Motor Control Unit (MCU) - Service Campaign (SC-15-002)

MOTOR CONTROL UNIT (MCU) - SERVICE CAMPAIGN

SERVICE CAMPAIGN BULLETIN

PURPOSE

Due to a manufacturing error, the electrical resistance of the insulated base inside the Motor Control Unit (MCU) may decrease and lead to unstable voltage within the circuit. This condition can result in reduced electric motor power (turtle mode) and in the worst case, prevent the vehicle from being restarted or the Main Drive lithium-ion battery from being recharged.

This campaign bulletin instructs dealers to replace the MCU on all affected vehicles with a countermeasure unit.

AFFECTED VEHICLES

Certain 2012 i-MiEVs built November 4, 2011 to May 8, 2012.

CUSTOMER NOTIFICATIONS

A letter will be sent to all owners of affected vehicles requesting they schedule an appointment with their local Certified  Mitsubishi i-MiEV dealer to have their vehicle remedied. A copy of the customer notification letter appears at the end of this bulletin.

REQUIRED OPERATIONS

Repairs must be completed by a certified i-MiEV technician.

SPECIAL EQUIPMENT

The following equipment is needed to remove and install the MCU and air bleed the radiator coolant: 

• Kit, OTC Hybrid Meter - 3990
• Gloves Set, Electric Insulated - MB99264801

• Socket, Insulated - MB992337
• VCI (Vehicle Communication Interface) or VCI Lite - MB991824 or MB992744V.
• MEDIC Laptop/Tablet with A/C power adapter - 520924, or FZG1MK2.
• MUT-III main harness 'A' (blue connector at the DLC end) - MB991910 or MB992745V.
• USB 2.0 cable - MB991827 or RRAR1MBR-108L.

MCU REPLACEMENT PROCEDURE

1. Partially discharge the Main Drive lithium-ion battery.
   1. 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.
   2. 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 driver 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: Use the electric insulated gloves to protect from electric shock.
   CAUTION: Prior to removing the service plug, wait five minutes or more after disconnecting the 12V battery negative (-) battery cable instructed in Step 3.
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.
11. Remove the service lid (1) on the Motor Control Unit (MCU).
    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).
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.
    WARNING: Use the electric insulated gloves and socket to protect from electric shock.
13. Use the electric insulated gloves and insulated socket to remove the five cable mounting bolts from inside the MCU.
14. Use the electric insulated gloves and insulated socket to remove the eight outer cable mounting bolts from the rear of the MCU.
    NOTE: Do not remove the five inner cable mounting bolts from the rear of the MCU.
    WARNING: Be careful because the coolant may be hot.
    CAUTION: 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.
15. [Figure 1] Mark the radiator hose (7) 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 MCU's coolant inlet/outlet to prevent coolant spillage during MCU removal.
17. [Figure 1] Mark the radiator hose (8) 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 MCU's coolant inlet/outlet to prevent coolant spillage during MCU removal.
    CAUTION: Prior to new MCU installation, ensure the area and the harness connectors are clean and dry.
19. [Figure 1] Remove and replace the MCU (9) with the countermeasure part indicated in the PARTS INFORMATION  section.
    NOTE: [Figure 1] Reinstall the ground bolt (10) where indicated. Ground bolt (left) is marked with an "E".
    NOTE: [Figure 1] During removal of the wiring harness connectors highlighted in section A, ensure the support bracket is removed first  to prevent damage to the connectors and clips.
20. [Figure 1] Reinstall the radiator hoses (7) and (8), ensuring the hose clips are secured in the marked, original location. Remove the hose clamps from the radiator hoses.
    WARNING: Use the electric insulated gloves and socket to protect from electric shock.
    CAUTION: Prior to high voltage battery cable reinstallation, ensure the area is clean and dry.
21. Use the electric insulated gloves and insulated socket to replace the two o-rings (P/N 9499A790 and P/N 9499A969) and reinstall the eight outer cable mounting bolts on the rear of the MCU. Torque to 62 ± 26 in-lb (7.0 ± 3.0 N-m).
22. Use the electric insulated gloves and insulated socket to reinstall the five inner cable mounting bolts inside the MCU. Torque to 62 ± 26 in-lb (7.0 ± 3.0 N-m).
23. Remove the cap or plug from the old MCU's coolant inlet/outlet and empty coolant into the coolant container.
24. Replace MCU service lid o-ring (P/N 9499A797) 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.
25. Remove the tape covering the service plug terminal. Use the electric insulated gloves to reinstall the service plug. Secure the service lid with the two thumbscrews and fasten the floor carpet to cover the area.
26. Remove the tape from the negative (-) battery post and reinstall the negative (-) battery 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.
27. Refill the rear radiator condenser tank with the collected coolant until it reaches the "F" (Full) mark.

