Maintenance
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12-6-2c Periodical inspection item chart for i-MiEV [For USA / CANADA]
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Note:
Since 2010MY i-MiEV exported to USA / CANADA is for Japanese specification only, maintenance intervals of these
pilot cars have not been established individually.
As for these cars, please refer to the maintenance interval for G.EXP and follow them without overdue.
In those cases, inspection at first 1000km could be disregarded.
５６
Maintenance
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Maintenance
12-9 Power plant cooling system: Water (LLC) filling procedure
Basically, the water (LLC) for Power plant (Motor for driving) cooling system is not required the periodical replacement.
Proceed the following steps if replacement of the coolant is required.
[Caution]
Water pump motor uses LLC as lubricants therefore, it will be damaged if the water pump motor runs without filling the
LLC to the cooling system.
Pay attention to the LLC level at condenser tank while the re-filling and if it is difficult to manage, stop the activation of
the water pump motor by turn the power switch to LOCK(OFF) position.
Step Work
1 Prepare the appropriate amount of LLC. [ Total volume of LLC: Approx. 5.1 L ]
2 Set the power switch position to LOCK(OFF).
3 Fill-up the condenser tank by LLC up to the neck. area.
Activate the “Water pump actuate” mode. MUT-III Screen shot
[With using MUT-III]
[1] Connect MUT-III to the vehicle through VCI
[2] Turn the power switch to ON position
[3] System select
> EV-ECU
> Actuator test
> Item No.3: Water pump actuate
[4] Water pump actuate mode will be
4
activated after 20 seconds.
[Without using MUT-III]
[1] Pull the parking brake lever.
[2] Turn the power switch to ON position
[3] Push the TCL switch 10 times within 7 seconds after turn ON the power switch.
[4] Water pump actuate mode will be activated after 20 seconds.
After 20 seconds, water pump motor runs for 4 seconds and stop for 30 seconds and continue it repeatedly.
[Note]
5 -Keep the LLC level at neck area all the time.
-The LLC filling control mode will continue the activation for 7 minutes, and it activates the pump
4 seconds x 12 times.
Repeat step 5 until the coolant level become steady .
6 [Note]
-It will take 3 to 4 minutes to complete the LLC filling.
For air bleeding purpose, activate the water pump for 1 minutes or more either with MUT-3 or without MUT-3.
[With using MUT-III]
[1] Confirm the LLC level at condenser is “Full” position.
[2] Turn the power switch to “READY” position
[3] System select > EV-ECU > Actuator test > Item No.9: Water pump actuate 2
7
[Without using MUT-III]
[1] Confirm the LLC level at condenser is “Full” position,
[2] Turn the power switch to “READY” position
[3] Leave the vehicle for 15 minutes or more.
(While 15 minutes of READY condition, Total time of water pump activation reaches 1 minutes.)
８ Turn the power switch to LOCK position to stop the water pump, then confirm the level of LLC.
[If the coolant level at condenser is “LOW” position or higher]
Air bleeding is completed.
9
[If the coolant level at condenser is “lower than LOW” position]
Fill the coolant up to “FULL” line, and rework “step 7 and 8” .
10 Adjust the LLC level at “Full “position, then operation is completed.
５９
Maintenance
12-10 Cabin Heater System
Condense tank Heater core
Electric water heater
Electric water pump
Make sure to remove the service plug when make service on the parts using high voltage.
12-10-1 Cabin Heater system: Water (LLC) draining procedure
LLC can be drained by removing the drain plug.
[Caution] Since the drain plug is quite narrow, pay attention for the applying torque.
Drain plug
12-10-2 Cabin Heater system: Water (LLC) filling procedure
Basically, the water (LLC) for cabin heater is not required the periodical replacement.
Proceed the following steps if replacement of the coolant is required,
[Caution]
Water pump motor uses LLC as lubricants therefore, it will be damaged if the water pump motor runs without filling the
LLC to the cooling system.
Pay attention to the LLC level at condenser tank while the re-filling and if it is difficult to manage, stop the
activation of the water pump motor by turn the power switch to LOCK(OFF) position.
1 Prepare the appropriate amount of LLC.
2 Set the power switch position to LOCK(OFF).
3 Fill-up the condenser tank by LLC up to the neck. area.
4 Set the vehicle as READY” mode.
5 Turn ON the heater switch to operate the Water pump for the cabin heater
6 Maintain the LLC level at reservoir tank and do not empty it.
7 Confirm the LLC movement (Blow out) at the circled area shown in the right photo.
8 Keep “STEP 6” condition for 60 seconds for Air bleeding purpose.
9 Turn OFF the power switch, level the LLC to “FULL” line, then operation is completed.
６０
Maintenance
12-10-3 Cabin Heater system: Heater unit dismantle procedure
-Dismount the condenser tank as pre-work.
-Disconnect the Return hose at pump side and the Disconnect Feeder hose at heater unit side.
-Do not disconnect the DC 12V/DC 330V electrical harnesses at heater unit side.
-Dismount the bracket together with the heater unit.
Return hose Split point when dismantle
Feeder hose
Electric Water pump
Make sure to remove the service plug when make service on the parts using high voltage.
Do not disconnect the electrical cables at the heater unit side.
[For both DC 330V and DC 12V]
Unnecessary to separate
Heater unit and Bracket for dismantle
DC 12V Harness
Heater unit and Bracket can be DC 330V Harness
dismantled together
In order to keep the enough space for dismantle the electrical water pump,
Holding clips for DC 330V harness
unit, remove the Clips for DC 330V harness for A/C compressor.
