NHTSA ID Number: 10175779
Manufacturer Communication Number: TSB-20-54-003
TSB/Document Date: 2020-05-26
Summary
This TSB updates the Chassis Electrical section of the affected Service Manuals to add procedures to On Board Charger/DC-DC Converter diagnosis in 54D, Electric Motor Unit and Traction Battery section. These procedures have been added because a new service part is available for the on board charger/DC-DC converter.
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TSB/Document ID: TSB-20-54-003
Replacement Service Bulletin Number:
MFR Communication Date: 2020-04-22
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
MFR Component Subsystem:
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TSB-20-54-003
Page 1 of 95
SUBJECT:
ADDITIONAL PROCEDURES FOR ON BOARD
CHARGER/DC-DC CONVERTER - SMR
No:
TSB-20-54-003
DATE:
April 2020
MODEL:
2012-2013 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 Manuals to add procedures
to On Board Charger/DC-DC Converter diagnosis in 54D, Electric Motor Unit and Traction Battery
section. These procedures have been added because a new service part is available for the on board
charger/DC-DC converter.
Use the procedures in this bulletin for servicing the new on board charger/DC-DC converter.
D
New part has a marking on the part number label.
(Refer to the procedures in this TSB for details.)
D
Previous part has no marking on the part number label.
AFFECTED VEHICLES
D
2012 - 2013 i-MiEV (2013 sold in Canada only)
AFFECTED SERVICE MANUALS
D
2012 - 2013 i-MiEV Service Manual, Group 54-Chassis Electrical
Copyright 2020, 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).
(4724)
TSB-20-54-003
Page 2 of 95
Please make the indicated changes below to the 2012 and 2013 i-MiEV Service Manual, Group
54-Chassis Electrical -> 54D-Electric Motor Unit And Traction Battery -> Electric Motor Control Unit
(EMCU) And Motor (Electric Motor Unit) -> Diagnosis Function.
See next 3 pages
TSB-20-54-003
Page 3 of 95
TSB-20-54-003
Page 4 of 95
TSB-20-54-003
Page 5 of 95
TSB-20-54-003
Page 6 of 95
Please make the indicated changes below to the 2012 and 2013 i-MiEV Service Manual, Group
54-Chassis Electrical -> 54D-Electric Motor Unit And Traction Battery -> On Board Charger/DC-DC
Converter (OBC) -> Inspection Chart for Diagnostic Trouble Code.
TSB-20-54-003
Page 7 of 95
Refer to corresponding
code in the “DIAGNOSTIC
TROUBLE CODE
PROCEDURES ”
section in this TSB for
the new part
Refer to corresponding
code in the “DIAGNOSTIC
TROUBLE CODE
PROCEDURES ”
section in this TSB for
the new part
TSB-20-54-003
Page 8 of 95
Refer to corresponding
code in the “DIAGNOSTIC
TROUBLE CODE
PROCEDURES ”
section in this TSB for
the new part
TSB-20-54-003
Page 9 of 95
Please make the indicated changes below to the 2012 and 2013 i-MiEV Service Manual, Group
54-Chassis Electrical -> 54D-Electric Motor Unit And Traction Battery -> On Board Charger/DC-DC
Converter (OBC) -> Diagnosis Code Procedures.
TSB-20-54-003
Page 10 of 95
Please make the indicated changes below to the 2012 and 2013 i-MiEV Service Manual, Group
54-Chassis Electrical -> 54D-Electric Motor Unit And Traction Battery -> On Board Charger/DC-DC
Converter (OBC) -> Diagnostic Trouble Code Procedures.
NOTE: Refer to the added “DIAGNOSTIC TROUBLE CODE PROCEDURES ” in this TSB (40 pages) when diagnosing DTCs on the new On Board
Charger/DC-DC Converter.
TSB-20-54-003
Page 11 of 95
DIAGNOSTIC TROUBLE CODE PROCEDURES
DTC P1C00: DCDC Input Voltage Abnormal
High voltage circuit
On board charger/DC-DC converter
O
G-13
1
2
O
1
2
O
O
Inverter
4
20A
High voltage
fuse
Discharge
circuit
G-06
1
1
O
To traction battery
G-05
1
1
O
From traction battery
NOTE
:Indicates the high voltage cables,
wiring harnesses or connectors.
Wire color code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKB00070 AB
TSB-20-54-003
Page 12 of 95
Connectors: G-05, G-06
Connector: G-13
G-13 (O)
G-06
G-05
AK900332 AD
AKA00714 AC
.
