DAMAGED VEHICLE HANDLING

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Warning
<<High voltage>>
•  If the high voltage parts of an electric vehicle are damaged due to an accident, improper handling could cause a serious accident such as electrical shock and result in serious injury or, in the worst case, death. When handling a vehicle damaged in an accident, follow the cautions and perform the correct procedures.

Measures in Case of Accident

Caution
<<High voltage>>
•  The high voltage battery electrolyte and its vapor may react with the moisture in the air and produce an acidic substance that irritates the skin and eyes. In addition, if handled incorrectly, it could cause electrical shock and result in serious injury or, in the worst case, death. Follow the cautions and perform the correct procedures.

Items to be prepared

Items to be prepared

Purpose
Protective equipment
Protection against high voltage
(Insulating gloves, electrical-hazard safety shoes, protective eye wear)
•  Prevent an electrical shock accident of the worker.
•  Protect the eyes from an arc flash caused by short circuiting of the high voltage circuit.
Protection against electrolyte
(Protective rubber gloves, protective eye wear)
•  Protect the skin and eyes when high voltage battery electrolyte is leaking.
Electrical tape (Insulating tape)
•  Used for insulation of damaged wiring harnesses or removed lead-acid battery terminals.
•  Used for insulation of parts such as high voltage wiring harnesses.
Voltmeter (Capable of measuring DC 450 V or more)
•  Used for measuring the voltage of damaged wiring harnesses and locations being serviced.
Absorbing mat, cloth
•  Absorb oils and high voltage battery electrolyte.
Sealed container
•  Used for disposal of cloth that was used to wipe off high voltage battery electrolyte.
Tools
Wrenches (size: 10 mm)
Phillips screwdriver
•  Used to remove the lead-acid battery terminals.
•  Used to remove the service plug cover.
Fire extinguisher (ABC fire extinguisher)
•  Used for early-stage fire extinguishing.


Handling in case of accident

Warning
<<High voltage>>
•  Do not touch wiring with broken insulation that may be high voltage wiring harnesses. If they need to be touched or may be touched, use insulating gloves and insulate the wiring harnesses with broken insulation using electrical tape.
•  Do not remove the service plug in water. Also, do not touch the high voltage areas and high voltage wiring harnesses. Touching them could cause electrical shock and result in serious injury or, in the worst case, death. If the vehicle is flooded or submerged in water, pull the vehicle completely out of the water and then perform work on the vehicle.
•  Only extinguish a fire with water when large amounts of water is available such as from a fire hydrant. Extinguishing a fire with a small amount of water is dangerous. If a large amount of water is not available, do not try to extinguish the fire but evacuate to a safe place and wait for firefighters to arrive.
•  When using a fire extinguisher to extinguish a fire, use an ABC fire extinguisher (effective for normal fire, oil fire (fire caused by gasoline and other petroleum oils) and electrical fire (fire caused by electrical wiring and equipment).

1.  Verify leakage from the high voltage battery.

Warning
<<High voltage>>
•  The high voltage battery uses lithium-ion battery. The electrolyte used for the high voltage battery is flammable. If the electrolyte is leaking, immediately keep it away from any flames. In addition, verify that the area is sufficiently ventilated, and wear solvent-resistant protective equipment and wipe off the leaked electrolyte using cloth. Put the used cloth in a sealed container.
•  The leaked electrolyte and its vapor may react with the moisture in the air and produce an acidic substance that irritates the skin and eyes. Therefore, if the electrolyte comes in contact with the skin or eye, wash off well with plenty of running water and promptly seek medical attention.
Caution
<<High voltage>>
•  Dispose of the absorbing mat and cloth used to clean the electrolyte leakage according to a method specified by the laws and regulations.
Note
•  The high voltage battery electrolyte is clear and has an aromatic odor.

2.  Wear insulating gloves (when servicing high voltage areas) or protective rubber gloves (when disposing of electrolyte), and safety shoes and protective eye wear.

3.  If the high voltage parts and wiring harnesses may be damaged, cut off the high voltage using the following procedure.

