Posted on 2 Comments

Is possible to save Kia Soul battery?

🇺🇸Possible, but not without detailed measurement and materials. This Soul, at 100k km, has a State of Health (SOH) of around 50%, which is not accurate; degradation is closer to 70%, or SOH 30%. Many mistakenly believe it’s just one or two cells that are faulty, but after DCIR measurements, it’s clear it’s not just one. In this case, the Soul had 28 groups, totaling 56 cells to replace, out of 95 groups, roughly 30% of the battery replaced with used and better cells. Previously, the range was about 40km, but after the repair, we managed to achieve around 105km in very cold conditions, while in warm conditions, it should be around 150km. Unlike the Nissan Leaf, this battery has active air cooling from the cabin and heating. Additionally, there’s PTC foil on all blocks to heat the battery if it’s below 0 degrees. Where exactly the problem arises, causing overheating to damage the upper cells of all blocks, is not clear to us either. This Soul is one of the most neglected EVs on the market, completely overlooked and forgotten by the media, yet it’s a very good EV, better equipped than all others from that time. Steering wheel heating, ventilated seats, CarPlay, comfortable seats, spacious, and without any faults except battery degradation. The cells are 35Ah SK Innovative, some strange chemistry, with a form factor without substituting replacement cells. But all of that is not important, because besides the Twizy, eGolf, and Smart Valhalla projects, we will design a battery for the Kia Soul with at least a 36kWh capacity.

OEM Kia : 22000€+tax

EVC: 3200€tax

🇭🇷 Reparacija baterije KIA Soul 2015 ? Može, ali ne bez detaljnog mjerenja i materijala. Ovaj Soul na prijedjenih 100k km ima SOH na 50% što od prilike nije tocno, jer je degradacija blize 70% tj SOH 30%. Mnogi se varaju da je samo jedna ili dvije celije neispravne, medjutim nakon DCir mjerenja ćelija očigledno je da nije samo jedna. U ovom slučaju Soul je imao 28 grupa tj. ukupno 56 ćelija za izmjenu, od okupno 95 grupa. Što je od prilike 30% baterije izmjeneno rabljenim i boljim celijama. Domet je prije bio oko 40km a mi smo uspjeli nakon reparacije dobiti oko 105 km dometa u jako hladnim uvjetima, dok bi u toplim uvjetima trebao imati oko 150km. Ova baterija za razliku od Nissan Leaf promašaja, ima aktivno hladjenje zrakom iz kabine, isto tako i grijanje. Osim toga na svim blokovima ima PTC foliju koja grije bateriju ako je uspod 0 stupnjeva. Gdje problem tocno nastane da pregrijavanje osteti gornje celije svih bolokova, nije ni nama jasno. Ovaj Soul je jedan od najzanemarenijih EV na tržištu, totalno zapostavljen i zaboravljen od medija, a u biti je jako dobar EV, bolje opremljen opremom od svih ostalih iz tog vremena. Grijanje volana, ventilirajuca sjedista, carplay, udobna sjedista, pregledan, prostran i bez ikakvih kvarova osim degradacije baterije. Ćelije su 35Ah SK Innovative neke čudne kemije a formfactor bez substitucije zamjenskih celija. Ali to sve nije bitno, jer osim Twizy, eGolf i Smarta Valhala projekta, budemo jednu bateriju dizajnirali i za Kia Soul sa bar 36kWh baterijom.

OEM Kia : 22000€+tax

EVC: 3200€tax

Posted on 3 Comments

Can a Tesla battery be repaired for €1000?

🇺🇸 Of course, it can, depending on the severity of the damage. Recently, we mentioned how important it is to inspect and perform a “reseal” on the battery after 6-7 years. Here, the original battery from a 2015 Tesla Model S P85D had water ingress directly into the high-voltage part where the pyrofuse is located. The vehicle shut down immediately and was brought from Austria through our partner channels for vehicle towing service. Tesla offered a complete new battery for around €20,000 (cheaper than a new CRT Audi 3.0 TDI diesel engine), even though the procedure could have been simple for them if they had removed and inspected it; they probably would have offered a Reseal, as we did. We won’t even use the word “repair” here because that procedure wasn’t even performed. We replaced the fuse cover, installed a new pyrofuse, new valves, and performed a full EVC reseal (business secret), so this battery, with 250k km on it, is ready for at least another 300k km. This is not full battery remanufacturing because this job doesnt include full battery opening. We do no open any original seals on battery lid. For other defects like BMS_u018, f107 f098 f097 u025 or most notorious BMS_u029 it is necessary to make RESEAL + FULL REMANUFACTURING where we need between 50-90 labor hours.