Electrical water pump
６１
Maintenance
12-11 A/C system
12-11-1 A/C system: Removal procedure
[Removal procedure]
Since A/C compressor is driven by electrical motor which uses DC 330V, special attention is required to handle it.
Make sure to remove the service plug when make service on the parts using high voltage.
Register
[Pay attention for high temperature]
A/C compressor
12-11-2 A/C system: A/C refrigerant and lubricant
[1] A/C refrigerant
HFC134a is used as same as petrol powered “i”.
[2] Oil
Due to the adoption of the electrical motor driven compressor, following oil which has high
insulation performance are specified.
Oil (POE) :MA68EV [Special oil for i-MiEV supplied by Mitsubishi Heavy Industries]
Minimum Supply unit : 100ml Canned for service use
[Note]
PAG (Polyalkylene Glycol) is used for Petrol powered ‘i”
POE (Polyol Esters) is used for i-MiEV
[Caution points on handling the POE oil]
-Expiration date-
Since the POE oil has a potential of deterioration by moisture absorption (hydrolytic cleavage),
expiration date for use is specified as follows.
Expiration date for use : 5 years (with unopened condition)
[Note:]Storage of oil is not allowed once the can is opened.
- Charging -
It is strictly prohibited to mix up of PAG to POE, exclusive Charger and charging hose is required for i-MiEV.
A/C gas recycling charger ＰＡＧ charging hose ＰＯＥcharging hose
Recycle OK OK
Charger for PAG
Charge OK NG
Recycle NG OK
Charger For POE
Charge NG OK
６２
Maintenance
12-12 DC 330V Battery
[Caution]
-Technical staff who inspect / maintenance the i-MiEV as Electrical vehicle should be completed the special
training course for the electric power handling.
-Make sure to remove the service plug when make service on the parts using high voltage.
12-12-1 DC 330V Battery: Removal
[STEP-1] Pre-work from cabin side
[1] Remove front passenger’s seat, floor console ass’y, side trim, scuff plate, then peel off the floor carpet.
[2] Remove floor duct
[3] Release the each rubber catch.
[3]
[2]
[3]
Make sure to remove the service plug when make service on the parts using high voltage.
[STEP-2] Disconnection of DC 330V harness
[1] Disconnection of P-Line & N-Line to the MCU
[2] Disconnection of the Line from the quick charging plug socket
[3] Disconnection of the line to the Heater
[4] Disconnection of the line to the A/C compressor
[3]
[4]
[1]
[2]
Vehicle forward direction
Make sure to remove the service plug when make service on the parts using high voltage.
６３
Maintenance
[STEP-2] Disconnection of DC 330V harness [Close-up for Disconnect ion of P-Line & N-Line to the MCU]
[Note:] O-ring of the work hole lid can not be reused.
O-ring on the work hole lid
(Can not be reused)
1. Remove the work hole lid
Make sure to remove the service plug when make service on the parts using high voltage.
2. Remove the bolts at cable holder
1. Remove the bolts at cable terminal 3. Remove the bolts at cable terminal
Make sure to remove the service plug when make service on the parts using high voltage.
６４
Maintenance
[STEP-3] Disconnection of other harness
[1] Disconnection of Ground cable to the body (Disconnect at body side)
[2] Disconnection of DC 12V harness to the battery pack (Rear end)
[3] Disconnection of DC 12V harness to the battery pack (Center)
[1]
[3]
[2]
Make sure to remove the service plug when make service on the parts using high voltage.
[STEP-4] Removal of the Floor flame plate
[1] Remove these bolts at the Floor flame plate.
[Note] : Loose prevention agent is used for these bolts.
Make sure to remove the service plug when make service on the parts using high voltage.
６５
Maintenance
[STEP-５] Dismounting from the body
[1] With Battery on board condition, loosen all holding bolts.
[2] Remove out 2 bolts located at the front end.
[3] Place the EV battery cart(MB992353) under the vehicle and put the two wood blocks (size 4 inch x 4 inch x 5 feet).
[4] Down the lift until the battery pack touches to the wood block slightly.
[5] Remove out the all holding bolts, then Up the lift.
Wood blocks (size 4 inch x 4 inch x 5 feet)
（Required Max. load is 250kg)
Wood blocks
[Note] EV battery lifting cart (MB992659)
fine control of the height.
EV battery lifting cart can be used for dismounting the battery, if the lift is difficult to make
６６
Maintenance
12-12-2 DC 330V Battery: Installation
[1] Set the EV battery guides [MB992327] to the body(2 locations).
[2] Align the battery guides and the holes on the battery unit flame, then down the lift little by little.
[3] Tighten the battery flame fixing bolts temporally (Except the bolts occupied by EV battery guides[MB992327] )
[4] Remove the EV battery guides[MB992327], tighten the remain 2 bolts then tighten all bolts fully(115N・m).
Tightening torque of
DC 330V battery frame fixing bolts;
115±37N・m
Apply the loose preventing agent (Threebond 1342 or equivalent)
to the Fixing bolt for Floor flame plate No.10.
６７
Maintenance
12-12-3 DC 330V Battery: Convey battery
To convey DC 330V Battery, sling it by using the EV battery sling tool kit(MB992347).
[1] Set the Eye bolt(MB992344), Hexagon nut(MU001480), Washers[MF450156] for 4 locations.
