Vehicle - New Model Service Information/Features
No: TSB 12-00-005DATE: February, 2012
MODEL: 2012 i-MiEV
SUBJECT:
2012 i-MiEV NEW MODEL SERVICE INFORMATION AND FEATURES - REVISED
This bulletin supercedes TSB-11-00-012, issued December, 2011, to change the instruction for indicated traction battery storage state of charge and remove the battery compensation procedure. Changes are italicized and indicated by asterisks.
PURPOSE
This bulletin contains important new model service information for the 2012 i-MiEV (U.S. Models). Refer to the 2012 i-MiEV service manual on MEDIC or CD (p/n MCSD-018B-2012) the Technical Information Manual (p/n MSSP218B-2012) and the owner's manual for details on these and other features.
A Quick Reference Guide is shipped in the owners Welcome Envelope. Please be sure that the Quick Reference Guide is in the vehicle at customer delivery.
MODEL LINEUP
NEW FEATURE INFORMATION
^ Full plug-in electric powered vehicle
^ 62 mile (EPA 5 cycle) driving range
^ Energy Consumption
^ Full plug-in electric powered vehicleEPA fuel economy equivalent - 126MPGe highway, 99MPGe
city, 112MPGe combined
^ Electric Consumption - 30 Kwh/100 miles
^ EPA Estimated Annual Fuel Cost $550
^ Main Drive Lithium Ion Battery with a capacity of 16Kwh
^ High Voltage Protection System - Shuts down the high voltage circuits if a battery pack failure or leak is detected. Also shuts down high voltage circuits in the event of certain moderate to sever collisions.
^ Liquid cooled electric motor driving the rear wheels though a single speed, gear reduction transaxle.
^ Three charging levels are available:
^ Standard - Level 1 (120V) and Level 2 (240V) using household current
^ Optional - Level 3 Quick Charge using commercial or public equipment
^ "i" Remote - Standard on all models. Driver can control several electric vehicle tasks up to a distance of approximately 328 feet (100m).
^ Regenerative braking - charges battery during deceleration and braking
^ All electric HVAC system
^ Electric power steering
^ Active Stability Control with Traction Control (ASC-TC)
^ Acoustic Vehicle Alert System (AVAS) - Electric vehicles are extremely quiet, especially at low speeds. A sound generator that operates at "parking lot" speeds (0 - 23 mph) alerts pedestrians of the vehicle's approach.
^ Special low rolling resistance Dunlop Enesave 01AIS (All season) tires Front- 145165R15 Rear- 175160R15
^ Tire repair kit replaces spare tire to save weight.
^ Halogen projector type headlights fitted to all models
^ Fog lamps standard on all SE models.
^ Optional 40Gb HDD Navigation System with real time traffic information, rear view camera system and music server.
NOTE:
SIRIUS satellite radio is not available on i-MiEV models.
^ FUSE Hands-free Link System optional on SE
GETTING STARTED
Battery Charging
Main Drive Lithium-ion Battery (Traction Battery)
Caution!
During traction battery charging, the A/C will occasionally turn on. The cooling fan will run to prevent overheating of the main battery, on board charger and the DC/DC inverter. Caution should be used if it is necessary to work under the hood while charging the traction battery.
*^ The traction battery is charged using a port located in either quarter panel. All vehicles are equipped with a 120V/240V connection on the passenger's side. A 120V charging cable with a Charging Circuit Interrupting Device (CCID) is provided with the vehicle. There is a charging port door on the driver's side of all vehicles but only those equipped with the optional Quick Charge system (standard on SE models) are equipped with the 330V connection. Approximate charging times are:
^ Standard household current (120V) - approximately 22.5 hours from zero charge
^ EVSE charging dock (240V) public or home system - approximately 6 hours from zero charge
^ Quick Charge from public charging station - approximately 30 minutes (to a charge* of 80% of maximum).
The quick charging option is factory installed only. It cannot be added as an accessory.
^ Repeated Level 3 Quick Charging may reduce traction battery capacity and life expectancy. The traction battery should be charged using regular charging (120V1240V) at least once a week.
^ The release lever for the regular charging port door is low on the dash, to the left of the steering column.
