NHTSA ID Number: 10158409
Manufacturer Communication Number: TSB-19-54-004
TSB/Document Date: 2019-04-15
Summary
This is a Technical Service Bulletin that was sent to dealers. The bulletin updates the Chassis Electric section of the affected Service Manual to add the Main Drive Lithium-ion Disassembly & Maintenance procedure to the Electrical Motor Unit and Main Drive Lithium-ion Battery.
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TSB/Document ID: TSB-19-54-004
Replacement Service Bulletin Number:
MFR Communication Date: 2019-03-13
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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Page 1 of 231
SUBJECT:
ADDITION OF MAIN DRIVE LITHIUM-ION
BATTERY DISASSEMBLY & MAINTENANCE
PROCEDURE - SERVICE MANUAL REVISION
No:
TSB-19-54-004
DATE:
March 2019
MODEL:
2013-14 i-MiEV
CIRCULATE TO:
[ ] GENERAL MANAGER
[ X ] PARTS MANAGER
[ X ] TECHNICIAN
[ X ] SERVICE ADVISOR
[ X ] SERVICE MANAGER
[ ] WARRANTY PROCESSOR
[ ] SALES MANAGER
PURPOSE
This TSB updates the Chassis Electrical section of the affected Service Manual to add the Main Drive
Lithium-ion Battery Disassembly & Maintenance procedure to 54D-Electric Motor Unit and Main
Drive Lithium-ion Battery.
The information in this bulletin should be added after “Main Drive Lithium-ion Battery Removal
and Installation.”
AFFECTED VEHICLES
D
2013 - 2014 i-MiEV (2013 for Canada only)
AFFECTED SERVICE MANUALS
D
2013 - 2014 i-MiEV Service Manual, Group 54-Chassis Electrical
Copyright 2019, Mitsubishi
Motors North America, Inc.
Continued
The information contained in this bulletin is subject to change. For the latest version of this document, go to the
Mitsubishi Dealer Link, MEDIC, or the Mitsubishi Service Information website (www.mitsubishitechinfo.com).
(4630)
54D-1
GROUP 54D
ELECTRIC MOTOR
UNIT AND MAIN
DRIVE LITHIUM-ION
BATTERY
CONTENTS
GENERAL INFORMATION . . . . . . . .
54D-4
DTC P1AFC QUICK CHARGING CURRENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-49
PRECAUTIONS BEFORE SERVICE.
54D-4
DTC P1AFD QUICK CHARGING VOLTAGE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-52
PRECAUTIONS . . . . . . . . . . . . . . . . .
54D-4
DTC P1B01 QUICK CHARGER VEHICLE ERROR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-56
EV-ECU . . . . . . . . . . . . . . . . . . . . . . .
54D-5
DIAGNOSTIC TROUBLE CODE CHART . .
54D-5
DIAGNOSTIC TROUBLE CODE PROCEDURES
......................................
54D-6
DTC P0A0A INTER LOCK SW . . . . . . . . . .