[2] Check the center of the sling belt and
mark 275mm from the center for both side (Left and Right).
[3] Set the Sling belts to the each side of Eye bolts, and
position the marks on the sling belt and the Eye bolts.
[4] Gather the belts and sling by crane.
６８
Maintenance
12-14 MCU Removal
[1] Disconnect the P-Line and N-Line from DC 330V battery to the MCU
[2] Disconnect the Three phases lines to the motor
[3] Disconnect the P-Line and N-Line from Charging system and DC/DC converter to MCU
[3]
[2]
[1]
Remove 5 bolts Vehicle forward
Remove 8 bolts
６９
Maintenance
12-15 OBC Removal
[1] Disconnect the connector “A” [PN line from MCU]
[2] Disconnect the connector “B” [Charging line from the plug for household charger 200V/100V]
Make sure to remove the service plug when make service on the parts using high voltage.
“B” Vehicle front
“A”
７０
Maintenance
12-16 Electrical motor removal
Make sure to remove the service plug when make service on the parts using high voltage.
[Note] : Bolts/Nuts indicated with “*” mark must me tightened under following steps.
(1) Tighten temporary
(2) Tighten fully after the motor and transmission are loaded without any support.
*
*
* * *
*
Power unit mounting insulator (Rear)
*
Power unit mounting insulator (Rear)
７１
Maintenance
12-17 Data writing to the MCU by MUT-3 [Initial phase angle of motor]
Initial phase angle of the motor shall be set to MCU by using MUT-III, when the electrical motor and/or MCU
is/are replaced.
[When the electrical motor is replaced]
[1] Readout the initial phase angle of the motor from the paper tag which is attached on the electrical motor, and
write it to the MCU through MUT-III.
[When the MCU is replaced]
[1] Start/connect the MUT-III and read out the initial phase angle of the motor as the service data.
[2] Replace the MCU with brand new one and write the initial phase angle to the new MCU through MUT-III.
[Note] If you fail to read out the initial phase angle through MUT-III, please contact to the following address to obtain it.
E-mail: TBD .
Select MCU
Readout the “Initial phase position” from the data list
(When the EV-ECU is going to be replaced)
Input the “Initial phase position” from the special function
７２
Maintenance
12-18 Transmission Removal
Transmission can be dismantled from the vehicle as alone.
To dismantle the transmission, follow the steps in below.
[1] Remove the drive shafts (both side) . The same procedure for petrol powered “i” can be applied.
[2] Disconnect the connectors for inhibitor switch(2 connectors).
[3] Remove the shift cable and breather hose.
[4] Loosen the electrical motor mounting bolts (Do not remove the bolts yet)
[5] Hold up the motor by jack, and remove the remove the all motor mounting bolts.
Location of the electrical motor mounting bolts
(6 positions)
７３
Maintenance
12-19 Front positioning light bulb replacement
i-MiEV utilizes the LED headlights, the location of positioning lights has been changed from petrol powered “I”.
To replace the positioning light bulb, followings are required.
-Removal of Head lights ass’y from the body.
-Removal of LED unit driver from the Head lights ass’y.
1 [LED type head lights] 2
Positioning light Headlight (Low beam)
with positioning light
Low beam
High beam
Turn signal light
3 4
LED unit driver
socket
Bolts
７４
Maintenance
12-20 Body repair / Paint
12-20-1 Body repair / Paint General
- Technical staff who works at the body repair / paint shop should be completed the special training course for
the electric power handling, before treat the i-MiEV.
- DC 330 V battery and related parts must be removed before order to the outside paint shop, if the shop staff is not
completed the said training course.
- Body repair / paint for i-MiEV must be completed within 2 months. Deterioration of the DC 330V battery
is expected due to the full discharge of the battery.
- Since DC 330V battery and related parts does not use body as ground, unnecessary to remove them
for welding work as MIG or Spotting.
- Maintain the temperature of DC 330V battery at 60℃ or less. Remove out the DC 330V battery if it is difficult.
- Basically remove out the battery DC 330V battery at 60℃ or less. Remove out the DC 330V battery if it is
difficult.
YES Diagnose the system and
DTC is stored. Remove the damaged parts
NO
YES
Bring the vehicle to the
Body Paint damage only Body/Paint shop for repair
NO
No damage / No deform /
Nor crack / No hit mark NO Carry out the OK Bring the vehicle to the
on the DC 330V battery Battery pack quality check Body/Paint shop for repair
and other connected parts
NG
YES
(1)Dismantle the battery pack
(2)Bring the vehicle to the
Body/Paint shop for repair
(1) Disconnect the P-Line & N-Line
Wait 5 minutes from the
DC 12V battery YES disconnection of the DC 12V Confirmed (2) Remove out the damaged DC 330V
battery and other connected parts
can be disconnected. battery, Confirm the No voltage (3)Bring the vehicle to the Body/Paint
between P-Line & N-Line.
shop for repair
NO
Not Confirmed
(1) Disconnect the P-Line & N-Line
Service plug YES Confirm the No voltage be- Confirmed (2) Remove out the damaged DC 330V
battery and other connected parts
can be removed tween P-Line & N-Line. (3)Bring the vehicle to the Body/Paint
shop for repair
NO
Not Confirmed
(1) Remove the all fuses from battery pack
(2) Disconnect the P-Line & N-Line
(3) Remove out the damaged DC 330V
battery and other connected parts
(3)Bring the vehicle to the Body/Paint shop
for repair
７５
Maintenance
12-20-2 Damage check of the batteries after the collision
If the vehicle got a collision, carry out the battery pack quality check in accordance with the following steps.