Alert: BMS_F123

Tesla OEM: 20000€

Tesla with commitment: 2000€

EVC: 1450€ + tax

🇭🇷Može li se Tesla baterija reparirati za 1000€? Naravno da može i ovisi o težini kvara. Nedavno smo spominjali kaoliko je važno nakon 6-7 godina pregledati, ispitati i napraviti “reseal” baterije. Ovdje je originalna baterija iz 2015 sa Tesla Model S P85D imala prodor vode direktno u visokonaponski dio gdje se nalazi pyrofuse. Vozilo je se ugasilo odmah i doveženo je iz Austrije putem naših partner kanala za dovoz vozila. Tesla je u ponudi tražila kompletno novu bateriju nekih 20000€ (jeftinije od novog CRT Audi 3.0 TDI dizel motora) iako je zahvat i njima mogao biti jednostavan da su je skinuli i pregledali, vjerovatno bi ponudili Reseal kao i mi. Ovdje “reparacija” riječ necemo ni koristiti, jer taj zahvat nije ni napravljen. Ovdje smo izmjenili poklopac osiguraca, stavljen je novi pyrofuse, novi ventili i napravljen je puni EVC reseal (poslovna tajna) tako da je ova baterija da sa predjenih 250k km spremna za sledećih bar 300k km.

Tesla OEM: 20000€

Tesla with commitment: 2000€

EVC: 1450€ + tax

Posted on Leave a comment

Smart 453EQ fire hazard – Recall needed

🇭🇷🇺🇸Smart 453EQ sa zapaljenim inverterom. Zasto EU ne štiti EU vozače od tvorničkih grešaka? Ne samo na strujićima već i na fosilcima/hybridima. Ona vozila koja su sa razlogom u opozivu jer je tvornička greška, ista je opasnost u Americi, Norveškoj, Kini i u opozivu je, besplatno mjenjaju dio o svom trošku. Kao nissan leaf sa škart opasnom baterijom zbog napuhavanja ćelija i kratkog spoja, kao što je Kia Soul u opozivu za bateriju i opasnost od napuhavanja ćelija pa mjenjaju besplatno, kao Stellantis OBC i baterije… i 50 drugih primjera, vozila su opozivu i mjenja se tvornicka greska svagdje osim u EU. Unutar EU vlasnici placaju tudje greške. Smart 453EQ ima osim programiranih kvarova i ne evidentiranu tvornicku gresku DCDC invertera koji je se u 5 evidentiranih slučajeva zapalio samo u Zagrebu, za dva vozila iz njemačke znamo da su i vozila nagorila kompletno. DCDC se nalazi u modulu motora (powertrain jedinica), osim glupog i nefunkcionalnog dizajna gdje za svaki kvar skidas kompletan zadnji kraj takodjer je i preskup, totalno neodrživ. DCDC je ovom vozilu “alternator” za punjenje malog akumulatora, sto se tocno desi niie jasno ali osim programirane greske kad se izbriše, poremeti, nije moguce ni fleshanjem online SCN osposobiti. Samo reparacija na stolu pomaže. Ustanovili smo da i loš akumulator ga ošteti. Takodjer ga ošteti ako antifriz nije pravilno ozračen, jer on se nalazi u samom vrhu sustava a hladi se sa antifrizom. A najzanimljivije je to što vecina vlasnika u garanciji ni nezna da im se zapalio DCDC, a sam razvoj horora ide ovako: ujutro se probudite smart ne vozi, odvezes u servis, javljaju da je velika baterija neispravna… ok garancija, čekaš, oni montiraju i zovu da je JOS NEŠTO NEISPRAVNO(to je znak). U nekim slučajevima ako je nagoreni dcdc zalijepio kontaktore i skurio bateriju/osigurac moguce da je DCDC i dalje u kratkom spoju od 0 ohm. Decki ugrade novu bateriju pa spale i nju. Nekad znaju dva puta mjenjati bateriju, dok ne skuže da je šlus i na autu. Onda zamjene powertrain jedinicu i bateriju pa Smart proradi. Ovlasteni servisi vracaju stare dijelove tvornici i niti ne znaju da je požar bio u modulu, koji srećom nije eskalirao dalje. Proizvodjač zna za problem ali od 2017 godine nitko nije napravio opoziv. Isti se problem desava na Twingu, Zoe i elektricnom Smartu 453EQ. Vrlo opasan problem za koji bi netko od proizvodjača trebao u zatvor. Problem je jako kompleksan jer dovodi u problem sve, i radi ogromnu stetu svima. Prvo mi ugradjujemo nove original komponente u DCDC kad je neispravan, medjutim on je i dalje tvornicka greška dizajnom, jer je i nov tvornička greška. Odgovornost prenose na nas da se čak razmišljamo kompletno obustaviti radove na ovom tipu vozila kao i za Nissan Leaf bateriie. Ovo je wakeup call vlasnicima da ipak kontaktiraju zastitu potrosaca i prijave problem jer na ovim temama i istazivanjima ne radi niko. Možda čak i NHTSA prijaviti. I vrlo bitno za napomenuti je da tehnicari ovlastenog servisa imaju vezane ruke, ne smiju otvarati powertrain za provjeru, odgovornost je najmanje na njima, samo na proizvodjuču. Ovo vozilo je za totalni opoziv DCDC invertera.

Part number: 292A05698R, A4533404500

Supplier: Delta

Engineering: Renault

🇺🇸 Why isn’t the EU protecting its drivers from factory defects, not only in electric vehicles but also in ICE and hybrid cars? Take the Smart 453EQ for example, which has a recurring issue with a burning inverter. In other markets like the US, Norway, and China, vehicles are recalled, and faulty parts are replaced at no cost to the owner when factory defects pose safety risks. Examples include the Nissan Leaf’s battery issues due to cell swelling and short circuits, the Kia Soul’s recall over dangerous battery defects, and Stellantis’ recalls for onboard chargers and batteries. Yet in the EU, it’s a different story—owners end up paying for manufacturers’ mistakes.