54D-6
DTC P0AA1 MAIN CONTACTOR P WELD
54D-9
DTC P0AA4 MAIN CONTACTOR N WELD
54D-13
DTC P0ADB MAIN CONTACTOR P CIRCUIT LOW,
P0ADF MAIN CONTACTOR N CIRCUIT LOW
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-18
DTC P0AE2 PRE-CHARGE CONTACTOR WELD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-21
DTC P0AE6 PRE-CHARGE CONTACTOR CIRCUIT
LOW, P0AE7 PRE-CHARGE CONTACTOR CIRCUIT
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-26
DTC P1A15 HIGH VOLTAGE CIRCUIT (1)
54D-28
DTC P1A17 HIGH VOLTAGE CIRCUIT (3)
54D-38
DTC P1AFA QUICK CHARGER READY TIMEOUT,
P1AFE QUICK CHARGER MALFUNCTION, P1AFF
QUICK CHARGER CONNECTOR LOCK, P1B00
QUICK CHARGER BATTERY ERROR . . . 54D-42
DTC P1AFB QUICK CHARGING TIME OVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-47
DTC P1B04 CHARGING CELL MAX VOLTAGE HIGH,
P1B05 CHARGING CELL MIN VOLTAGE LOW,
P1B07 CHARGING TOTAL BATTERY VOLTAGE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-60
DTC P1B06 CHARGING CELL MAX TEMPERATURE
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-62
DTC P1B0C ON BOARD CHARGING OVER
CURRENT, P1B21 OBC OUTPUT CURRENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-63
DTC P1B0D QUICK CHARGING OVER CURRENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-66
DTC P1B72 QUICK CHARGER CHARGING
CURRENT 1 . . . . . . . . . . . . . . . . . . . . . . . . 54D-69
DTC P1B73 QUICK CHARGER CHARGING
CURRENT 2 . . . . . . . . . . . . . . . . . . . . . . . . 54D-72
DTC P1B74 QUICK CHARGER DIS-CHARGING
CURRENT 1 . . . . . . . . . . . . . . . . . . . . . . . . 54D-75
DTC P1B75 QUICK CHARGER DIS-CHARGING
CURRENT 2 . . . . . . . . . . . . . . . . . . . . . . . . 54D-78
DTC P1B76 QUICK CHARGER DIS-CHARGING
CURRENT 3 . . . . . . . . . . . . . . . . . . . . . . . . 54D-81
DTC P1B77 QUICK CHARGER DIS-CHARGING
CURRENT 4 . . . . . . . . . . . . . . . . . . . . . . . . 54D-84
DTC P1B78 QUICK CHARGER RECEIVED
CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . .
54D-87
54D-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . .
54D-90
SYMPTOM PROCEDURES . . . . . . . . . . . .
54D-90
THE CRUISING RANGE SHORTENED. . .
54D-90
CODE NO. P1A9A: CMU ID AUTO NUMBERING
ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-157
ELECTRIC MOTOR CONTROL UNIT (EMCU)
AND MOTOR (ELECTRIC MOTOR UNIT)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-92
CODE NO. P1AXX: CHANGE ID (CMU XX)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-158
DIAGNOSTIC TROUBLE CODE CHART . .
54D-92
DIAGNOSTIC TROUBLE CODE PROCEDURES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-93
DTC P0A0D MOTOR DRIVE VOLTAGE HIGH (HW
DETECT). . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-93
BATTERY MANAGEMENT UNIT (BMU) AND
MAIN DRIVE LITHIUM-ION BATTERY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-95
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . .
54D-95
RECOMMENDED TOOLS . . . . . . . . . . . . .
54D-97
INSPECTION CHART FOR DIAGNOSIS CODE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-99
DIAGNOSTIC CODE PROCEDURES . . . . 54D-103
CODE NO. P1A40: TRACTION BATTERY CURRENT
SENSOR (HIGH) ABNORMAL . . . . . . . . . . 54D-103
CODE NO. P1A41: TRACTION BATTERY CURRENT
SENSOR (LOW) ABNORMAL . . . . . . . . . . 54D-107
CODE NO. P1A42: POWER SUPPLY CIRCUIT OF
TRACTION BATTERY CURRENT SENSOR
ABNORMAL . . . . . . . . . . . . . . . . . . . . . . . . 54D-110
CODE NO. P1A43: DETECTION CIRCUIT OF
TRACTION BATTERY CURRENT SENSOR
ABNORMAL . . . . . . . . . . . . . . . . . . . . . . . . 54D-113
CODE NO. P1A44: DETECTING GROUND FAULT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-116
CODE NO. P1A46: DETECTION CIRCUIT OF
TRACTION BATTERY GROUND FAULT DETECTOR
ABNORMAL . . . . . . . . . . . . . . . . . . . . . . . . 54D-130
CODE NO. P1A48: OUTPUT CIRCUIT OF TRACTION
BATTERY FAN ABNORMAL . . . . . . . . . . . 54D-144
CODE NO. P1A4B: VOLTAGE OF EACH BATTERY
CELL ABNORMAL . . . . . . . . . . . . . . . . . . . 54D-146