Check if DTC is stored
-Check DTC by MUT-III
-Brief check for inside of the battery pack
NG OK
Check damage/crack on frames/battery tray
-Visual check of the DC 330V battery on board condition
-Brief check for inside of the battery pack
-Brief check for outside of the battery pack
NG OK
Measurement of Relative deforming amount of Frames
-Measurement of Relative deforming amount of Frames
(Refer to page 66 [1] for the procedure)
-Brief check for the air tightness of the battery pack
NG OK
Measurement of gap between Frames and battery pack
-Measurement of gap between Frames and battery pack
(Refer to page 66 [2] for the procedure)
-Brief check for the air tightness of the battery pack
OK
Replace DC 330V battery to brand new one as Assembly DC 330V battery can be re-used
７６
Maintenance
[1] Measurement of Relative deforming amount of Frames
Measure the distances listed in the following table by using tracking gauge.
Unit
Vehicle forward
Vehicle forward
Vehicle forward
Standard Measure point Basic dimension Dimension by drawing
№ （mm.）
Base point End point Dimension Tolerance
1 F A 975 Dimension ±1.1
2 F B 627 627.2 ±1.1
3 F C 980 979.6 ±1.1
4 Ｆ D 263 262.5 ±1.0
5 Ｆ E 977 977.0 ±0.9
6 Ｆ G 1122 1121.7 ±1.2
7 Ｆ H 551 551.0 ±0.9
8 Ｆ I 1259 1259.0 ±1.3
9 Ｆ J 894 893.6 ±1.0
７７
Maintenance
[2] Measurement of gap between Frames and battery pack
Measure the gaps at the every positions indicated by arrows and confirm the every gaps are
3.9mm or less.
Front floor side member
(Lower)
Battery
Tray
Bracket
Cross member
For Battery tray
Battery tray 3.9mm or less
７８
Troubleshooting
13. Troubleshooting
13-1 Key points on trouble shooting
As same as petrol powered “i”, DTC (Diagnosis Trouble Code) will be stored when the system has failure,
and system backup and/or fail sale process will be carried out if necessary.
Followings are example of DTCs for EV-ECU.
13-1-1 P1A44: Detection of Electric leak
Judgment Criterion : Electric leak sensor detects electrical leak for 5 second or more.
Probable cause : Electric leak at DC 330V circuit.
: Malfunction of Electric leak sensor or its circuit.
: Malfunction of BMU.
Fail sale control : Regeneration mode is cancelled.
: Power of driving motor is restricted.
: Shut down the DC 330V after vehicle stop.
Make sure to remove the service plug when make service on the parts using high voltage.
[Note]: The following procedure is only for the case if the DTC P1A44 is stored.
1. Remove the service plug and shut off the high voltage to the parts using DC 330V.
2. Open the service lid of MCU, and check the connectivity between
P-line terminal to ground or N-line terminal to ground by
insulation resistance tester.
[If the no connectivity is observed]
No electric leak will be expected. [Inspection is completed]
P-line N-line
[If the connectivity is observed] terminal terminal
Electric leak will be expected. Go to STEP 3.
3. While monitoring the connectivity between P-line terminal to ground or
N-line terminal by to ground by insulation resistance tester,
disconnect the following connector one by one. [Inspection points: P & N line terminal]
- Cabin heater
- A/C Compressor
- OBC and DC/DC converter Heater unit Heater Heater unit
- Motor for driving connector
A/C A/C
compressor compressor
A/C Comp.
connector
Cabin heater A/C Compressor
MCU V terminal
MCU W terminal MCU U terminal
Connector for MCU -
OBC & DC/DC converter
OBC and DC/DC converter Motor for driving
4. If the connectivity between P-line terminal to ground or no connectivity is changed to “no connectivity” while
STEP 3, replace the leaked parts to brand new one.
5. If the connectivity between P-line terminal to ground or no connectivity is not changed, Malfunction of MCU is
Expected. Replace MCU to brand new one.
７９
Troubleshooting
13-1-2 P1B28: Detection of collision
Judgment Criterion : SRS ECU detects the collision and send the signal for DC 330V shut down.
Fail sale control : Shut off the DC 330V (It is not reset / cancelled by re-start of system.)
[Outline of operation]
Collision is detected by SRS ECU according to the signal from the following sensors.
- Front airbag safing G-sensor [in SRS ECU]
- Analog G-sensor [in SRS ECU]
- G-sensor for Rear impact [under rear seat]
- G-sensor for Side impact [under rear seat]
If the SRS ECU detects the collision and determines the shut off of the DC 330V, SRS-ECU send the signal of “DC
330V shut off ” to EV-ECU.
If EV-ECU receives the signal of “DC 330V shut off “, it makes turn off the main contactor to shut off the DC 330V
circuit and out put the DTC P1B28.
Once SRS ECU send the signal of “DC 330V shut off ” , it continues to output the signal every time while the power
switch is on, unless it is replaced with brand new one.
[System recovery]
Once the SRS ECU detects the collision, SRS-ECU and the related parts are required to repair/replacement.
Make sure to erase the DTC after the repair/replacement of SRS-ECU and related parts, otherwise the DC 330V
circuit never be reverted from shut off mode.