^ The release lever for the Quick Charge port (if equipped) is under the left side of the driver's seat. Repeated "topping up" of a traction battery that is near its capacity (approximately 80% or more, 13 segments on the battery indicator gauge) may reduce battery life expectancy. It is recommended that the traction battery not be charged until it reaches an indicated charge level of approximately 20% (3 segments on the gauge).
^ To maintain the life expectancy of the traction battery, customers should charge it to its capacity every two weeks using regular (120V or 240V) charging.
^ Driving range and charging times are affected by:
a. Cold weather - Batteries are not as efficient during cold weather. Friction also increases when components are cold
Check and adjust tire pressures as necessary to compensate for lower tire pressures to maintain driving range in cold weather.
b. Heater or A/C operation - The HVAC system uses traction battery voltage.
*^ Vehicles to be stored after PDI should have the traction battery charged to 3 segments on the battery indicator gauge. Over long periods of inactivity, this level promotes long battery life and does not have a significant effect on capacity.*
Driving
The i-MiEV uses a conventional immobilizer key with integrated RKE buttons and a conventional four position (LOCK ACC ON START) electric motor switch (ignition switch) mounted to the steering column.
NOTE:
ACC power (12V) is automatically shut off if the electric motor switch is left in the ACC position for 30 minutes. Cycling the key will restore ACC function. This setting can be changed by customizing ETACS.
1. With the shift selector in P (park) insert the key into the electric motor switch turn it to the START position and hold it for 1 - 2 seconds. A green "READY" light illuminates on the instrument panel and a single chime is heard.
NOTE:
The vehicle cannot be started with the gear selector in N (neutral). The green READY light will never illuminate.
2. Gear selection is similar to an automatic transmission.
^ P - Park: The electric motor switch can only be turned to LOCK with the gear selector in P
^ R - Reverse: Normal rearward driving.
^ N - Neutral: Same as a conventional vehicle.
^ D - Drive: Normal forward driving.
The following modes are unique to the "i."
^ Eco - Economy: Power to the drive wheels is reduced to extend driving range.
^ B - Brake: Maximum regenerative battery charging during deceleration and braking. Reduces brake pedal pressure needed when driving downhill and also has a positive effect on driving range.
3. Instrument Panel - Gauges and warning indicators.
Unique warning indicator descriptions:
^ AVAS Indicator - Comes on briefly when key is turned to "ON." Illuminates when a fault occurs.
^ RBS Indicator - Comes on briefly when status is set to READY. Illuminates when regenerative brake function is reduced due to malfunction. Refer to the service manual for further information
^ Low Power Warning (Low Energy Warning) - Indicates when vehicle is being operated in reduced power mode. Warning and energy level gauge flash when the charge indicator shows 2 segments. The gauge and warning flash alternately when the gauge shows 1 segment. Power is also reduced if motor or drive battery temperature are too low or too high.
^ Aux. Battery (12V) Warning - Comes on when there is a fault in the 12V charging system.
^ Electric Motor Warning Light - Comes on when there is a fault with a high voltage component.
^ Charging indicator. Flashes when the vehicle is connected to a charger. Stays on when charging begins and goes out when charging is completed.
SERVICE INFORMATION
^ Diagnostic communication requires MUT-III version 26.0 or higher using the blue DLC connection cable.
^ DO NOT attempt to repair the EV system or its components before completing MMNA online (course code 120) and instructor led (course code MEVTT) Technical Training.
Log on to www.mitsubishiacademy.com to enroll in these classes.
^ Warranty Claims for EV system submitted for repair of the EV system or its components by dealers who are not MMNA trained will be charged back.
^ Techline will not assist dealers or technicians who have not completed MMNA online and instructor led training with repairs.
MOTOR/EV COMPONENTS
Electric Motor
The vehicle is driven by a rear mounted 49 kW (66 hp) electric motor mounted directly to the transmission driving the rear wheels. Operation is controlled by a Motor Control Unit located in the motor compartment. The electric motor on-board charger & DC/DC converter and the motor control unit are cooled with DiaQueen Super LLC Premium Coolant (MZ320125) circulated through a front mounted radiator by an electric water pump. Because the motor is not subject to contamination like an internal combustion engine normal periodic maintenance is limited to checking the coolant reservoir level (located in the motor compartment) periodically and changing coolant every 20 years.