TROUBLE JUDGMENT
Check Conditions
The EV-ECU allows the DC-DC converter to operate.
Judgment Criterion
The input voltage is less than 200 V or more than 420 V.
.
FAIL-SAFE AND BACKUP FUNCTION
The output of DC-DC converter is stopped.
.
PROBABLE CAUSES
Traction battery assembly is failed.
High voltage system component of except DC-DC converter
is failed.
EV-ECU is failed.
Fuse meltdown between DC-DC converter and inverter
Open circuits or damage of high voltage circuits between
DC-DC converter and traction battery; or poor contact of
connector
The DC-DC converter 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 DTC of other
systems.
Q: Is the diagnostic trouble code of EV-ECU system set?
YES : Check EV-ECU system (Refer to GROUP 54D EVECU Inspection Chart for Diagnostic Trouble Code
).
NO : Go to Step 2.
TSB-20-54-003
Page 13 of 95
STEP 2. Continuity check on fuse between DC-DC
converter and inverter
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 continuity of fuse both ends.
OK: Continuity
Fuse
AK900333AD
Q: Is the check result normal?
YES : Go to Step 3.
NO : Replace the fuse.
STEP 3. Connector check: G-13 intermediate connector, G05 inverter ( terminal) connector, G-06 inverter (+
terminal) connector
Q: Is the check result normal?
YES : Go to Step 4.
NO : Repair.
STEP 4. Check harness between G-13 intermediate
connector and on board charger/DC-DC converter
connector.
Check power supply line for open circuit and damage.
Q: Is the check result normal?
YES : Go to Step 5.
NO : Repair or replace the on board charger/DC-DC
converter (Refer to OBC Removal & Installation in this TSB).
STEP 5. Check harness between G-06 inverter (+ terminal)
connector, G-05 inverter ( terminal) connector and G-19
traction battery (+ terminal) connector, G-18 traction
battery ( terminal) connector.
Check power supply line for open circuit and damage.
Q: Is the check result normal?
YES : Go to Step 6.
NO : Repair or replace the traction battery cable.
TSB-20-54-003
Page 14 of 95
STEP 6. Recheck for diagnostic trouble code.
Check again if the diagnostic trouble code is set in the DC-DC
converter.
(1) Erase the DTC.
(2) Set the electric motor switch from the LOCK (OFF) position
to the ON, and then to the START position temporarily.
(3) Check if the DTC is set.
Q: Is the DTC set?
YES : Replace the on board charger/DC-DC converter
(Refer to OBC Removal & Installation in this TSB).
NO : Intermittent malfunction (Refer to GROUP 00 − How
to Use Troubleshooting/Inspection Service Points,
How to Cope with Intermittent Malfunctions ).
DTC P1C02: DCDC Output Voltage Abnormal
DTC P1C22 DCDC Output Voltage Abnormal (2)
.
TROUBLE JUDGMENT
Check Conditions
The EV-ECU allows the DC-DC converter to operate.
Judgment Criterion
The output (B terminal) voltage is more than 16.0 V.
The system detects a failure "overvoltage abnormal detection circuit" in the output section by predetermined times or
more.
.
FAIL-SAFE AND BACKUP FUNCTION
The output of DC-DC converter is stopped.
.
PROBABLE CAUSE
The DC-DC converter is failed.
DIAGNOSIS
STEP 1. Recheck for diagnostic trouble code.
Check again if the DTC is set in the DC-DC converter.
(1) Erase the DTC.
(2) Set the electric motor switch from the LOCK (OFF) position
to the ON, and then to the START position temporarily.
(3) Check if the DTC is set.
Q: Is the DTC set?
YES : Replace the on board charger/DC-DC converter
(Refer to OBC Removal & Installation in this TSB).
NO : Intermittent malfunction (Refer to GROUP 00 − How
to Use Troubleshooting/Inspection Service Points,
How to Cope with Intermittent Malfunctions ).
TSB-20-54-003
Page 15 of 95
DTC P1C04: DCDC Output Voltage Reduction
FUSIBLE
LINK 26
ON BOARD
CHARGER/
DC-DC
CONVERTER
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple SI : Silver
ACI00444
Judgment Criterion
The output (B terminal) voltage is less than 6.0 V.
Connector: E-01
.
FAIL-SAFE AND BACKUP FUNCTION
The output of DC-DC converter is restricted.
(B)
.
AC902340AG
.
TROUBLE JUDGMENT
Check Conditions
The EV-ECU allows the DC-DC converter to
operate.
PROBABLE CAUSES
The Auxiliary battery is failed
The installation of the auxiliary battery terminal is
failed.
