SC-15-001

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SERVICE CAMPAIGN BULLETIN
SUBJECT:
ON BOARD CHARGER −
SERVICE CAMPAIGN
No:
SC−15−001
DATE:
September, 2015
MODEL:
2010 i−MiEV
CIRCULATE TO:
[X] GENERAL MANAGER
[X] PARTS MANAGER
[X] TECHNICIAN
[X] SERVICE ADVISOR
[X] SERVICE MANAGER
[X] WARRANTY PROCESSOR
[X] SALES MANAGER
PURPOSE
The On Board Charger (OBC) installed in certain 2010 i−MiEV vehicles may have an improperly
manufactured condenser on the control board that is susceptible to failure. If failure occurs, certain OBC
related functions such as charging of the Main Drive lithium−ion battery and/or the 12V battery may be
prohibited.
This campaign bulletin instructs dealers to replace the OBC on all affected vehicles with a countermeasure
unit.
AFFECTED VEHICLES
Three 2010 i−MiEVs: JA3EE1HA3W0001662, JA3EE7HA3W0001664 and JA3EE1HA3W0001760.
REQUIRED OPERATIONS
Repairs must be completed by a certified i−MiEV technician.
! WARNING
Since this procedure involves the handling of high voltage components
(330V), there is a possibility of electric leakage and/or risk of electric shock. Caution must be
used to avoid serious injury, especially during removal, disassembly, or disconnection of the
high voltage wiring (orange in color). Ensure the service plug is unplugged prior to working with
the high voltage wiring.
IMPORTANT
Affected new or used inventory vehicles must be repaired before the vehicle is delivered.
Dealers must check their inventory vehicles’ VINs on the Warranty Super Screen to verify
whether the vehicle is involved in this service action.
IMPORTANT
Please ensure the Main Drive battery is fully charged prior to vehicle delivery. This will limit
customer inconvenience and maximize customer satisfaction.
SPECIAL EQUIPMENT
The following equipment is needed to remove and install the OBC and air bleed the radiator
coolant:
D Kit, OTC Hybrid Meter − 3990
D
Gloves Set, Electric Insulated − MB99264801
D
VCI (Vehicle Communication Interface) or VCI Lite − MB991824 or MB992744V.
D
MEDIC Laptop/Tablet with A/C power adapter − 520924, or FZG1MK2.
D
MUT−III main harness ’A’ (blue connector at the DLC end) − MB991910 or MB992745V.
D
USB 2.0 cable − MB991827 or RRAR1MBR−108L.
Copyright 2015, 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).
(4322)
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OBC REPLACEMENT PROCEDURE
1. Partially discharge the Main Drive lithium−ion battery.
a. Set the electric motor switch to the “ON” position.
Confirm the “READY” light is displayed. Set the
heater to the highest temperature and the blower
speed to MAX. Allow the battery to discharge until
the power down warning light (turtle) is illuminated
on the gauge cluster.
b. Open the liftgate.
2. Set the electric motor switch to “LOCK” (Off). Wait one minute before proceeding to Step 3.
REMINDER: If not equipped with MMCS Navigation, please record all radio station presets and
reprogram when repair is completed.
! WARNING
To avoid causing any trouble to the electric motor unit components, do not
disconnect the 12V battery negative (−) terminal for one minute after turning off the electric motor
switch to “LOCK” (Off).
3. Open the hood. Remove the 12V battery cover and
disconnect the negative (−) terminal of the battery.
Insulate disconnected negative (−) terminal post with
electrical tape.
4. Slide the front passenger side seat to its rearmost
position. Reach under the seat and release the floor
carpet hook and loop fastener to expose the service
lid.
5. Remove the two service lid thumb screws and the
service lid.
! WARNING
! CAUTION
Use the electric insulated gloves to protect from electric shock.
Prior to removing the service plug, wait five minutes or more after
disconnecting the 12V battery negative (−) battery cable instructed in Step 3.
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6. Use the electric insulated gloves and pull up on the lever to remove the service plug.
Place the service plug in a secure location to prevent inadvertent reinstallation.