Beyond programmed faults, the Smart 453EQ has an undocumented factory defect in its DCDC inverter, which has caused fires in five cases just in Zagreb, with two cars imported from Germany completely burning. The DCDC, responsible for charging the 12V battery, is placed within the powertrain module in a poorly designed, hard-to-access location that requires removing the entire rear end for repairs. Not only is this setup impractical, but it’s also costly and unsustainable.

The root issue is unclear, but besides the programmed fault that causes it to malfunction, attempts to enable it via online SCN coding have failed. It can only be fixed on the workbench. We’ve discovered that a bad battery or improper antifreeze circulation—since it’s cooled at the top of the system—can also damage the DCDC. What’s more alarming is that many owners are unaware their DCDC failed during the warranty period. Here’s how it often plays out: the car won’t start in the morning, it goes to the service center, they identify a problem with the main battery, and you wait for the warranty replacement. But then they inform you there’s “something else wrong,” indicating deeper issues.

In some instances, a burnt DCDC can weld its contactors, damaging both the battery and fuse, leading to a short circuit. Service centers may install a new battery, only for it to burn out again because they didnt check HV output resistance directly on the cable. It’s sometimes only after two battery replacements that the real problem is identified, prompting the replacement of the entire powertrain module. Yet, authorized service centers often return the damaged parts to the manufacturer, unaware that a fire occurred within the module. The manufacturer has known about this problem since 2017 but has not issued a recall. This issue extends to the Renault Twingo, Zoe, and electric Smart 453EQ, posing a significant safety hazard that should lead to accountability for the manufacturers.

The complexity of the issue means it affects everyone involved, causing substantial losses. Even after replacing the DCDC with new original components, the defect remains due to a flawed design. DCDC input and output doesnt have its own FUSE. Given the risks and responsibilities being unfairly placed on us, we are considering halting repairs on this model as well as on Nissan Leaf batteries. Owners need to take action by contacting consumer protection agencies to report these problems, as there are no ongoing investigations or corrective measures. Reporting to the NHTSA might be a necessary step.

Part number: 292A05698R

Supplier: Delta

Engineering: Renault

Other example: https://www.smartcarofamerica.com/threads/smart-fortwo-453-eq.163345/

Example when DCDC inverter destroys electric Smart 453EQ but battery survives:

Example when DCDC catch fire and destroys Renault Zoe in Croatia Varazdin:

OTHER PICTURES

Posted on Leave a comment

24000€ ICE Engine is more Expensive than Battery

These are OEM NEW Audi EPC catalog prices : Motor 24000 EUR – Transmission 13000 – Camshaft 3600 – NOx 1200 – DPF (Diesel Particulate Filter) 5000 – Turbine 4000 – EGR (Exhaust Gas Recirculation) 1500 – CR Pump (Common Rail Pump) 2800 – Injectors 7200 – Crankshaft 4000 – Mildhybrid 48V Battery 2800 – Alternator 2200 = Consumable parts over 100,000 km amount to 71300 EUR. AT THE END OF POST YOU HAVE EPC CATALOG PRICE SCREENSHOTS

For years, we have warned that “cheaper” fossil fuel vehicles (FFVs) are generally more expensive than electric vehicles (EVs), often costing at least twice as much over time. With 14 years of experience and insights from various sources, including tuners and technicians from authorized Porsche Interauto service centers, we’ve seen that new FFVs are often poorly made. They are constructed from low-quality and weakened materials, incorporate overly complicated solutions, are prone to programmed failures, and have excessively expensive parts. For instance, the 3.0 TDI engines installed since around 2014 have been problematic, yet this issue has largely gone unaddressed for nearly a decade.

The public only became aware of these problems when they experienced them firsthand. Despite the widespread issues, fossil fuel vehicles rarely face recalls or part revisions for even the most serious faults. In contrast, every detail of EVs is scrutinized and criticized. Mainstram media often provide shallow opinions and fail to hold FFVs to the same standard of reporting and journalism. They rarely question the cost of parts in gasoline or diesel vehicles, which are often more expensive than the entire EV they criticize.

These media outlets praise fossil fuel vehicles because they are paid to do so. If they criticize them, they risk losing exclusive access to new models for test drives. This biased reporting contributes to the declining quality of FFVs, making journalists who sell such propaganda complicit in the degradation of automotive standards. In multiple notable examples mainstream anti-EV media propagate misleading information.

As a result, consumers have a hard time finding reliable information about both EVs and FFVs. The automotive industry suffers from this lack of accountability, and the true cost of owning an FFV remains hidden, while the benefits of EVs are unfairly criticized.

After years of enduring journalistic bias and discrimination of EV in the automotive industry, it’s clear there is a significant lack of independent, unbiased information from ordinary users and crucially, experienced mechanics. Mechanics, the essential link in providing reliable information to vehicle owners, have been sidelined and demonized as “scammers” by journalists and self-proclaimed “car enthusiasts.”