(1)  Switch the main power OFF.
Note
•  If the main power cannot be switched OFF, disconnect the lead-acid battery in the motor compartment.
(2)  Wear insulating gloves and remove the service plug. Refer to the Workshop Manual for the [SERVICE PLUG REMOVAL/INSTALLATION].
Caution
<<High voltage>>
•  Do not switch the main power ON (READY on) with the service plug removed or a malfunction could occur.


Handling High Voltage Battery on Vehicle Damaged in Accident

•  
Warning
<<High voltage>>
•  The high voltage battery is covered with a cover and direct verification of damage to internal parts is impossible. Determine if there is internal damage using the following procedure. If internal damage is determined, contact the technical assistance for your market.
•  If the necessary measures are not taken before servicing an electric vehicle, it could cause electrical shock and result in serious injury or, in the worst case, death. Before servicing the electric vehicle, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and implement the necessary measures. (See HIGH VOLTAGE SERVICE CAUTIONS.)

High voltage part inspection notes

Warning
<<High voltage>>
•  The inspection and removal/installation of the high voltage parts of this vehicle must be performed by persons who have acquired qualifications specified by the laws and regulations.
•  The protective equipment indicated in the workshop manual is recommended by Mazda. Use equipment specified by the laws and regulations of each country.
•  Wear insulating gloves when inspecting or removing/installing the high voltage parts. Touching the high voltage parts without wearing insulating gloves could cause electrical shock and result in serious injury or, in the worst case, death.
•  Before inspecting or removing/installing the high voltage parts, remove the service plug and wait until 10 min have elapsed. Servicing without removing the service plug or before 10 min have elapsed after removing the service plug could cause electrical shock and result in serious injury or, in the worst case, death. Refer to the Workshop Manual for the [SERVICE PLUG REMOVAL/INSTALLATION].
•  Do not spin the tires while inspecting or removing/installing the high voltage parts. If the tires spin, power generation occurs even if the service plug is removed. If power generation occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.
•  Verify that the charge connector is not connected to the vehicle when inspecting or removing/installing the high voltage parts. If the charge connector is connected to the vehicle, high voltage may be supplied to the vehicle. If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.
•  Always observe the following thoroughly to ensure safety when inspecting or removing/installing the high voltage parts. Otherwise, the high voltage circuit may operate on the vehicle regardless of whether or not the main power is switched OFF or ON (READY off or on). If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.
―  Do not perform normal charge or quick charge
―  Switch to connected vehicle maintance mode (MyMazda App connected vehicle)
―  Cancel climate control timer
•  When inspecting or removing/installing the high voltage parts, place a high voltage work sign on the vehicle to alert other workers.
Caution
<<High voltage>>
•  Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, a malfunction may occur with the vehicle.
Note
•  The high voltage parts can be identified as follows.
―  Parts that are connected using orange wiring harnesses
―  Parts with a high voltage warning label attached

Items to be prepared

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Procedure for Determining Need for High Voltage Battery Internal Inspection

Warning
<<High voltage>>
•  Inspections that require installation/removal of the high voltage battery cover cannot be performed because the high voltage battery cannot be disassembled. Perform troubleshooting for DTCs output by the PCM and the BECM. Refer to the Workshop Manual for the [SERVICE PLUG REMOVAL/INSTALLATION].
•  Do not touch damaged or exposed internal areas of high voltage parts and wiring harnesses. If they need to be touched, always wear insulating protective gear.
•  Wear insulating protective gear and then insulate damaged high voltage parts and wiring harnesses with electrical tape.
•  The need for a high voltage battery internal inspection is determined by the following table based on the results of all of the following verifications.
―  Air bag deployment/pre-tensioner seat belt operation verification (See Air bag deployment/pre-tensioner seat belt operation verification.)
―  DTC verification (See DTC verification.)
―  Verification of external appearance of high voltage battery and vehicle body dimensions (See Verification of external appearance of high voltage battery and vehicle body dimensions.)
•  If it is determined that a high voltage battery internal inspection is necessary, contact the technical assistance for your market.

