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Mitsubishi Electric OUTLANDER PHEV Dismantling Manual
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Mitsubishi Electric OUTLANDER PHEV Dismantling Manual

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OUTLANDER PHEV
Drive Battery Removal Procedure
and Dismantling Guide

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Summary of Contents for Mitsubishi Electric OUTLANDER PHEV

  • Page 1 OUTLANDER PHEV Drive Battery Removal Procedure and Dismantling Guide...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Section Page 1. INTRODUCTION ................1 2. HOW TO IDENTIFY AN OUTLANDER PHEV ......2 UNIQUE OUTLANDER PHEV FEATURES ........2 EXTERIOR FEATURES ............... 2 CHASSIS NUMBER AND MODEL CODE ........3 3. SAFETY PRECAUTIONS ............. 4 PROPER HANDLING OF THE HIGH VOLTAGE BATTERY..

  • Page 3: Introduction

    1. INTRODUCTION The Outlander PHEV (Plug-in Hybrid Electric Vehicle) is a vehicle equipped with a high voltage main drive lithium-ion battery. The battery provides high voltage electricity to power the two electric drive motors. The vehicle also has a gasoline powered engine/generator which recharges the battery and assists the drive motors under certain conditions.

  • Page 4: How To Identify An Outlander Phev

    2. HOW TO IDENTIFY OUTLANDER PHEV 1) Unique features of the Outlander PHEV compared to the gasoline engine Outlander. - PHEV logo marks - Charging lid and portal - Lithium-ion main drive battery (maximum voltage is 336V) - 60 kW twin electric drive motors...

  • Page 5: Chassis Number And Model Code

    The chassis number is stamped on the passenger side cowl top panel inside the engine compartment. panel). When the fifth position (car line) is "2" on the plate, it means "Outlander PHEV". ② Vehicle information code plate, on the passenger’s door sill.

  • Page 6: Safety Precautions

    Information on the 12V Auxiliary Battery (located in rear cargo area, page 11) The 12V auxiliary battery of the Outlander PHEV is located in the left rear of the vehicle. It provides power to multiple ECUs (Electronic control units) in the vehicle and operates all the 12V vehicle accessories. The multiple ECUs that are powered by the 12V battery include the ECUs that operate the High Voltage electric drive components.

  • Page 7: High Voltage Components Layout

    4. HIGH VOLTAGE COMPONENTS LAYOUT High voltage (maximum 336V) components and wiring cables are located as shown in the figure below. Service plug High-voltage components The high-voltage components are described below. Also, wiring harness and connectors of high-voltage circuit are (orange in color.) •...

  • Page 8: Personal Protective Equipment

    5. PERSONAL PROTECTIVE EQUIPMENT (REFERENCE ONLY) Use personal protective equipment that complies with applicable state and local requirements. This equipment should include the following: • When you are in contact with exposed live wiring of a damaged vehicle • To prevent the risk of electric shock •...

  • Page 9: Precautions On Removing Outlander Phev Main Lithium-Ion Drive Battery From Vehicle

    (national legal requirements) proper safety procedure outlined in this guide and use personal protective equipment. 2. Two types of batteries are used on the Outlander PHEV, a normal 12V lead battery (auxiliary battery) and a special 336V (maximum) high-voltage lithium-ion battery (Main drive battery).

  • Page 10: Removal And Disposal Of The Outlander Phev Main Drive Lithium-Ion Battery From A Scrap Vehicle

    Batteries not collected properly pose a safety risk that can result in serious injury or death. If the Outlander PHEV main drive battery is used or modified for use on any vehicle other than the Outlander PHEV, an accident such as electric shock, heat, smoke,...

  • Page 11: Main Drive Lithium-Ion Battery Removal Procedure

    (including modification) of the Outlander PHEV main drive battery. 2. The Outlander PHEV main drive battery is a Lithium-ion battery, handle with care so as not to damage the battery while removing it. If the drive battery is severely damaged, even after the high voltage circuit has been shut off, there is still a risk of electrical shock and/or fire.