The fusible link is fused.
Open circuits of output (B terminal) voltage, damage or poor contact of connector
The DC-DC converter is failed.
TSB-20-54-003
Page 16 of 95
DIAGNOSIS
STEP 1. Check auxiliary battery.
Check auxiliary battery (Refer to GROUP 54A Auxiliary
battery On-vehicle Service Battery Test ).
Q: Is the check result normal?
YES : Go to Step 2.
NO : Replace the auxiliary battery.
STEP 2. Connector check: E-01 on board charger/DC-DC
converter connector, fusible link (No. 26)
Check the terminals for deformation, looseness, etc.
Q: Is the check result normal?
YES : Go to Step 3.
NO : Repair the damaged connector.
STEP 3. Check the wiring harness between E-01 on board
charger/DC-DC converter connector (terminal No. 1) and
the fusible link (No. 26).
Check the power supply line for open, short circuit and damage.
Q: Is the check result normal?
YES : Go to Step 4.
NO : Repair the wiring harness.
STEP 4. Recheck for diagnostic trouble code.
Check again if the DTC is set in the DC-DC converter.
(1) Erase the DTC.
(2) Set the electric motor switch from the "LOCK" (OFF)
position to the ON, and then to the START position
temporarily.
(3) Check if the DTC is set.
Q: Is the DTC set?
YES : Replace the on board charger/DC-DC converter
(Refer to OBC Removal & Installation in this TSB).
NO : Intermittent malfunction (Refer to GROUP 00 − How
to Use Troubleshooting/Inspection Service Points
How to Cope with Intermittent Malfunctions ).
TSB-20-54-003
Page 17 of 95
DTC P1C06: DCDC IGCT Voltage Abnormal
FUSIBLE
LINK 21
RELAY
BOX
GROUNDING
CONNECTOR
EARTH
EV-ECU
ON BOARD
CHARGER/
DC-DC
CONVERTER
EV-ECU
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple SI : Silver
AKC00310 AB
TSB-20-54-003
Page 18 of 95
Connector: E-03
Connector: A-08X
A-08X
E-03 (GR)
AKA00716 AD
AKA00651AC
.
TROUBLE JUDGMENT
Check Condition
The EV-ECU is activated.
Judgment Criterion
The DC-DC converter control power supply voltage is less
than 7.2 V.
or
The DC-DC converter control power supply voltage is more
than 17.6 V.
.
FAIL-SAFE AND BACKUP FUNCTION
The output of DC-DC converter is stopped.
.
PROBABLE CAUSES
The Auxiliary battery incorrect connection by user
The installation of the auxiliary battery terminal is failed.
The EV control relay is failed.
Open circuits of DC-DC converter power supply, short circuits to ground, damage or poor contact of connector
The DC-DC converter is failed.
DIAGNOSIS
STEP 1. Check auxiliary battery.
Check auxiliary battery (Refer to GROUP 54A Auxiliary
battery On-vehicle Service Battery Test ).
Q: Is the check result normal?
YES : Go to Step 2.
NO : Replace the auxiliary battery.
STEP 2. Use scan tool MB991958 to confirm a DTC of other
systems.
Q: Is diagnostic trouble code of EV-ECU system set?
YES : Check EV-ECU system (Refer to GROUP 54D EVECU Inspection Chart for Diagnostic Trouble Code
).
NO : Go to Step 3.
TSB-20-54-003
Page 19 of 95
STEP 3. Connector check: E-03 on board charger/DC-DC
converter connector, A-08X EV control relay (relay box)
connector
Q: Is the check result normal?
YES : Go to Step 4.
NO : Repair the damaged connector. Correct or replace the
relay box.
STEP 4. Check the wiring harness between A-08X EV
control relay (relay box) connector (terminal No. 1) and E03 on board charger/DC-DC converter connector (terminal
No. 8).
Check the power supply line for open, short circuit and damage.
Q: Is the check result normal?
YES : Go to Step 5.
NO : Repair the wiring harness.
STEP 5. Recheck for diagnostic trouble code.
Check again if the DTC is set in the DC-DC converter.
(1) Erase the DTC.
(2) Set the electric motor switch from the LOCK (OFF) position
to the ON, and then to the START position temporarily.
(3) Check if the DTC is set.
Q: Is the DTC set?
YES : Replace the on board charger/DC-DC converter
(Refer to OBC Removal & Installation in this TSB).
NO : Intermittent malfunction (Refer to GROUP 00 − How
to Use Troubleshooting/Inspection Service Points,
How to Cope with Intermittent Malfunctions ).
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