7. Apply duct tape over the terminal to prevent intrusion of foreign material.
8. Fold the rear seatbacks forward into the passenger
compartment.
9. Remove and store the rear access cover.
10. Unscrew the four wing nuts from the power unit
inspection lid and open the lid.
Wing Nuts
11. Remove the service lid (1) on the Motor Control Unit
(MCU).
3
NOTE: The service lid o−ring (2) must be replaced.
NOTE: One bolt securing the center of the service lid (3) is a Torx
bolt (T30).
Front of
Vehicle
! WARNING
! CAUTION
12. Using a high voltage multimeter, ensure the measured
voltage at the terminals shown in the picture, is
approximately 0V. If it is not approximately 0V, then
wait until the measurement is approximately 0V.
Be careful because the coolant may be hot.
Do not disconnect the radiator hoses (1) and (2) connected to the radiator
condenser tank when performing Step 13.
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13. Separate the rear radiator condenser tank from the
OBC by removing the two bolts (3).
3
2
14. Set aside the rear radiator condenser tank and secure
it with a string.
4
FIGURE 1
1. Hose (1)
2. Hose (2)
3. OBC (On Board
Charger)
4. Ground Bolt
Ground bolt (left) is
marked with an “E”.
! WARNING
! CAUTION
Be careful because the coolant may be hot.
Prior to radiator hose disconnection, place a clean container under the
coolant inlet/outlet to collect coolant spillage. Wipe clean any surface exposed to spilled coolant.
Keep the coolant clean since it will be reused.
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15. [Figure 1] Mark the radiator hose (1) clip location with a marker or tape. Place a hose clamp on the
hose to prevent coolant leakage. Squeeze and reposition the hose clip further down the hose and
disconnect the hose.
16. Place a cap or plug over the OBC’s coolant inlet/outlet to prevent coolant spillage during OBC
removal.
17. [Figure 1] Mark the radiator hose (2) clip location with a marker or tape. Place a hose clamp on the
hose to prevent coolant leakage. Squeeze and reposition the hose clip further down the hose and
disconnect the hose.
18. Place a cap or plug over the OBC’s coolant inlet/outlet to prevent coolant spillage during OBC
removal.
! CAUTION
Prior to new OBC installation, ensure the area is clean and dry.
19. [Figure 1] Remove and replace the OBC (3) with the countermeasure part indicated in the PARTS
INFORMATION section.
NOTE: [Figure 1] Reinstall the ground bolt (4) where indicated.
20. [Figure 1] Reinstall the radiator hoses (1) and (2), ensuring the hose clips are secured in the marked,
original location. Remove the hose clamps from the radiator hoses.
21. Remove the cap or plug from the old OBC’s coolant inlet/outlet and empty coolant into the coolant
container.
22. Unfasten the rear radiator condenser tank and reinstall it. Torque bolts to 62 + 26 in−lb (7.0 + 3.0
N−m).
23. Replace the o−ring on the MCU service lid and reinstall the service lid. Torque the torx bolt to 53 +
17 in−lb (6.0 + 2.0 N−m) and the remaining 5 bolts to 62 + 26 in−lb (7.0 + 3.0 N−m).
! WARNING
Use the electric insulated gloves to protect from electric shock.
24. Use the electric insulated gloves to remove the tape covering the service plug terminal. Reinstall the
service plug. Secure the service lid with the two thumbscrews and fasten the floor carpet to cover the
area.
25. Remove the tape from the negative (−) battery post and reinstall the negative (−) ground cable. Torque
specifications for the negative (−) terminal is 44 + 8 in−lb (5 + 1 N−m).
! CAUTION
To prevent water pump damage, do not turn on the vehicle and engage
“READY” mode until the coolant is refilled.
26. Refill the rear radiator condenser tank with the collected coolant until it reaches the “F” (Full) mark.
COOLANT SYSTEM BLEEDING PROCEDURE
1. Attach a battery charger (with a charging rate not to
exceed 10 amps) to the 12V battery.
NOTE: Ensure battery charger does not time out
during this procedure.
