOR UNDER COVER LH

    Click here

  6. REMOVE REAR MOTOR UNDER COVER RH

    Click here

  7. REMOVE FRONT FLOOR COVER LH

    Click here

  8. REMOVE FRONT FLOOR COVER RH

    Click here

  9. DRAIN HYBRID TRANSAXLE FLUID

    Click here

  10. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  11. SEPARATE HEATER WATER INLET B HOSE


    1. A01MK2B

      Disengage the clamp to separate the heater water inlet b hose from the FC radiator inlet pipe.

  12. SEPARATE NO. 2 WATER HOSE SUB-ASSEMBLY


    1. A01MJZ5

      Disengage the clamp to separate the No. 2 water hose sub-assembly from the No. 1 FC cooling water valve outlet hose.

  13. SEPARATE FC RADIATOR INLET PIPE


    1. A01MH0W

      Remove the 2 bolts to separate the FC radiator inlet pipe from the center frame crossmember sub-assembly.

  14. SEPARATE FC COOLING WATER VALVE INLET PIPE


    1. A01MIDX

      Remove the 2 bolts to separate the FC cooling water valve inlet pipe from the inverter cooling outlet pipe.

  15. SEPARATE FC COOLING BY-PASS PIPE


    1. A01MG8U

      Remove the 2 nuts to separate the FC cooling by-pass pipe from the electric heater sub-assembly.

  16. SEPARATE FC COOLING WATER TEMPERATURE CONTROL VALVE


    1. A01MIKU

      Disconnect the electric heater sub-assembly connector.

    2. A01MIGM

      Remove the bolt and 2 nuts to separate the FC cooling water temperature control valve from the electric heater sub-assembly.

    3. A01MGOU

      Move the FC cooling water temperature control valve in the direction indicated by the arrow in the illustration.

      Note

      Do not apply excessive force to any of the hoses.

  17. DISCONNECT NO. 1 INVERTER COOLING OUTLET HOSE

    Click here

  18. SEPARATE INVERTER COOLING OUTLET PIPE


    1. A01MGG3

      Remove the 2 bolts to separate the inverter cooling outlet pipe from the electric heater sub-assembly.

  19. REMOVE UPPER NO. 1 RELAY BLOCK COVER

    Click here

  20. REMOVE NO. 1 RELAY BLOCK COVER

    Click here

  21. DISCONNECT MOTOR WIRE


    1. A01MH8A

      Disconnect the 3 connectors.

    2. Remove the 3 bolts to disconnect the motor wire.

    3. Disengage the 4 clamps to separate the motor wire.

    4. A01MIJZ

      Disconnect the 5 connectors.

    5. Disengage the 5 clamps to separate the motor wire.

  22. REMOVE FCV TRACTION MOTOR BOND CABLE ASSEMBLY


    1. A01MI5J

      Remove the 3 bolts and FCV traction motor bond cable assembly from the center frame crossmember sub-assembly, FC air compressor with motor assembly and FCV transaxle with motor assembly.

  23. SEPARATE MOTOR CABLE

    CAUTION:

    Wear insulated gloves.


    1. A01MIGD

      Disengage the clamp to separate the motor cable from the motor cable bracket.

  24. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  25. SECURE STEERING WHEEL

    Click here

  26. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  27. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  28. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  29. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  30. SEPARATE HYDROGEN PUMP CABLE BRACKET


    1. A01MJUP

      Remove the bolt to separate the hydrogen pump cable bracket from the rear motor mounting insulator.

  31. SEPARATE FC STACK COOLING WATER OUTLET BRACKET


    1. A01MGZB

      Remove the bolt to separate the FC stack cooling water outlet bracket from the rear motor mounting insulator.

  32. DISCONNECT NO. 3 MOTOR COOLING HOSE


    1. A01MJFJ

      Slide the hose clip and disconnect the No. 3 motor cooling hose from the oil cooler union sub-assembly.

  33. DISCONNECT NO. 1 MOTOR COOLING HOSE


    1. A01MIUX

      Slide the hose clip and disconnect the No. 1 motor cooling hose from the oil cooler inlet tube sub-assembly.

  34. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  35. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Click here

  36. SUPPORT FCV TRANSAXLE WITH MOTOR ASSEMBLY


    1. A01MHC9C01
      *a Lashing Belt

      Using a transmission jack, support the FCV transaxle with motor assembly.

      Note


      • Adjust the attachment of the transmission jack to securely fix the FCV transaxle with motor assembly to the transmission jack.

      • Using a lashing belt or a rope, fix the FCV transaxle with motor assembly to the transmission jack.

  37. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY

    Click here

  38. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  39. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  40. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  41. SEPARATE FC COOLING WATER PUMP ASSEMBLY


    1. A01MISS

      Remove the bolt and 2 nuts from the FC cooling water pump assembly.

    2. A01MFGM

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts to separate the FC cooling water pump assembly from the FC air compressor with motor assembly.

      Note

      Suspend the FC cooling water pump assembly with a piece of rope so as not to apply excessive force to the wire harness and hoses.

  42. SUPPORT FC AIR COMPRESSOR WITH MOTOR ASSEMBLY


    1. A01MHZ2C01
      B000ZUW Attachment Placement Position

      Using a height adjustment attachment and a plate lift attachment, support the FC air compressor with motor assembly with a engine lifter or a transmission jack.

  43. REMOVE MOTOR MOUNTING INSULATOR LH


    1. A01MID5

      Remove the nut to separate the motor mounting insulator LH from the motor mounting bracket LH.

    2. A01MJAB

      Remove the 3 bolts and motor mounting insulator LH from the center frame crossmember sub-assembly.