The media landscape is dominated by biased reporting that fails to criticize low-quality, expensive engines and programmed failures. Only a few voices, like colleague Bagrameli, consistently highlight these issues from a fossil fuel perspective. Mechanics with their extensive experience should be respected and proud of their contributions to the automotive industry.

Audi has particularly struggled with their diesel models since 2012. Issues range from high-pressure pumps that deteriorate and cost €10,000 to repair on the 2.0 TDI, to catastrophic failures in the 3.0 TDI engines. These engines, identified by codes CRT, CUA, CZV, and DEWA, have fundamental design flaws. For example, a spring in the camshaft meant to tension the gear disintegrates as early as 50,000 km. Additionally, after an oil change, an air pocket can remain on the pressure valve or oil pressure regulation sensor, potentially destroying the entire engine block. Every component, from the crankshaft and camshaft to the oil system, 48V generator, and 48V Li-Ion battery, is prohibitively expensive and prone to failure.

Most of these vehicles face severe, costly problems by 50,000 km, where a vehicle with 200 kW can only be driven gently to ensure it lasts to 100,000 km. The state of the German auto industry raises serious concerns, and the lack of critical voices to address these issues is troubling.

As a result, many people will inevitably switch to EVs, not due to coercion, but because they have no alternative. These fossil fuel powertrains often fail before 100,000 km, with repair costs around €28,000. The need for reliable, critical reporting and recognition of the valuable insights from experienced mechanics has never been more urgent.

These vehicles are so risky that even simple oil change services, where the poorly designed engine can blow out the engine block, will result in blaming the mechanic, as it usually happens. Owners have started to harass mechanics with invented expensive problems, “it wasn’t like this when I came,” so there are fewer and fewer mechanics and services willing to work on these vehicles. It’s less of a hassle to replace the battery on an EV than to do a small service on an Audi diesel CRT engine.

Therefore, it is certain that fossil fuel vehicles have dug their own grave with poor quality. Those who drive them and charge once for subpar parts will realize that even the battery on a Tesla, costing 20,000 euros, is cheaper than diesel trash. We have been working on and servicing them for years, and we switched to EV primarily because of wasting money on oil, and the last straw was the poor quality of the engine and increasingly expensive maintenance parts. So, dear audience, the EV battery is 4 times cheaper than a fossil fuel engine.

Posted on Leave a comment

Dizel motor od 24000 € = Anal Intruder

Motor 24000eur – Mjenjač 13000 – Bregaste 3600 – NOx 1200 – DPF 5000 – Turbina 4000 – EGR 1500 – CR Pumpa 2800 – Dizne 7200 – Radilica 4000 – Mildhybrid 48V Aku 2800 – Alternator 2200 = Potrošnih dijelova na 100000km je 71300 EURA
Ono sto već godinama upozoravamo nakon 14 godina iskustva, da su “jeftiniji” fosilci od EV u principu skuplji od EV, u najmanju ruku duplo skuplji. Tema za koju smo mi znali, iz više razlicitih izvora upozoravali (ne samo što ih mi radimo već) od Tjunera pa do tehničara ovlaštenih servisa Porsche Interauto, da su novi fosilci smeće. Smeće od nekvalitetnih materijala, oslabljenih materijala, prekompliciranih riješenja, programiranih kvarova pa do abnormalno skupih dijelova. Motori 3.0tdi koji su se počeli ugradjivati ako se ne varam jos od 2014, znači prije 10 godina, kako je moguće da to isto smeće niko nikad nije prozvao, propitkivao ili izvještavao. Kako je moguće da se to poluproizvod smeće prodavalo skoro 10 godina i da šira publik sazna o problemu tek na vlastitoj kože, a odgovor leži doslovno u svakom mogućem članku Revijahak, Autoportal, Jutarnji, Auto Klub, Start Shitnews, Index Auto i ostalim portalima kojima je mišljenje podmazano da bude površno. Kritikuje se samo EV za svaku sitnicu, a smeće od fosilaca i za najopasnije greške ne dobije ni opoziv, a kamo li reviziju dijela. Temama koliko koji dio košta na novom autu je samo propitkivan kad je u pitanju ono sto oni mrze i sto neobjektivno žele dezinformirti publiku, a to je koliko košta EV baterija ali ne znaju koliko košta ijedan pogonski dizel benzin motora tih vozila koja oni hvale a koji je u principu skoplji od CIJELOG FOSILCA (upravo ono sto tvrde za EV), a hvale jer im je plaćeno a ako kritikuju onda nemaj “eksluziv” pristup novim modelima na test voznju. Zato ako se pitate zašto su fosilci sve veće i veće smeće, glavni krivci su automotive destruktori – novinari koji prodaju propagandu za prodaju hvaleći nešto o čemu nemaju pojma ni kako radi. Šebalji, Ilko autofašista sa automobili.hr , novinari indexa , jutarnjeg i ostalog propagandno desktruktivnog kartela su zaslužni za stanje užasne kvalitete u automotive sektoru. Običan vjerni ljubitelj limenih igrački se nema gdje informirati niti o EV niti o Fosilcima.

