MB992753 MB992750 or MB992959 ACC06823AF Code No. Diagnosis item Reference page P1A40 Battery current sensor ( 350A) P.54D-108 P1A41 Battery current sensor ( 30A) P.54D-110 P1A42 BATT. current SNS. power circuit P.54D-112 P1A43 BATT. current SNS. detect circuit P.54D-113 P1A44 Leak detection (BMU) P.54D-115 P1A46 Leak sensor detection circuit P.54D-130 P1A48 BATT. cooling fan output circuit P.54D-132 P1A6A CMU01 Battery temperature P.54D-134 P1A6B CMU02 Battery temperature P.54D-134 P1A6C CMU03 Battery temperature P.54D-134 P1A6D CMU04 Battery temperature P.54D-134 P1A6E CMU05 Battery temperature P.54D-134 P1A6F CMU06 Battery temperature P.54D-134 P1A70 CMU07 Battery temperature P.54D-134 MSB-17M54̲55-001(17AB037) TSB Revision 567 54D-106 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Code No. Diagnosis item Reference page P1A71 CMU08 Battery temperature P.54D-134 P1A72 CMU09 Battery temperature P.54D-134 P1A73 CMU10 Battery temperature P.54D-134 P1A74 CMU11 Battery temperature P.54D-134 P1A75 CMU12 Battery temperature P.54D-134 P1A76 CMU01 Cell voltage sensor P.54D-136 P1A77 CMU02 Cell voltage sensor P.54D-136 P1A78 CMU03 Cell voltage sensor P.54D-136 P1A79 CMU04 Cell voltage sensor P.54D-136 P1A7A CMU05 Cell voltage sensor P.54D-136 P1A7B CMU06 Cell voltage sensor P.54D-136 P1A7C CMU07 Cell voltage sensor P.54D-136 P1A7D CMU08 Cell voltage sensor P.54D-136 P1A7E CMU09 Cell voltage sensor P.54D-136 P1A7F CMU10 Cell voltage sensor P.54D-136 P1A80 CMU11 Cell voltage sensor P.54D-136 P1A81 CMU12 Cell voltage sensor P.54D-136 P1A82 CMU01 Battery temperature sensor P.54D-138 P1A83 CMU02 Battery temperature sensor P.54D-138 P1A84 CMU03 Battery temperature sensor P.54D-138 P1A85 CMU04 Battery temperature sensor P.54D-138 P1A86 CMU05 Battery temperature sensor P.54D-138 P1A87 CMU06 Battery temperature sensor P.54D-138 P1A88 CMU07 Battery temperature sensor P.54D-138 P1A89 CMU08 Battery temperature sensor P.54D-138 P1A8A CMU09 Battery temperature sensor P.54D-138 P1A8B CMU10 Battery temperature sensor P.54D-138 P1A8C CMU11 Battery temperature sensor P.54D-138 P1A8D CMU12 Battery temperature sensor P.54D-138 P1A8E CMU01 Battery balancing unit P.54D-139 P1A8F CMU02 Battery balancing unit P.54D-139 P1A90 CMU03 Battery balancing unit P.54D-139 P1A91 CMU04 Battery balancing unit P.54D-139 P1A92 CMU05 Battery balancing unit P.54D-139 P1A93 CMU06 Battery balancing unit P.54D-139 P1A94 CMU07 Battery balancing unit P.54D-139 P1A95 CMU08 Battery balancing unit P.54D-139 MSB-17M54̲55-001(17AB037) TSB Revision 568 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-107 Code No. Diagnosis item Reference page P1A96 CMU09 Battery balancing unit P.54D-139 P1A97 CMU10 Battery balancing unit P.54D-139 P1A98 CMU11 Battery balancing unit P.54D-139 P1A99 CMU12 Battery balancing unit P.54D-139 P1AA8 Local CAN (for Main Drive Lithium-ion Battery) signal time-out P.54D-140 P1AA9 Cell number mismatch P.54D-146 P1AB5 CMU01 Battery low temperature P.54D-147 P1AB6 CMU02 Battery low temperature P.54D-147 P1AB7 CMU03 Battery low temperature P.54D-147 P1AB8 CMU04 Battery low temperature P.54D-147 P1AB9 CMU05 Battery low temperature P.54D-147 P1ABA CMU06 Battery low temperature P.54D-147 P1ABB CMU07 Battery low temperature P.54D-147 P1ABC CMU08 Battery low temperature P.54D-147 P1ABD CMU09 Battery low temperature P.54D-147 P1ABE CMU10 Battery low temperature P.54D-147 P1ABF CMU11 Battery low temperature P.54D-147 P1AC0 CMU12 Battery low temperature P.54D-147 P1AC1 Battery cooling fan (Drive fail) P.54D-148 P1AC2 Battery cooling fan (SHT to BAT) P.54D-152 P1AC3 Battery cooling fan (Rest fail) P.54D-156 P1AC6 Each Cell VOLT. diff. (Hi side) P.54D-159 P1ADF +B line voltage P.54D-161 P1AE0 Clock IC time counter P.54D-163 P1AE1 Clock IC alarm P.54D-164 P1AE3 BMU TEMP. sensor (Open/Short) P.54D-165 P1AE4 BMU TEMP. sensor (Rationality) P.54D-165 U1082 Bat-CAN Bus-off P.54D-166 U11A0 CMU01 CAN timeout P.54D-169 U11A1 CMU02 CAN timeout P.54D-169 U11A2 CMU03 CAN timeout P.54D-169 U11A3 CMU04 CAN timeout P.54D-169 U11A4 CMU05 CAN timeout P.54D-169 U11A5 CMU06 CAN timeout P.54D-169 U11A6 CMU07 CAN timeout P.54D-169 U11A7 CMU08 CAN timeout P.54D-169 U11A8 CMU09 CAN timeout P.54D-169 MSB-17M54̲55-001(17AB037) TSB Revision 569 54D-108 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Code No. Diagnosis item Reference page U11A9 CMU10 CAN timeout P.54D-169 U11AA CMU11 CAN timeout P.54D-169 U11AB CMU12 CAN timeout P.54D-169 U1925 CMU ID numbering reception error P.54D-175 U1926 EV-ECU V-CAN error P.54D-179 DIAGNOSTIC CODE PROCEDURES DTC P1A40 Battery Current Sensor ( 350A) . TROUBLE JUDGMENT Check Conditions  The electric motor switch is ON position or while the main drive lithium-ion battery is charged.  The following diagnostic trouble code is not set. a. P1A42: BATT. circuit SNS. power circuit Judgment Criterion  The output voltage of the main drive lithium-ion battery current sensor (high) is less than 0.2 volt. or  The output voltage of the main drive lithium-ion battery current sensor (high) is more than 4.8 volts. . FAIL-SAFE AND BACKUP FUNCTION  The system turns OFF the balancer drive.  The energy level gauge displays the 0 segment. . PROBABLE CAUSES  The main drive lithium-ion battery current sensor is failed.  Open circuits of main drive lithium-ion battery current sensor circuit, short circuits to ground, short circuits to power supply system or damage; poor contact of connector.  The BMU is failed. DIAGNOSIS STEP 1. Scan tool MB991958 data list  Refer to Data List Reference Table.  Item 12: battery current  Item 13: BAT. current HI control value Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). NO : Go to Step 2. MSB-17M54̲55-001(17AB037) TSB Revision 570 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-109 STEP 2. Connector check: BMU connector and main drive lithium-ion battery electric current sensor connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 3. NO : Repair the connector. Lock position 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector Harness side STEP 3. Check the wiring harness between BMU connector (terminal No.7, 6, 22, 8) and main drive lithium-ion battery electric current sensor connector (terminal No.1, 2, 3, 4) Check power supply or signal line for open or short circuit. Q: Is the check result normal? YES : Go to Step 4. NO : Repair the wiring harness. Current sensor connector ACC07057AZ STEP 4. Perform resistance measurement at BMU connector  Disconnect connector, and measure at BMU side.  Resistance between terminal No.3 and No.21, No.22. OK: Continuity (2  or less) Q: Is the check result normal? YES : Go to Step 5. NO : Replace the BMU (Refer to P.54D-188). Then go to Step 5 . STEP 5. Check the current sensor in main drive lithium-ion battery (1) Removal the current sensor in main drive lithium-ion battery (Refer to P.54D-207). (2) Check the current sensor in main drive lithium-ion battery (Refer to P.54D-218). Q: Is the check result normal? YES : Go to Step 6. NO : Replace the current sensor in main drive lithium-ion battery (Refer to P.54D-207). MSB-17M54̲55-001(17AB037) TSB Revision 571 54D-110 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 6. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC P1A41 Battery Current Sensor ( 30A) . TROUBLE JUDGMENT Check Conditions  The electric motor switch is ON position or while the main drive lithium-ion battery is charged.  The following diagnostic trouble code is not set. a. P1A42: BATT. circuit SNS. power circuit Judgment Criterion  The output voltage of the main drive lithium-ion battery current sensor (low) is less than 0.2 volt. or  The output voltage of the main drive lithium-ion battery current sensor (low) is more than 4.8 volts. . FAIL-SAFE AND BACKUP FUNCTION  Use the main drive lithium-ion battery current sensor (high) to control and turn off the balancer drive when the main drive lithium-ion battery current sensor (high) is normal. . PROBABLE CAUSES  The main drive lithium-ion battery current sensor is failed.  Open circuits of main drive lithium-ion battery current sensor circuit, short circuits to ground, short circuits to power supply system or damage; poor contact of connector.  The BMU is failed. DIAGNOSIS STEP 1. Scan tool MB991958 data list  Refer to Data List Reference Table.  Item 12: battery current  Item 14: BAT. current LO control value Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). NO : Go to Step 2. MSB-17M54̲55-001(17AB037) TSB Revision 572 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-111 STEP 2. Connector check: BMU connector and main drive lithium-ion battery electric current sensor connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 3. NO : Repair the connector. Lock position 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector Harness side STEP 3. Check the wiring harness between BMU connector (terminal No.7, 6, 22, 8) and main drive lithium-ion battery electric current sensor connector (terminal No.1, 2, 3, 4) Check power supply or signal line for open or short circuit. Q: Is the check result normal? YES : Go to Step 4. NO : Repair the wiring harness. Current sensor connector ACC07057AZ STEP 4. Perform resistance measurement at BMU connector  Disconnect connector, and measure at BMU side.  Resistance between terminal No.3 and No.21, No.22. OK: Continuity (2  or less) Q: Is the check result normal? YES : Go to Step 5. NO : Replace the BMU (Refer to P.54D-188). Then go to Step 5 . STEP 5. Check the current sensor in main drive lithium-ion battery (1) Removal the current sensor in main drive lithium-ion battery (Refer to P.54D-207). (2) Check the current sensor in main drive lithium-ion battery (Refer to P.54D-218). Q: Is the check result normal? YES : Go to Step 6. NO : Replace the current sensor in main drive lithium-ion battery (Refer to P.54D-207). MSB-17M54̲55-001(17AB037) TSB Revision 573 54D-112 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 6. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC P1A42 BATT. Current SNS. Power Circuit . TROUBLE JUDGMENT Check Condition  The electric motor switch is ON position or while the main drive lithium-ion battery is charged. Judgment Criterion  The power supply voltage of the main drive lithium-ion battery current sensor is more than 5.3 volts. or  The power supply voltage of the main drive lithium-ion battery current sensor is less than 4.7 volts. . FAIL-SAFE AND BACKUP FUNCTION  Turn off the balancer drive. . PROBABLE CAUSES  The main drive lithium-ion battery current sensor is failed.  Open circuits of main drive lithium-ion battery current sensor circuit, short circuits to ground or damage; poor contact of connector.  The BMU is failed. DIAGNOSIS STEP 1. Connector check: BMU connector and main drive lithium-ion battery electric current sensor connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 2. NO : Repair the connector. MSB-17M54̲55-001(17AB037) TSB Revision 574 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Lock position 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector Harness side 54D-113 STEP 2. Check the wiring harness between BMU connector (terminal No.6) and main drive lithium-ion battery electric current sensor connector (terminal No.2) Check power supply or signal line for open or short circuit. Q: Is the check result normal? YES : Go to Step 3. NO : Repair the wiring harness. Current sensor connector ACC07057AZ STEP 3. Check the current sensor in main drive lithium-ion battery (1) Removal the current sensor in main drive lithium-ion battery (Refer to P.54D-207). (2) Check the current sensor in main drive lithium-ion battery (Refer to P.54D-218). Q: Is the check result normal? YES : Go to Step 4. NO : Replace the current sensor in main drive lithium-ion battery (Refer to P.54D-207). STEP 4. Scan tool MB991958 diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC P1A43 BATT. Current SNS. Detect Circuit . TROUBLE JUDGMENT Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged.  The control value of the main drive lithium-ion battery current sensor (high) is more than 20 amperes and less than 20 amperes.  Either one of the following diagnostic trouble codes is not set. a. P1A42: BATT. circuit SNS. power circuit b. P1A40: Battery current sensor ( 350A) c. P1A41: Battery current sensor ( 30A) MSB-17M54̲55-001(17AB037) TSB Revision 575 54D-114 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Judgment Criterion  The difference is more than 10 amperes between the control value of the Main Drive Lithium-ion Battery current sensor (high) and the control value of the Main Drive Lithiumion Battery current sensor (low). Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged.  Either one of the following diagnostic trouble codes is not set. a. P1A42: BATT. circuit SNS. power circuit b. P1A40: Battery current sensor ( 350A) c. P1A41: Battery current sensor ( 30A) Judgment Criterion  The output voltage of the main drive lithium-ion battery current sensor (high) is less than 0.3 volt. or  The output voltage of the main drive lithium-ion battery current sensor (high) is more than 4.7 volts. . FAIL-SAFE AND BACKUP FUNCTION  Turn off the balancer drive. . PROBABLE CAUSES  The main drive lithium-ion battery current sensor is failed.  Damage of main drive lithium-ion battery current sensor circuit; poor contact of connector.  The BMU is failed. DIAGNOSIS STEP 1. Scan tool MB991958 data list  Refer to Data List Reference Table. a. Item 12: battery current b. Item 13: BAT. current HI control value c. Item 14: BAT. current LO control value Q: Are all check results normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). NO : Go to Step 2. STEP 2. Connector check: BMU connector and main drive lithium-ion battery electric current sensor connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 3. NO : Repair the connector. MSB-17M54̲55-001(17AB037) TSB Revision 576 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Lock position 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector Harness side 54D-115 STEP 3. Check the wiring harness between BMU connector (terminal No.7, 6, 22, 8) and main drive lithium-ion battery electric current sensor connector (terminal No.1, 2, 3, 4) Check power supply or signal line for open or short circuit. Q: Is the check result normal? YES : Go to Step 4. NO : Repair the wiring harness. Current sensor connector ACC07057AZ STEP 4. Perform resistance measurement at BMU connector  Disconnect connector, and measure at BMU side.  Resistance between terminal No.3 and No.21. OK: Continuity (2  or less) Q: Is the check result normal? YES : Go to Step 5. NO : Replace the BMU (Refer to P.54D-188). Then go to Step 5 . STEP 5. Check the current sensor in main drive lithium-ion battery (1) Removal the current sensor in main drive lithium-ion battery (Refer to P.54D-207). (2) Check the current sensor in main drive lithium-ion battery (Refer to P.54D-218). Q: Is the check result normal? YES : Go to Step 6. NO : Replace the current sensor in main drive lithium-ion battery (Refer to P.54D-207). STEP 6. Scan tool MB991958 diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC P1A44 Leak Detection (BMU) . MSB-17M54̲55-001(17AB037) TSB Revision 577 54D-116 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY TROUBLE JUDGMENT Check Conditions  After the electric motor switch is turned ON, or after the main drive lithium-ion battery starts to be charged.  Not during the quick charge. Judgment Criterion  Ground fault is detected. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  Ground fault of high voltage system component  The BMU is failed. DIAGNOSIS DANGER  When high voltage system components are ser- viced, be sure to remove service plug to shut down high voltage (Refer to GROUP 00  Precautions before service, Precautions on how to use the high-voltage vehicle).  When removing service plug, wear the specified protective equipment. STEP 1. Use scan tool MB991958 to confirm a diagnostic trouble code.  Electric motor switch: 20 seconds elapse after ON  Select lever position: P range Q: Is the diagnostic trouble code set? YES : If the diagnostic trouble code is set during the electric motor switch ON, the ground fault could occur inside the main drive lithium-ion battery. Then go to Step 2. NO : Go to Step 8. MSB-17M54̲55-001(17AB037) TSB Revision 578 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-117 STEP 2. Check the service plug for the insulation resistance DANGER  Check the high-voltage circuit while reading care- fully the precautions on handling a high-voltage vehicle.  