Description of verification

Need for high voltage battery internal inspection

Air bag deployment/pre-tensioner seat belt operation verification

DTC verification

Verification of external appearance and vehicle body dimensions
1
Undeployed/no operation
No DTCs
Normal
No
2
Malfunction*1
Yes
3
DTCs
Normal
Yes*2
4
Malfunction*1
Yes
5
Deployed/operated
No DTCs
Normal
6
Malfunction*1
7
DTCs
Normal
8
Malfunction*1

*1  :External appearance damage (cracks, deformation) or body frame dimensions are not within specification
*2  :Troubleshooting of verified DTCs was performed and malfunctioning location is high voltage battery

Air bag deployment/pre-tensioner seat belt operation verification

Verify if any of the air bags or pre-tensioner seat belts equipped on the vehicle is deployed/operated.
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DTC verification

•  Perform a DTC inspection using the following flowchart.
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*1  :To inspect for electrical leakage, perform the following electrical leakage inspection.
Electrical leakage inspection
Warning
<<High voltage>>
•  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester.
Caution
<<High voltage>>
•  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts.
•  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows.
During high voltage (+) side circuit measurement:
―  Measuring terminal: Voltage application side probe
―  Body ground side: Ground side probe
During high voltage (-) side circuit measurement:
―  Measuring terminal side: Ground side probe
―  Body ground side: Voltage application side probe
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*2  :To measure the electric potential difference and the insulation resistance, measure both sockets (a) and (b) on the high voltage battery side.
Measurement locations for electric potential difference and insulation resistance
a.  Bolt — High voltage battery (+) side socket
b.  Bolt — High voltage battery (-) side socket
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Warning
<<High voltage>>
•  Electrical leakage could occur after connecting the service plug for a DTC inspection. After connecting the service plug, do not perform servicing such as part removal/installation. If electrical leakage occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.
Note
•  If the M-MDS cannot communicate with the vehicle due to vehicle damage from an accident, remove the service plug again and repair the damaged location.
•  BECE Refer to the Workshop Manual for the [SERVICE PLUG REMOVAL/INSTALLATION].
P0B25:00, P0B29:00, P0B2D:00, P0B31:00, P0ECE:00, P0ED2:00, P1B50:00, P1B51:00, P1B52:00, P1B53:00, P1B54:00, P1B55:00, P1B56:00, P1B57:00, P1B58:00, P1B59:00, P0B26:00, P0B2A:00, P0B2E:00, P0B32:00, P0ECF:00, P0ED3:00, P1B40:00, P1B41:00, P1B42:00, P1B43:00, P1B44:00, P1B45:00, P1B46:00, P1B47:00, P1B48:00, P1B49:00, P0DAF:00, P0DB3:00, P0DB7:00, P0DBB:00, P0DBF:00, P0DC3:00, P0DC7:00, P0DCB:00, P0DCF:00, P0DD3:00, P0DD7:00, P0DDB:00, P0DDF:00, P0DE3:00, P1B5B:00, P1B5C:00, P0DAB:00, P1B5D:00, P0B8E:00, P0B93:00, P0B98:00, P0B9D:00, P0BA2:00, P0BA7:00, P0B8D:00, P0B92