  • Page 12: Battery

    8. INSPECTION PROCEDURE FOR MAIN DRIVE LITHIUM-ION BATTERY 1. If any abnormality, damage or defect is found after inspection, replace the main drive battery. 1) Check if there are diagnostic trouble codes stored. 2) Check if the battery tray and frame is cracked or damaged. 3) MEASURE THE DISTANCES ON THE SHEETMETAL TRAY (DRIVE BATTERY).
  • Page 13 9. MAIN DRIVE LITHIUM-ION BATTERY REMOVAL PROCEDURE ● Wear electric insulation “personal protective equipment” such as gloves etc., when removing the service plug or when working on high voltage components. ● Do not disassemble any component of the main drive lithium-ion battery other than those described in this manual.
  • Page 14 ③ Remove the battery maintenance lid. Pull up service lid cover Back Side of Lid Procedure 2 Remove the Service Lid *Please use the check sheet on page 34. Remove the service lid 4 mounting nuts (10 mm bolt head) and then remove the service lid Service Plug...
  • Page 15 Procedure 3 Remove Service Plug *Please use the check sheet on page 34. The voltage of the smooth condenser in the MCU must be discharged thoroughly. Wait 5 minutes after disconnecting negative terminal of 12V battery before removing the service plug. Wear protective electric insulation gloves when removing the service plug.
  • Page 16 After removing the service plug, insulate the open safety plug receptacle of the main drive battery opening to prevent serious injury or death from electrical shock. Electric insulation tape Remove Rubber Boot from Body Remove the rubber boot from the body after service plug was removed. Rubber boot...
  • Page 17 Do not disassemble any component of the main drive lithium-ion battery other than those described in this manual and do not perform any other work that would possibly damage battery assembly. Damage to battery may cause smoke, heat, fire and explosion which can lead to personal injury or death.
  • Page 18 Procedure 6 Remove Front Left Side Battery Protector Front of Vehicle Procedure 7 Remove Front Right-Side Battery Protector...
  • Page 19 Procedure 8 Remove A/C Pipe (recover A/C refrigerant prior to removal, refrigerant type is R1234YF) Front of Vehicle Remove mounting bolt and then pull off pipe form battery. Pull off pipe from battery...
  • Page 20 Procedure 9 Remove Battery Grounding Bracket Front of Vehicle Remove Front Service Lid Always wear Personal Protective Equipment (PPE: electric insulator glove) and use insulated tools when removing the front service lid. ＊Note: Removed O-ring will be used in Procedure 25. Back side of lid...
  • Page 21 Procedure 11 Remove Cable Protector Front of Vehicle Measuring High Voltage (DC) Check voltage using high voltage circuit tester. If value is not within ± 1V stop and contact the nearest Mitsubishi dealer for service. (Voltage may increase to Max 336V) Always wear Personal Protective Equipment (PPE: electric insulator gloves) and use insulated tools when measuring voltage.
  • Page 22 Front of Vehicle Procedure 12 Remove Inner and Outer Cable from Main Drive Battery ① Remove 2 inner cable mounting bolts. ② Remove 2 outer cable mounting bolts. ③ Remove battery front cable (positive and negative) from drive battery assembly.
  • Page 23 Procedure 13 Remove Battery Side Protector Front of Vehicle Procedure 14 Remove 3 (12V) Connectors...
  • Page 24 Procedure 15 Remove Battery Grounding Bracket Front of Vehicle Procedure 16 Remove Rear Service Lid Always wear Personal Protective Equipment (PPE: electric insulator gloves) and use insulated tools when measuring voltage. ＊Note: Removed O-ring will be used in Procedure 25 -ring O-ring...