８０
Troubleshooting
13-2 Charging cable plug inspection
Check the gun, plug and cable, and conform there is no damage, rust or corrosion.
If there is, replace the cable ass’y to brand new one.
If there is no damage, rust or corrosion, check the connectivity at the positions shown in below.
Connect plug Charging gun At normal condition
Terminal №１ Terminal №１
Terminal № 2 Terminal № 2 Connectivity will be observed.
Terminal № 3 Terminal № 5
Check the connectivity between No. 4 and No.5 at charging gun.
Button at charging gun At normal condition
Without pushing the button 135-145Ω [at 20℃]
While pushing the button 432-528Ω [at 20℃]
８１
Troubleshooting
13-3 DTC list
13-3-1 DTCs [EV-ECU related 1/ 5 ]
DTC Description
C2005 Power supply low voltage1 (VP)
C2006 Power supply low voltage2 (VP)
C2007 Power supply high voltage (VP)
C200A Fail safe relay coil (VP)
C200E Fail safe relay stuck ON (VP)
C200F Fail safe relay stuck OFF (VP)
C2010 Control relay1 coil (VP)
C2011 Control relay2 coil (VP)
C2016 Control relay1 stuck ON (VP)
C2018 Control relay1 stuck OFF (VP)
C2019 Control relay2 stuck OFF (VP)
C201A Pump motor stuck (VP)
C2020 Vacuum sensor power VOLT. (VP)
C2021 Vacuum SNS.fail output VOLT.(VP)
C2022 Vacuum sensor value stuck (VP)
C202A Pump motor drive long time (VP)
C202B Vacuum PRS.abnormal loss (VP)
C202C Pressure long time low (VP)
C202E Pump operation watch (VP)
P00B3 Water temperature sensor short
P00B4 Water temperature sensor open
P0557 BPS high input (Brake Pressure Switch)
P0558 BPS low input (Brake Pressure Switch)
P0560 Battery voltage
P0562 Battery voltage too low
P0604 RAM error
P0605 ROM error
P060B ECU (AD Converter fail)
P060C ECU (Processor fail)
P062F EEPROM fail
P0646 A/C power supply relay low
P0647 A/C clutch relay circuit high
P0691 Low speed fan circuit low
P0692 Low speed fan circuit high
P0693 High speed fan circuit low
P0694 High speed fan circuit high
P0705 Inhibitor switch
P0A01 Radiator fan1,2 malfunction
P0A05 Water pump (drive signal line)
P0A09 DCDC converter fail (1)
８２
Troubleshooting
13-3-1 DTCs [EV-ECU related 2 / 5 ]
DTC Description
P0A0A Inter lock SW
P0A10 DCDC converter fail (2)
P0A2A Motor coil TEMP. sensor(MCU)
P0A3D IGBT2 temperature high(MCU)
P0A51 Current sensor(MCU)
P0A78 IGBT fail(MCU)
P0A90 Motor over current 2 (MCU)
P0AA1 Main contactor P weld
P0AA4 Main contactor N weld
P0ABA Motor drive voltage sensor(MCU)
P0ABF Battery current sensor(BMU)
P0ADB Main contactor P circuit low
P0ADF Main contactor N circuit low
P0AE2 Pre-charge contactor weld
P0AE6 Pre-charge contactor circuit low
P0AE7 Pre-charge contactor circuit HI
P0AED IGBT temperature sensor(MCU)
P0C73 Water pump (low speed)
P0C74 Water pump (high speed)
P1602 System LSI communication
P1A00 APS(main) power supply circuit
P1A01 APS(sub) power supply circuit
P1A02 Shift position SW :P
P1A03 Shift position SW :R
P1A04 Shift position SW :N
P1A05 Shift position SW :D
P1A06 Shift position SW :E
P1A07 Shift position SW :B
P1A08 Inhibitor SW :P
P1A09 Inhibitor SW :R
P1A0A Inhibitor SW :N
P1A0B Inhibitor SW :D
P1A0C Inhibitor SW :B
P1A0D Inhibitor SW :E
P1A0E Backlamp relay circuit low
P1A0F Backlamp relay circuit high
P1A10 OBC power supply circuit low
P1A11 OBC power supply circuit high
P1A12 OBC abnormal stop
P1A14 Quick CHG.contactor circuit low
８３
Troubleshooting
13-3-1 DTCs [EV-ECU related 3 / 5 ]
DTC Description
P1A15 High voltage circuit (1)
P1A16 High voltage circuit (2)
P1A17 High voltage circuit (3)
P1A18 MCU shut down circuit
P1A19 MCU shut down circuit (internal)
P1A1A MCU processor
P1A1B Motor drive voltage low(MCU)
P1A1C Motor drive voltage high(MCU)
P1A1E EEPROM fail(MCU)
P1A1F Motor coil temperature high(MCU)
P1A20 Motor RPM fail(MCU)
P1A21 Motor resolver value(MCU)
P1A22 Motor drive volt. ultra HI(MCU)
P1A23 EV ECU mode unknown(MCU)
P1A24 READY signal timeout(MCU)
P1A25 Discharge ON timeout(MCU)
P1A26 Discharge OFF timeout(MCU)
P1A27 EV torque request error(MCU)
P1A28 EV ECU fail(MCU)
P1A29 Motor over current 1 (MCU)
P1A2A IGBT over current(MCU)