CODE No. P1AXX: CMUXX BATTERY CELL LOW
VOLTAGE ABNORMAL . . . . . . . . . . . . . . . 54D-148
CODE NO. P1AXX: CMU01 BATTERY CELL HIGH
VOLTAGE ABNORMAL . . . . . . . . . . . . . . . 54D-149
CODE NO. P1AXX: CMU01 MODULE
TEMPERATURE ABNORMAL (HIGH INPUT)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-150
CODE NO. P1AXX: CMU01 BATTERY CELL
VOLTAGE SENSOR ABNORMAL . . . . . . . 54D-152
CODE NO. P1AXX: CMU01 MODULE
TEMPERATURE SENSOR ABNORMAL . . 54D-154
CODE NO. P1AXX: CMU01 BALANCER ABNORMAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-155
CODE NO. P1AA8: LOCAL CAN (FOR TRACTION
BATTERY) SIGNAL TIME-OUT . . . . . . . . . 54D-159
CODE NO. P1AA9: CELL NUMBER MISMATCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-162
CODE NO. P1AAB: NUMBERS OF CELLS
ABNORMAL . . . . . . . . . . . . . . . . . . . . . . . . 54D-163
CODE NO. P1AXX: CMU01 MODULE
TEMPERATURE ABNORMAL (LOW INPUT)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-164
CODE NO. P1AC1: TRACTION BATTERY FAN
FAILED (DRIVING ABNORMAL) . . . . . . . . 54D-166
CODE NO. P1AC2: TRACTION BATTERY FAN
FAILED (SHORT CIRCUITS TO POWER SUPPLY
SYSTEM). . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-171
CODE NO. P1AC3: TRACTION BATTERY FAN
FAILED (STOP ABNORMAL) . . . . . . . . . . . 54D-176
CODE NO. P1AC6: VOLTAGE OF EACH BATTERY
CELL ABNORMAL (HI SIDE) . . . . . . . . . . . 54D-178
CODE NO. U1082: LOCAL CAN (FOR TRACTION
BATTERY) BUS OFF . . . . . . . . . . . . . . . . . 54D-179
CODE NO. U11A0: CMU01 TIME-OUT . . . 54D-183
CODE NO. U1925: CMU ID NUMBERING
RECEPTION ERROR . . . . . . . . . . . . . . . . . 54D-189
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 54D-194
CHECK ON COIL RESISTANCE OF CONTACTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-194
CHECK ON SERVICE PLUG SWITCH . . . . 54D-196
LOCAL CAN ( FOR TRACTION BATTERY)
TERMINATING RESISTANCE CHECK . . . 54D-197
CHECK ON TRACTION BATTERY CURRENT
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-197
CHECK AND REPLACEMENT OF THE HIGHVOLTAGE FUSE INSIDE THE MAIN DRIVE LITHIUMION BATTERY. . . . . . . . . . . . . . . . . . . . . . . 54D-198
MAIN DRIVE LITHIUM-ION BATTERY DISASSEMBLY
AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 54D-200
SERVICE PROCEDURE . . . . . . . . . . . . . . . 54D-200
SERVICE PROCEDURE CHECK SHEET . 54D-203
MAIN DRAIVE LITHIUM-ION BATTERY COVER
REMOVAL AND INSTALLATION . . . . . . . . 54D-206
AIR DUCT REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-208
PAD REMOVAL AND INSTALLATION . . . . 54D-208
BUS BAR REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-209
EIGHT-CELL MODULE REMOVAL AND
54D-3
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 54D-210
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-222
JFB COVER REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-214
COOLING FAN REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-223
FOUR-CELL MODULE REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 54D-215
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 54D-223
GROUND FAULT DETECTOR REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 54D-219
CONTACTOR CHECK . . . . . . . . . . . . . . . . 54D-228
ELECTRIC CURRENT SENSOR REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 54D-219
JFB REMOVAL AND INSTALLATION . . . . 54D-220
RESISTOR REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-221
CONTACTOR REMOVAL AND INSTALLATION
AIR LEAK CHECK . . . . . . . . . . . . . . . . . . . . 54D-223
SERVICE PLUG SWITCH INSPECTION . . 54D-229
LOCAL CAN TERMINATING RESISTOR CHECK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54D-229
MAIN DRIVE LITHIUM-ION BATTERY ELECTRIC
CURRENT SENSOR CHECK . . . . . . . . . . . 54D-230
RESISTOR CHECK. . . . . . . . . . . . . . . . . . . 54D-230
54D-4
ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY
GENERAL
GENERAL
M1549226500212
OUTLINE OF CHANGES
The DTC for the EMCU is changed.