Screenshot Primjer jednog fakenews portala koji agendom ne kritizirajuci fosilce, neobjektivno bombardira dezinformacijama. Novinari koji poprilično nesposobnim vještinama poznavanja ijedne automotive materije kopiraju clanak dodaju narativ da dobiju par klikova i izmjišljaju nepostojeći debilizam o automobilima, dok istovremeno ne prenosi recimo temu o dizelskim pogonima koji su smeće u cilju da zaštiti kupca ili budućeg vlasnika i da prizvođač ponudi trajno riješenje. Ne prenosi kvarove i cijene dijelova istih.

COPY PASTE FAKE NEWS PORTAL

Tako da nakon svih ovih godina slušanja novinarskog automobilskog fašizma i diskriminacije onih tema kojima se njima ne podmazuju možemo doći do zaključka da jako nedostaje neovisnog i neucjenjenog auditorijuma u režiji običnih korisnika i vrlo ključnih mehaničara koji su zanemarena karika i glas u informiranju vlasnika. Mehaničarima sa iskustvom oduzeto je pravo na glas, oduzeli su novinari i samoprozvani “automobilisti” i još su u tom procesu mehaničare demonizirali u “prevarante”. Skoro da uopće nemamo takav medijski podij sa realnom “pljuvačinom” na smeće, nekvalitetne i skupe pogone, programirane kvarove. Iskazuje se jedino kolega Bagrameli sa tim temama i dugogodišnjim iskostvom koji vjerno prenosi teme i iz fosilnog kutka. Mehaničari sa svojim iskustvom bi trebali biti ponos tog dijela automobilizma.

Audi je sa novim dizel modelima od 2012 fulao sve od visokotlačne pumpe koja se počne perutati i sanacija košta 10000eura na 2.0 tdi, pa do kompletnog 3.0 tdi motora gdje su u bregastu smjestili oprugu da napinje zupčanik koji se raspane već na 50k km. Prijavljeni poluproizvod kodovi motora su CRT CUA CZV DEWA. Osim toga, motor je toliko loše konstruiran da nakon izmjene ulje ostane airpocket na ventilu tlaka ili senzoru regulacije tlaka ulja da razbije kompletan blok motora. Na motoru se raspada radilica, bregasta, uljni sistem, 48v generator, 48v Li-Ion akumulator… i svaka kompnenta je kao suho zlato.
Velika većina tih vozila jako skupe probleme ima već na 50000km, gdje vozilo od 200kw bi morali voziti do 50kmh i sa balerinkama na nozi da penetrirate samo 5% pedale gasa i da bi ste sačuvali motor da izdrži 100k km. Žalosno da se čovjek zapita koji je klinac sa tom Njemačkom autoindustrijom i gdje je taj glas kritike da se to zaustavi. Realno ekipa će prelaziti na EV samo zato što nemaju alternativu, čak i bez (kako bi rekli ravnozemljaši) prisile.
Ta vozila su toliko rizična i najjednostavnije male servise izmjene ulja, gdje ce loš dizajna motora izbiti blok motora pa će biti “majstor kriv” kako to inače bude. Mehaničare su vlasnici počeli silovati izmišljenim skupim problemima “nije to tako bile kad sam dosao” da sve manje mehanicara i servisa ima koji uopce žele raditi na tim vozilima. Manja je šteta da na EV probijete bateriju nego da radite mali servis na Audi dizel CRT motoru.

Zato je sigurno da su totalno nepouzdani fosilci sami sebi iskopali grob nekvalitetom, tko ih vozi i naplaća se jednom škart dijelova shvatit će da i sama baterija na Tesli od 20000eura je jeftinija od dizel smeća. Mi ih godinama radimo i servisiramo, a na EV smo prešli primarno zbog bacanja love na naftu a zadnja kap je bila nekvaliteta pogona i sve skuplji dijelovi za održavanje.

Tako da draga publiko, baterija na EV je 4x jeftinija od pogona fosilca.

Posted on 1 Comment

32000€ Battery repaired for 500€ – VW eUP

The repair, costing €32,000, was resolved for €500 on a 2015 VW eUp. It generally doesn’t require major interventions and has proven extremely reliable with very few issues. The owner reported the vehicle being immobilized for a couple of months. An authorized service performed a diagnosis and determined a new battery was needed.

Due to a backlog of diesel Mercedes Bravas, DSG transmissions, and other activities, there was barely any time to inspect the eUp that arrived over two weeks ago. However, a detailed OBD analysis was done before removing or opening the battery.

Interestingly, the battery error was an interlock issue. Interlock is a safety mechanism that creates a short circuit in all high-voltage components and cables (orange-colored) to disconnect the battery in case someone tries to manipulate or open a module that’s under voltage. This prevents accidents. Initially suspected to be the BMS (Battery Management System), it was confirmed not to be the battery after testing the interlock lines.

Further examination revealed irregular values on the interlock lines towards the vehicle on the BMS connector pins 4 and 11. It was then discovered that the issue was not with the battery but with the “service” interlock switch used to safely disconnect the vehicle for maintenance. A pin had broken within the connector. Replacing this switch allowed the eUp to indicate readiness and operate again.

While the cause of the problem wasn’t crucial, this specific switch, designed by the Germans for EVs, proved intricate to handle. It required a high level of expertise to manipulate safely, taking two hours of work. The needle broke while attempting to disconnect the switch for maintenance or by someone not equipped to handle EVs.