P1A2B Three phase line(MCU)
P1A2D Battery cooling fan (BMU)
P1A2E CMU drive relay(BMU)
P1A2F Cell malfunction(BMU)
P1A30 Cell voltage low(BMU)
P1A31 Cell voltage high(BMU)
P1A32 Battery temperature(BMU)
P1A33 Cell Voltage sensor(BMU)
P1A34 Battery temperature sensor(BMU)
P1A35 Balancer error(BMU)
P1A38 Cell number error(BMU)
P1A39 Charge state signal error(BMU)
P1A3D A/D reference voltage(MCU)
P1A3E CPU atmosphere temp.high(MCU)
P1A3F CPU temperature sensor(MCU)
P1A44 Leak detection(BMU)
P1A45 Leak SNSR.detection circuit(BMU)
P1AC5 MCU message lost(BMU)
P1AE6 EEPROM fail(BMU)
８４
Troubleshooting
13-3-1 DTCs [EV-ECU related 4 / 5 ]
DTC Description
P1AF0 BPS power supply circuit
P1AF1 MCU READY signal timeout
P1AF2 MCU discharge direction F/B
P1AF3 BMU READY timeout
P1AF4 Control power supply VOLT. (BMU)
P1AF6 On board charging time over
P1AF7 OBC READY timeout
P1AF8 OBC charging stop process T/out
P1AF9 Quick Charger initial CHK T/out
P1AFA Quick Charger READY timeout
P1AFB Quick charging time over
P1AFC Quick charging current
P1AFD Quick charging voltage
P1AFE Quick Charger malfunction
P1AFF Quick Charger connector lock
P1B00 Quick Charger battery Error
P1B01 Quick Charger vehicle error
P1B02 Quick charge current stop T/out
P1B03 Quick charge stop process T/out
P1B04 Charging Cell MAX voltage high
P1B05 Charging Cell MIN. voltage low
P1B06 Charging Cell MAX temp. high
P1B07 Charging total battery voltage
P1B08 Charging condenser voltage
P1B09 MCU CAN timeout/Not equipped
P1B0A Quick CHG.contactor circuit high
P1B0B ABS vehicle speed data
P1B0C On board charging over current
P1B0D Quick charging over current
P1B1C ETACS message lost(MCU)
P1B1D Meter message lost(MCU)
P1B1E ETACS message lost(BMU)
P1B1F Meter message lost(BMU)
P1B21 OBC output current
P1B22 FL wheel speed data
P1B23 FR wheel speed data
P1B24 RL wheel speed data
P1B25 RR wheel speed data
P1B26 F/R tire diameter difference(1)
P1B27 F/R tire diameter difference(2)
８５
Troubleshooting
13-3-1 DTCs [EV-ECU related 5 / 5 ]
DTC Description
P1B28 Crash detection
P1B29 On board charge connector high
P1B2A On board charge connector low
P1B2B WP power supply relay open/short
P1B2C Place error of destination
P2122 APS(main) low
P2123 APS(main) high
P2127 APS(sub) low
P2128 APS(sub) high
P2138 APS(main/sub) correlation
P2805 Shift/Inhibitor POS. difference
U1073 Bus-off
U1080 V-CAN Bus-off(MCU)
U1081 V-CAN Bus-off(BMU)
U1090 Bat-CAN error(BMU)
U1102 ASC/TCL/ABS timeout/Not equipped
U1108 Meter CAN timeout/Not equipped
U1109 ETACS CAN timeout/Not equipped
U1110 A/C CAN timeout/Not equipped
U111B MCU CAN timeout
U111C MCU CAN timeout
U111D OBC CAN timeout
U1160 EV ECU message lost(MCU)
U1161 EV ECU message lost(BMU)
U116A CHG-CAN Bus-off
U116B Quick Charger CHG-CAN timeout
U1190 No receive fault detect signal
U1801 Airbag communication line short
U1802 Airbag communication line open
U1803 Airbag signal frame error
U1804 Airbag signal parity error
U1805 Airbag signal receive cycle
U1806 Airbag signal data error
U1900 Loss of MCU message (K-line)
U1901 Loss of BMU message (K-line)
U1910 Received error from MCU (K-line)
U1911 Received error from BMU (K-line)
U1920 K-line error(MCU)
U1921 K-line error(BMU)
U1924 Bat-LIN bit error(BMU)
８６
Troubleshooting
13-3-2 DTCs [MCU related 1 / 2 ]
DTC Description
P0562 Battery voltage too low
P0563 Battery voltage too high
P0604 RAM error
P0605 ROM error
P062F ECU (EEPROM fail)
P0A0D Motor drive VOLT.high(HW detect)
P0A3C IGBT1 temperature high
P0A3D IGBT2 temperature high(MCU)
P0A43 Motor resolver open/short
P0A44 Motor RPM fail
P0A51 Current sensor(MCU)
P0A78 IGBT fail(MCU)
P0A90 Motor over current 2 (MCU)
P0ABA Motor drive voltage sensor(MCU)
P0AEF IGBT1 TEMP. sensor circuit low
P0AF0 IGBT1 TEMP. sensor circuit high
P0AF4 IGBT2 TEMP. sensor circuit low
P0AF5 IGBT2 TEMP. sensor circuit high
P0C11 Motor coil U phase TEMP.(high)
P0C12 Motor coil V phase TEMP.(high)
P0C13 Motor coil W phase TEMP.(high)
P1A1B Motor drive voltage low(MCU)