The motor is replaced as a unit. Only external connections and mounts can be repaired or replaced.
Motor Control Unit
^ Controlled by the EV-ECU
^ Contains an integrated inverter to convert traction battery 330V DC to 330V AC (3 phase) for the electric motor.
^ Manages battery voltage to the motor.
^ Contains a smoothing condenser to reduce current pulses from the traction battery under acceleration.
Main Drive Lithium-ion Battery (Traction Battery)
The traction battery is located under the floor in a protective container. It is connected to the motor by wiring harness insulated by orange covering.
The traction battery is equipped with a service plug. When removed it creates an open circuit in the battery to prevent the flow of high voltage when the drive system is being serviced or if emergency personnel have to assist an occupant after a collision. It is accessed by sliding the driver's seat to its full rear position lifting the carpet and removing 2 wing nuts securing an access plate to the floor.
^ High voltage connections must be inspected for looseness every 24 months or 30,000 miles. Refer to the Group 54D - Traction Battery in the service manual for the proper inspection and safety procedures.
^ Vehicles are equipped with a Battery Temperature Conditioning System controlled by the Battery Management Unit (BMU). Forced air ventilation from the air conditioning cools the battery if the temperature gets too high during quick charging. If the EV-ECU judges the battery temperature is too low (below -13°F -25°C) the system uses the heater to force warm air over the battery during regular charging.
^ In extreme cold weather the vehicle may not set to READY status if the battery temperature is judged to be below -22°F (-30°C) regardless of the level of charge.
Caution!
If it is necessary to heat the vehicle to more than 150°F during painting, the main drive battery must removed from the vehicle or it may be damaged.
Electric Vehicle ECU (EV-ECU)
The EV-ECU is the vehicle's integrated controller. It communicates with other ECUs via the CAN-BUS and receives direct input from other controls (i.e. accelerator transmission shift lever) to insure all systems operate together as designed.
Battery Management Unit (BMU)
Uses information from 12 Cell Monitoring Units (CMU) a leak sensor and a current sensor to calculate the traction battens condition. The BMU relays this data to the EV-ECU.
The BMU calculates:
^ Battery state of charge
^ Estimated traction battery capacity depending upon usage and elapsed time (battery deterioration).
^ Maximum output from the traction battery.
^ Maximum input from a charging source.
Cell Monitoring Unit (CMU)
There is one CMU for each battery module 12 in all. They are a part of the traction battery and cannot be serviced separately. They provide information to the Battery Management Unit (BMU) regarding the condition of the traction battery.
High Voltage Cables
High voltage cables are identified by the orange plastic insulating material in which they are wrapped. Care must be taken when working with these cables and their attached components.
The maintenance schedule calls for cable connections to be inspected for looseness and damage every 24 months or 30K miles. Refer to the service manual for proper procedures.
On-board Charger
The on-board charger has two main functions:
^ Controls traction battery charging - Converts AC voltage (120V or 240V) to DC voltage and boosts the voltage to approximately 370V DC for the traction battery.
^ Contains the DC/DC converter - Converts 330V DC to 14.4V to charge the 12V DC auxiliary battery while the vehicle is connected to a level 1 or 2 charger (if the battery is not fully charged) or while the green READY indicator is illuminated.
"i" REMOTE
^ "i" Remote - Standard on all models. Driver can control several electric vehicle tasks up to a distance of approximately 328 feet (100 meters) with a clear line of sight (see owner's manual for details) as follows:
^ Traction battery level display and charging indicator
^ Pre-activation of the climate control to cool the vehicle on hot days or warm the vehicle on cold days prior to driving (vehicle must be charging in Level 1 or Level 2 only).
^ Timed traction battery charging - Select charging start delay or length of charging.
TRANSAXLE
The transaxle is a single speed gear reduction unit. The single speed is made possible by the characteristics of the electric motor. It is lubricated by 0.8 quarts of Dia-Queen ATF SPIII (ACH1ZC1X05). Regular scheduled maintenance involves checking for leaks and checking the level and condition of the fluid every 12 months or 15000 miles (24000km). Refer to the Scheduled Maintenance Table in Group 00 - General in the Service Manual for details.