After replacing a second small battery and the interlock switch, totaling about 10 working hours, €31,000 was saved. The notion that battery repairs are always costly becomes even more dubious. The VW eUp, one of the most sought-after small urban cars, has had no major issues with its batteries or engines. Only three vehicles were serviced in total. Known issues include the Charging Module (BD), gear lever not detecting the parking position for charging, and faults in the OBC (On-Board Charger). OBC issues are mostly caused by external network influences like short circuits or lightning strikes.

The new OBC costs around €4000, used ones around €800, and repairs around €600. The earliest 2015 models had only AC charging and lacked CCS DC. The small 18kWh battery is sensitive in winter, reducing the range to 60-70km. Among all small vehicles on the market, the eUp stands out as a top choice alongside others like C0, Smart, Ami, Twingo, etc.

HRVATSKI

Kvar od 32,000€ riješen za 500€ na VW eUp 2015, koji generalno uopće ne dolazi na lobotomiju i koji je se pokazao izuzetno pouzdanim, sa vrlo malim brojem kvarova. Vlasnik javlja da je vozilo nepokretno već par mjeseci, da je ovlasteni servis napravio dijagnostiku i da je procjena nova baterija. Kako smo pretrpani dizel mercedes bravama, DSG mjenjačima i ostalim sponzorskim dinosaur aktivnostima jedva nadjemo koji dan da pregledamo eUp koji je stigao orije 2 tjedna, da napravimo OBD detaljnu analizu prije skidanja i otvaranja baterije. Gle vraga, greška u bateriji je interlock. Interlock je “safety loop” mehanizam koji ima kratkospojku u svim visokonaponskim komponentama i kablovima (narandzaste boje) da ako mehaničar ili neko treći proba čačkati po istim, odpajati ili otvarati modul koji je pod naponom , da baterija izvrši odpajanje kontaktora u bateriji, tj interlock zaštitu. S obzirom da je taj mehanizam zaštite u bateriji, postoji sumnja da je baterija tj BMS. Ali prvo treba potvrditi da je BMS ili ostatak vozila. Nakon ispitivanja interlock linije na prema vozilu na žicama od BMS konektora, na pinu 4 i 11 , vrijednosti nisu pravilne. Ohoooo momenat, 100% nije baterija. Sad ispitati SVE HV kablove i komponente. Sve u redu. Na kraju dodjemo do “servisnog” interlock prekidača koji služi sa odpajanje vozila za rad na siguran način, i gle vraga opet, pukla igla u konektoru. Stavimo odmah drugi servisni prekidač i eUp pokaza Ready i vozi. Kako je došlo do ovog, nije ni bitno, tko radi taj i griješi, medjutim ovo je jedan od prekidača koji su Njemci izmislili za EV i treba vam doktorat da ga otvorite. Ponovno ogledalo nesposobnosti dizajnirati “fail proof” prekidač da mehaničar u servisu može početi sa radom tj da može odpojiti visoki napon za siguran rad bez trošenja 2 radna sata. Igla je pukla nekom dok je pokusavao odpojiti prekidač i raditi na vozilu. Ili neko tko uopce nije spreman da radi na EV. Nakon drugog malog akumulatora, drugog interlock prekidača i 10ak radnih sati spašeno je 31000€, a priča da su kvarovi na bateriji uvjek skupi postaju samo još bljeđi mainstreem stereotip. VW eUp je jedan od najpoželjnijih malih gradskih vozila, do sada pravih kvarova na baterijema ili motorima je bilo ukupno 0. Ukupno vozila na servisu je bilo 3. Poznati kvarovi su Modul punjenja (BD) , ručica mjenjača koja ne vidi parking poziciju da bi se punio, kvar OBC. Kvar na OBC najčešće je uzrokovan vanjskim utjecajem na mreži, kratak spoj, grom ili slično. Nov je oko 4000€, rabljen oko 800€ a reparacija oko 600€. Postoje prvi 2015 modeli koji imaju samo AC punjenje, nemaju CCS DC. Mala baterija od 18kWh je osjetljiva zimi i domet pada na 60-70km. Od svih malih vozila koja postoje na tržištu, mali eUp je definitvno najbolji izbor pored ostalih C0, Smart, Ami, Twingo itd.

Part number: 12E915590L

Error: P0B3700, P0A0A00

OEM Price: 31500€

EVC Price: 500€

Savings: 31000€

Posted on 2 Comments

DS9 Plug-in Hybrid 2022 Battery Pack review Not-a-Munro style

We received one new battery from DS9 to recycle it into usable second life. The first thing we noticed is that the battery is excellent in terms of its size for some kind of quad swap or mini Morris swap, as it integrates everything from water cooling to all necessary components for safe usage, including contactors, pre-charge circuits, etc. The battery pack’s manufacturer is the defunct A123 company, known for creating robust systems, even for the military and automotive industries. The battery cover isn’t glued but secured with screws and a rubber seal. Its total weight is around 96 kilograms. The system consists of 8 blocks in a 12S configuration, likely composed of LFP prismatic cells, probably from A123’s production line, judging by the block’s length matching those of VW, Ford, Mazda prismatic 12S blocks, but with cell width in the block housing at 13.8 cm, about 1.5 cm less wider than other manufacturers in similar configurations. One block has a capacity of 1.485 kWh and weighs 9.6 kg. Total capacity of the battery pack is 11.9kWh, but usable probably below 10kWh. The coolant plates are affixed using thermally conductive silicone on the underside of the cells, or blocks. The BMS system comprises 2 slave controllers and one master. Commendably, they designed the battery with active cooling and heating, ensuring a longer battery life, although the cell power of 35Ah might not survive charges up to 200k km. The processor is Tricore SAK-TC234LP, commonly found in Stellantis battery systems, even among different suppliers, (among Renesas, Texas Instruments, etc.)