NOTE: Connect the positive (+) terminal of the 12V
battery (1) to the positive (+) battery charger
cable (2). Connect the negative (—) battery
charger cable (3) to the designated ground
location (4).
Battery Charger
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2. Connect the equipment as follows:
D
Turn the MEDIC PC/tablet on. If the battery indicator in the lower right hand corner of the screen
does not show a full charge, it is recommended that either the battery be charged prior to
beginning, or be used with the A/C power adaptor connected.
D
Connect the USB cable to the VCI/VCI Lite.
D
When the laptop/tablet displays the MUT−III main screen, connect the USB cable to the device.
D
Connect the MUT−III main harness with the blue DLC connection to the VCI/VCI Lite.
D
Connect the blue connection of the MUT−III main harness to the vehicle’s data link connector.
D
Turn the VCI power switch ON . Verify that the indicator lamp in the upper right corner of the screen
is green.
NOTE: VCI and MEDIC 3 Laptop shown for illustration purposes only
USB CABLE
VCI − LAPTOP
MEDIC−3 / MUT−III
MAIN HARNESS
BLUE END
VCI\VCI Lite
MEDIC 3 / MUT−III PC
3. Set the electric motor switch to the “ON” position. Confirm the “READY” light is displayed. Turn off
all electrical systems (exterior/interior lights, blower motor, radio, etc…).
4. From the MUT−III menu, select “Special Function.”
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5. Select “All DTCs.”
6. Select “Read all DTCs.”
7. Ensure the vehicle information matches the vehicle
being inspected. Select the “car” icon.
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(2)
8. If the VIN listed does not match the vehicle being
inspected, click on the eraser icon at the bottom of the
page (1).
Click on the VIN button (2).
(1)
9. Click on the icon in the lower RH corner of the screen
to have the MUT−III automatically read the VIN (1). If
a message appears saying that the VIN cannot be
read automatically, manually type the 17 digit VIN into
the VIN field (2).
(2)
When the VIN is entered correctly, click on the check
mark icon to continue (3).
(1)
(3)
(1)
10. Ensure the VIN entered is correct (1).
When prompted, select the appropriate transmission.
Click on the check mark icon to continue (2).
(2)
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11. Click on the check mark icon at the bottom of the page
to initiate DTC scan.
Confirm scanning for all DTCs by clicking on the check
mark icon when prompted.
12. When the DTC scan completes, there may be 4 DTCs
displayed with codes “U1111” and “U1116”. This is
normal. If there are separate DTCs displayed, trouble
shoot the DTC’s according to the service manual.
13. From the MEDIC main page, click on MUT−III.
14. Select “System select.”
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15. Select EV−ECU. Click on the check mark icon to
continue.
16. Select “Actuator Test.”
17. Select item “No. 3 Water pump actuate.”
Press the check mark icon to continue. This will initiate
water pump actuation in 20 seconds.
NOTE: If water pump actuation cannot be completed, or if
the vehicle cannot enter “READY” mode, reset the
system by setting the electronic motor switch to the
“OFF” position and wait at least 60 seconds. Once
60 seconds have elapsed, set the electric motor
switch to the “ON” position and confirm the vehicle
can be placed in “READY” mode.
Repeat the water pump actuation process starting
from Step 15.
18. Within 20 seconds of performing Step 17, position yourself next to the rear radiator condenser tank.
Once the 20 seconds have elapsed, the water pump will actuate for 4 seconds. Once the water pump
stops actuating, there will be a 30 second intermission until the water pump starts actuating again for
4 seconds. During this 30 second intermission, fill the radiator condenser tank with coolant until it
reaches the “F” (Full) mark.
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19. Water pump actuation (4 seconds) and intermission (30 seconds) will cycle 11 more times (12 cycles
total − approximately 7 minutes in length). Add coolant to the rear radiator condenser tank to the “F”
(Full) mark during each intermission. When water pump actuation does not decrease the amount of
coolant in the radiator condenser tank, you may stop the water pump actuation process by turning
the vehicle OFF.
