54Dc-SERVICE PROCEDURE

SERVICE PROCEDURE

Required Special Tools:

caution

When you assemble and disassemble the main drive lithium-ion battery assembly, 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 bus bars (F, G) from the front and rear modules to reduce the possibility of electric shock. Do not connect the bus bars (F, G) until you complete the service work.
Use the 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 assembly, check the followings:

Before mounting the main drive lithium-ion battery assembly on the vehicle, check the main drive lithium-ion battery assembly for air leaks.(Refer to .)
Use the scan tool (M.U.T.-IIISE) to check that no diagnostic trouble code is set.

Rear JB removal and installation

Service procedure	Work description	Reference page
1	Battery tray cover and plug hole cover removal and installation
2	Bus bars (F, G) removal and installation
3	JB cables (P and N lines) removal and installation
4	Sub-battery management unit (BMU SUB) removal and installation
8	Service plug assembly removal and installation
12	Rear JB cover removal and installation
13	Rear JB assembly, rear JB bus bars (A, B, C, D, F, G, I, M, N, U and V), contactor, fuse and rear plate removal and installation

Front JB removal and installation

Service procedure	Work description	Reference page
1	Battery tray cover and plug hole cover removal and installation
2	Bus bars (F, G) removal and installation
3	JB cables (P and N lines) removal and installation
5	Evaporator duct assembly, main drive lithium-ion battery cooling fan, main drive lithium-ion battery cooling fan bracket removal and installation
6	PTC heater cable and main drive lithium-ion battery heater temperature sensor removal and installation
7	Main drive lithium-ion battery harness removal and installation
9	Battery cooling duct removal and installation
10	Bus bars (B, D) and rubber pad removal and installation
14	Front JB cover removal and installation
15	Front JB assembly, front JB bus bars (D, E, F, N and P), electric current sensor, contactor, resistor and front plate removal and installation

Evaporator (for cooling the main drive lithium-ion battery) or PTC heater removal and installation

Service procedure	Work description	Reference page
1	Battery tray cover and plug hole cover removal and installation
2	Bus bars (F, G) removal and installation
3	JB cables (P and N lines) removal and installation
5	Evaporator duct assembly, main drive lithium-ion battery cooling fan, main drive lithium-ion battery cooling fan bracket removal and installation
6	PTC heater cable, main drive lithium-ion battery heater temperature sensor and battery cooling duct removal and installation
7	Main drive lithium-ion battery harness removal and installation
9	Battery cooling duct removal and installation
10	Bus bars (B, D) and rubber pad removal and installation
14	Front JB cover removal and installation
15	Front JB assembly, front JB bus bars (D, E, F, N and P), electric current sensor, contactor, resistor and front plate removal and installation
16	PTC heater on main drive lithium-ion battery removal and installation
17	Evaporator (for cooling the main drive lithium-ion battery) removal and installation

Electric current sensor removal and installation

Service procedure	Work description	Reference page
1	Battery tray cover and plug hole cover removal and installation
2	Bus bars (F, G) removal and installation
3	JB cables (P and N lines) removal and installation
5	Evaporator duct assembly, main drive lithium-ion battery cooling fan, main drive lithium-ion battery cooling fan bracket removal and installation
6	PTC heater cable main drive lithium-ion battery heater temperature sensor and battery cooling duct removal and installation
7	Main drive lithium-ion battery harness removal and installation
9	Battery cooling duct removal and installation
10	Bus bars (B, D) and rubber pad removal and installation
14	Front JB cover removal and installation
15	Front JB assembly, front JB bus bars (D, E, F, N and P), electric current sensor, contactor, resistor and front plate removal and installation

Sub-battery management unit (BMU SUB) removal and installation

Service procedure	Work description	Reference page
1	Battery tray cover and plug hole cover removal and installation
2	Bus bars (F, G) removal and installation
4	Sub-battery management unit (BMU SUB) removal and installation

Cell monitoring unit (CMU) removal and installation

Service procedure	Work description	Reference page
1	Battery tray cover and plug hole cover removal and installation
2	Bus bars (F, G) removal and installation
3	JB cables (P and N lines) removal and installation
4	Sub-battery management unit (BMU SUB) removal and installation
5	Evaporator duct assembly, main drive lithium-ion battery cooling fan, main drive lithium-ion battery cooling fan bracket removal and installation
6	PTC heater cable main drive lithium-ion battery heater temperature sensor and battery cooling duct removal and installation
7	Main drive lithium-ion battery harness removal and installation
8	Service plug assembly removal and installation
9	Battery cooling duct removal and installation
10	Bus bars (B, D) and rubber pad removal and installation
11	Bus bar (C) removal and installation
18	Battery support holders (A, B, C) removal and installation
19	Battery module assembly removal and installation
20	Battery upper holder (A) and battery lower holder (A) removal and installation
21	Cell monitoring unit (CMU) removal and installation