Price OEM: Unknown

Part numbers: A123 PHEV.EMC00, 9832854680, 9835365680, WXAA-BI03V1100, A123

Posted on Leave a comment

EV Pioneers Achilles’ heel- ION ZERO iMiev OBC

Peugeot Ion, Citroën C-Zero, and Mitsubishi i-MiEV – one and the same vehicle, one of the unbreakable pioneers and one of the few that outlasted most of the competition in that segment. Back in 2012, at the age of 24, while I was dreaming of buying a Tesla that was just being promoted, I didn’t even have enough money for this Ion, but it would have been sufficient for most needs if my diesel didn’t swallow up everything I earned. With the Ion, we do absolutely nothing except for the OBC module, which is an integrated ‘rectifier’ module in the vehicle, converting 220 AC to DC 400. Many mainstream disinformants would be surprised if they managed to ‘digest’ the fact that in almost all EVs (except the Nissan Leaf), the biggest problem isn’t the battery but rather the electric motors or OBC, depending on the model. OBC usually fails due to overheating, unstable power grid interruptions, lightning strikes, or simply material fatigue in the chips, causing one component to burn half of the controller. The OBC for this vehicle, at an authorized service center, costs an incredible €8000 new, which makes it no longer profitable for many to even repair these old power units. Finding a used one is nearly impossible, and there are 3 different series that are not cross-compatible.

Last week, we received two units, one from ZG and one from VŽ, both with the same problem but this time with an issue we hadn’t encountered, meaning we have to spend another 20-30 hours investigating the cause and how to solve it. After 2 weeks, both owners were saved from the guillotine, and the OBC was repaired. The vehicle doesn’t have to go to the scrapyard, and the mission of the vehicle continues to prove that the lifespan of an EV isn’t just 7 but over 11 years with the original battery and motor. A fairly solid, not overly luxurious EV, but excellent for city commutes and short distances to work without clogging your DPF every Friday.

HRVATSKI

Peugeot Ion Citreon C0 i Misubishi iMiev – Jedno te isto vozilo, jedan od neslomljivih pionira i jedan od rijetkih koji je nadživio vecinu konkurencije iz tog segmenta. Te davne 2012 sa 24 godine dok sam sanjario kako kupiti Teslu koja se tek promovirala, nisam ni za ovaj Ion imao love ali bio bi dovoljan za vecinu potreba samo da mi dizelas ne guta sve sto zaradim. Na Ionu ne radimo apsolutno nista osim OBC modula, koji je integrirani modul “ispravljac” u vozilu a koji pegla 220AC u DC400. Mnogi mainstream dezinformatori bi se začudili kad bi uspjeli “progutati” činjenicu da na skoro svim EV (osim nissan leaf) nije najveci problem baterija već elektromotori ili OBC ovisno od modela do modela. OBC strada najčešće zbog nekog uzroka pregrijavanja, nestabilne mreže napajanja/prekidanja, grom ili samog zamora materijala u čipovima pa jedna komponenta skuri pola kontrolera. OBC za ovo vozilo, u ovlastenom servisu košta novo nevjerovatnih 8000€ zbog čega mnogima nije isplativo vise ni popravljati ove stare strujice. Rabljen je skoro nemoguce naci i postoje 3 razlicite serije i nisu kompatabilne unakrsno.

Prosli tjedan dobili smo dva komada, jedan iz ZG i jedan i VŽ, oba sa istim problemom ali ovaj put sa problemom sa kojim se nismo sretali sto znaci opet moramo potrositi 20-30 sati istrazivati sto je uzrok i kako rijesiti. Nakon 2 tjedna oba vlasnika su spašena giljotine i OBC repariran, vozilo ne mora na otpad a misija vozila nastavlja i dalje dokazivati da vjek EV nije 7 vec preko 11 godina sa original baterijom i motorom. Sasvim solidan, ne pretjerano luksuzan EV ali odličan za grada i na posao par kilometara a da vam se ne začepi DPF svaki petak.

Part number: Nichicon 9499A437

Error: AC Charging not starting

OEM: 8000€

EVC: 800+tax

https://evclinic.eu/product/ion-c0-imiev-obc-9499a437-nichicon-repair-servi/?fbclid=IwAR2sDYnaCmdkjickO0lkC6SiJ5nccXSEg9-o7DDvNDBLUl9vjfzqV2-S6OM

EVC Academy: 1440€+tax

https://evclinic.eu/evc-knowhow-academy/psa/ev-ion-c0-miev/obc-9499a437-nichicon-repair-operation-manual-0712202341234/?fbclid=IwAR1IB25sxnH3j7EJfdD1KrMz7gGmx-mP0RvuszD_qDgTCq5W0Vi9LPEDMjI

Posted on Leave a comment

Smart 453EQ – 8000€ fuse defect – No charging

The Smart 453 EQ encountered a significant charging issue, with the manufacturer in Germany quoting €8,000 for repairs, despite the actual cost of the faulty component being just €2. The issue stemmed from an inability to charge via Type 2. OEMs often opt to replace entire powertrain units rather than diagnosing and repairing individual components, but at EV Clinic, we specialize in in-depth diagnostics and component-level repairs.