Be sure to wear the specified protective equipment when pulling the service plug. Front of vehicle CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.  Use the special tool electric insulation tester (MB992355) to set the range to 500 V.  Insulation resistance between service plug forward terminal and ground. Service plug connector ACA03985 AB Front of vehicle Service plug connector  Insulation resistance between service plug backward terminal and ground. OK: 10 M or more Q: Is the check result normal? YES : Go to Step 7. NO : Go to Step 3. ACA03985 AC MSB-17M54̲55-001(17AB037) TSB Revision 579 54D-118 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 3. Check the service plug for the insulation resistance DANGER  Check the high-voltage circuit while reading care- fully the precautions on handling a high-voltage vehicle.  Be sure to wear the specified protective equipment when pulling the service plug. Front of vehicle CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.  Use the special tool electric insulation tester (MB992355) to set the range to 500 V.  Removal the each contactor (Refer to P.54D-189).  Insulation resistance between service plug forward terminal and main drive lithium-ion battery mounting. Service plug connector ACA03985 AB Front of vehicle Service plug connector  Insulation resistance between service plug backward terminal and main drive lithium-ion battery mounting. OK: 10 M or more Q: Is the check result normal? YES : Check the each contactor (Refer to P.54D-216). NO : Go to Step 4. ACA03985 AC MSB-17M54̲55-001(17AB037) TSB Revision 580 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-119 STEP 4. Check the service plug for the insulation resistance DANGER  Check the high-voltage circuit while reading care- fully the precautions on handling a high-voltage vehicle.  Be sure to wear the specified protective equipment when pulling the service plug. Front of vehicle CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.  Use the special tool electric insulation tester (MB992355) to set the range to 500 V.  Removal the resistor (Refer to P.54D-189).  Insulation resistance between service plug forward terminal and main drive lithium-ion battery mounting. Service plug connector ACA03985 AB Front of vehicle Service plug connector  Insulation resistance between service plug backward terminal and main drive lithium-ion battery mounting. OK: 10 M or more Q: Is the check result normal? YES : Check the resistor (Refer to P.54D-218). NO : Go to Step 5. ACA03985 AC MSB-17M54̲55-001(17AB037) TSB Revision 581 54D-120 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 5. Check the service plug for the insulation resistance DANGER  Check the high-voltage circuit while reading care- fully the precautions on handling a high-voltage vehicle.  Be sure to wear the specified protective equipment when pulling the service plug. Front of vehicle CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.  Use the special tool electric insulation tester (MB992355) to set the range to 500 V.  Remove cable between the BMU and bus bar (Refer to P.54D-189).  Insulation resistance between service plug forward terminal and main drive lithium-ion battery mounting. Service plug connector ACA03985 AB Front of vehicle Service plug connector  Insulation resistance between service plug backward terminal and main drive lithium-ion battery mounting. OK: 10 M or more Q: Is the check result normal? YES : Replace cable between the BMU and bus bar (Refer to P.54D-197) or BMU (Refer to P.54D-188). NO : Go to Step 6. ACA03985 AC MSB-17M54̲55-001(17AB037) TSB Revision 582 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-121 STEP 6. Check the service plug for the insulation resistance DANGER  Check the high-voltage circuit while reading care- fully the precautions on handling a high-voltage vehicle.  Be sure to wear the specified protective equipment when pulling the service plug. Front of vehicle CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.  Use the special tool electric insulation tester (MB992355) to set the range to 500 V.  Remove the bus bar (Refer to P.54D-189).  Insulation resistance between service plug forward terminal and main drive lithium-ion battery mounting. Service plug connector ACA03985 AB Front of vehicle Service plug connector  Insulation resistance between service plug backward terminal and main drive lithium-ion battery mounting. OK: 10 M or more Q: Is the check result normal? YES : heck to tighten the bus bar in the main drive lithiumion battery (Refer to P.54D-197). NO : Go to Step 7. ACA03985 AC STEP 7. Use scan tool MB991958 to check diagnostic trouble code related to the other systems Check if the diagnostic trouble code is stored in the BMU. Q: Is the diagnostic trouble code stored? YES : Carry out troubleshooting for the diagnostic trouble code. NO : Go to Step 8. MSB-17M54̲55-001(17AB037) TSB Revision 583 54D-122 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 8. Use scan tool MB991958 to confirm a diagnostic trouble code.  Electric motor switch: READY  Select lever position: P range  A/C switch: OFF Q: Is the diagnostic trouble code set? YES : Go to Step 22. NO : Go to Step 9. STEP 9. Use scan tool MB991958 to confirm a diagnostic trouble code.  Electric motor switch: READY  Select lever position: D range Q: Is the diagnostic trouble code set? YES : Go to Step 10. NO : Go to Step 18. STEP 10. Connector check: G-07 inverter (U terminal) connector, G-08 inverter (V terminal) connector, G-09 inverter (W terminal) connector DANGER  When high voltage system components are ser- viced, be sure to remove service plug to shut down high voltage (Refer to GROUP 00  Precautions before service, Precautions on how to use the high-voltage vehicle).  When removing service plug, wear the specified protective equipment. Q: Is the check result normal? YES : Go to Step 11. NO : Repair the terminals. MSB-17M54̲55-001(17AB037) TSB Revision 584 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-123 STEP 11. Check the G-07 inverter (U terminal) connector, G-08 inverter (V terminal) connector and G-09 inverter (W terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Disconnect connector, and measure at harness side.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and body ground. OK: 10 M or more Q: Is the check result normal? YES : The inverter could have ground fault. Check the insulation resistance of inverter. NO : Go to Step 12. STEP 12. Connector check: G-16 motor (electric motor unit: U terminal) connector Q: Is the check result normal? YES : Go to Step 13. NO : Repair the terminal. STEP 13. Check the G-07 inverter (U terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Disconnect connector, and measure at harness side.  Disconnect G-16 motor (electric motor unit: U terminal) connector.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and case shield ground. OK: 10 M or more Q: Is the check result normal? YES : Go to Step 14. NO : Replace the motor (electric motor unit) cable. MSB-17M54̲55-001(17AB037) TSB Revision 585 54D-124 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 14. Connector check: G-15 motor (electric motor unit: V terminal) connector Q: Is the check result normal? YES : Go to Step 15. NO : Repair the terminal. STEP 15. Check the G-08 inverter (V terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Disconnect connector, and measure at harness side.  Disconnect G-15 motor (electric motor unit: V terminal) connector.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and case shield ground. OK: 10 M or more Q: Is the check result normal? YES : Go to Step 16. NO : Replace the motor (electric motor unit) cable. STEP 16. Connector check: G-14 motor (electric motor unit: W terminal) connector Q: Is the check result normal? YES : Go to Step 17. NO : Repair the terminal. MSB-17M54̲55-001(17AB037) TSB Revision 586 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-125 STEP 17. Check the G-09 inverter (W terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Disconnect connector, and measure at harness side.  Disconnect G-14 motor (electric motor unit: W terminal) connector.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and case shield ground. OK: 10 M or more Q: Is the check result normal? YES : Replace the motor (electric motor unit). NO : Replace the motor (electric motor unit) cable. STEP 18. Use scan tool MB991958 to confirm a diagnostic trouble code.  Electric motor switch: READY  A/C set temperature: minimum temperature  A/C switch: ON  MAX switch: ON Q: Is the diagnostic trouble code set? YES : Go to Step 19. NO : Go to Step 20. STEP 19. After replacing the A/C refrigerant and the compressor oil, check the diagnosis trouble code again.  Electric motor switch: READY  A/C set temperature: minimum temperature  A/C switch: ON  MAX switch: ON Q: Is the diagnostic trouble code set? YES : Replace the A/C compressor (Refer to GROUP 55  Compressor Assembly). NO : Check end. STEP 20. Use scan tool MB991958 to confirm a diagnostic trouble code.  Electric motor switch: READY  A/C set temperature: maximum temperature  MAX switch: ON Q: Is the diagnostic trouble code set? YES : Replace the electric hot water heater (Refer to GROUP 55  Heater). NO : Go to Step 15. MSB-17M54̲55-001(17AB037) TSB Revision 587 54D-126 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 21. Use scan tool MB991958 to confirm a diagnostic trouble code. NOTE: Turn the electric motor switch ON position and connect the charging cable. Then turning the electric motor switch LOCK (OFF) position can check the monitor during the regular charging.  Electric motor switch: "LOCK" (OFF)  During the regular charging Q: Is the diagnostic trouble code set? YES : Replace the on board charger/DC-DC converter. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). STEP 22. Check the G-05 inverter ( terminal) connector or the G-06 inverter (+ terminal) connector for the insulation resistance. DANGER  When high voltage system components are ser- viced, be sure to remove service plug to shut down high voltage (Refer to GROUP 00  Precautions before service, Precautions on how to use the high-voltage vehicle).  When removing service plug, wear the specified protective equipment. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Measure the insulation resistance with the connector connected.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and body ground. OK: 10 M or more Q: Is the check result normal? YES : Check on main drive lithium-ion battery ground fault detector circuit (Refer to DTC P1A46 Leak sensor detection circuit P.54D-203). NO : Go to Step 23. MSB-17M54̲55-001(17AB037) TSB Revision 588 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-127 STEP 23. Check the G-05 inverter ( terminal) connector or the G-06 inverter (+ terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Measure the insulation resistance with the connector connected.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and body ground. Q: When the G-20 A/C compressor connector is disconnected, does the insulation resistance change by the value more than 10 M? YES : The A/C compressor could have ground fault. Check the insulation resistance of A/C compressor. NO : Go to Step 24. STEP 24. Check the G-05 inverter ( terminal) connector or the G-06 inverter (+ terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Measure the insulation resistance with the connector connected.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and body ground. Q: When the G-21 heater connector is disconnected, does the insulation resistance change by the value more than 10 M? YES : The heater could have ground fault. Check the insulation resistance of heater. NO : Go to Step 25. MSB-17M54̲55-001(17AB037) TSB Revision 589 54D-128 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 25. Check the G-05 inverter ( terminal) connector or G-06 inverter (+ terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Measure the insulation resistance with the connector connected.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and body ground. Q: When the G-05 inverter ( terminal) connector and the G-06 inverter (+ terminal) connector are disconnected, does the insulation resistance change by the value more than 10 M? YES : Go to Step 26. NO : Go to Step 29. STEP 26. Connector check: G-18 main drive lithium-ion battery connector, G-19 main drive lithium-ion battery connector Q: Is the check result normal? YES : Go to Step 27. NO : Repair the terminals. STEP 27. Check the G-05 inverter ( terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Disconnect connector, and measure at harness side.  Disconnect G-18 main drive lithium-ion battery connector.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and body ground. OK: 10 M or more Q: Is the check result normal? YES : Go to Step 28. NO : Replace the main drive lithium-ion battery cable. MSB-17M54̲55-001(17AB037) TSB Revision 590 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-129 STEP 28. Check the G-06 inverter (+ terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Disconnect connector, and measure at harness side.  Disconnect G-19 main drive lithium-ion battery connector.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and body ground. OK: 10 M or more Q: Is the check result normal? YES : Go to Step 30. NO : Replace the main drive lithium-ion battery cable. STEP 29. Check the G-05 inverter ( terminal) connector or the G-06 inverter (+ terminal) connector for the insulation resistance. CAUTION When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 volts. When the insulation resistance is measured at the range more than 500 volts, the component may be damaged.  Measure the insulation resistance with the connector connected.  Use the special tool electric insulation tester (MB992355) to set the range to 500 volts.  Insulation resistance between terminal No. 1 and body ground. Q: When the G-26 inverter and on board charger/DC-DC converter combination connector is disconnected, does the insulation resistance changes by the value more than 10 M? YES : The on board charger/DC-DC converter could have ground fault. Check the insulation resistance of on board charger/DC-DC converter. NO : Go to Step 30. STEP 30. After check for insulation resistance of the inverter, reconfirm the scan tool MB991958 diagnostic trouble code  Recheck if the diagnostic trouble code is set again after check for insulation resistance of the inverter. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Check end. MSB-17M54̲55-001(17AB037) TSB Revision 591 54D-130 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY DTC P1A46 Leak Sensor Detection Circuit . TROUBLE JUDGMENT Check Conditions  After the electric motor switch is turned ON, or after the main drive lithium-ion battery starts to be charged.  Not during the quick charge. Judgment Criterion  Defective leakage-of-electricity detection circuit. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  Ground fault of high voltage system component.  The main drive lithium-ion battery ground fault detector is failed.  Open circuits of main drive lithium-ion battery ground fault detector circuit, short circuits to ground, short circuits to power supply system or damage; poor contact of connector.  The BMU is failed. DIAGNOSIS DANGER  When high voltage system components are ser- viced, be sure to remove service plug to shut down high voltage (Refer to GROUP 00  Precautions before service, Precautions on how to use the high-voltage vehicle).  When removing service plug, wear the specified protective equipment. STEP 1. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Carry out troubleshooting for DTC P1A44. Then go to Step 2. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 2. Use scan tool MB991958 to confirm a diagnostic trouble code Q: Is the diagnostic trouble code set? YES : Go to Step 3. NO : Check end. MSB-17M54̲55-001(17AB037) TSB Revision 592 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-131 STEP 3. Connector check: C-21 main drive lithium-ion battery connector Q: Is the check result normal? YES : Go to Step 4. NO : Repair the connector. STEP 4. Perform resistance measurement at C-21 main drive lithium-ion battery connector  Disconnect connector, and measure at vehicle harness side.  