The DTC for the BMU is changed.
The on-vehicle service of the BMU is changed.
The Main Drive Lithium-ion Battery disassembly/
assembly is added.
The Main Drive Lithium-ion Battery inspection is
added.
Due to the addition of Main Drive Lithium-ion Battery
disassembly/assembly, the service procedure
has been established. The other service procedures are the same as before.
The DTC for the EV-ECU is changed.
The troubleshooting of symptom procedures for
the EV-ECU is changed.
SERVICE PRECAUTION
Disassembly, assembly and inspections of the Main
Drive Lithium-ion Battery should be carried out by
only specially trained mechanics. Carry out the work
at the place which the rain, snow, sand, or dust will
not enter. Make sure that the floor of the work place
is dry (not wet). Make sure that the Main Drive Lithium-ion Battery is not wet.
M1549406100012
PRECAUTIONS ON INSIDE OPERATION OF THE MAIN
DRIVE LITHIUM-ION BATTERY
M1549403700015
DANGER
Observe the following precautions during service operations inside the Main Drive Lithiumion Battery as they may cause an electric shock, electric leak, vehicle fires or disabled driveaway.
.
1. Precautions on handling high-voltage terminals
When doing any repair work in vicinity of the areas
below, pay attention to the following.
Affected areas: Module terminal, bus bar, orange
wiring harness and connectors, fuses, resistors and service plugs
Touching two different terminals by bare hands
simultaneously may cause burns.
Touching two different terminals simultaneously
by a rubber or metal object may cause fires due
to a short circuit.
Touching a terminal and its surrounding area by
bare hands simultaneously may cause electric
shocks or burns. (by leakage of electricity)
Touching a terminal and its surrounding area
simultaneously by a rubber or metal object may
cause fires due to a short circuit. (by leakage of
electricity)
TSB Revision
NOTE: In the descriptions above, "rubber" indicates a part containing graphite such as tires or
coolant hoses. Isolated rubber products are not
included.
A contaminated or damaged terminal seating will
increase contact resistance. This will cause vehicle fires due to overheat.
A contaminated or damaged terminal thread will
decrease terminal contact pressure. This will
cause vehicle fires due to overheat.
NOTE: Check not only that a terminal nut is
seated securely, but also that terminal contact
surfaces are seated securely.
.
224
ELECTRIC MOTOR UNIT AND MAIN DRIVE LITHIUM-ION BATTERY
EV-ECU
54D-5
2. Precautions on other operations
How to handle tools
Electric shocks, burns or fires may be caused if a
tool, which is put or left on a component, contacts
a high-voltage circuit.
How to handle metal parts
If a metal part drops inside the Main Drive Lithium-ion Battery, leakage of electricity or short circuit may cause vehicle fires.
How to handle waterproof seals
A deteriorated waterproof seal may cause water
ingress inside the Main Drive Lithium-ion Battery.
This will cause leakage of electricity, thus disabling the vehicle drive-away.