  • Page 25 Front of Vehicle Measuring High Voltage (DC) Check voltage using high voltage circuit tester. ■ Normal voltage: ± 1V ■ In case value is not within ± 1V stop and contact the nearest Mitsubishi dealer for service. (Voltage may increase to Max 336V) Always wear Personal Protective Equipment (PPE: electric insulator gloves) and use insulated tools when measuring voltage.
  • Page 26 Front of Vehicle Procedure 17 Remove Main Drive Battery Rear Cable (Positive and Negative) Outer Mounting Bolts ① Using insulated tools remove 2 inner cable mounting bolts. ② Using insulated tools remove 2 outer mounting bolts. Inner Cable Mounting Bolts ③...
  • Page 27 Procedure 18 Remove Battery Grounding Bracket (vehicles with fast charger only) Front of Vehicle Procedure 19 Remove Rear Service Lid (vehicles with fast charger only) Always wear Personal Protective Equipment (PPE: electric insulator gloves) and use insulated tools when removing service lid.
  • Page 28 Front of Vehicle Measuring High Voltage (DC) Check voltage using high voltage circuit tester. ■ Normal voltage: ± 1V ■ In case value is not within ± 1V stop and contact the nearest Mitsubishi dealer for service. (Voltage may increase to Max 336V) Always wear Personal Protective Equipment (PPE: electric insulator gloves) and use insulated tools when measuring voltage.
  • Page 29 Front of Vehicle Procedure 20 Remove EV Charge Cable from Main Drive Battery (vehicles with fast charger only) Inner Cable Mounting Bolts ① Using insulated tools remove 2 inner cable mounting bolts. ② Using insulated remove 2 outer cable bolts. Outer Cable Mounting Bolts ③...
  • Page 30 Procedure 21 Remove Grounding Bracket Front of Vehicle Remove Grounding Bracket...
  • Page 31 Procedure 23 Remove left side battery grounding bracket Front of Vehicle...
  • Page 32 Procedure 25 Remove battery assembly from vehicle Handle with care while working on the battery. If the drive battery is severely damaged, there is a risk of electrical shock and/or fire even after the high voltage circuit has been shut off. ①...
  • Page 33 ② Use the following special tools (or equivalent) and 2 wood blocks. (RH: 90 × 90 × 1500mm, LH: 90 × 90 × 1650mm) (i) Special tool: EV battery cart (MB992336) Remove the cart handle and set the 2 wood blocks. MB99233 (ii) Special tool EV battery lifting car (MB992659) and 2 wood blocks.
  • Page 34 ④ Loosen 4 remaining bolts Remaining 4 mounting bolts Front of Vehicle ⑤ Lower the vehicle with the lift until the bottom of the drive battery just makes contact with the wood blocks. Main battery ⑥ Remove all 4 of the mounting bolts on the drive battery.
  • Page 35 ⑦ Raise the vehicle and remove the main drive battery. Main battery Be careful not to damage the wiring harness. Do not expose the drive battery to fire or heat of 140°F (60 ℃) or more • Store the drive battery in a dry safe place. •...
  • Page 36 ⑨ When moving the drive battery with a crane or other device, use the EV battery sling tool kit (special tool: MB992343) to sling it up in accordance with the following procedure. EV battery sling tool kit(MB992343) Eye bolts (MB992344 x 4) EV battery sling belts (MB992345 x 2) Washers (MF450156 x 8) Hexagon nuts (MU001480 x 4)

  • Page 37: High Voltage Sign Board

    Outlander PHEV Battery Dismantle Manual Check Sheet ＊Service Plug Removal Check Sheet 1- ① Check Procedure Notes Power switch off. - Wait for 2 minutes. - There is a possibility that the power switch is broken. 1- ② Wait for 2 minutes! Remove the ground terminal of the 12V battery.

  • Page 38: Warning Sign

    *When doing high-voltage work, please put up this signboard. Fold along the dotted line and place it on top of the Outlander PHEV’s roof.
  • Page 39 It is recommended that a warning sign (example provided above) is fixed to or on the vehicle during any emergency work on the vehicle. A sign that complies with local regulation should be used.

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