UNDERHOOD
The underhood area of the "i" provides easy access to the 12V auxiliary battery brake master cylinder/booster and reservoir heater coolant reservoir and the windshield washer fluid reservoir. Further inside the hood area but accessed from under the vehicle is the electric air conditioning compressor electric heating unit and the electronic power steering (EPS) motor.
^ The hood release lever is located at the passenger's kick panel.
^ Use only DiaQueen Super LLC Long Life Coolant (Premium) - MZ320125 when filling the heater coolant reservoir.
^ Auxiliary Battery
The 12V auxiliary battery (288 CCA) is a conventional flooded battery that powers regular 12 volt automotive systems such as the radio windshield wipers/washers headlights etc. It also "starts" the car. Turning the key to the START position supplies 12V to the EV-ECU. If the auxiliary battery is discharged, the vehicle's status cannot be set to READY for driving even though the battery is fully charged.
STEERING
The vehicle is equipped with an electric power steering system. Its operation and diagnosis are similar to that of the 2011 Lancer. No power steering fluid is used and no scheduled maintenance is required. Refer to Group 37 - Steering of the service manual for further service information.
BRAKES
^ Brake assist is performed by an electric vacuum pump. When the vehicle is initially started, or when the brake pedal is depressed, pump operation may be heard. This is a normal condition and does not indicate a system malfunction. Refer the customer to page 3-74 of the owner's manual for further information.
^ All "i" models are equipped with Active Skid Control (ASC), which includes anti-lock brakes (ABS) and traction control (TCL). ASC defaults to ON when the electric motor switch is turned ON. Operation is similar to other models.
ASC can be turned off by pressing the ASC OFF switch for 3 seconds. It can be turned back on with a simple press of the switch.
^ When vacuum falls below a predetermined level, an audible warning is heard until sufficient vacuum is restored.
^ Regenerative brake force is automatically increased to assist the vacuum pump in the event of decrease vacuum output or sudden stops from high speed.
^ Use only DOT 3 or 4 brake fluid for service and repair. Scheduled brake fluid replacement is 3 years or 45,000 miles (72,000km).
SAFETY
^ Acoustic Vehicle Alerting System (AVAS) - All "i" models are equipped with a sound generator to alert pedestrians to the vehicle's presence at slow speeds. The system is active in any shift position except P) between 1 mph (1.2 km/h) and approximately 22 mph (35 km/h).
An AVAS indicator light is illuminated when the electric motor switch is turned to ON as a self check. It goes out after a few seconds. It also indicates when there is trouble with the system.
^ All "i" models are equipped with daytime running lights (no option to turn them off).
^ All "i" models are equipped with a Tire Pressure Monitoring System (TPMS). Sensor registration is done using the MUT-III and the tire pressure drop method.
^ A tire repair kit is provided in place of a spare tire. It is stored under the rear seat on the passenger's side. The repair kit includes:
^ Sealant bottle - A sealant that is less damaging to TPMS sensors is used. Do not use the kit after the expiration date has passed. Commercially available sealant should not be used.
^ Filler Hose - Attaches the sealant bottle to the tire valve when filling.
^ Air Compressor - Powered by 12V accessory power socket.
^ Extension hose - Used by a service facility for removal of sealant. Not used in puncture repair.
^ Spare valve insert - Nickel plated valve insert can be used with TPMS equipped wheels.
Do not use valve inserts made of other materials.
^ Valve insert remover
^ Speed restriction sticker that advises the owner to not exceed 50mph (80 kph) on a repaired tire.
BODY
ETACS
^ ETACS communicates with the key ring antenna as part of the immobilizer system. It prohibits operating the vehicle without a registered key. The immobilizer system also includes the EV-ECU and MCU.
^ Accessory power is automatically shut off if the electric motor switch is left in the ACC position for 30 minutes. Cycling the key OFF and back to ACC will provide an additional 30 minutes of accessory power. This function can be disabled by customizing ETACS.
^ Interior overhead lighting is automatically turned off after 30 minutes if the dome lamp switch is in the DOOR position. This function can be disabled by customizing ETACS.
^ The ETACS stores coding information required for vehicle operation. Refer to the following chart when replacing the EV-ECU MCU or ETACS:
HVAC
The HVAC is controlled by the A/C control unit (Compressor & Heater ECU) which drives these high voltage components.