In some cases, design choices prioritize aesthetics over serviceability, leading to complex and costly repairs for owners. In this instance, the fault appeared to be related to the onboard charger (OBC). However, after thoroughly inspecting the powertrain and finding no faults, we discovered a hidden fuse within the charge port cable. If this fuse fails, there is no redundant failsafe system to detect or report it. Despite this, an authorized service center had proposed replacing the entire powertrain for approximately €8,000, when the actual solution was simply replacing a €2 fuse in the charge port cable—an evident diagnostic oversight.

Additionally, it appears that multiple different failures, such as those involving the DC-DC converter, OBC, and inverter, are often addressed through full powertrain replacements, each reportedly costing around €8,000. This raises concerns about cost-effective repair strategies. In contrast, we find the older Smart 451 ED to be of notably higher quality and more serviceable, offering a more sustainable long-term ownership experience.

Part number: 4539019900, 4539029007

OEM Reparatur: 8000€

EVC Reparatur: Teile 2€ und Arbeit 798€.

Fehler: P07A023

Posted on Leave a comment

Fiat 500e USA – Onboard charger Failure 05185004AH

Failure of the OBC integrated module responsible for charging the battery in an EV. There are no used ones available, and even new ones are unavailable. If a used one were available, it used to cost around €3500-5000 (according to Google), and a new one likely costs even more. This situation puts the responsibility of deciding whether the vehicle becomes subject for spare parts or goes back on the road, and decision is in our hands, so the decision’s outcome is crucial. There’s no repair manual available, and we’ve reached a point where we have no one to ask for help, especially when dealing with an exotic car like the 500E. It’s even more exotic than a Ferrari. The OBC is burned out for some reason, and what we mostly encounter is that in EVs, the OBC module is frequently more in defect. This contradicts the misinformation spread by the media that batteries are mostly the problem; that’s an inaccurate lie. Our main issue is with the OBC module, which often gets damaged due to external influences that accelerate component fatigue within the module, as well as other unforeseen events like lightning strikes, power grid shorts, strong oscillations from other inductive consumers, etc. After two weeks of testing almost all individual components and replacing the damaged ones, the OBC still doesn’t work. Today’s final attempt was to intuitively replace one more component; if that didn’t work, we’d have to inform the owner that the “patient didn’t make it”. We were five minutes away from the fateful call to inform customer bad news when we connected the charger and it started working, it was great moment. The owner was saved from ‘euthanizing’ the Fiat. So, all you diesel turbo fans with engine oil leaks, don’t worry about the “challenging battery recycling” when EV dies because this Fiat keeps on going killing the stereotypes.

🇭🇷

Kvar OBC integriranog modula koji sluzi za punjenje baterije u EV. Rabljen ne postoji a ne postoji ni novi. Rabljen ako je i postojao je kostao oko 3500-5000€ (google) a novi vjerovatno i više. Znači situacija gdje jedan dio odlučuje jel vozilo ide u dijelove ili ide natrag na cestu, tako da odgovornost gdje mi odlučujemi o ishodu je velika. Upustvo za reparaciju ne postoji a mi smo dosli do tog nivoa i broja problema da mi nemam koga pitati za pomoci, niti nam tko može i pomoći pogotovo kad je egzotika u pitanju kao 500E. Egzoticniji uzorak i od ferarija. OBC je iz nekog razloga spaljen, a ono što se mi susrećemo najcesce je to da na EV najcesce strada OBC modul, znaci to sto vas infodemijski mediji dezinformiraju da su baterije problem, to je naprotiv netocna laž. Najvise problema imamo sa OBC modulom koji strada najcesce zbog vanjskih utjecaja koji ubrzavaju zamor komponenti u modulu a i ostali neplanirani dogadjaji kao grom, kratak spoj u mreži objekta, jake oscilacije drugih induktivnih potrošača itd. Nakon 2 tjedna ispitivanja skoro svih pojedinacnih komponenti i mjenjanja ostecenih, OBC i dalje ne radi. Zadnji pokusaj je bio danas da na predosjecaj zamjenimo jos jednu komponentu ako ne proradi, zvati vlasnika da je pacijenat podlegao. 5 minuta nas dijeli od sudbonosnog poziva, spajamo punjač i punjač proradio. Vlasnik spašen eutanazije fiata. Tako da svi dizel turbo fanovi kojima curi ulje sa motora pjesacima u ćevape, nemate brige za bateriju jer fićo vozi dalje, ne treba se “reciklirati”.

Part number: 05185004AH

Suplier: Delta

OEM Price: 7000€

EV Clinic price: 1400€ (tax inc)

Voucher code: “sustainability”