Peugeot Ion On-Board-Charger fix

[@volkhen0]

I think you forgot to show us what failed on old board. Maybe component level repair is possible? You said in the video that we will look at the old board.

[@DalasEVRepair]

Yes, the board had three damaged things; - Some potted Input AC component blown up - 5000running hour max electrolytic capacitors that were starting to bulge - Overheated components on the left side, shrink wrap even melted (transformers) Not feasible to repair all these, so we replaced the board.

[@benbaselet2026]

Those black discs looked like blown MOVs on the input? Pretty typical for them to fail short when they get old. That should lead to a blown fuse though, so yeah probably there's something else going on too. Not worth anyone's time to spend a whole day replacing bits to a bad design to begin with.

[@miloe436]

@@DalasEVRepair Yeah, there even was a service note on the charger explaining the quality issue of the capacitors. Service note TSB-19-54-016.

[@SultansAudio]

It is a common failure for a lot of chargers and also solar inverters++ Its the X2 caps(usually 1- 3.3uF ) that is loosing capacitance over time due to small amount of moisture getting into it. And finally it pops open or even worse; it shorts! The it usually kills the power stage nearby. This is getting better as manufacturers of these type of caps have started to test/certify caps with high amount of humidity AND full voltage +ripple. Standard X2 caps will loose capacitance quite quick in such conditions. But now you have a new type called several things, but something like this one: content.kemet.com/datasheets/KEM_F3092_F862_X2_310.pdf So if you replace an old charger, ALWAYS check if this type of caps are broken! And replace them on old chargers before putting them in your car.

[@benjaminnead8557]

Just writing to say thanks for your videos showing repairs on these cars. The My i-MiEV forum is an excellent resource and I need to check in there more often. I've owned a 2012 North American trim (wider body) i-MiEV with CHAdeMO since late 2015. The factory gave me a warranty replacement battery in mid 2020 when the old pack started to lose capacity. Mine has very little rust, thanks to the dry Arizona desert climate. I plan to keep it running for as long as I can.

[@jimcabezola3051]

I really like these Mitsubishi/Peugeot/Citroen EVs. Thanks for featuring one of these!

[@Stefan_Dahn]

Very interesting. Great work! 👍👍 2:40 I suggest a vacuum cleaner to avoid dirt falling into the electronics. 😉

[@LarsDahlin]

Sweet! I got an iOn as my previous car. 2011. Got exactly the same fault. Luckily for me I swapped it on the warranty. Great work with the slow charger.

[@matejorsag6515]

Hi Dala, thanks for such great content and for Your effort in keeping those old yet functional EVs on the road! Keep up the good work. Looking forwards to future videos. Greetings from the Czech Republic!

[@RajGiandeep]

Thank you for your efforts in keeping old EVs going on the roads! Keep up the videos

[@Stefan_Dahn]

4:57 You could blast it with dry ice. Often used for vintage cars to gently remove dirt and paint from components. Then wax conservation with Tectyl "Amber" or other wax to conserve it.

[@bartek3253]

The problem with chademo and i-miev is that, when you plug chademo it should start in few seconds, if not car block charging possibility, the same with AC. Try to click start on charger and connect to car. I had this problem many times before I noticed this feature of i-miev. (my is 2012)

[@floriandiefenthaler2553]

It is quite interesting, that the DC-DC converters fan just be swapped between 2010-2011 and 2012-EOP. The first battery packs were 88 volts like on all Mitsubishi I-MiEV vehicles. The Citroën and Peugeot from after 2012 had 80 cells.

[@stopburningstuff649]

Awesome. Would be good to pass the failed charger to someone else to diagnose the components that failed and whether it's possible to fix. That would be an option to people who might not be able to source a replacement unit

[@mk-jl3zd]

Thank you sir,appreciate your work.

[@toyotaprius79]

Dealerships are unnecessarily scared of servicing these vehicles

[@usmanchaudhry7991]

Good stuff man!! 👍🏼

[@JamieLovick]

I have a 2013 i-MiEV and am looking at options to replace the onboard charger with something that can charge at a higher rate, either 7.2 kW, 11 kW, or even 22 kW. Do you know of a similar unit that could be adapted and would actually fit in the available space? Some CAN logging would be involved and maybe a CAN bridge used in between to make it talk to the car.

[@David45G]

Wonderful video. I own a 2014 Mitsubishi I MiEV and the positive DC -DC terminal is corroded badly. When the technician tried to disconnect it he actually broke the connector. It seems that we now have a funky chalenge to somehow fix the connector. Alternatively, I could replace the whole on board charger for well over 5000-6000 canadian dollars! I welcome any recommendation!