Resistance between terminal No.2 and No.13. OK: Continuity (2  or less) Q: Is the check result normal? YES : Go to Step 5. NO : Repair the wiring harness. STEP 5. Connector check: BMU connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 6. NO : Repair the connector. STEP 6. Check the wiring harness between BMU connector (terminal No.3, 26) and C-21 main drive lithium-ion battery connector (terminal No.2, 13) Check signal line for open or short circuit. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness. 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector C-21 (GR) ACC07057BA STEP 7. Check the ground fault detector cable between BMU connector and bus bar Check line for open or short circuit. Q: Is the check result normal? YES : Go to Step 8. NO : Repair the ground fault detector cable (Refer to P.54D-197). MSB-17M54̲55-001(17AB037) TSB Revision 593 54D-132 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 8. Use scan tool MB991958 to confirm a diagnostic trouble code Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Check end. DTC P1A48 BATT. Cooling Fan Output Circuit . TROUBLE JUDGMENT Check Conditions  The electric motor switch is ON position or while the main drive lithium-ion battery is charged. Judgment Criterion  The PWM output signal of the main drive lithium-ion battery cooling fan is 100 % (while the fan is stopped) and the PWM output signal status of the main drive lithium-ion battery cooling fan is High (during the rotation). . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  The main drive lithium-ion battery cooling fan is failed.  Short circuits to power supply system of main drive lithiumion battery cooling fan circuit; poor contact of connector.  The BMU is failed. DIAGNOSIS STEP 1. Connector check: C-14 main drive lithium-ion battery connector Q: Is the check result normal? YES : Go to Step 2. NO : Repair the connector. STEP 2. Perform voltage measurement at C-14 main drive lithium-ion battery connector.  Disconnect the connector and measure the voltage at the female side.  Electric motor switch: ON  Voltage between terminal No. 2 and ground. OK: 0  0.1 volt Q: Is the check result normal? YES : Go to Step 8. NO : Go to Step 3. MSB-17M54̲55-001(17AB037) TSB Revision 594 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-133 STEP 3. Connector check: C-21 main drive lithium-ion battery connector Q: Is the check result normal? YES : Go to Step 4. NO : Repair the connector. STEP 4. Check harness between C-14 (terminal No.2) main drive lithium-ion battery connector and C-21 (terminal No.7) main drive lithium-ion battery connector  Check output line for short circuit to power supply. Q: Is the check result normal? YES : Go to Step 5. NO : Repair the wiring harness. STEP 5. Connector check: BMU connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 6. NO : Repair the connector. STEP 6. Check the wiring harness between BMU connector (terminal No.9) and C-21 main drive lithium-ion battery connector (terminal No.7)  Check output line for short circuit to power supply. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness. 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector C-21 (GR) ACC07057BA STEP 7. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 8. Scan tool MB991958 diagnostic trouble code Q: Is the diagnostic trouble code stored? YES : Go to Step 9. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). MSB-17M54̲55-001(17AB037) TSB Revision 595 54D-134 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 9. Connector check: C-14 main drive lithium-ion battery fan connector, cooling fan connector Removal the main drive lithium-ion battery cover (Refer to P.54D-189). Q: Is the check result normal? YES : Go to Step 10. NO : Repair the damaged connector. STEP 10. Check the wiring harness between C-14 (terminal No.2) Main Drive Lithium-ion Battery fan connector and cooling fan (terminal No.4) connector Check power supply line, out signal line and ground line for open circuit. Harness side Cooling fan connector C-14 (GR) Q: Is the check result normal? YES : Replace the cooling fan in main drive lithium-ion battery (Refer to P.54D-211). NO : Repair the wiring harness. ACC07057 AJ DTC P1A6A CMU01 Battery Temperature, P1A6B CMU02 Battery Temperature, P1A6C CMU03 Battery Temperature, P1A6D CMU04 Battery Temperature, P1A6E CMU05 Battery Temperature, P1A6F CMU06 Battery Temperature, P1A70 CMU07 Battery Temperature, P1A71 CMU08 Battery Temperature, P1A72 CMU09 Battery Temperature, P1A73 CMU10 Battery Temperature, P1A74 CMU11 Battery Temperature, P1A75 CMU12 Battery Temperature . TROUBLE JUDGMENT Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged.  Either one of the following diagnostic trouble codes is not set. a. P1AA8: Bat-CAN signal time out b. U1082: Bat-CAN bus-off Judgment Criterion  The module temperature is more than 60C (140F). . FAIL-SAFE AND BACKUP FUNCTION  Drive the Main Drive Lithium-ion Battery fan for 10 minutes after judging malfunctions. . PROBABLE CAUSES  The main drive lithium-ion battery cooling is insufficient with the failed air conditioning control system. MSB-17M54̲55-001(17AB037) TSB Revision 596 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-135  The module (battery cell, CMU and module temperature sensor) in the main drive lithium-ion battery is failed. DIAGNOSIS STEP 1. Scan tool MB991958 other system diagnostic trouble code. Q: Is diagnostic trouble code of A/C control unit set? YES : Check the A/C control unit. (Refer to GROUP 55  A/ C Diagnosis  DTC Chart ). NO : Go to Step 2. STEP 2. Scan tool MB991958 actuator test (1) Check the A/C control unit. (Refer to GROUP 55  Actuator Test Reference Table ).  Item No. 02: Battery cooling flap motor Q: Is the check result normal? YES : Go to Step 3. NO : Main drive lithium-ion battery cooling selection damper motor check. STEP 3. Scan tool MB991958 data list  Check the data list reference table corresponding to the diagnostic trouble code. OK: At ambient temperature (atmospheric temperature) or equivalent (when the vehicle driving and the charge are not performed for a long time) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). NO : Go to Step 4. MSB-17M54̲55-001(17AB037) TSB Revision 597 54D-136 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 4. Use scan tool MB991958 to confirm a diagnostic trouble code of other systems. (1) Select "Reset" on the special function screen of the relevant CMU ID (Refer to GROUP 00  Precautions Before Service, How to Reset Failure Information in the CMU EEPROM), and then execute it. (2) Check the data list corresponding to the relevant CMU ID.  Item No. 14: Reference low voltage  Item No. 15: Reference high voltage  Item No. 16  No. 21: Temperature sensor (1  6) (open)  Item No. 22  No. 27: Temperature sensor (1  6) (short)  Item No. 44  No. 49: Temperature sensor (1  6) underflow  Item No. 50  No. 55: Temperature sensor (1  6) overflow  Item No. 67: A/D conversion (Reference volt)  Item No. 68  No. 73: A/D conversion (temp. sensor 1  6) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). NO : Check to tighten the bus bar in the main drive lithiumion battery or replace the main drive lithium-ion battery assembly. DTC P1A76 CMU01 Cell Voltage Sensor, P1A77 CMU02 Cell Voltage Sensor, P1A78 CMU03 Cell Voltage Sensor, P1A79 CMU04 Cell Voltage Sensor, P1A7A CMU05 Cell Voltage Sensor, P1A7B CMU06 Cell Voltage Sensor, P1A7C CMU07 Cell Voltage Sensor, P1A7D CMU08 Cell Voltage Sensor, P1A7E CMU09 Cell Voltage Sensor, P1A7F CMU10 Cell Voltage Sensor, P1A80 CMU11 Cell Voltage Sensor, P1A81 CMU12 Cell Voltage Sensor . TROUBLE JUDGMENT Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged.  Either one of the following diagnostic trouble codes is not set. a. P1AA8: Bat-CAN signal time out b. U1082: Bat-CAN bus-off Judgment Criterion  The signal is received from the appropriate module CMU, which shows that one of the battery cell voltage has an invalid value. . MSB-17M54̲55-001(17AB037) TSB Revision 598 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-137 FAIL-SAFE AND BACKUP FUNCTION  If the CMU detecting abnormalities also detects the module temperature sensor abnormalities, drive the main drive lithium-ion battery fan for 10 minutes. . PROBABLE CAUSE  The module (battery cell, CMU and battery cell voltage sensor) in the main drive lithium-ion battery is failed.  The BMU is failed. DIAGNOSIS STEP 1. Scan tool MB991958 data list  Check the data list reference table corresponding to the diagnostic trouble code. OK: Not 2.51 volts (initial value) (electric motor switch: LOCK (OFF)  ON) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). NO : Go to Step 2. STEP 2. Scan tool MB991958 data list of others system (1) Select "Reset" for the relevant CMU ID on the special function screen (Refer to GROUP 00  Precautions Before Service, How to Reset Failure Information in the CMU EEPROM), and then execute it. (2) Check the data list on the relevant CMU ID.  Item No. 1: Module voltage  Item No. 2: Cell total voltage  Item No. 3: Voltage diff. (Module  Total cell)  Item No. 4  No. 11: Cell (A  H) voltage  Item No. 12: Cell Monitor IC  Item No. 13: Voltage sensor  Item No. 28  No. 35: Cell (A  H) voltage underflow  Item No. 36  No. 43: Cell (A  H) voltage overflow Q: Is the check result normal? YES : Go to Step 3. NO : Replace the main drive lithium-ion battery assembly. STEP 3. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Check end. MSB-17M54̲55-001(17AB037) TSB Revision 599 54D-138 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY DTC P1A82 CMU01 Battery Temperature Sensor, P1A83 CMU02 Battery Temperature Sensor, P1A84 CMU03 Battery Temperature Sensor, P1A85 CMU04 Battery Temperature Sensor, P1A86 CMU05 Battery Temperature Sensor, P1A87 CMU06 Battery Temperature Sensor, P1A88 CMU07 Battery Temperature Sensor, P1A89 CMU08 Battery Temperature Sensor, P1A8A CMU09 Battery Temperature Sensor, P1A8B CMU10 Battery Temperature Sensor, P1A8C CMU11 Battery Temperature Sensor, P1A8D CMU12 Battery Temperature Sensor . TROUBLE JUDGMENT Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged.  Either one of the following diagnostic trouble codes is not set. a. P1AA8: Bat-CAN signal time out b. U1082: Bat-CAN bus-off Judgment Criterion  The signal is received from the appropriate module CMU, which shows that one of the module temperatures has an invalid value. . FAIL-SAFE AND BACKUP FUNCTION  If the CMU detecting abnormalities also detects the battery cell voltage sensor abnormalities, drive the main drive lithium-ion battery fan for 10 minutes. . PROBABLE CAUSES  The module (battery cell, CMU and module temperature sensor) in the main drive lithium-ion battery is failed.  The BMU is failed. DIAGNOSIS STEP 1. Scan tool MB991958 data list  Check the data list reference table corresponding to the diagnostic trouble code. NOTE: To precisely judge the diagnose, do not perform the diagnosis at the temperature of 35C (95F) around the main drive lithium-ion battery. OK: Not 35C (95F) (initial value) (electric motor switch: LOCK (OFF)  ON) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). NO : Go to Step 2. MSB-17M54̲55-001(17AB037) TSB Revision 600 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-139 STEP 2. Scan tool MB991958 data list of others system (1) Select "Reset" for the relevant CMU ID on the special function screen (Refer to GROUP 00  Precautions Before Service, How to Reset Failure Information in the CMU EEPROM), and then execute it. (2) Check the data list on the relevant CMU ID.  Item No. 14: Reference low voltage  Item No. 15: Reference high voltage  Item No. 16  No. 21: Temperature sensor (1  6) (open)  Item No. 22  No. 27: Temperature sensor (1  6) (short)  Item No. 44  No. 49: Temperature sensor (1  6) underflow  Item No. 50  No. 55: Temperature sensor (1  6) overflow  Item No. 67: A/D conversion (Reference volt) Q: Is the check result normal? YES : Go to Step 3. NO : Replace the main drive lithium-ion battery assembly. STEP 3. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Check end. DTC P1A8E CMU01 Battery Balancing Unit, P1A8F CMU02 Battery Balancing Unit, P1A90 CMU03 Battery Balancing Unit, P1A91 CMU04 Battery Balancing Unit, P1A92 CMU05 Battery Balancing Unit, P1A93 CMU06 Battery Balancing Unit, P1A94 CMU07 Battery Balancing Unit, P1A95 CMU08 Battery Balancing Unit, P1A96 CMU09 Battery Balancing Unit, P1A97 CMU10 Battery Balancing Unit, P1A98 CMU11 Battery Balancing Unit, P1A99 CMU12 Battery Balancing Unit . TROUBLE JUDGMENT Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged.  Balancer allowed to be driven is OFF.  Either one of the following diagnostic trouble codes is not set. a. P1AA8: Bat-CAN signal time out b. U1082: Bat-CAN bus-off Judgment Criterion  The signal is received from the appropriate module CMU, which shows that one of the balancer driving conditions is turned ON. . FAIL-SAFE AND BACKUP FUNCTION  Not available . MSB-17M54̲55-001(17AB037) TSB Revision 601 54D-140 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY PROBABLE CAUSES  The module (CMU) in the main drive lithium-ion battery is failed.  The BMU is failed. DIAGNOSIS STEP 1. Scan tool MB991958 data list  Check the data list reference table corresponding to the diagnostic trouble code. OK: OFF (electric motor switch: ON) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). NO : Go to Step 2. STEP 2. Scan tool MB991958 data list of others system (1) Select "Reset" for the relevant CMU ID on the special function screen (Refer to GROUP 00  Precautions Before Service, How to Reset Failure Information in the CMU EEPROM), and then execute it. (2) Check the data list on the relevant CMU ID.  Item No. 58: CAN controller Q: Is the check result normal? YES : Go to Step 3. NO : Replace the main drive lithium-ion battery assembly. STEP 3. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Check end. DTC P1AA8: Bat-CAN Signal Time Out . TROUBLE JUDGMENT Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged.  None of the following diagnostic trouble codes is set at the same time. a. Code No. U1082: Bat-CAN bus-off Judgment Criterion  One of the CMU signals cannot be received through the CAN communication. . MSB-17M54̲55-001(17AB037) TSB Revision 602 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-141 FAIL-SAFE AND BACKUP FUNCTION  Drive the main drive lithium-ion battery fan for 10 minutes after judging malfunctions. . PROBABLE CAUSES  The Local CAN (for main drive lithium-ion battery) bus is failed.  The BMU is failed. DIAGNOSIS STEP 1. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Go to Step 2. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 2. Check CMU12 from CMU01 Check the CMU, which has timed out. Q: Have all the CMUs been timed out? YES : Go to Step 8. NO : Check the CMU, which has timed out. Then go to Step 3. STEP 3. Connector check: C-22, C-26 main drive lithiumion battery connector, CMU12 from CMU01 connector, resistor (local CAN terminating) connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 4. NO : Repair the damaged connector. STEP 4. Check the wiring harness between C-22 (terminal No. 4) main drive lithium-ion battery connector and CMU12 from CMU01 (each terminal No. 1) connector NOTE: .  Before checking harness, check intermediate connector (1) (terminal No. 4, No. 11 from No. 6, No. 22 from No. 15) of out signal line, and repair if necessary. MSB-17M54̲55-001(17AB037) TSB Revision 603 54D-142 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Check power supply line for open circuit. Lock position Harness side CMU ID CMU12 Q: Is the check result normal? YES : Go to Step 5. NO : Repair the wiring harness. CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 C-22 (GR) CMU07 ACC07057AO Intermediate connector (1) (GR) ACC07057 AP STEP 5. Check the wiring harness between C-26 (terminal No. 5) main drive lithium-ion battery connector and CMU12 from CMU01 (terminal No. 8) connector, resistor (local CAN terminating) (terminal No. 1) connector NOTE: .  Before checking harness, check intermediate connector (CAN1) (terminal No. 11 from No. 3), intermediate connector (CAN2) (terminal No. 9 from No. 3) of out signal line, and repair if necessary. Check signal line (CANH) for open circuit. Lock position Harness side Harness side CMU12 Resistor (Local CAN terminating) CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 CMU ID Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness. C-26 (B) CMU07 Intermediate connector (CAN2) (GR) ACC07057 AK Intermediate connector (CAN1) (GR) ACC07057AL MSB-17M54̲55-001(17AB037) TSB Revision 604 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 6. Check the wiring harness between C-26 (terminal No. 10) main drive lithium-ion battery connector and CMU12 from CMU01 (terminal No. 4) connector, resistor (local CAN terminating) (terminal No. 2) connector NOTE: .  