  44. REMOVE FCV TRANSAXLE WITH MOTOR ASSEMBLY


    1. Operate the transmission jack to slightly tilt the FCV transaxle with motor assembly downward.

      Note

      Be careful not to apply excessive force to the wire harnesses and hoses, etc.

    2. A01MJUU

      Remove the bolt to separate the FC air compressor cable bracket from the FCV transaxle with motor assembly.

    3. A01MIVQC01
      *1 Knock Pin

      Remove the 7 bolts.

      Note

      Make sure that the FCV transaxle with motor assembly is clear of all wire harnesses and hoses.

    4. Disengage the 2 knock pins and separate the FCV transaxle with motor assembly from the FC air compressor with motor assembly.

    5. A01MHLNC01
      B006JDZ Be careful to avoid contact with this area.

      Because the motor portion of the FC air compressor with motor assembly is inside the housing of the FCV transaxle with motor assembly, use the following procedure to remove the FCV transaxle with motor assembly without allowing the housing to contact the motor.


      1. Slightly move the FCV transaxle with motor assembly, together with the transmission jack, towards the outer side of the vehicle. (Step 1)

        Note

        Do not allow the FCV transaxle with motor assembly to contact the front side member.

      2. Operate the transmission jack and slightly tilt the FCV transaxle with motor assembly. (Step 2)

        Note

        Do not tilt the FCV transaxle with motor assembly any more than necessary.

      3. Operate the transmission jack and slightly lower the FCV transaxle with motor assembly. (Step 3)

        Note

        Do not allow the FCV transaxle with motor assembly to contact the FC air compressor with motor assembly.

      4. Repeat Step 1 through Step 3 several times to remove the FCV transaxle with motor assembly.

  45. REMOVE MOTOR WIRE


    1. A01MFWO

      Disconnect the 3 connectors.

    2. Disengage the 7 clamps to remove the motor wire from the FCV transaxle with motor assembly.

  46. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01MHYW

      Remove the 2 bolts and 2 wire harness clamp brackets from the FCV transaxle with motor assembly.

  47. REMOVE FRONT MOTOR MOUNTING INSULATOR


    1. A01MHBX

      Remove the nut and front motor mounting insulator from the front motor mounting bracket.

  48. REMOVE FRONT MOTOR MOUNTING BRACKET


    1. A01MIFP

      Remove the 4 bolts and front motor mounting bracket from the FCV transaxle with motor assembly.

  49. REMOVE REAR MOTOR MOUNTING INSULATOR


    1. A01MINC

      Remove the bolt and rear motor mounting insulator from the rear motor mounting bracket.

  50. REMOVE REAR MOTOR MOUNTING BRACKET


    1. A01MGEO

      Remove the 3 bolts and rear motor mounting bracket from the FCV transaxle with motor assembly.

  51. REMOVE MOTOR MOUNTING BRACKET LH


    1. A01MJI0

      Remove the 4 bolts and motor mounting bracket LH from the FCV transaxle with motor assembly.

  52. SEPARATE MOTOR CABLE

    CAUTION:

    Wear insulated gloves.


    1. A01MICV

      Disengage the clamp to separate the motor cable from the motor cable bracket.

  53. REMOVE AUTOMATIC TRANSMISSION CASE COVER


    1. A01MHCXC01
      B006JFV Remove in this Direction

      Disengage the 2 grommets to remove the automatic transmission case cover from the No. 2 automatic transmission case cover.

  54. REMOVE FCV TRANSAXLE MASS DAMPER


    1. A01MG3O

      Remove the bolt and FCV transaxle mass damper from the FCV transaxle with motor assembly.

  55. REMOVE NO. 2 AUTOMATIC TRANSMISSION CASE COVER


    1. A01MHDS

      Remove the clip.

    2. Remove the 2 bolts and No. 2 automatic transmission case cover from the FCV transaxle with motor assembly.

  56. REMOVE MOTOR CABLE BRACKET


    1. A01MGDP

      Remove the bolt and motor cable bracket from the FCV transaxle with motor assembly.

  57. REMOVE STRAIGHT SCREW PLUG


    1. A01MISKC01
      *1 Gasket

      Using a 10 mm hexagon socket wrench, remove the straight screw plug and gasket from the FCV transaxle with motor assembly.

  58. REMOVE OIL COOLER UNION SUB-ASSEMBLY


    1. A01MJOPC01
      *1 Gasket

      Loosen the union bolt.

    2. Remove the bolt and No. 2 oil cooler tube clamp from the No. 1 oil cooler tube clamp.

    3. Remove the union bolt, oil cooler union sub-assembly and gasket from the FCV transaxle with motor assembly.

  59. REMOVE OIL COOLER INLET TUBE SUB-ASSEMBLY


    1. A01MINB

      Using a 17 mm union nut wrench, loosen the flare nut.

      Note

      While holding the transaxle housing union in place, loosen the flare nut.

    2. Remove the bolt and No. 2 oil cooler tube clamp from the No. 1 oil cooler tube clamp.

    3. Separate the flare nut to remove the oil cooler inlet tube sub-assembly from the FCV transaxle with motor assembly.

  60. REMOVE TRANSAXLE HOUSING UNION


    1. A01MIZ5C01
      *1 O-ring

      Remove the transaxle housing union from the FCV transaxle with motor assembly.

    2. Remove the O-ring from the transaxle housing union.

  61. REMOVE TRANSAXLE BREATHER PLUG


    1. A01MFLJ

      Using a 14 mm deep socket wrench, remove the transaxle breather plug from the FCV transaxle with motor assembly.