[@DalasEVRepair]

I would take some pictures and post it on a discussion forum, try the diyelectriccar or speakev one

[@carlosgarcialalicata]

the black disks look like MOV, and they are usually there to avoid the rest of the electronic to burn (or catch fire) if something goes wrong. Interesting that they covered them, most PCBs have them placed in a way they can be replaced easily

[@MartinLV.]

Hi there! You are a LEGEND! You will get Nobel price if you hack old evs to have VTG availability, specially renault kangoo or env200.. Thanks for your hacking input!👍👍👍

[@CubbyTech]

I can't help but wonder if there's some sort of software / registering the new charger to the car that is preventing DC fast charging. Still not an easy fix, thank you Dala.

[@jjjhietala]

Nice job! 👍🏻

[@TihamérGorjánácz]

Dear Dala, How did you solve the different connectors? The video does not explain. I need to replace the OBC and I don't want to cut the wires. Do you deal with dismantled I-miev cells? I need LEV50N cells.

[@DalasEVRepair]

Cut and splice the new connector I do not sell anything, sorry!

[@TheHauttis]

when you open the lid it smells like an old radio :-)

[@danielegstedt4223]

Hello great video ! Had the Sam Robles with my Citroen’s , send it to company in Barcelona , they repaired it 1000 euros ! New one from Citroen’s they wanted 2700 euros in spain . Will you do more of these i-miev ? I would love if some one hacked them so you can make your own battery . Mine only does 85 km (2011, 90000 km ) love the car easy to park , drive and good space inside . Maybe you want to come to spain and do my battery and film it for your Chanel ?

[@Silicore007]

DC charging not use this modul. Is AC charge stay 3.7kw? Thank you!

[@DalasEVRepair]

Correct, this is only for AC charging

[@Patchworkdaddy007]

You are still a Genius!👍👍👍👍🇪🇺🇺🇦🕊️

[@timothymoroney3561]

Thank you Dala for this very helpful video . May I ask what your budget repair cost the owner ? My 2012 iMi just developed the same issue and is now out of warranty . The dealership quoted us $4500 to repair/replace the on-board charger .

[@DalasEVRepair]

900€ fix!

[@timothymoroney3561]

@@DalasEVRepair I finally pulled apart my on-board charger this weekend and found the circuit board looking good . However the component on the top of the cover which has four wires going to it (it's about 5"x5" square) was melted and burned ! It has a label on it that reads : TZ1529RFLT011-2R02-0030 Do think you could find this component or another later model charger ? I have a 2012 iMiEV ES (US model).

[@DalasEVRepair]

@@timothymoroney3561 you better ask the imiev forums!

[@mwahlgreen]

Please Dala, contact me. I am pretty sure the car has more issues than just not charging... I have much more experience with these cars than most. My guess is that the AC is not working and therefore the CHAdeMO is not willing to work. Try to ask the owner if AC works?

[@DalasEVRepair]

? Vehicle was fixed and in use for a week now!

[@L3N1NVEVO]

I have air conditioning that leaked coolant and it doesnt work. no problems with chademo charging here.

[@paulusegersunder2029]

Hei. Bra, hjeplfull video, men mangler noen detaljer. Hvordan fant du ut hvilken kabel til 330V er + eller -minus?

[@DalasEVRepair]

Det är märkt på PCBt om jag minns rätt!

[@paulusegersunder2029]

@@DalasEVRepair I den nye er 2 koblinger "CHGP" hvor jeg kobler den røde og "CHGN" hvor jeg kobler den blå. Riktig?

[@DalasEVRepair]

@@paulusegersunder2029 sorry, minns inte!

[@herrtichy]

Jeez, did they take that thing offroad daily or is everything just in the splash zone from the rear wheels?

[@DalasEVRepair]

There is not a single splash shield to protect the components from the weather! It's such a crazy setup!

[@herrtichy]

@@DalasEVRepair Yikes. Yeah well, the entire MIEV/ion/c-zero lineup was probably designed in south France where they know bad weather only from 1970s arthouse movies 😁

[@Stefan_Dahn]

@@herrtichy Designed in southern Japan. It is Engineered and manufactured in Japan. 😉

[@sjokomelk]

The i-MiEV is a compliance car in Japan. It was originally a small "kei car" with a tiny petrol engine in the back. And was later retrofitted into an EV version putting the EV components in the engine bay over the rear axle.