Before checking harness, check intermediate connector (CAN1) terminal No. 22 from No. 14, intermediate connector (CAN2) terminal No. 20 from No. 14 of out signal line, and repair if necessary. Check signal line (CANL) for open circuit. Lock position Harness side Harness side CMU12 Resistor (Local CAN terminating) CMU ID Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness. CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 54D-143 C-26 (B) CMU07 Intermediate connector (CAN2) (GR) ACC07057 AK Intermediate connector (CAN1) (GR) ACC07057AL STEP 7. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the main drive lithium-ion battery. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 8. Check the local CAN (for main drive lithium-ion battery) terminating resistance itself (1) Removal the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-189). (2) Check the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-217). Q: Is the check result normal? YES : Go to Step 13. NO : Go to Step 9. MSB-17M54̲55-001(17AB037) TSB Revision 605 54D-144 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 9. Connector check: C-26 main drive lithium-ion battery connector, CMU12 from CMU01 connector, BMU connector, resistor (local CAN terminating) connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 10. NO : Repair the damaged connector. STEP 10. Check the wiring harness between C-26 (terminal No. 5) main drive lithium-ion battery connector and CMU12 from CMU01 (terminal No. 8) connector, BMU (terminal No.24) connector, resistor (local CAN terminating) (terminal No. 1) connector NOTE: .  Before checking harness, check intermediate connector (CAN1) (terminal No. 11 from No. 3), intermediate connector (CAN2) (terminal No. 9 from No. 2) of out signal line, and repair if necessary. Check signal line (CANH) for open circuit. Lock position Harness side Harness side CMU12 Resistor (Local CAN terminating) CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 CMU ID Q: Is the check result normal? YES : Go to Step 11. NO : Repair the wiring harness. C-26 (B) CMU07 Intermediate connector (CAN2) (GR) ACC07057 AK Intermediate connector (CAN1) (GR) ACC07057AL 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector ACC07057BB MSB-17M54̲55-001(17AB037) TSB Revision 606 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 11. Check the wiring harness between C-26 (terminal No. 10) main drive lithium-ion battery connector and CMU12 from CMU01 (terminal No. 4) connector, BMU (terminal No.23) connector, resistor (local CAN terminating) (terminal No. 2) connector NOTE: .  Before checking harness, check intermediate connector (CAN1) terminal No. 22 from No. 14, intermediate connector (CAN2) terminal No. 20 from No. 13 of out signal line, and repair if necessary. Check signal line (CANL) for open circuit. Lock position Harness side Harness side CMU12 Resistor (Local CAN terminating) CMU ID Q: Is the check result normal? YES : Go to Step 12. NO : Repair the wiring harness. CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 54D-145 C-26 (B) CMU07 Intermediate connector (CAN2) (GR) ACC07057 AK Intermediate connector (CAN1) (GR) ACC07057AL 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector ACC07057BB MSB-17M54̲55-001(17AB037) TSB Revision 607 54D-146 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 12. Check the local CAN (for main drive lithium-ion battery) terminating resistor (1) Removal the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-189). (2) Check the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-217). Q: Is the check result normal? YES : Go to Step 13. NO : Replace the local CAN terminating resister (Refer to P.54D-209). STEP 13. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC P1AA9 Cell Number Mismatch . TROUBLE JUDGMENT Check Conditions  When the CMUs are numbered for identification.  The following diagnostic trouble code is set at the same time. a. U1925: CMU ID numbering reception error Judgment Criterion  The number of cells are invalid. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  Improper installation of the main drive lithium-ion battery.  The BMU is failed. DIAGNOSIS STEP 1. Scan tool MB991958 other diagnostic trouble code. Check if DTC U1925 is set. Q: Is the diagnostic trouble code set? YES : Carry out troubleshooting for DTC U1925 (Refer to P.54D-175). NO : Go to Step 2. MSB-17M54̲55-001(17AB037) TSB Revision 608 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-147 STEP 2. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Go to Step 3. STEP 3. Use scan tool MB991958 to confirm a diagnostic trouble code. (1) Select "CMU ID numbering" on the special function screen of the BMU, and execute it. Q: Is the diagnostic trouble code set? YES : Replace the main drive lithium-ion battery assembly. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). DTC P1AB5 CMU01 Battery Low Temperature, P1AB6 CMU02 Battery Low Temperature, P1AB7 CMU03 Battery Low Temperature, P1AB8 CMU04 Battery Low Temperature, P1AB9 CMU05 Battery Low Temperature, P1ABA CMU06 Battery Low Temperature, P1ABB CMU07 Battery Low Temperature, P1ABC CMU08 Battery Low Temperature, P1ABD CMU09 Battery Low Temperature, P1ABE CMU10 Battery Low Temperature, P1ABF CMU11 Battery Low Temperature, P1AC0 CMU12 Battery Low Temperature . TROUBLE JUDGMENT Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged.  Either one of the following diagnostic trouble codes is not set. a. P1AA8: Bat-CAN signal time out b. U1082: Bat-CAN bus-off Judgment Criterion  The module temperature is less than 30C (22F). . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSE  The module (battery cell, CMU and module temperature sensor) in the main drive lithium-ion battery is failed. MSB-17M54̲55-001(17AB037) TSB Revision 609 54D-148 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY DIAGNOSIS STEP 1. Scan tool MB991958 data list  Check the data list reference table corresponding to the diagnostic trouble code. OK: At ambient temperature (atmospheric temperature) or equivalent (when the vehicle driving and the charge are not performed for a long time) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). NO : Go to Step 2. STEP 2. Scan tool MB991958 data list of others system (1) Select "Reset" for the relevant CMU ID on the special function screen (Refer to GROUP 00  Precautions Before Service, How to Reset Failure Information in the CMU EEPROM), and then execute it. (2) Check the data list on the relevant CMU ID.  Item No. 14: Reference low voltage  Item No. 15: Reference high voltage  Item No. 16  No. 21: Temperature sensor (1  6) (open)  Item No. 22  No. 27: Temperature sensor (1  6) (short)  Item No. 44  No. 49: Temperature sensor (1  6) underflow  Item No. 50  No. 55: Temperature sensor (1  6) overflow  Item No. 67: A/D conversion (Reference volt)  Item No. 68  No. 73: A/D conversion (temp. sensor 1  6) Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). NO : Check to tighten the bus bar in the main drive lithiumion battery or replace the main drive lithium-ion battery. DTC P1AC1 Battery Cooling Fan (Drive Fail) . TROUBLE JUDGMENT Check Conditions  The electric motor switch is ON position or while the main drive lithium-ion battery is charged. Judgment Criterion  For more than 5 seconds, the PWM output signal of the main drive lithium-ion battery fan is 10 percent (while the fan is being driven). The output of the rotational speed is less than 2 volts (less than 1,645 r/min or equivalent). MSB-17M54̲55-001(17AB037) TSB Revision 610 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-149 . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  The main drive lithium-ion battery fan relay is failed.  The main drive lithium-ion battery fan is failed.  Open circuits of main drive lithium-ion battery fan relay circuit, short circuits to ground or damage; poor contact of connector.  Open circuits of main drive lithium-ion battery fan circuit, short circuits to ground or damage; poor contact of connector.  The BMU is failed. DIAGNOSIS STEP 1. Connector check: A-115X main drive lithium-ion battery fan relay connector Q: Is the check result normal? YES : Go to Step 2. NO : Repair the connector. STEP 2. Check main drive lithium-ion battery fan relay itself.  Check main drive lithium-ion battery fan relay itself. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the main drive lithium-ion battery fan relay. STEP 3. Perform voltage measurement at A-115X main drive lithium-ion battery fan relay  Remove the relay, and measure at relay box side.  Voltage between terminal No.4 and ground. OK: System voltage Q: Is the check result normal? YES : Go to Step 4. NO : Check and repair harness between 12V starter battery and A-115X (terminal No.4) main drive lithium-ion battery fan relay connector.  Check power supply line for open circuit, short circuit to ground STEP 4. Connector check: C-14 main drive lithium-ion battery connector, A-107 intermediate connector Q: Is the check result normal? YES : Go to Step 5. NO : Repair the connector. MSB-17M54̲55-001(17AB037) TSB Revision 611 54D-150 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 5. Perform voltage measurement at C-14 main drive lithium-ion battery connector  Disconnect connector, and measure at harness side.  Remove the A-115X main drive lithium-ion battery fan relay, and short-circuit the terminal No.4  3 at the relay box side.  Voltage between terminal No.1 and ground. OK: System voltage Q: Is the check result normal? YES : Go to Step 6. NO : Check intermediate connector A-107, and repair if necessary. If intermediate connector is normal, check and repair harness between A-115X (terminal No.3) main drive lithium-ion battery fan relay connector and C-14 (terminal No.1) main drive lithium-ion battery connector.  Check output line for open circuit, short circuit to ground. STEP 6. Perform resistance measurement at C-14 main drive lithium-ion battery connector  Disconnect connector, and measure at harness side.  Resistance between terminal No.4 and ground. OK: Continuity (2  less) Q: Is the check result normal? YES : Go to Step 7. NO : Check and repair harness between C-14 (terminal No.4) main drive lithium-ion battery connector and body ground.  Check grounding line for open circuit and damage. STEP 7. Check the wiring harness between 12V starter battery and A-115X (terminal No.4) main drive lithium-ion battery fan relay connector  Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 8. NO : Repair the wiring harness. STEP 8. Check the wiring harness between A-115X (terminal No.3) main drive lithium-ion battery fan relay connector and C-14 (terminal No.1) main drive lithium-ion battery connector NOTE: Before checking the wiring harness, check intermediate connector A-107, and repair if necessary.  Check output line for damage. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness. MSB-17M54̲55-001(17AB037) TSB Revision 612 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-151 STEP 9. Perform voltage measurement at C-21 main drive lithium-ion battery connector  Measure main drive lithium-ion battery terminal voltage.  Right after starting the regular charge.  Voltage between terminal No.8 and ground. OK: 2 volts or more  1 volt or less (After several seconds elapse) Q: Is the check result normal? YES : Go to Step 11. NO : Go to Step 10. STEP 10. Scan tool MB991958 data list  Refer to Data List Reference Table. a. Item 32: Battery cooling fan rotations Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). NO : Replace the BMU (Refer to P.54D-188). STEP 11. Connector check: C-21 main drive lithium-ion battery connector Q: Is the check result normal? YES : Go to Step 12. NO : Repair the connector. STEP 12. Check harness between C-14 (terminal No. 3) main drive lithium-ion battery connector and C-21 (terminal No.8) main drive lithium-ion battery connector  Check output line for open circuit, short circuit to ground and damage. Q: Is the check result normal? YES : Go to Step 13. NO : Repair the wiring harness. STEP 13. Connector check: BMU connector, main drive lithium-ion battery cooling fan connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 14. NO : Repair the connector. MSB-17M54̲55-001(17AB037) TSB Revision 613 54D-152 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 14. Check harness between main drive lithium-ion battery fan connector (terminal No.1) and C-14 (terminal No.3) main drive lithium-ion battery connector, between C21 (terminal No.8) main drive lithium-ion battery connector and BMU connector (terminal No.11)  Check output line for open circuit, short circuit to earth and damage. Q: Is the check result normal? YES : Go to Step 15. NO : Repair the wiring harness. Harness side Cooling fan connector C-14 (GR) ACC07057 AJ 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector C-21 (GR) ACC07057BA STEP 15. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the cooling fan in the main drive lithium-ion battery (Refer to P.54D-211). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). DTC P1AC2 Battery Cooling Fan (SHT to BAT) . TROUBLE JUDGMENT Check Conditions  The electric motor switch is ON position or while the main drive lithium-ion battery is charged. Judgment Criterion  For more than 5 seconds, the PWM output signal of the main drive lithium-ion battery fan is 10 percent (while the fan is being driven). The output of the rotational speed is more than 5 volts (more than 4,112 r/min or equivalent). MSB-17M54̲55-001(17AB037) TSB Revision 614 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-153 . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSE  The main drive lithium-ion battery fan relay is failed.  Open circuits of main drive lithium-ion battery fan relay circuit, short circuits to ground or damage; poor contact of connector.  The main drive lithium-ion battery fan is failed.  Short circuits to power supply system of main drive lithiumion battery fan circuit; poor contact of connector.  The BMU is failed. DIAGNOSIS STEP 1. Connector check: A-115X main drive lithium-ion battery fan relay connector Q: Is the check result normal? YES : Go to Step 2. NO : Repair the connector. STEP 2. Check main drive lithium-ion battery fan relay itself.  Check main drive lithium-ion battery fan relay itself. Q: Is the check result normal? YES : Go to Step 3. NO : Replace the main drive lithium-ion battery fan relay. STEP 3. Perform voltage measurement at A-115X main drive lithium-ion battery fan relay  Remove the relay, and measure at relay box side.  Voltage between terminal No.4 and ground. OK: System voltage Q: Is the check result normal? YES : Go to Step 4. NO : Check and repair harness between 12V starter battery and A-115X (terminal No.4) main drive lithium-ion battery fan relay connector.  Check power supply line for open circuit, short circuit to ground. STEP 4. Connector check: C-14 main drive lithium-ion battery connector, A-107 intermediate connector Q: Is the check result normal? YES : Go to Step 5. NO : Repair the connector. MSB-17M54̲55-001(17AB037) TSB Revision 615 54D-154 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 5. Perform voltage measurement at C-14 main drive lithium-ion battery connector  Disconnect connector, and measure at harness side.  Remove the A-115X main drive lithium-ion battery fan relay, and short-circuit the terminal No.4  3 at the relay box side.  Voltage between terminal No.1 and ground. OK: System voltage Q: Is the check result normal? YES : Go to Step 6. NO : Check intermediate connector A-107, and repair if necessary. If intermediate connector is normal, check and repair harness between A-115X (terminal No.3) main drive lithium-ion battery fan relay connector and C-14 (terminal No.1) main drive lithium-ion battery connector.  Check output line for open circuit, short circuit to ground. STEP 6. Check the wiring harness between 12V starter battery and A-115X (terminal No. 4) main drive lithium-ion battery fan relay connector  Check power supply line for damage. Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness. STEP 7. Check the wiring harness between A-115X (terminal No.3) main drive lithium-ion battery fan relay connector and C-14 (terminal No.1) main drive lithium-ion battery connector NOTE: Before checking the wiring harness, check intermediate connector A-107, and repair if necessary.  Check output line for damage. Q: Is the check result normal? YES : Go to Step 8. NO : Repair the wiring harness. STEP 8. Perform voltage measurement at C-21 main drive lithium-ion battery connector  Measure main drive lithium-ion battery terminal voltage.  Disconnect C-14 main drive lithium-ion battery connector.  Electric motor switch: ON  Voltage between terminal No.8 and ground. OK: 0  0.1 volt Q: Is the check result normal? YES : Go to Step 10. NO : Go to Step 9. MSB-17M54̲55-001(17AB037) TSB Revision 616 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-155 STEP 9. Connector check: C-21 main drive lithium-ion battery connector Q: Is the check result normal? YES : Check and repair harness between C-14 (terminal No.3) main drive lithium-ion battery connector and C-21 (terminal No.8) main drive lithium-ion battery connector.  Check output line for short circuit to power supply. NO : Repair the connector. STEP 10. Perform voltage measurement at C-21 main drive lithium-ion battery connector  Measure main drive lithium-ion battery terminal voltage.  Right after starting the regular charge.  Voltage between terminal No.8 and ground. OK: 5 volts or less (while the main drive lithium-ion battery fan is driving) Q: Is the check result normal? YES : Go to Step 11. NO : Go to Step 12. STEP 11. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 12. Connector check: BMU connector, main drive lithium-ion battery cooling fan connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 13. NO : Repair the connector. MSB-17M54̲55-001(17AB037) TSB Revision 617 54D-156 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 13. Check harness between main drive lithium-ion battery fan connector (terminal No.1) and C-14 (terminal No.3) main drive lithium-ion battery connector, between C21 (terminal No.8) main drive lithium-ion battery connector and BMU connector (terminal No.11)  Check output line for open circuit, short circuit to earth and damage. Q: Is the check result normal? YES : Go to Step 14. NO : Repair the wiring harness. Harness side Cooling fan connector C-14 (GR) ACC07057 AJ 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector C-21 (GR) ACC07057BA STEP 14. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the cooling fan in the main drive lithium-ion battery (Refer to P.54D-211). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). DTC P1AC3 Battery Cooling Fan (Rest Fail) . TROUBLE JUDGMENT Check Conditions  The electric motor switch is ON position or while the main drive lithium-ion battery is charged. Judgment Criterion  For more than 5 seconds, the PWM output signal of the main drive lithium-ion battery fan is 100 percent (while the fan stops). The output of the rotational speed is more than 0.7 volt (more than 493 r/min or equivalent). MSB-17M54̲55-001(17AB037) TSB Revision 618 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-157 . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  The main drive lithium-ion battery fan is failed.  Open circuits of main drive lithium-ion battery fan relay circuit, short circuits to power supply system or damage; poor contact of connector.  The BMU is failed. DIAGNOSIS STEP 1. Connector check: C-21 main drive lithium-ion battery, C-14 main drive lithium-ion battery fan connector Q: Is the check result normal? YES : Go to Step 2. NO : Repair the connector. STEP 2. Check harness between C-14 (terminal No.2) main drive lithium-ion battery connector and C-21 (terminal No.7) main drive lithium-ion battery connector  Check signal line for open circuit and damage. Q: Is the check result normal? YES : Go to Step 3. NO : Repair the wiring harness. STEP 3. Perform voltage measurement at C-21 main drive lithium-ion battery connector  Measure main drive lithium-ion battery terminal voltage.  Disconnect C-14 main drive lithium-ion battery connector.  Electric motor switch: ON  Voltage between terminal No.8 and ground. OK: 0  0.1 volt Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4. STEP 4. Connector check: C-21 main drive lithium-ion battery connector Q: Is the check result normal? YES : Check and repair harness between C-14 (terminal No.3) main drive lithium-ion battery connector and C-21 (terminal No.8) main drive lithium-ion battery connector.  Check output line for short circuit to power supply. NO : Repair the connector. MSB-17M54̲55-001(17AB037) TSB Revision 619 54D-158 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 5. Perform voltage measurement at C-21 main drive lithium-ion battery connector  Measure main drive lithium-ion battery terminal voltage.  Right after starting the regular charge.  Voltage between terminal No.8 and ground. OK: 5 volt or less (while the main drive lithium-ion battery fan is driving) Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 7. STEP 6. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 7. Connector check: BMU connector, main drive lithium-ion battery cooling fan connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 8. NO : Repair the connector. MSB-17M54̲55-001(17AB037) TSB Revision 620 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-159 STEP 8. Check harness between main drive lithium-ion battery fan connector (terminal No.1) and C-14 (terminal No.3) main drive lithium-ion battery connector, between C21 (terminal No.8) main drive lithium-ion battery connector and BMU connector (terminal No.11)  Check output line for open circuit, short circuit to earth and damage. Q: Is the check result normal? YES : Go to Step 9. NO : Repair the wiring harness. Harness side Cooling fan connector C-14 (GR) ACC07057 AJ 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector C-21 (GR) ACC07057BA STEP 9. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the cooling fan in the main drive lithium-ion battery (Refer to P.54D-211). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). DTC P1AC6 Each Cell VOLT. Diff. (HI Side) . TROUBLE JUDGMENT Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged.  The absolute value of the current is less than 1 ampere.  The battery total voltage is more than 350 volts.  Either one of the following diagnostic trouble codes is not set. MSB-17M54̲55-001(17AB037) TSB Revision 621 54D-160 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY a. P1AA8: Bat-CAN signal time out b. U1082: Bat-CAN bus-off Judgment Criterion  Difference in voltage values each battery cell is more than 0.05 volt NOTE: If the module is replaced, a diagnostic trouble code will be always set, because the state of the new battery cell is different from others. This diagnostic trouble code does not indicate a malfunction. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSE  The module (battery cell and CMU) in the main drive lithium-ion battery is failed. DIAGNOSIS STEP 1. Scan tool MB991958 other diagnostic trouble code. Confirm whether DTC P1A4B is set in the BMU. Q: Is the diagnostic trouble code set? YES : Perform the troubleshooting of DTC P1A4B. NO : Go to Step 2. STEP 2. Main drive lithium-ion battery condition check Q: Does replace the module in the main drive lithium-ion battery recently? YES : Erase the DTC, check end. NO : Go to Step 3. STEP 3. Scan tool MB991958 data list Refer to Data List Reference Table.  Item No. 6: Minimum voltage cell ID  Item No. 7: Battery total voltage OK: Total battery voltage of 350 volts or more Q: Is check result normal? YES : Go to Step 4. NO : Go to Step 5. MSB-17M54̲55-001(17AB037) TSB Revision 622 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-161 STEP 4. Scan tool MB991958 data list of others system (1) Select "Reset" for ID of the cell of the lowest voltage (CMU ID) on the special function screen (Refer to GROUP 00  Precautions Before Service, How to Reset Failure Information in the CMU EEPROM), and then execute it. (2) Check the data list corresponding to the cell ID of lowest voltage. Q: Is the check result normal? YES : Go to Step 5. NO : Replace the main drive lithium-ion battery assembly. STEP 5. Use scan tool MB991958 to confirm a diagnostic trouble code. Charge and discharge the main drive lithium-ion battery. Then reconfirm whether the diagnostic trouble code is set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. The total voltage of the battery should be 350 volts when the system is deenergized. NOTE: .  If the total voltage exceeds 350 volts, activate the air conditioning system to discharge the battery.  If the total voltage is under 350 volts, charge the battery in the regular manner. 3. After 10 seconds, confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Replace the main drive lithium-ion battery assembly. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC P1ADF +B Line Voltage . TROUBLE JUDGMENT Check Condition  Every time after the BMU is activated. Judgment Criterion  The BMU control power supply voltage is less than 8 volts. or  The BMU control power supply voltage is more than 16 volts. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  The 12V starter battery is failed. MSB-17M54̲55-001(17AB037) TSB Revision 623 54D-162 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY  When starting at the voltage more than 16 volts from the outside of the vehicle.  The installation of the 12V starter battery terminal is failed.  Open circuits of BMU control power supply circuit, short circuits to ground or damage; poor contact of connector  The BMU is failed. DIAGNOSIS STEP 1. 12V starter battery condition check Q: Does the 12V starter battery start at the voltage more than 16 volts from the outside of the vehicle recently? YES : Erase the diagnostic trouble code, check end. NO : Go to Step 2. STEP 2. 12V starter battery condition check Q: Is the installation status of the 12V starter battery terminal abnormal? YES : Repair. NO : Go to Step 3. STEP 3. Check 12V starter battery  Check 12V starter battery (Refer to GROUP 54A  12V starter battery  On-vehicle Service  Battery Test). Q: Is the check result normal? YES : Go to Step 4. NO : Replace the 12V starter battery. STEP 4. Connector check: C-26 main drive lithium-ion battery connector Q: Is the check result normal? YES : Go to Step 5. NO : Repair the connector. STEP 5. Perform voltage measurement at C-26 main drive lithium-ion battery connector  Disconnect connector, and measure at harness side.  Voltage between terminal No.1 and ground. OK: System voltage Q: Is the check result normal? YES : Go to Step 6. NO : Check intermediate connectors A-107, and repair if necessary. If intermediate connectors are normal, check and repair harness between C-26 (terminal No.1) main drive lithium-ion battery connector and 12V starter battery.  Check power supply line for open circuit, short circuit to ground. MSB-17M54̲55-001(17AB037) TSB Revision 624 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-163 STEP 6. Connector check: BMU connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 7. NO : Repair the connector. STEP 7. Check the wiring harness between BMU connector (terminal No.1) and C-26 main drive lithium-ion battery connector (terminal No.1) Check power supply for open or short circuit. Q: Is the check result normal? YES : Go to Step 8. NO : Repair the wiring harness. 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector C-26 (B) ACC07057BC STEP 8. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC P1AE0 Clock IC Time Counter . TROUBLE JUDGMENT Check Condition  After the electric motor switch is turned ON, or after the main drive lithium-ion battery starts to be charged.  Thirty minutes have passed since the BMU was activated. Judgment Criterion  The system detects an error in the counter function. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSE  The BMU (clock IC) is failed. MSB-17M54̲55-001(17AB037) TSB Revision 625 54D-164 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY DIAGNOSIS STEP 1. Scan tool MB991958 other diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. Electric motor switch: LOCK (OFF)  ON 3. Confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC P1AE1 Clock IC Alarm . TROUBLE JUDGMENT Check Condition  After the electric motor switch is turned ON, or after the main drive lithium-ion battery starts to be charged.  At least 6 hours have passed since the last time the BMU was deactivated. Judgment Criterion  The system detects an error in the alarm function. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSE  The BMU (clock IC) is failed. DIAGNOSIS STEP 1. Scan tool MB991958 other diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. Electric motor switch: LOCK (OFF)  ON after at least 6 hours have passed 3. Confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). MSB-17M54̲55-001(17AB037) TSB Revision 626 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-165 DTC P1AE3 BMU TEMP. Sensor (Open/Short) . TROUBLE JUDGMENT Check Condition  After the electric motor switch is turned ON, or after the main drive lithium-ion battery starts to be charged. Judgment Criterion  The system detects an error in the BMU temperature sensor. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSE  The BMU (temperature sensor) is failed. DIAGNOSIS STEP 1. Scan tool MB991958 other diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. Electric motor switch: LOCK (OFF)  ON 3. Confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC P1AE4 BMU TEMP. Sensor (Rationality) . TROUBLE JUDGMENT Check Condition  Immediately after the BMU is activated.  At least 6 hours have passed since the last time the BMU was deactivated.  The system communicates with the CMU via local CAN.  None of the other DTC P1A82 to P1A8D, P1AE0 or P1AE1 is not set. Judgment Criterion  The system detects an error in the BMU temperature sensor. . FAIL-SAFE AND BACKUP FUNCTION  Not available MSB-17M54̲55-001(17AB037) TSB Revision 627 54D-166 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY . PROBABLE CAUSE  The BMU (temperature sensor) is failed. DIAGNOSIS STEP 1. Scan tool MB991958 other diagnostic trouble code. Confirm whether DTC P1AE3 is set in the BMU. Q: Is the diagnostic trouble code set? YES : Perform the troubleshooting of DTC P1AE3. NO : Go to Step 2. STEP 2. Use scan tool MB991958 to confirm a diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. Electric motor switch: LOCK (OFF)  ON after at least 6 hours have passed 3. Confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). DTC U1082 Bat-CAN Bus-Off . TROUBLE JUDGMENT Check Condition  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged. Judgment Criterion  When the bus off of the BMU is judged. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  The harnesses and connectors are failed.  The Local CAN (for main drive lithium-ion battery) bus is failed.  The BMU is failed. MSB-17M54̲55-001(17AB037) TSB Revision 628 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-167 DIAGNOSIS STEP 1. Check the local CAN (for main drive lithium-ion battery) terminating resistance itself  Check the local CAN (for main drive lithium-ion battery) terminating resistance itself (Refer to P.54D-185). Q: Is the check result normal? YES : Go to Step 6. NO : Go to Step 2. STEP 2. Connector check: CMU12 from CMU01 connector, BMU connector, resistor (local CAN terminating) connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 3. NO : Repair the damaged connector. STEP 3. Perform resistance measurement at intermediate (CAN1) or intermediate (CAN2) connector  Ensure that the positive and negative battery terminals of the auxiliary battery are disconnected.  Disconnect mail terminal of intermediate connector (CAN1), and measure at wiring harness side.  Resistance between terminal No.4 and No.15, terminal No.5 and No.16, terminal No.6 and No.17, terminal No.7 and No.18, terminal No.8 and No.19, terminal No.9 and No.20, terminal No.10 and No.21, terminal No.11 and No.22.  Disconnect mail terminal of intermediate connector (CAN2), and measure at wiring harness side.  