EV-ECU
DIAGNOSTIC TROUBLE CODE CHART
M1549200600208
DTC
Diagnostic item
Reference
page
P0A0A
Service plug switch
P.54D-6
P0AA1
Main contactor (+) (seizure)
P.54D-9
P0AA4
Main contactor () (seizure)
P.54D-13
P0ADB
Main contactor (+) circuit (low input)
P.54D-18
P0ADF
Main contactor () circuit (low input)
P0AE2
Charging contactor (seizure)
P.54D-21
P0AE6
Charging contactor (low input)
P.54D-26
P0AE7
Charging contactor (high input)
P1A15
High-voltage system error (1)
P.54D-28
P1A17
High-voltage system error (3)
P.54D-38
P1AF2
EMCU condenser discharge command F/B
P.54D-21
P1AFA
Quick charger READY timeout
P.54D-42
P1AFB
Quick charging time timeout
P.54D-47
P1AFC
Quick charging current error
P.54D-49
P1AFD
Quick charging voltage abnormality
P.54D-52
P1B01
Quick charged vehicle error
P.54D-56
P1B04
Maximum cell voltage abnormality during charging
P.54D-60
P1B05
Minimum cell voltage abnormality during charging
P1B06
Maximum cell temperature abnormality during charging
P.54D-62
P1B07
Total battery voltage abnormality during charging
P.54D-60
P1B0C
On board charging current error (overcurrent)
P.54D-63
P1B0D
Quick charging current error (overcurrent)
P.54D-66
P1B21
On board charger output current error
P.54D-63
P1B72
Quick charger charging current 1
P.54D-69
P1B73
Quick charger charging current 2
P.54D-72
TSB Revision
225
54D-6
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- 【Up to 38 Reset Services】MB V3.0 2026 Version diagnostic tool performs Up to 38 maintenance services - Oil Rest , SAS, EPB, ETC, D-P-F, TPMS, ABS, Suspension, Air Conditioner, Head Lamp, Body Stability, Engine Control, Seat, Fuel Pump, Air-Filter, Engine Idle, Door, Im-mo-bilizer, Injector Coding, Transmission Control, Miscellaneous, Adblue, BMS, Cluth, Water Pump, NOxSensor, Rain/Light Sensor, Start/Stop, Radar/Camera, Cylinder Shutoff Test, Speed Limit Assist, Control Unit Reset, Oxygen Sensor, Seat Belt, Cruise Control System, Turbocharger, Crankshaft, Language Setting and etc. (Tips: Please update the software after receiving the product to obtain new service functions)
- 【OE-Level All System OBD2 Scanner】iCarsoft MB V3.0 (2026 Version) diagnostic scanner offers comprehensive OBDII services, allowing you to quickly scan all systems, including the Engine, ABS, SAS, SRS, TPMS, TCM, Fuel Pump System, ESP, EPB, EPS, Suspension, SCM, Adaptive Systems, and more. It supports functions such as reading and erasing codes, checking I/M readiness, viewing freeze frame data, performing O2 sensor tests, conducting on-board monitoring, testing the evap system, auto VIN retrieval, and reading both generic and specific codes, as well as DTCs and battery tests.
- 【Bidirectional Scan Tool】iCarsoft MB V3.0 (2026 Version) Bidirectional scanner supports activate or control a vehicle system or component, allows commanding cars’ modules and receiving info from the ECU to perform active tests on individual components, including EVAP/ABS Motor Pump/Windows/Sunroof and more, to pinpoint fault causes & resolve issues,and allows you to re-learn certain components after making repairs or replacement.
- 【Real Time Record & Graph View】iCarsoft MB V3.0 (2026 Version) can automatically record vehicle text history and identify vehicle information. Preserve real-time data information. View & Graph Live Data. Support Data Review and Print. Multi-language: English, German, Dutch, Spanish, French and so on. We promise to offer Lifetime updates (Lifetime free Update via PC), and confidence in products. We also provide 1 year warranty + extra lifetime hardware free repair if you need it in the future. We prioritize user experience & strive to meet your expectations. Please do feel free to reach out to us if you have any question or problem about the usage, our tech team will service you in time.
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Last update on 2026-05-12 / Affiliate links / Images from Amazon Product Advertising API