:00, P0B97:00, P0B9C:00, P0BA1:00, P0BA6:00, P0B8C:00, P0B91:00, P0B96:00, P0B9B:00, P0BA0:00, P0BA5:00, P0B3B:00, P0B40:00, P0B45:00, P0B4A:00, P0B4F:00, P0B54:00, P0B59:00, P0B5E:00, P0B63:00, P0B68:00, P0B6D:00, P0B72:00, P0B77:00, P0B7C:00, P0B81:00, P0B86:00, P1B5A:00, P0A7E:00, P1B32:00, P1B33:00, P1B34:00, P1B35:00, P2D46:00, P2D47:00, P2D48:00, P2D49:00, P2D4A:00, P2D4B:00, P2D4C:00, P2D4D:00, P2D4E:00, P2D4F:00, P2D50:00, P0A9D:00, P0AC7:00, P0ACC:00, P0AEA:00, P0BC4:00, P0C35:00, P0C7E:00, P0C83:00, P0C8A:00, P0C8F:00, P0C94:00, P0C99:00, P0CAA:00, P0CAF:00, P0CB4:00, P0CB9:00, P0A9E:00, P0AC8:00, P0ACD:00, P0AEB:00, P0BC5:00, P0C36:00, P0C7F:00, P0C84:00, P0C8B:00, P0C90:00, P0C95:00, P0C9A:00, P0CAB:00, P0CB0:00, P0CB5:00, P0CBA:00, P0A9C:00, P0AC6:00, P0ACB:00, P0AE9:00, P0BC3:00, P0C34:00, P0C7D:00, P0C82:00, P0C89:00, P0C8E:00, P0C93:00, P0C98:00, P0CA9:00, P0CAE:00, P0CB3:00, P0CB8:00, P0AC2:00, P0AC1:00, P0B11:00, P0B10:00, P0AC3:00, P0B12:00, P0B13:00, P0CA6:00, P0CA7:00, P0A7F:00, P0EDD:00, P0EDE:00, P0EDF:00, P0EE0:00, P0EE1:00, P1B71:00, P1B72:00, P2CCC:00, P2CCD:00, P2CCE:00, P2CCF:00, P2CD0:00, P2CD1:00, P2CD2:00, P2CD3:00, P1B60:00, P1B61:00, P1B62:00, P1B63:00, P1B64:00, P1B65:00, P1B66:00, P1B67:00, P1B68:00, P1B69:00, P1B6A:00, P1B6B:00, P1B6C:00, P1B6D:00, P1B6E:00, P1B6F:00, P091F:00, P092E:00, P091E:00, P0CDF:00, P0CE2:00, P0D1D:00, P0DE8:00, P0DEB:00, P1B75:00, P1B74:00, P1B76:00, P0CE3:00, P0D1E:00, P0DEC:00, P0EC2:00, P0EC3:00, P2517:00, P2518:00, P1B73:00, P058D:00, P06A6:00, P06E4:00, P0A1F:00, P0AA7:00, P0DAC:00, P0DB0:00, P0DB4:00, P0DB8:00, P0DBC:00, P0DC0:00, P0EEC:00, P0EF7:00, P0EF9:00, P0EFA:00, P1B00:00, P1B01:00, P1B03:00, P1B04:00, P1B13:00, P1B14:00, P1B15:00, P1B16:00, P1B17:00, P1B18:00, P1B19:00, P1B1A:00, P1B1B:00, P1B1C:00, P1B1D:00, P1B1E:00, P1B1F:00, P1B30:00, P1B31:00, P1B5E:00, P24F0:00, P24F1:00, U0100:00, U0115:00, U0140:00, U016B:00, P1B05:00, P262B:00
•  PCM Refer to the Workshop Manual for the [SERVICE PLUG REMOVAL/INSTALLATION].
P0AA1:00, P0AA2:00, P0AA4:00, P0AA5:00, P0AA6:00, P0AE1:00, P0AE2:00, P0AE3:00, P0E14:00, P2D3B:00


Verification of external appearance of high voltage battery and vehicle body dimensions

Warning
<<High voltage>>
•  Electrical leakage may occur due to damage related to the high voltage system. When performing the following procedure, wear insulating protective gear. If electrical leakage occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

1.  Remove the gussets connecting the front crossmember to the vehicle body. Refer to the Workshop Manual for the [SERVICE PLUG REMOVAL/INSTALLATION].

2.  Remove the floor under cover (No.1 — No.4) covering the high voltage battery. Refer to the Workshop Manual for the [SERVICE PLUG REMOVAL/INSTALLATION].

3.  Visually inspect the exterior appearance of the high voltage battery for cracks and deformation.

Note
•  For dimension measurements, obtain advice from a sheet metal repair specialist if necessary.

4.  Measure the dimensions between each vehicle body point shown in the figure and determine if the body frame is deformed.

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