Resistance between terminal No.2 and No.13, terminal No.4 and No.15, terminal No.5 and No.16, terminal No.6 and No.17, terminal No.7 and No.18, terminal No.8 and No.19. OK: 120  20  Q: Is the check result normal? YES : Go to Step 5. NO : Go to Step 4. Intermediate connector (CAN2) (GR) Intermediate connector (CAN1) (GR) ACC07057AL MSB-17M54̲55-001(17AB037) TSB Revision 629 54D-168 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Lock position Harness side Harness side CMU12 Resistor (Local CAN terminating) CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 CMU ID STEP 4. Perform resistance measurement at BMU connector, CMU12 from CMU01 connector, resistor (local CAN terminating) connector  Disconnect BMU connector, and resistance measurement between terminal No.23 and No.24 at BMU side.  Disconnect CMU12 from CMU01 connector, and resistance measurement between terminal No.4 and No.8 at CMU12 from CMU01 connector side.  Disconnect resistor (local CAN terminating) connector, and resistance measurement between terminal No.1 and No.2 at resistor (local CAN terminating) connector side. OK: 120  20  Q: Is the check result normal? YES : Repair the wiring harness between intermediate connector (CAN1), intermediate connector (CAN2) and BMU connector, CMU12 from CMU01 connector, resistor (local CAN terminating) connector. NO : Replace the BMU, CMU12 from CMU01, resister (local CAN terminating) (Refer to P.54D-189). C-26 (B) CMU07 Intermediate connector (CAN2) (GR) ACC07057 AK Intermediate connector (CAN1) (GR) ACC07057AL 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector ACC07057BB MSB-17M54̲55-001(17AB037) TSB Revision 630 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-169 STEP 5. Check the local CAN (for main drive lithium-ion battery) terminating resistor (1) Removal the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-189). (2) Check the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-217). Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points  How to Cope with Intermittent Malfunctions). NO : Replace the local CAN terminating resister (Refer to P.54D-209). STEP 6. Use scan tool MB991958 to confirm a diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. Electric motor switch: LOCK (OFF)  ON 3. Confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). Then go to Step 7. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 7. Use scan tool MB991958 to confirm a diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. Electric motor switch: LOCK (OFF)  ON 3. Confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Go to Step 1. NO : Check end. DTC U11A0 CMU01 CAN Timeout, U11A1 CMU02 CAN Timeout, U11A2 CMU03 CAN Timeout, U11A3 CMU04 CAN Timeout, U11A4 CMU05 CAN Timeout, U11A5 CMU06 CAN Timeout, U11A6: CMU07 CAN Timeout, U11A7 CMU08 CAN Timeout, U11A8 CMU09 CAN Timeout, U11A9 CMU10 CAN Timeout, U11AA CMU11 CAN Timeout, U11AB: CMU12 CAN Timeout . TROUBLE JUDGMENT Check Conditions  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the Main Drive Lithium-ion Battery starts to be charged. MSB-17M54̲55-001(17AB037) TSB Revision 631 54D-170 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY  The following diagnostic trouble code is not set. a. U1082 Bat-CAN Bus-off Judgment Criterion  For more than 3 seconds, the signal cannot be received from one of CMUs through the CAN communication. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  The module (CMU) in the main drive lithium-ion battery is failed.  The harnesses and the connectors of the local CAN (for main drive lithium-ion battery) bus.  Short circuits to ground of CMU power supply circuits; poor contact of connector.  The BMU is failed. DIAGNOSIS STEP 1. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Go to Step 2. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 2. Check CMU12 from CMU01 Check the CMU, which has timed out. Q: Have all the CMUs been timed out? YES : Go to Step 8. NO : Check the CMU, which has timed out. Then go to Step 3. STEP 3. Connector check: C-22, C-26 main drive lithiumion battery connector, CMU12 from CMU01 connector, resistor (local CAN terminating) connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 4. NO : Repair the damaged connector. STEP 4. Check the wiring harness between C-22 (terminal No. 4) main drive lithium-ion battery connector and CMU12 from CMU01 (each terminal No. 1) connector NOTE: .  Before checking harness, check intermediate connector (1) (terminal No. 4, No. 11 from No. 6, No. 22 from No. 15) of out signal line, and repair if necessary. MSB-17M54̲55-001(17AB037) TSB Revision 632 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-171 Check power supply line for open circuit. Lock position Harness side CMU ID CMU12 Q: Is the check result normal? YES : Go to Step 5. NO : Repair the wiring harness. CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 C-22 (GR) CMU07 ACC07057AO Intermediate connector (1) (GR) ACC07057 AP STEP 5. Check the wiring harness between C-26 (terminal No. 5) main drive lithium-ion battery connector and CMU12 from CMU01 (terminal No. 8) connector, resistor (local CAN terminating) (terminal No. 1) connector NOTE: .  Before checking harness, check intermediate connector (CAN1) (terminal No. 11 from No. 3), intermediate connector (CAN2) (terminal No. 9 from No. 3) of out signal line, and repair if necessary. Check signal line (CANH) for open circuit. Lock position Harness side Harness side CMU12 Resistor (Local CAN terminating) CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 CMU ID Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness. C-26 (B) CMU07 Intermediate connector (CAN2) (GR) ACC07057 AK Intermediate connector (CAN1) (GR) ACC07057AL MSB-17M54̲55-001(17AB037) TSB Revision 633 54D-172 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 6. Check the wiring harness between C-26 (terminal No. 10) main drive lithium-ion battery connector and CMU12 from CMU01 (terminal No. 4) connector, resistor (local CAN terminating) (terminal No. 2) connector NOTE: .  Before checking harness, check intermediate connector (CAN1) terminal No. 22 from No. 14, intermediate connector (CAN2) terminal No. 20 from No. 14 of out signal line, and repair if necessary. Check signal line (CANL) for open circuit. Lock position Harness side Harness side CMU12 Resistor (Local CAN terminating) CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 CMU ID Q: Is the check result normal? YES : Go to Step 7. NO : Repair the wiring harness. C-26 (B) CMU07 Intermediate connector (CAN2) (GR) ACC07057 AK Intermediate connector (CAN1) (GR) ACC07057AL STEP 7. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the main drive lithium-ion battery. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 8. Check the local CAN (for main drive lithium-ion battery) terminating resistance itself (1) Removal the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-189). (2) Check the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-217). Q: Is the check result normal? YES : Go to Step 13. NO : Go to Step 9. MSB-17M54̲55-001(17AB037) TSB Revision 634 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-173 STEP 9. Connector check: C-26 main drive lithium-ion battery connector, CMU12 from CMU01 connector, BMU connector, resistor (local CAN terminating) connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 10. NO : Repair the damaged connector. STEP 10. Check the wiring harness between C-26 (terminal No. 5) main drive lithium-ion battery connector and CMU12 from CMU01 (terminal No. 8) connector, BMU (terminal No.24) connector, resistor (local CAN terminating) (terminal No. 1) connector NOTE: .  Before checking harness, check intermediate connector (CAN1) (terminal No. 11 from No. 3), intermediate connector (CAN2) (terminal No. 9 from No. 2) of out signal line, and repair if necessary. Check signal line (CANH) for open circuit. Lock position Harness side Harness side CMU12 Resistor (Local CAN terminating) CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 CMU ID Q: Is the check result normal? YES : Go to Step 11. NO : Repair the wiring harness. C-26 (B) CMU07 Intermediate connector (CAN2) (GR) ACC07057 AK Intermediate connector (CAN1) (GR) ACC07057AL 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector ACC07057BB MSB-17M54̲55-001(17AB037) TSB Revision 635 54D-174 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 11. Check the wiring harness between C-26 (terminal No. 10) main drive lithium-ion battery connector and CMU12 from CMU01 (terminal No. 4) connector, BMU (terminal No.23) connector, resistor (local CAN terminating) (terminal No. 2) connector NOTE: .  Before checking harness, check intermediate connector (CAN1) terminal No. 22 from No. 14, intermediate connector (CAN2) terminal No. 20 from No. 13 of out signal line, and repair if necessary. Check signal line (CANL) for open circuit. Lock position Harness side Harness side CMU12 Resistor (Local CAN terminating) CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 CMU ID Q: Is the check result normal? YES : Go to Step 12. NO : Repair the wiring harness. C-26 (B) CMU07 Intermediate connector (CAN2) (GR) ACC07057 AK Intermediate connector (CAN1) (GR) ACC07057AL 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector ACC07057BB MSB-17M54̲55-001(17AB037) TSB Revision 636 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-175 STEP 12. Check the local CAN (for main drive lithium-ion battery) terminating resistor (1) Removal the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-189). (2) Check the local CAN terminating resistor in main drive lithium-ion battery (Refer to P.54D-217). Q: Is the check result normal? YES : Go to Step 13. NO : Replace the local CAN terminating resister (Refer to P.54D-209). STEP 13. Use scan tool MB991958 to confirm a diagnostic trouble code. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC U1925 CMU ID Numbering Reception Error . TROUBLE JUDGMENT Check Condition  When the CMUs are numbered for identification. Judgment Criterion  Within 5 seconds after the system has numbered a CMU, the system cannot receive any information pertaining to that identification number from the CMU. or  A parity error is detected in communication data. or  A checksum error is detected in communication data. . FAIL-SAFE AND BACKUP FUNCTION  Not available . PROBABLE CAUSES  The module (CMU) in the main drive lithium-ion battery is failed.  The harnesses and connectors are failed.  Short circuits to ground of CMU power supply circuits; poor contact of connector.  Noise interruption in communication wires.  The BMU is failed. MSB-17M54̲55-001(17AB037) TSB Revision 637 54D-176 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY DIAGNOSIS STEP 1. Use scan tool MB991958 to confirm a diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Electric motor switch: LOCK (OFF)  ON 2. Select "BMU" from System Select Screen of the scan tool MB991958. 3. Select "Special Function" from BMU Screen. 4. Select "CMU ID numbering" from Special Function. Q: Is the diagnostic trouble code set? YES : Go to Step 2. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 2. Connector check: C-21, C-22 main drive lithiumion battery connector, CMU12 from CMU01 connector, resistor (local CAN terminating) connector Removal the main drive lithium-ion battery cover (Refer to P.54D-194). Q: Is the check result normal? YES : Go to Step 3. NO : Repair the damaged connector. STEP 3. Check the wiring harness between C-22 (terminal No. 4) main drive lithium-ion battery connector and CMU12 from CMU01 connector (each terminal No. 1) NOTE: .  Before checking harness, check intermediate connector (1) (terminal No. 4, No. 11 from No. 6, No. 22 from No. 15) of out signal line, and repair if necessary. MSB-17M54̲55-001(17AB037) TSB Revision 638 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-177 Check power supply line for open circuit. Lock position Harness side CMU ID CMU12 Q: Is the check result normal? YES : Go to Step 4. NO : Repair the wiring harness. CMU01 to 05 (B) CMU06 CMU09 to 11 C-22 (GR) CMU08 CMU07 ACC07057AO Intermediate connector (1) (GR) ACC07057 AP Lock position Harness side CMU ID STEP 4. Check the wiring harness between C-21 (terminal No. 3) main drive lithium-ion battery connector and CMU12 from CMU01 connector (each terminal No. 7) NOTE: .  Before checking harness, check intermediate connector (2) (terminal No. 16 from No. 12, No. 22 from No. 18) or intermediate connector (3) (terminal No.1, No. 2, No. 10 from No. 6) of ground line, and repair if necessary. Check ground line for open circuit. Q: Is the check result normal? YES : Go to Step 5. NO : Repair the wiring harness. CMU12 CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 C-21 (GR) CMU07 Intermediate connector (2) ACC07057 AQ Intermediate connector (3) (GR) ACC07057AR MSB-17M54̲55-001(17AB037) TSB Revision 639 54D-178 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Lock position Harness side CMU ID STEP 5. Check the wiring harness between BMU connector (terminal No. 13, 12) and CMU12 from CMU01 connector (each terminal No. 2, 6) NOTE: .  Check the wiring harness between BMU connector (terminal No. 13) and CMU07 connector (terminal No. 2), CMU07 connector (terminal No. 6) and CMU08 connector (terminal No. 2), CMU08 connector (terminal No. 6) and CMU09 connector (terminal No. 2), CMU09 connector (terminal No. 6) and CMU10 connector (terminal No. 2), CMU10 connector (terminal No. 6) and CMU11 connector (terminal No. 2), CMU11 connector (terminal No. 6) and CMU12 connector (terminal No. 2), CMU12 connector (terminal No. 6) and CMU01 connector (terminal No. 2), CMU01 connector (terminal No. 6) and CMU02 connector (terminal No. 2), CMU02 connector (terminal No. 6) and CMU03 connector (terminal No. 2), CMU03 connector (terminal No. 6) and CMU04 connector (terminal No. 2), CMU04 connector (terminal No. 6) and CMU05 connector (terminal No. 2), CMU05 connector (terminal No. 6) and CMU06 connector (terminal No. 2), CMU06 connector (terminal No. 6) and BMU connector (terminal No. 12), and repair if necessary. Check signal line for open circuit. Q: Is the check result normal? YES : Go to Step 6. NO : Repair the wiring harness. CMU12 CMU01 to 05 (B) CMU06 CMU09 to 11 CMU08 C-21 (GR) CMU07 ACC07057 AQ 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side BMU connector ACC07057BB MSB-17M54̲55-001(17AB037) TSB Revision 640 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-179 STEP 6. Use scan tool MB991958 to confirm a diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. Electric motor switch: LOCK (OFF)  ON 3. Confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). DTC U1926 EV-ECU V-CAN Error . TROUBLE JUDGMENT Check Condition  3 seconds elapse after the electric motor switch is turned ON, or 3 seconds elapse after the main drive lithium-ion battery starts to be charged. Judgment Criterion  When one of the following diagnostic trouble codes is set in the EV-ECU. a. U1073 Bus-off b. U111C BMU CAN Timeout . FAIL-SAFE AND BACKUP FUNCTION  When the K-LINE is normal, use the K-LINE communication data. . PROBABLE CAUSES  The EV-ECU is failed.  The harnesses and the connectors of the CAN bus are failed.  The BMU is failed. DIAGNOSIS STEP 1. Scan tool MB991958 CAN bus diagnosis  Using scan tool MB991958, perform CAN bus line diagnosis. Q: Is the check result normal? YES : Go to Step 2. NO : Repair CAN bus line (Refer to GROUP 54C  Troubleshooting  CAN Bus Diagnostics Table). After repairing CAN bus line, go to Step 4. MSB-17M54̲55-001(17AB037) TSB Revision 641 54D-180 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY STEP 2. Scan tool MB991958 other system diagnostic trouble code.  Confirm whether the diagnostic trouble codes are set in the EV-ECU. Q: Is the diagnostic trouble code set? YES : Perform the troubleshooting of the EV-ECU. NO : Go to Step 3. STEP 3. Use scan tool MB991958 to confirm a diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. Electric motor switch: LOCK (OFF)  ON 3. Confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Replace the BMU (Refer to P.54D-188). Then go to Step 4. NO : Intermittent malfunction (Refer to GROUP 00  How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions). STEP 4. Use scan tool MB991958 to confirm a diagnostic trouble code. Reconfirm whether the diagnostic trouble codes are set in the BMU. 1. Erase the diagnostic trouble codes being set. 2. Electric motor switch: LOCK (OFF)  ON 3. Confirm whether the diagnostic trouble codes are set. Q: Is the diagnostic trouble code set? YES : Go to Step 1. NO : Check end. MSB-17M54̲55-001(17AB037) TSB Revision 642 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-181 ON-VEHICLE SERVICE CHECK ON COIL RESITANCE OF CONTACTOR (for main drive lithium-ion battery) M1549402100225 DANGER  When high voltage system components are ser- viced, be sure to remove service plug to shut down high voltage (Refer to GROUP 00  Precautions before service, Precautions on how to use the high-voltage vehicle).  