NOTE: If coolant recovered from the old OBC is insufficient in filling the rear radiator condenser tank, procure
additional coolant as necessary.
20. Select item “No. 9 Water pump actuate 2.”
Press the check mark icon to continue. This will initiate
water pump actuation.
NOTE: If water pump actuation cannot be completed, or if
the vehicle cannot enter “READY” mode, reset the
system by setting the electronic motor switch to the
“OFF” position and wait at least 60 seconds. Once
60 seconds have elapsed, set the electric motor
switch to the “ON” position and confirm the vehicle
can be placed in “READY” mode.
Repeat the water pump actuation process starting
from Step 15 and skipping Steps 17 − 19.
21. Allow the water pump to operate for at least 1 minute. Then set the electric motor switch to the ”LOCK”
(OFF) position to stop the water pump.
22. Check the coolant level in the rear radiator condenser tank:
NOTE: If coolant recovered from the old OBC is insufficient in filling the rear radiator condenser tank, procure
additional coolant as necessary.
a. If the coolant level is lower than the “L” (Low) mark, refill the coolant to the “F” (Full) mark and
repeat Steps 20 − 22.
b. If the coolant level is above the “L” (Low) mark, air bleeding is complete. Refill coolant to the “F”
(Full) mark and secure the rear radiator condenser tank cap (ensure click is heard).
23. Ensure the vehicle is not leaking any coolant.
24. Reinstall the 12V battery cover. Torque specifications is 35 + 8 in−lb (4.0 + 1.0 N−m).
25. Reinstall the power unit lid and rear access cover. Return the rear seatbacks to its original position.
Set the clock. Fully charge the i−MiEV Main drive lithium−ion battery. If not equipped with MMCS
Navigation, set radio station presets previously noted before returning the vehicle to the customer.
PARTS INFORMATION
Use the genuine Mitsubishi Part listed below:
Description
Part Number
Quantity
Converter and Charging Unit
9481A093
1
Packing, EV Control Electrical (O−Ring)
9499A797
1
DiaQueen SUPER LONG LIFE COOLANT PREMIUM or Equivalent
MZ320125
As needed
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WARRANTY INFORMATION
There is only 1 repair scenario for each specific campaign number.
If involved in C1509E01
# Campaign Op# Labor Time
Repair Description
1
C1509E01
Part Number
9481A093
9499A797
Involved vehicles require the On
Board Charger to be replaced
1.1 hrs
MZ320125
WARRANTY / RECALL CAMPAIGN CLAIM INFORMATION
Enter all claims as claim type ’C’ − Recall/Campaign Claims
Please follow the campaign instructions when entering each claim in order to select applicable
operation code that correctly matches up with the work that was actually performed. A claim
example is provided below.
Certain 2010MY i−MiEV Models (Only 3 vehicles involved)
Required Operation to be performed
1. 2010 i−MiEV On Board Charger −
Labor Operation
Labor Time
C1509E01
1.1 hrs
Claim Header Section:
Enter in the first 6 characters of the
applicable campaign number: C1509E.
C1509E
15000
JA…………..….
This campaign is for repairs to the On Board Charger on
certain 2010 MY i−MiEVs. (NOTE: Only 3 vehicles)
Check the Open Campaign area of the Superscreen each
time to be certain of a vehicle’s eligibility and what campaign number applies. Only 3 i−MiEV VINs showing
C1509E as open are involved.
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Labor and Parts:
There is only 1 possible repair scenario for this campaign. The Superscreen will show one of
the three vehicles involved in this campaign. Campaign C1509E01 requires the on board
charger to be replaced and claimed along with 2 other part numbers.
Claim Entry Sample:
Parts: No other parts may be claimed other than what are shown below.
Labor: Labor time is 1.1 hours.
Rental Cars:
If there is a need to provide the owner with a rental car, claim the applicable charges in this
section of the claim on the lower portion of the labor entry screen.
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Replaced Parts Retention:
Retain all replaced parts for the standard parts retention holding period of 30 days past the end
of month claim statement where the claim was shown as paid.