Air Conditioning
^ The air conditioner uses R-134a refrigerant circulated by an electric compressor. The electric compressor uses voltage from the traction battery (therefore affecting driving range).
^ Because the system is electric air outlet temperature does not fluctuate with engine speed changes like a conventional system does.
^ The compressor requires a special POE refrigerant oil (MA68EV) developed for use in electric compressors. Use only Mitsubishi Genuine POE Refrigerant Oil for "i" (p/n MZ341005) or equivalent. PAG compressor oil is electrically conductive and MUST NOT be used. Dealers must obtain a set of pressure gauges and a refrigerant recycling system to only be used for POE oil Systems.
Warning!
Refrigerant oil used in electric compressors CANNOT be mixed with conventional PAG refrigerant oil. Dealers must obtain separate gauge sets and refrigerant recycling systems and use them only for POE oil systems, or have a dual mode recycling unit designed to accommodate both PAG and POE refrigerant oils. (e.g. Robinaire 34788-H)
Heater
^ The heater uses an electric water pump to circulate coolant through the system. The heater system is separate from the motor coolant, but uses the same specification coolant (DiaQueen Super LLC Long Life Coolant (Premium) - MZ320125). Coolant is heated by an electric heater which is also driven by voltage from the traction battery. The coolant reservoir is under the hood
^ Heating coolant for the HVAC takes less time than in a conventional system.
^ The water pump is made of a special resin.
NOTE:
When the "power down" warning is illuminated on the instrument panel, the electric heater and air conditioning are shut oft to maximize driving range.
SPECIAL TOOLS
The following essential tools will be were shipped to certified "i" dealers in the middle of November.
^ MB992337 - Socket, Insulated: Required for high voltage repairs.
Read the owner's manual (included) prior to use.
!! IMPORTANT!! Always check this tool for signs of wear or damage to the insulation. There are two layers of insulation: a red base layer and a yellow outer layer. If the red base layer becomes visible, STOP USING THE TOOL IMMEDIATELY. This is a sign the insulation is getting thin or is damaged. If the user continues to use the tool with the red layer visible it will wear further and expose the user to electric shock and possible personal injury.
The tool must be inspected three (3) years from the last inspection date (marked on the tool), even if no insulation damage or wear is seen. The insulation can degrade over time and reduce its effectiveness. Continued use past the inspection date printed on the tool can cause electric shock and possible personal injury. Refer to documentation packaged with the tool for additional information.
^ MB992648-01: Gloves Set, Electric Insulated: Required for high voltage repair/diagnosis.
!! IMPORTANT!! Gloves must be inspected prior to each use and go through re-certification 6 months after the first use (or 12 months from the date listed on the gloves) and every 6 months thereafter. Refer to documentation packaged with the gloves for further information.
^ MB992327 - Guide, EV Battery: Required for proper installation of the traction battery.
^ 3990 - Kit, Hybrid Meter: Required for measurement of insulation resistance during troubleshooting.
^ MB992343-01: Sling Kit Battery Lift: Required for safely moving the traction battery.
^ MB992659-01: Boot-Electric Insulated. Required for certain high voltage repair/diagnosis.
^ Organizational Materials for MIT-ICAR-KIT: Store all tools in the "i" tools storage bag. Kit includes:
^ 561987-Bag, Cloth ^ 18878 - Carton
^ 550866 - Instruction Sheet ^ 218271 - Label
FACTORY OPTION PACKAGES
PREMIUM PACKAGE - Optional on 2012 "i" SE
^ HDD Navigation System with rear view ^ Battery Warming System
camera ^ DC Quick-charge port
^ FUSE Hands-free Link System TM w/USB ^ Steering wheel audio controls port
COLD ZONE PACKAGE - Optional on all 2012
^ Battery warming system ^ Heated door mirrors
WARRANTY
!! IMPORTANT!!
The following components require DPSM prior work authorization (PWA) before repairs begin. You will not be able to submit claims for repairs to these components without a DPSM issued PWA. Technicians are encouraged to contact Techlme prior to beginning diagnosis on any EV (330V) component.
^ Main Drive Lithium Ion Battery
^ Electric Drive Motor
^ Motor Control Unit (MCU)
The 2012 i-MiEV is covered by the warranty terms shown.