When removing service plug, wear the specified protective equipment. CHECK ON COIL RESITANCE OF CHARGING CONTACTOR 1. Disconnect the main drive lithium-ion battery connector "A"and "B". Connector "A" Connector "B" 1 2 3 4 5 6 7 Connector "A" equipment side connector Connector "B" equipment side connector ACE01048 AB 2. Measure the resistance between terminal No.5 of the main drive lithium-ion battery connector "A" and No.6 of the main drive lithium-ion battery connector "B". Standard value: 36  [at 23C (73F)] Connector "B" equipment side connector 3. If the resistance deviates from the standard value, replace charging contactor (Refer to P.54D-191). 1 2 3 4 5 6 7 Connector "A" equipment side connector MSB-17M54̲55-001(17AB037) ACD03131 AB TSB Revision 643 54D-182 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY CHECKING COIL RESITANCE OF QUICK CHARGING CONTACTOR (+) 1. Disconnect the main drive lithium-ion battery connector "A" and "B". Connector "A" Connector "B" 1 2 3 4 5 6 7 Connector "A" equipment side connector Connector "B" equipment side connector ACE01048 AB 2. Measure the resistance between terminal No.5 of the main drive lithium-ion battery connector "A" and No.11 of the main drive lithium-ion battery connector "B". Standard value: 36  [at 23C (73F)] Connector "B" equipment side connector 3. If the resistance deviates from the standard value, replace quick charging contactor (+) (Refer to P.54D-191). 1 2 3 4 5 6 7 Connector "A" equipment side connector ACD03131 AC CHECKING COIL RESITANCE OF QUICK CHARGING CONTACTOR () 1. Disconnect the main drive lithium-ion battery connector "A" and "B". Connector "A" Connector "B" 1 2 3 4 5 6 7 Connector "A" equipment side connector Connector "B" equipment side connector MSB-17M54̲55-001(17AB037) ACE01048 AB TSB Revision 644 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-183 2. Measure the resistance between terminal No.5 of the main drive lithium-ion battery connector "A" and No.12 of the main drive lithium-ion battery connector "B". Standard value: 36  [at 23C (73F)] Connector "B" equipment side connector 3. If the resistance deviates from the standard value, replace quick charging contactor () (Refer to P.54D-191). 1 2 3 4 5 6 7 Connector "A" equipment side connector ACD03131 AD CHECK ON COIL RESITANCE OF MAIN CONTACTOR (+) 1. Disconnect the main drive lithium-ion battery connector "A". Connector "A" 1 2 3 4 5 6 7 Connector "A" equipment side connector AK900489 AC 2. Measure the resistance between terminal No. 3 and No. 5 of the main drive lithium-ion battery connector "A". Standard value: 36  [at 23C (73F)] Connector "A" equipment side connector 1 2 3 4 5 6 7 3. If the resistance deviates from the standard value, replace main contactor (+) (Refer to P.54D-191). AK900491 AB MSB-17M54̲55-001(17AB037) TSB Revision 645 54D-184 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY CHECK ON COIL RESITANCE OF MAIN CONTACTOR () 1. Disconnect the main drive lithium-ion battery connector "A"and "B". Connector "A" Connector "B" 1 2 3 4 5 6 7 Connector "A" equipment side connector Connector "B" equipment side connector ACE01048 AB 2. Measure the resistance between terminal No.5 of the main drive lithium-ion battery connector "A" and No.5 of the main drive lithium-ion battery connector "B". Standard value: 36  [at 23C (73F)] Connector "B" equipment side connector 3. If the resistance deviates from the standard value, replace main contactor () (Refer to P.54D-191). 1 2 3 4 5 6 7 Connector "A" equipment side connector ACD03131 AE CHECK ON SERVICE PLUG SWITCH M1549402400215 1. Disconnect the connector "A" and the connector "B" of the main drive lithium-ion battery. Connector "A" Connector "B" 1 2 3 4 5 6 7 8 9 10 Connector "A" equipment side connector Connector "B" equipment side connector ACE01050 AB MSB-17M54̲55-001(17AB037) TSB Revision 646 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-185 DANGER When removing service plug, wear the specified protective equipment (Refer to GROUP 00  Precautions before service, Precautions on how to use the highvoltage vehicle). 2. Measure the resistance between the main drive lithium-ion battery connector "A" terminal No. 3 and the main drive lithium-ion battery connector "B" terminal No. 4. Connector "B" equipment side connector 1 2 3 4 5 6 7 8 9 10 Connector "A" equipment side connector ACD03129 AB Service plug status Normal condition Locked service plug Continuity (2  or less) Disconnected service plug No continuity 3. If the resistance deviates from the standard value, replace service plug (Refer to P.54D-191). Local CAN (for main drive lithium-ion battery) terminating resistance check M1549402500223 1. Disconnect the main drive lithium-ion battery connector "A". Connector "A" 1 2 3 4 5 6 7 8 9 10 Connector "A" equipment side connector AKA00718 AD 2. Measure the resistance between terminal No. 5 and No. 10 of main drive lithium-ion battery connector "A". Standard value: 44  57  [at 20C (68F)] 3. If the resistance deviates from the standard value, troubleshoot the BMU or replace BMU (P.54D-188), local CAN terminating resistor in main drive lithium-ion battery. 1 2 3 4 5 6 7 8 9 10 Connector "A" equipment side connector AKA00722 AD MSB-17M54̲55-001(17AB037) TSB Revision 647 54D-186 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY CHECK AND REPLACEMENT OF THE HIGHVOLTAGE FUSE INSIDE THE MAIN DRIVE LITHIUM-ION BATTERY M1549403000209 DANGER When servicing the high-voltage system parts, be sure to wear the specified protection equipment and disconnect the service plug to interrupt the high-voltage supply (Refer to GROUP 00  Precautions before service, Precautions on how to use the high-voltage vehicle). 1. Remove the front floor covers A and B (Refer to GROUP 51  Under Cover). 2. Remove the work hole lid for the main drive lithium-ion battery. High-voltage fuse No. 3 (Heater, 50 A) CAUTION To pull out high-voltage fuse No. 3 (heater, 50A), wedge the ornament remover (special tool: MB990784) into the JFB ribs to counterhold the fuse. JFB rib MB990784 ACF04156AB 3. Remove each mounting bolt and remove each high-voltage fuse. 4. check the resistance between the high-voltage fuses, and if there is no continuity (open circuit), replace the high-voltage fuses. High-voltage fuse No. 1 (Main, 280 A) AC902222AB High-voltage fuse No. 3 (Heater, 50 A) High-voltage fuse No. 2 (A/C, 50 A) MSB-17M54̲55-001(17AB037) AC902221AB TSB Revision 648 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY CAUTION When tightening the mounting bolts, secure the high-voltage fuse terminal portion, because there is a risk of damage to the high-voltage fuse when an excessive force applies to the high-voltage fuse main body. 5. Tighten each mounting bolt to the specified torque. Tighten each mounting bolt for the high-voltage fuse No. 2 and 3 to the specified torque using the torque wrench (special tool: MB992295). Tightening torque: High-voltage fuse No. 1: 9.0  3.0 Nm (80  26 in-lb) High-voltage fuse No. 2 and 3: 7.0  3.0 Nm (62  26 in-lb) MB992295 AC902845AC MSB-17M54̲55-001(17AB037) 54D-187 6. Install the work hole lid for the main drive lithium-ion battery. 7. Install the front floor covers A and B (Refer to GROUP 51  Under Cover). TSB Revision 649 54D-188 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) REMOVAL AND INSTALLATION M1549401200081 DANGER  When high voltage system components are serviced, be sure to remove service plug to shut down high voltage (Refer to GROUP 00  Precautions before service, Precautions on how to use the high-voltage vehicle).  Do not disassemble any battery management unit (BMU) other than those described in this manual. CAUTION  When replacing the battery management unit (BMU), use the M.U.T.-III to perform the learned value writing (Refer to GROUP 00  Procedures for Writing BMU Learning Value).  While the special tool (MB992924) is set, the vehicle can not be driven to avoid an accident. If you attempt to drive the vehicle, the vehicle will vibrate due to a torque "hunting". Pre-removal operation  Main Drive Lithium-ion Battery Cover Removal (Refer to P.54D-194) Post-installation operation  Main Drive Lithium-ion Battery Cover Installation (Refer to P.54D-194) 7.0 ± 3.0 N·m 1 2 Main drive lithium-ion battery ACE02714 AC MSB-17M54̲55-001(17AB037) TSB Revision 650 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY <> 1. 2. 54D-189 Removal steps BMU reinforcement Battery management unit (BMU) REMOVAL SERVICE POINT . <> BATTERY MANAGEMENT UNIT (BMU) REMOVAL Ensure that the weld nuts do not fall down from the JFB. MAIN DRIVE LITHIUM-ION BATTERY DISASSEMBLY AND ASSEMBLY SERVICE PROCEDURE M1549403800120 CAUTION  When you assemble and disassemble the main drive lithium-ion battery, always wear electric-insulated gloves, boots and protection glasses.  After you remove the main drive lithium-ion battery, be sure to disconnect all of the four bus bars from the front and rear modules to reduce the possibility of electric shock. Do not connect the bus bars until you complete the service work.  Use special tool (MB992915) to protect the unaffected area (which you do not service) of the removed main drive lithium-ion battery.  When you service an electric terminal on the module, remove the respective cover only (do not remove the other covers).  Before engaging the bus bar, make sure that it is not scratched or contaminated.  A damaged wiring harness clip should be replaced with new one.  Always use a torque wrench to tighten a nut or bolt to the specified torque. Then identify it with a paint mark. After assembling the main drive lithium-ion battery, check the followings: 1. Before mounting the main drive lithium-ion battery to the vehicle, check the main drive lithium-ion battery for air leaks (Refer to P.54D-211). 2. When any of the cell modules is replaced, use the M.U.T.-III to select and execute "CMU ID numbering" on the BMU special function menu to number the CMUs for identification after the main drive lithium-ion battery assembly has been mounted. Then measure the main drive lithium-ion battery capacity. 3. Use the scan tool MB991958 to check that no diagnostic trouble code is stored. NOTE: *: Using the recommended tools allows you to number the CMU and measure the main drive lithMSB-17M54̲55-001(17AB037) TSB Revision ium-ion battery capacity without mounting the main drive lithium-ion battery. 651 54D-190 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY EIGHT-CELL MODULE REMOVAL AND INSTALLATION Service procedure Work description Reference page 1 Main drive lithium-ion battery cover removal and installation P.54D-194 2 Air duct removal and installation P.54D-196 3 Pad removal and installation P.54D-196 4 Bus bar removal and installation P.54D-197 5 Eight-cell module removal and installation P.54D-198 FOUR-CELL MODULE REMOVAL AND INSTALLATION Service procedure Work description Reference page 1 Main drive lithium-ion battery cover removal and installation P.54D-194 2 Air duct removal and installation P.54D-196 3 Pad removal and installation P.54D-196 4 Bus bar removal and installation P.54D-197 5 JFB cover removal and installation P.54D-202 6 Four-cell module removal and installation P.54D-203 ELECTRIC CURRENT SENSOR REMOVAL AND INSTALLATION Service procedure Work description Reference page 1 Main drive lithium-ion battery cover removal and installation P.54D-194 2 Air duct removal and installation P.54D-196 3 Pad removal and installation P.54D-196 4 Bus bar removal and installation P.54D-197 5 JFB cover removal and installation P.54D-202 6 Electric current sensor removal and installation P.54D-207 RESISTOR REMOVAL AND INSTALLATION Service procedure Work description Reference page 1 Main drive lithium-ion battery cover removal and installation P.54D-194 2 Air duct removal and installation P.54D-196 3 Pad removal and installation P.54D-196 4 Bus bar removal and installation P.54D-197 5 JFB cover removal and installation P.54D-202 6 JFB removal and installation P.54D-207 7 Resistor removal and installation P.54D-209 MSB-17M54̲55-001(17AB037) TSB Revision 652 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-191 CONTACTOR REMOVAL AND INSTALLATION Service procedure Work description Reference page 1 Main drive lithium-ion battery cover removal and installation P.54D-194 2 Air duct removal and installation P.54D-196 3 Pad removal and installation P.54D-196 4 Bus bar removal and installation P.54D-197 5 Battery management unit (BMU) removal and installation P.54D-188 6 JFB cover removal and installation P.54D-202 7 JFB removal and installation P.54D-207 8 Electric current sensor removal and installation P.54D-207 9 Resistor removal and installation P.54D-209 10 Contactor removal and installation P.54D-210 COOLING FAN REMOVAL AND INSTALLATION Service procedure Work description Reference page 1 Main drive lithium-ion battery cover removal and installation P.54D-194 2 Cooling fan removal and installation P.54D-211 SERVICE PLUG REMOVAL AND INSTALLATION Service procedure Work description Reference page 1 Main drive lithium-ion battery cover removal and installation P.54D-194 2 Air duct removal and installation P.54D-196 3 Pad removal and installation P.54D-196 4 Bus bar (service plug) removal and installation P.54D-197 SERVICE PROCEDURE CHECK SHEET CAUTION  When you assemble and disassemble the main drive lithium-ion battery, always wear electric-insulated gloves, boots and protection glasses.  After you remove the main drive lithium-ion battery, be sure to disconnect all of the four bus bars from the front and rear modules to reduce the possibility of electric shock. Do not connect the bus bars until you complete the service work.  Use special tool (MB992915) to protect the unaffected area (which you do not service) of the removed main drive lithium-ion battery.  When you service an electric terminal on the MSB-17M54̲55-001(17AB037) TSB Revision M1549403900105 module, remove the respective cover ONLY (do not remove the other covers).  Before engaging the bus bar, make sure that it is not scratched or contaminated.  A damaged wiring harness clip should be replaced with new one.  Always use a torque wrench to tighten a nut or bolt to the specified torque. Then identify it with a paint mark. 653 54D-192 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY ITEMS TO CHECK AFTER THE MAIN DRIVE LITHIUM-ION BATTERY HAS BEEN ASSEMBLED Check column Service procedure Work description 1 Check the battery assembly for air leaks. 2 Use the scan tool MB991958 to number the CMUs for identification. 3 Measure the main drive lithium-ion battery capacity. 