P1A1C Motor drive voltage high(MCU)
P1A23 EV ECU mode unknown(MCU)
P1A24 READY signal timeout(MCU)
P1A25 Discharge ON timeout(MCU)
P1A26 Discharge OFF timeout(MCU)
P1A27 EV torque request error(MCU)
P1A29 Motor over current 1 (MCU)
P1A2A IGBT over current(MCU)
P1A2B Three phase line(MCU)
P1A3D A/D reference voltage(MCU)
P1A3E CPU atmosphere temp.high(MCU)
P1A3F CPU temperature sensor(MCU)
P1B0E Motor coil temp. U phase high
P1B0F Motor coil temp. U phase low
P1B10 Motor coil temp. V phase high
P1B11 Motor coil temp. V phase low
P1B12 Motor coil temp. W phase high
P1B13 Motor coil temp. W phase low
８７
Troubleshooting
13-3-2 DTCs [MCU related 2 / 2 ]
DTC Description
P1B14 EV-ECU fail 1 (Temperature)
P1B15 EV-ECU fail 2 (Voltage)
P1B16 EV-ECU fail 3 (Torque request)
P1B17 EV-ECU fail 4 (IGBT heat)
P1B18 EV-ECU lost (300ms Timeout)
U1073 Bus-off
U1100 Engine CAN timeout
U1108 Meter CAN timeout/Not equipped
U1109 Meter CAN timeout/Not equipped
U1910 Received error from MCU (K-line)
U1920 K-line error(MCU)
８８
Troubleshooting
13-3-3 DTCs [BMU related 1 / 4 ]
DTC Description
P1A40 Battery current sensor（±350A）
P1A41 Battery current sensor（±30A）
P1A42 BATT.current SNS.power circuit
P1A43 BATT.current SNS.detect circuit
P1A44 Leak detection(BMU)
P1A46 Leak sensor detection circuit
P1A47 Battery cooling fan relay 1
P1A48 BATT.cooling fan output circuit
P1A49 CMU drive relay
P1A4A CMU drive relay deposition
P1A4B Each Cell Voltage difference
P1A4C OR line voltage
P1A4D IGCT line voltage
P1A4E Battery cooling fan relay 2
P1A4F ROM fail
P1A50 RAM fail
P1A51 EEPROM fail
P1A52 CMU01 Cell voltage low
P1A53 CMU02 Cell voltage low
P1A54 CMU03 Cell voltage low
P1A55 CMU04 Cell voltage low
P1A56 CMU05 Cell voltage low
P1A57 CMU06 Cell voltage low
P1A58 CMU07 Cell voltage low
P1A59 CMU08 Cell voltage low
P1A5A CMU09 Cell voltage low
P1A5B CMU10 Cell voltage low
P1A5C CMU11 Cell voltage low
P1A5D CMU12 Cell voltage low
P1A5E CMU01 Cell voltage high
P1A5F CMU02 Cell voltage high
P1A60 CMU03 Cell voltage high
P1A61 CMU04 Cell voltage high
P1A62 CMU05 Cell voltage high
P1A63 CMU06 Cell voltage high
P1A64 CMU07 Cell voltage high
P1A65 CMU08 Cell voltage high
P1A66 CMU09 Cell voltage high
P1A67 CMU10 Cell voltage high
P1A68 CMU11 Cell voltage high
８９
Troubleshooting
13-3-3 DTCs [BMU related 2 / 4 ]
DTC Description
P1A69 CMU12 Cell voltage high
P1A6A CMU01 Battery temperature
P1A6B CMU02 Battery temperature
P1A6C CMU03 Battery temperature
P1A6D CMU04 Battery temperature
P1A6E CMU05 Battery temperature
P1A6F CMU06 Battery temperature
P1A70 CMU07 Battery temperature
P1A71 CMU08 Battery temperature
P1A72 CMU09 Battery temperature
P1A73 CMU10 Battery temperature
P1A74 CMU11 Battery temperature
P1A75 CMU12 Battery temperature
P1A76 CMU01 Cell voltage sensor
P1A77 CMU02 Cell voltage sensor
P1A78 CMU03 Cell voltage sensor
P1A79 CMU04 Cell voltage sensor
P1A7A CMU05 Cell voltage sensor
P1A7B CMU06 Cell voltage sensor
P1A7C CMU07 Cell voltage sensor
P1A7D CMU08 Cell voltage sensor
P1A7E CMU09 Cell voltage sensor
P1A7F CMU10 Cell voltage sensor
P1A80 CMU11 Cell voltage sensor
P1A81 CMU12 Cell voltage sensor
P1A82 CMU01 Battery temperature sensor
P1A83 CMU02 Battery temperature sensor
P1A84 CMU03 Battery temperature sensor
P1A85 CMU04 Battery temperature sensor
P1A86 CMU05 Battery temperature sensor
P1A87 CMU06 Battery temperature sensor
P1A88 CMU07 Battery temperature sensor
P1A89 CMU08 Battery temperature sensor
P1A8A CMU09 Battery temperature sensor
P1A8B CMU10 Battery temperature sensor
P1A8C CMU11 Battery temperature sensor
P1A8D CMU12 Battery temperature sensor
P1A8E CMU01 Battery balancing unit
P1A8F CMU02 Battery balancing unit
P1A90 CMU03 Battery balancing unit
９０
Troubleshooting
13-3-3 DTCs [BMU related 3 / 4 ]
DTC Description
P1A91 CMU04 Battery balancing unit
P1A92 CMU05 Battery balancing unit
P1A93 CMU06 Battery balancing unit
P1A94 CMU07 Battery balancing unit
P1A95 CMU08 Battery balancing unit
P1A96 CMU09 Battery balancing unit
P1A97 CMU10 Battery balancing unit