[@W4rH4wkXX]

well you can not win them all, at least the user can still slow charge. great work 💪

[@DalasEVRepair]

Yeah I got some info that the chademo was optional on some trim levels, so it might be that this outlet wasn't even meant to work :D

[@bilymotyl7704]

At this point it would be nice to be able to replace the slow and bugged Type1 port on the Ion with CCS/Type2 and give it at least 6kW Level2 charging option. Dare I ask for 11kW Type2 three phase or even more? Of course CCS fast charge enabled port would be amazing too as the car would then be equipped with both Chademo and CCS fast charging options. Is it possible?

[@DalasEVRepair]

Agreed, anything is possible with enough time and money :)

[@bilymotyl7704]

@@DalasEVRepair There is a guy who figured out how to adapt BMW i3 CCS charging module for his custom EV remake, teasing us with charging his old wagon at Ionity, but those BMW CCS modules are pricey and might be discontinued soon, we need to ‘open hardware’ this CCS thing.

[@michaelpedersen8491]

Thanks for sharing 👍i am looking for a defect charger PCB to repair. I am working with power electronic , and found schematic for this PCB. Do you still have the defect PCB ?

[@DalasEVRepair]

Unfortunately not!

[@michaelpedersen8491]

@@DalasEVRepair ok, thanks

[@ивансерый-р5б]

Where you found the shematic. Please share.

[@pashko90]

This older miev chargers are sharing issues as well as most of power electronics with ze0 leaf...

[@DalasEVRepair]

Yes, one of the main reasons I wanted to update to the newer design. So many potential failure points on the early charger!

[@_a.z]

I don't think the 16 amp charger is a problem, they just draw what they want. I'm using a 7kw charger!

[@DalasEVRepair]

Socket was 10A...

[@homesteadandvideo]

Ive got an Mitsubishi imiev who got a fault code present P1A44 (bmu leakage detected ) How to fix that ? Is it an electrick leak or what does this realy mean ? Anyone knows .. ?

[@DalasEVRepair]

Try this forum: myimiev.com/forum/viewforum.php?f=23

[@benbaselet2026]

I'm surprised you didn't have to reset a gazillion fault codes and systems to wake things up? Or maybe the thing just resets when you have cut all power to it? I bet a newer car would be more trouble like that.

[@DalasEVRepair]

Yeah I was really surprised about that too :D

[@rkan2]

Usually cars are built with fault tolerance in mind

[@bilymotyl7704]

Thanks for this, very interesting. CHAdeMO is actually pretty dependable, never failed me unlike CCS. Maybe the Kempower charger does not support CHAdeMO protocol correctly.

[@DalasEVRepair]

Yeah I charged my own LEAF before charging the broken car, so it def works lol. It seems like the car is not latching the lock, which points toward a broken fuse or active fault code preventing Chademo use.

[@gregfordyce9476]

My iOn can be temperamental with some Chademo chargers, have the customer try Chademo on a public charger that they have previously used on this car.

[@bilymotyl7704]

I’ve seen the LEAF car being charged in your other video.., verifying the Kempower DC charger with the triplets would not hurt thought. Those early CHAdeMO implementations might be a bit out of spec on the car side there.

[@DalasEVRepair]

@@bilymotyl7704 Yeah no, I work for Kempower so I know for sure they work with the trio.

[@bilymotyl7704]

@@DalasEVRepair Great, thanks for the fancy Kempower charger vs iMiev workability confirmation. I am considering such a portable charger for our garage.

[@Georgatzis]

I have paid for a new charger 4000 euros model 2017! This was A big scam from Mitsubishi! They do not sell parts separately for this charger and they don t fix them either! Toyota does it! So these cars are not as green as they seme like. I hope new electric cars are different but I don t think so because they want to make money too!!! New battery for the Mitsubishi imiv is 10.000 Euros. The value of the car is 8000 Euros….. ridiculous !!!

[@DalasEVRepair]

Ouch! A used charger was ~500€ for this vehicle

[@DanBurgaud]

In the near future, gears and gasket mechanics will be out of job replaced by electricians and electronic hackers.

[@shaystern2453]

bad design is correct; it's filthy

[@amiramrani9194]

Hi Dala, Thanks for this amazing video. Could you please tell me, if you can replace damaged battery cells of my iOn EV ? If yes, how much does it cost approx. please ? Can I have your email or contact number please ? Thanks

[@DalasEVRepair]

Contact info via dalasevrepair.fi , lots of imiev battery repair videos on youtube!

[@martinwinlow]

I wonder if deleting any pre-existing diagnostic trouble codes after fitting the ‘new’ charger would have restored DC charging capability?