4 Use the scan tool MB991958 to check that no diagnostic trouble code is stored. EIGHT-CELL MODULE REMOVAL AND INSTALLATION Check column Service procedure Work description 1 Main drive lithium-ion battery cover removal and installation 2 Air duct removal and installation 3 Pad removal and installation 4 Bus bar removal and installation 5 Eight-cell module removal and installation FOUR-CELL MODULE REMOVAL AND INSTALLATION Check column Service procedure Work description 1 Main drive lithium-ion battery cover removal and installation 2 Air duct removal and installation 3 Pad removal and installation 4 Bus bar removal and installation 5 JFB cover removal and installation 6 Four-cell module removal and installation ELECTRIC CURRENT SENSOR REMOVAL AND INSTALLATION Check column Service procedure Work description 1 Main drive lithium-ion battery cover removal and installation 2 Air duct removal and installation 3 Pad removal and installation 4 Bus bar removal and installation 5 JFB cover removal and installation 6 Electric current sensor removal and installation RESISTOR REMOVAL AND INSTALLATION Check column Service procedure Work description 1 Main drive lithium-ion battery cover removal and installation MSB-17M54̲55-001(17AB037) TSB Revision 654 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Check column Service procedure Work description 2 Air duct removal and installation 3 Pad removal and installation 4 Bus bar removal and installation 5 JFB cover removal and installation 6 JFB removal and installation 7 Resistor removal and installation 54D-193 CONTACTOR REMOVAL AND INSTALLATION Check column Service procedure Work description 1 Main drive lithium-ion battery cover removal and installation 2 Air duct removal and installation 3 Pad removal and installation 4 Bus bar removal and installation 5 Battery management unit (BMU) removal and installation 6 JFB cover removal and installation 7 JFB removal and installation 8 Electric current sensor removal and installation 9 Resistor removal and installation 10 Contactor removal and installation COOLING FAN REMOVAL AND INSTALLATION Check column Service procedure Work description 1 Main drive lithium-ion battery cover removal and installation 2 Cooling fan removal and installation SERVICE PLUG REMOVAL AND INSTALLATION Check column Service procedure Work description 1 Main drive lithium-ion battery cover removal and installation 2 Air duct removal and installation 3 Pad removal and installation 4 Bus bar (service plug) removal and installation MSB-17M54̲55-001(17AB037) TSB Revision 655 54D-194 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY MAIN DRIVE LITHIUM-ION BATTERY COVER REMOVAL AND INSTALLATION M1549404000075 5.0 ± 2.0 N·m 44 ± 17 in-lb 5.0 ± 2.0 N·m 44 ± 17 in-lb ACC05936AC 1. Remove the four fasteners securing the service plug base to the main drive lithium-ion battery cover. ACC07225 2. Remove the four fasteners to remove the cooling duct. MSB-17M54̲55-001(17AB037) TSB Revision 656 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Upper front battery frame assembly 54D-195 Upper battery frame assembly (RH) 13 14 16 15 17 18 19 31 20 32 21 12 22 11 33 23 34 10 24 25 9 Upper rear battery frame and battery protector assembly 8 26 35 36 27 7 : Bolt (6X16) 6 5 4 3 2 1 30 38 29 37 28 Upper battery frame assembly (LH) 3. Remove the 38 fasteners securing the main drive lithium-ion battery cover to the main drive lithiumion battery tray. NOTE: Tighten the 38 fasteners securing the main drive lithium-ion battery cover to the main drive lithium-ion battery tray in the order shown. ACC05938AC Tightening torque: 10  2 Nm (89  17 in-lb) 4. Remove the frame or protector securing the main drive lithium-ion battery cover to the main drive lithium-ion battery tray. N Tray cover gasket A A Section A – A N Tray cover gasket Main Drive Lithium-ion Battery tray Outside of Main Drive Lithium-ion Battery ACC07263 ACD02614 AB MSB-17M54̲55-001(17AB037) TSB Revision 657 54D-196 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 5. Remove the cover of the main drive lithium-ion battery. NOTE: Make sure that the tray cover gasket is located between the main drive lithium-ion battery cover and the main drive lithium-ion battery tray as shown. AIR DUCT REMOVAL AND INSTALLATION M1549404100016 Air duct ACC05940AC 1. Remove the three mounting fasteners from the air duct. PAD REMOVAL AND INSTALLATION Pad A N 2. Remove the air duct. M1549404200013 N Pad B ACD02690 AB MSB-17M54̲55-001(17AB037) TSB Revision 658 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Remove the pad. 54D-197 Number of pads: A and B BUS BAR REMOVAL AND INSTALLATION 13.5 ± 1.5 N·m 119 ± 13 in-lb M1549404300054 13.5 ± 1.5 N·m 119 ± 13 in-lb 7.0 ± 3.0 N·m 62 ± 26 in-lb 13.5 ± 1.5 N·m 119 ± 13 in-lb 13.5 ± 1.5 N·m 119 ± 13 in-lb 13.5 ± 1.5 N·m 119 ± 13 in-lb 13.5 ± 1.5 N·m 119 ± 13 in-lb 13.5 ± 1.5 N·m 119 ± 13 in-lb 13.5 ± 1.5 N·m 119 ± 13 in-lb ACE01062 AB 1. Disconnect the bus bar from the module (nine locations) and loosen it (two locations). Bus bar B Bus bar C Service plug Bus bar D Bus bar A Ground fault detector cable ACF02331AB CAUTION Before installing the bus bar shown by "A" in the figure, use an multimeter to check that there is no potential difference between the two module MSB-17M54̲55-001(17AB037) TSB Revision terminals at the bus bar ends. 2. Remove the four bus bars in the alphabetical order shown. 659 54D-198 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY EIGHT-CELL MODULE REMOVAL AND INSTALLATION M1549404400062 NOTE: Front of vehicle CMU ID 11 CMU ID 10 CMU ID 12 CMU ID 02 CMU ID 09 CMU ID 03 CMU ID 08 CMU ID 07 CMU ID 01 CMU ID 04 CMU ID 06 CMU ID 05 ACC07060 AC The CMU IDs on the module are assigned as shown. CAUTION ACE03021AC MSB-17M54̲55-001(17AB037) TSB Revision 660 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-199 Use a straight wrench as the clearances among the modules are small. 13.5 ± 1.5 N·m 119 ± 13 in-lb 13.5 ± 1.5 N·m 119 ± 13 in-lb ACC05944AG 1. Loosen the eight fasteners securing the bus bars to the module. 12 ± 3 N·m 106 ± 26 in-lb 12 ± 3 N·m 106 ± 26 in-lb ACC05946AC 2. Remove the ten module securing fasteners. Then remove the plate from the module. MSB-17M54̲55-001(17AB037) TSB Revision 661 54D-200 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 10 ± 2 N·m 89 ± 17 in-lb Plates ACG03355AB 3. Remove the five module securing fasteners. 4. Remove the five plates from the module. 10 ± 2 N·m 89 ± 17 in-lb ACC05949AC 5. Remove the five module securing fasteners. MSB-17M54̲55-001(17AB037) TSB Revision 662 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-201 ACC05950 6. Disconnect the bus bars from the module, and then tilt the module to remove the four bus bars. ACC05951 7. Remove the five modules. MSB-17M54̲55-001(17AB037) TSB Revision 663 54D-202 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY JFB COVER REMOVAL AND INSTALLATION M1549404600055 A Refer to A ACF04654 AB 1. Disconnect the contactor connectors from the respective module to remove the wiring harnesss. JFB cover ACC05955AC 2. Disengage the six fasteners and the contactor connector from the JFB cover. MSB-17M54̲55-001(17AB037) TSB Revision 664 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-203 CAUTION Before loosening the JFB bar, make sure that the four bus bar are removed (Refer to P.54D-197). 3. Remove the JFB cover. FOUR-CELL MODULE REMOVAL AND INSTALLATION M1549404700052 NOTE: Front of vehicle CMU ID 11 CMU ID 10 CMU ID 01 CMU ID 12 CMU ID 02 CMU ID 09 CMU ID 03 CMU ID 08 CMU ID 07 CMU ID 04 CMU ID 06 CMU ID 05 ACC07060 AC The CMU IDs on the module are assigned as shown. Four-cell module (right side of the vehicle) removal 13.5 ± 1.5 N·m 119 ± 13 in-lb 7.0 ± 3.0 N·m* 62 ± 36 in-lb* 7.0 ± 3.0 N·m* 62 ± 36 in-lb* NOTE: Bolt size (Screw diameter × length mm) : M6 × 8 ACC05957AF 1. Disconnect the bus bar (three locations). Then remove the bus bar. MSB-17M54̲55-001(17AB037) TSB Revision 665 54D-204 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 10 ± 2 N·m 89 ± 17 in-lb 10 ± 2 N·m 89 ± 17 in-lb ACC05958AC 2. Remove the two module securing fasteners. ACC05959 3. Remove the module. MSB-17M54̲55-001(17AB037) TSB Revision 666 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-205 Four-cell module (left side of the vehicle) removal 13.5 ± 1.5 N·m 119 ± 13 in-lb ACC05960AF 1. Disconnect the bus bar (one location). JFB 5.5 ± 1.5 N·m* 49 ± 13 in-lb* 5.5 ± 1.5 N·m* 49 ± 13 in-lb* 5.5 ± 1.5 N·m* 49 ± 13 in-lb* NOTE: Bolt size (Screw diameter × length mm) * : M6 × 12 ACC05961AC 2. Remove the six fasteners from the JFB. MSB-17M54̲55-001(17AB037) TSB Revision 667 54D-206 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 10 ± 2 N·m 89 ± 17 in-lb 10 ± 2 N·m 89 ± 17 in-lb ACC05962AC 3. Remove the two module securing fasteners. ACC05963 4. Remove the module. MSB-17M54̲55-001(17AB037) TSB Revision 668 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY ELECTRIC CURRENT SENSOR REMOVAL AND INSTALLATION 54D-207 M1549404800059 Electric current sensor 7.0 ± 3.0 N·m* 62 ± 26 in-lb* NOTE: Bolt size (Screw diameter × length mm) * : M6 × 8 ACE01064 AB 1. Disconnect the bus bar (three locations). 2. Remove the bus bar and the electric current sensor. JFB REMOVAL AND INSTALLATION M1549404900078 7.0 ± 3.0 N·m 62 ± 26 in-lb 7.0 ± 3.0 N·m 62 ± 26 in-lb Harness High-voltage harness clip ACC05966AC MSB-17M54̲55-001(17AB037) TSB Revision 669 54D-208 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY CAUTION High-voltage fuse No. 3 (Heater, 50 A) To pull out high-voltage fuse No. 3 (heater, 50A), wedge the ornament remover (special tool: MB990784) into the JFB ribs to counterhold the fuse. When you disconnect the wiring harness from the fuse terminals, be careful not to deform the terminals. Remove the service hole lid from the bottom of the main drive lithium-ion battery, and loosen the four fuse securing fasteners. JFB rib MB990784 ACF04156AB 7.0 ± 3.0 N·m 62 ± 26 in-lb 13.5 ± 1.5 N·m 119 ± 13 in-lb : Bus bar connections : Wiring harness connections ACC05967AE 1. Loosen the bus bar (two locations) and the wiring harness wires (two locations). MSB-17M54̲55-001(17AB037) TSB Revision 670 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-209 JFB 5.5 ± 1.5 N·m* 49 ± 13 in-lb* 5.5 ± 1.5 N·m* 49 ± 13 in-lb* 5.5 ± 1.5 N·m* 49 ± 13 in-lb* NOTE: Bolt size (Screw diameter × length mm) * : M6 × 12 ACC05961AC 2. Remove the six fasteners from the JFB. 3. Remove the JFB. RESISTOR REMOVAL AND INSTALLATION Top surface side of drive battery M1549405000012 Bottom surface side of drive battery JFB 7.0 ± 3.0 N·m 62 ± 26 in-lb 7.0 ± 3.0 N·m 62 ± 26 in-lb ACC07051AC 1. Remove the two resistor securing fasteners. MSB-17M54̲55-001(17AB037) TSB Revision 2. Remove the resistor. 671 54D-210 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY CONTACTOR REMOVAL AND INSTALLATION 11 *5 4 7.0 ± 3.0 N·m* 3 62 ± 26 in-lb* 3 *6 *5 M1549405100053 7.0 ± 3.0 N·m* 4 62 ± 26 in-lb* 4 5.5 ± 1.5 N·m* 2 49 ± 13 in-lb* 2 7.0 ± 3.0 N·m* 4 62 ± 26 in-lb* 4 *7 7.0 ± 3.0 N·m* 4 62 ± 26 in-lb* 4 1 2 *7 10 3 5 9 7.0 ± 3.0 N·m* 4 62 ± 26 in-lb* 4 6 2 13 5.5 ± 1.5 N·m* 49 ± 13 in-lb* 2 Weld nut (Screw diameter) * M6 * 6 : M8 5: * 7: M6 7 8 * * 5 17 5 16 *7 * 5 *6 12 14 15 9.0 ± 3.0 N·m* 80 ± 26 in-lb*1 JFB base block  1. 2. 3. 4. 5. 6. 7. MSB-17M54̲55-001(17AB037) Removal steps Four-cell module connection (Refer to P.54D-203) JFB bus bar H JFB bus bar I JFB bus bar J JB base block assembly (LH) connection JB base block assemby (RH) connection Contactor (2P) Contactor (3P) TSB Revision 1 NOTE: Bolt size (Screw diameter × length mm) * 1 : M8 × 12 * 2 : M6 × 20 * 3 : M6 × 12 * 4 : M6 × 8 ACF04658AB 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Removal steps (Continued) JB centre base block assembly JFB bus bar F JFB bus bar G JB base block assembly (LH) JFB bus bar C JFB bus bar B High-voltage fuse JFB bus bar E JFB bus bar D JB base block assembly (RH) 672 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY COOLING FAN REMOVAL AND INSTALLATION 54D-211 M1549405900059 Cooling fan connector Main Drive Lithium-ion Battery cover Cooling fan Cooling fan cover ACC06111AB 1. Remove the 11 fasteners securing the cooling fan cover to the main drive lithium-ion battery cover. Tightening torque: 7.3  1.2 Nm (65  10 inlb) 2. Disconnect the cooling fan connector. 3. Remove the three fasteners securing the cooling fan to the cooling fan cover. Tightening torque: 5.0  2.0 Nm (44  17 inlb) INSPECTION AIR LEAK CHECK M1549405200113 Preparation for inspection CAUTION Set the special tool securely, or air leak may be caused. 1. Set the work hole lid. 2. Set the service plug cover (MB992928) to the service plug boot. MSB-17M54̲55-001(17AB037) TSB Revision 673 54D-212 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Service plug boot MB992928 (Plate A) (1) Set the plate A of the service plug cover (MB992928) to the service plug boot. ACC06079AB (2) Put the silicone rubber of the service plug cover (MB992928) on the service plug boot. MB992928 (Silicone rubber) ACC06080AB MB992928 (Plate B) (3) Set the plate B of the service plug cover (MB992928). Tighten the screws so that the clearance (A) between the plates A and B is even. ACC06081AB MB992928 (Plate B) A MB992928 (Plate A) ACC06082AB 3. Set the duct cover B (MB992933) to the cooling fan outlet. MSB-17M54̲55-001(17AB037) TSB Revision 674 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 54D-213 (1) Remove the rear duct assembly, and remove the butyl tape from the main drive lithium-ion battery side. Rear duct assembly Butyl tape ACC06203AB (2) Engage the plate A of the dust cover B (MB992933) into the groove above the cooling fan outlet. MB992933 (Plate A) ACC06096AB (3) Use the silicone rubber of the duct cover B (MB992933) to seal the cooling fan outlet. Then secure the plate B of the duct cover B (MB992933) on it. MB992933 (Silicone rubber) ACC06525AC MB992933 (Plate B) ACC06097AB MSB-17M54̲55-001(17AB037) TSB Revision 675 54D-214 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 4. Install the plug (MB992930) to the cooling fan inlet. (1) Make sure that the plug (MB992930) is flush with the cooling fan inlet boot. Boot MB992930 ACC06083AB 5. Insert the plugs (MB992939) into the ports for the EV charger cables. MB992939 ACC06084AB ACC06084 MSB-17M54̲55-001(17AB037) TSB Revision 676 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY MB992940 MB992937 54D-215 6. Install the pressure gauge unit (MB992935), the hoses (MB992937), the air pump (MB992938) and the nipple (MB992940) into the ports for the EV charger cables. Connect the longer tube spliced at rubber plug with nipples of pressure gauge unit (MB992935) to the gauge on the measuring bench, and connect the shorter tube to the main drive lithium-ion battery. MB992938 MB992935 Connect to the gauge side. Connect to the traction battery. MB992935 (Rubber plug with nipple) ACC06205AB How to check CAUTION Do not place the pressure gauge unit (MB992935) higher than the main drive lithium-ion battery, or water will intrude into the battery. 1. Pour 200 ml (7.4 fl oz) of water into the bottle of the pressure gauge unit (MB992935). MB992935 (Bottle) Gauge Water level Water MSB-17M54̲55-001(17AB037) ACC06093AB TSB Revision 677 54D-216 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY MB992938 Valve ACC06208AB Gauge 2. Operate the air pump (MB992938) to deliver water into the gauge side of the pressure gauge unit (MB992935) so that the water level in the gauge rises 320 mm (12.6 inch) above the water level in the bottle. 3. Close the valve of the special tool Air pump (MB992938) and then wait for five minutes, Then open the valve again. Then apply pressure to the system so that the water level rises 320 mm (12.6 inch). Then close the valve again and then wait for ten minutes. 4. Then measure the water level inside the gauge. OK: The water level inside the gauge should fluctuate within 20 mm (0.8 inch). 5. If the water level fluctuation exceeds the specified range, locate air leakage by using soapy water to repair it. Water level ACC06094AB CONTACTOR CHECK M1549405300024 Checks of main contactor (+), main contactor () and electric charging contactor 8 10 Main contactor (+) Battery voltage 12 Deenergized 9 11 Terminal Normal number condition s 10  11 13 Energized [between terminal 3 (+) and terminal 1 ()] ACC06017AB Main contactor () Battery voltage Deenergized Energized [between terminal 4 (+) and terminal 2 ()] MSB-17M54̲55-001(17AB037) TSB Revision No continuity Continuity exists (2  or less). Terminal Normal number condition s 12  13 No continuity Continuity exists (2  or less). 678 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY Electric charging contactor Battery voltage Deenergized 54D-217 Terminal Normal number condition s 89 No continuity Continuity exists (2  or less). Energized [between terminal 7 (+) and terminal 6 ()] Check of quick-charging contactors (+) and () 5 Quick-charging contactor (+) Battery voltage 7 Deenergized 6 Terminal Normal number condition s 56 8 Energized [terminal 1 (+), terminal 3 ()] Continuity exists (2  or less). ACC06142AB Quick charging contactor () Battery voltage Deenergized Terminal Normal number condition s 78 Energized [between terminal 2 (+) and terminal 4 ()] M1549405400010 Service plug Terminal Normal number condition s Removed 12 Inserted ACC07224AC No continuity Continuity exists (2  or less). SERVICE PLUG SWITCH INSPECTION Service plug No continuity No continuity Continuity exists (2  or less). LOCAL CAN TERMINATING RESISTOR CHECK M1549405500017 1. Remove the cover of the Main Drive Lithium-ion Battery. Refer to P.54D-194. MSB-17M54̲55-001(17AB037) TSB Revision 679 54D-218 ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY 2. Check the terminating resistor. Terminal number Normal conditions 12 120  Terminal resistor ACC06211AB MAIN DRIVE LITHIUM-ION BATTERY ELECTRIC CURRENT SENSOR CHECK M1549405600014 Terminal number Normal conditions 13 1  5 k [at 25C (77F)] 23 1  5 k [at 25C (77F)] 43 1  5 k [at 25C (77F)] ACC06015AB RESISTOR CHECK Measure the resistance of the resistor. Standard value: 22  26  M1549406300050 ACC07049AC MSB-17M54̲55-001(17AB037) TSB Revision 680