P1A98 CMU11 Battery balancing unit
P1A99 CMU12 Battery balancing unit
P1AA7 EV-ECU signal time out
P1AA8 Bat-CAN signal time out
P1AC1 Battery cooling fan (Drive fail)
P1AC2 Battery cooling fan (SHT to BAT)
P1AC3 Battery cooling fan (Rest fail)
P1AC4 Arithmetic processing
U1073 Bus-off
U1082 Bat-CAN Bus-off
U1100 Engine CAN timeout
U1108 Meter CAN timeout/Not equipped
U1109 ETACS CAN timeout/Not equipped
U111B MCU CAN timeout
U1190 No receive fault detect signal
U11A0 CMU01 CAN timeout
U11A1 CMU02 CAN timeout
U11A2 CMU03 CAN timeout
U11A3 CMU04 CAN timeout
U11A4 CMU05 CAN timeout
U11A5 CMU06 CAN timeout
U11A6 CMU07 CAN timeout
U11A7 CMU08 CAN timeout
U11A8 CMU09 CAN timeout
U11A9 CMU10 CAN timeout
U11AA CMU11 CAN timeout
U11AB CMU12 CAN timeout
U1922 EV K-line error
U1924 Bat-LIN bit error(BMU)
U1926 EV ECU V-CAN error
U1927 Bat-LIN checksum error(CMU01)
U1928 Bat-LIN checksum error(CMU02)
U1929 Bat-LIN checksum error(CMU03)
９１
Troubleshooting
13-3-3 DTCs [BMU related 4 / 4 ]
DTC Description
U192A Bat-LIN checksum error(CMU04)
U192B Bat-LIN checksum error(CMU05)
U192C Bat-LIN checksum error(CMU06)
U192D Bat-LIN checksum error(CMU07)
U192E Bat-LIN checksum error(CMU08)
U192F Bat-LIN checksum error(CMU09)
U1930 Bat-LIN checksum error(CMU10)
U1931 Bat-LIN checksum error(CMU11)
U1932 Bat-LIN checksum error(CMU12)
U1933 Bat-LIN slave error (CMU01)
U1934 Bat-LIN slave error (CMU02)
U1935 Bat-LIN slave error (CMU03)
U1936 Bat-LIN slave error (CMU04)
U1937 Bat-LIN slave error (CMU05)
U1938 Bat-LIN slave error (CMU06)
U1939 Bat-LIN slave error (CMU07)
U193A Bat-LIN slave error (CMU08)
U193B Bat-LIN slave error (CMU09)
U193C Bat-LIN slave error (CMU10)
U193D Bat-LIN slave error (CMU11)
U193E Bat-LIN slave error (CMU12)
U193F Bat-LIN No Bus activity error
９２
Rescue
- For the rescue operation, please refer the Rescue manual -
９３
New Special tool
15. New special tools
15-1. Special tool for the i-MiEV [Service on DC330V battery]
Please place an order from MAP (Mitsubishi Automotive Accessories & Products Co. Ltd.) as same manner as other
special tools.
Special tools Parts number Name Use / note
MB992355 Electric insulation resistance For Trouble shooting
meter -Insulation resistance measurement
-Electric leakage check
[Note]
You could use the equivalent available
at the local shops.
MB992337 Electric insulation socket -Disconnect the P-N cable at battery(*)
(10mm)9.5sq. -Disconnect the P-N cable at MCU(*)
(*)when the DC 330V could not shut off.
MB992336 EV Battery cart For battery module removal
a:MB992353x2 a: Rigid caster / installation
[Note]
b:MB992354x2 b: Swivel caster You could use the equivalent available
at the local shops.
MB992659 EV battery lifting cart For battery module removal
/ installation
If MB992336 could not be used.
[Note]
It might be also required if your garage
lift could not operate sensitively.
MB992343 EV battery sling tool kit Sling the battery for convey.
a:MB992344×4 a: Eye bolts
b:MB992345×2 b: EV battery sling belts
c:MF450156×8 c: Washers
d:MU001480×4 d:Hexagon nut
MB992327 EV battery guide For battery module installation.
2 pcs. of the guide are required for the
installation work.
９４
New Special tool
Special tools Parts number Name Use / note
MB992640 Electric insulation helmet -Handling of accident vehicle.
-Other repair/service works as needed.
MB992645 Electric insulation jacket -Handling of accident vehicle.
-Other repair/service works as needed.
MB992646 Electric insulation pants -Handling of accident vehicle.
-Other repair/service works as needed.
MB992647 [Ex.large] Electric insulation glove -Removal/installation of service plug.
MB992648 [Large] -Handling of accident vehicle.
-Other repair/service works as needed.
MB992649 [Medium]
MB992650 [Small]
MB992651[24.0cm] Electric insulation boots -Handling of accident vehicle.
MB992652[24.5cm] -Other repair/service works as needed.
MB992653[25.0cm]
MB992654[25.5cm]
MB992655[26.0cm]
MB992656[26.5cm]
MB992657[27.0cm]
MB992658[27.5cm]
９５
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