VIN WRITING AND 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).
2. Connect the equipment as follows:
   • 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.
   • Connect the USB cable to the VCI/VCI Lite.
   • When the laptop/tablet displays the MUT-III main screen, connect the USB cable to the device.
   • Connect the MUT-III main harness with the blue DLC connection to the VCI/VCI Lite.
   • Connect the blue connection of the MUT-III main harness to the vehicle's data link connector.
   • 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
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."
5. Select "All DTCs."
6. Select "Read all DTCs."
7. Ensure the vehicle information matches the vehicle being inspected. Select the "car" icon.
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).

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).

   When the VIN is entered correctly, click on the check mark icon to continue (3).

10. Ensure the VIN entered is correct (1).

    When prompted, select the appropriate transmission.

    Click on the check mark icon to continue (2).

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. Return to the MUT-III menu.
14. Select "System select."
15. Select "16. MCU." Click on the check mark icon to continue.
16. Select "Coding."
17. Select "Chassis No./VIN Writing."
18. Ensure the correct VIN is displayed.

    Click on the check mark icon to begin VIN writing. When prompted, click on the check mark icon again to execute VIN writing.

    When VIN writing is complete, click on the check mark icon to continue.

19. Return to the "System select" menu.
20. Select "11. EV-ECU." Click on the check mark icon to continue.
21. Select "Actuator Test."
22. 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 20.

23. Within 20 seconds of performing Step 22, 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.
24. 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 MCU is insufficient in filling the rear radiator condenser tank, procure additional coolant as necessary.
25. 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 20 and skipping Steps 22-24.

26. 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.
27. Check the coolant level in the rear radiator condenser tank:
    NOTE: If coolant recovered from the old MCU is insufficient in filling the rear radiator condenser tank, procure additional coolant as necessary.
    1. If the coolant level is lower than the "L" (Low) mark, refill the coolant to the "F" (Full) mark and repeat Steps 25-27.
    2. If the coolant level is above the "L" (Low) mark, air bleeding is complete. Refill coolant to the "F" (Full) mark and secure the radiator condenser tank cap (ensure click is heard).
28. Ensure there is no coolant leaking from the vehicle.
29. Reinstall the 12V battery cover. Torque specifications is 35 ± 8 in-lb (4.0 ± 1.0 N-m).
30. 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
Motor Control Unit, EV Kit	9410A092	1
Packing, EV Control Electrical (O-Ring) - MCU Service Lid	9499A797	1
Packing, EV Motor Cable Flange (O-Ring) - Electric Motor Cable	9499A969	Included in Kit 9410A092
Packing, EV Control Electrical (O-Ring) - EV Battery Cable	9499A790	Included in Kit 9410A092
DiaQueen SUPER LONG LIFE COOLANT PREMIUM or Equivalent	MZ320125	As needed

WARRANTY INFORMATION

There is only 1 repair scenario for this campaign number. 

If involved in C1508E01 

#	Campaign Op#	Labor Time	Repair Description	Part Number
1	C1508E01	1.4 hrs	Replace the motor control unit on involved vehicles only.	9410A092
				9499A797
				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 the applicable operation code that correctly matches up with the work that was actually performed. A claim example is provided below. 

Certain 2012 MY i-MiEV Models 

Required Operation to be performed	Labor Operation	Labor Time
1. 2012 MY i-MiEV Motor Control Unit -	C1508E01	1.4 hrs

Claim Header Section: 

After entering the required customer data, vehicle information, selecting the applicable repair campaign and scenario performed  (please note there is only 1 possible repair scenario  ), and then hitting the "Save and Continue" button, the system will automatically fill-in several fields.