Mitsubishi MOTORS OUTLANDER PHEV 2023 Dismantling Manual
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Mitsubishi MOTORS OUTLANDER PHEV 2023 Dismantling Manual

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2023 OUTLANDER PHEV
Drive Battery Removal Procedure and
Dismantling Guide
Pub. No. PMDU2201P

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Summary of Contents for Mitsubishi MOTORS OUTLANDER PHEV 2023

  • Page 1 2023 OUTLANDER PHEV Drive Battery Removal Procedure and Dismantling Guide Pub. No. PMDU2201P...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. INTRODUCTION ......................2 2. HOW TO IDENTIFY OUTLANDER PHEV ................3 3. SAFETY PRECAUTIONS ....................5 4. INSPECTION/TEST OF PROTECTIVE EQUIPMENT, BLOTTER STRAGE ......6 5. PROTECTIVE EQUIPMENT ..................... 6 6. TESTER AND SPECIAL TOOL ..................7 7.

  • Page 3: Introduction

    Mitsubishi Motors reserves the right to make changes in design and specification and/or to make additions to or improvements in this product without obligation to install them on products previously manufactured.

  • Page 4: How To Identify 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 650V) - Twin electric drive motors - Twin Super all-wheel control motors - Motors in front and rear axles - Lack of any engine noises when in EV mode.
  • Page 5 3) Chassis Number and Model Code GN0WPZ******* Chassis number GN0WXD******* PDU Cover Model code “Chassis number” shown in the engine compartment “Model code” shown in the Vehicle information code plate “PLUG-IN HYBRID EV” logo mark on the “PDU cover” in the engine compartment...

  • Page 6: Safety Precautions

    3. SAFETY PRECAUTIONS ● Always follow instructions described in this guide. Failure to follow these instructions can result in serious injury or death. ● Before dismantling, shut off the high voltage circuits or discharge the Main drive lithium-ion battery in accordance with instructions on the following pages.

  • Page 7: Inspection/Test Of Protective Equipment, Blotter Strage

    4. INSPECTION/TEST OF PROTECTIVE EQUIPMENT, BLOTTER STRAGE Check and store the protective equipment in accordance with national legal requirements. 5. PROTECTIVE EQUIPMENT  Use protective equipment that complies with the legal requirements of your country/local area.  Use insulating protective equipment which meets the requirements to withstand DC 650 V and AC 650 V.

  • Page 8: Tester And Special Tool

    Alternatively, when you prevent the • electric shock according to need Electric insulation When you may contact with the exposed • boots live wirings while handling the damaged vehicle Alternatively, when you prevent the • electric shock according to need 6.

  • Page 9: High-Voltage Components

    7. HIGH-VOLTAGE COMPONENTS The high-voltage components are described below. Also, wiring harness and connectors of high-voltage circuit are unified with a color of orange. Drive battery [with built-in Battery Management Unit (BMU)] • Power Drive Unit (PDU) [with built-in Front electric motor control unit (FEMCU) and Generator •...

  • Page 10: Main Drive Lithium-Ion Battery Removal Procedure

    8. MAIN DRIVE LITHIUM-ION BATTERY REMOVAL PROCEDURE 1. Drain the refrigerant completely as pre-removal operation. 2. Remove the charging cable if the vehicle is being charged. 3. Turn the power switch to OFF. 4. Open the hood and tail-gate. 5. Turn the ignition ON. 6.
  • Page 11 11. Remove 3 bolts and remove the service lid.  Wear the electrical insulation gloves when removing the service plug.  Do not pull out the service plug by halves. It is dangerous because the current is supplied during the lifting operation. Be sure to remove the entire service plug at once. The voltage of the smooth condenser in the inverter must be decreased thoroughly.
  • Page 12 13. Remove the service plug. Service plug 14. Remove the floor under cover. Floor under cover During inspection, wear the electric insulation gloves.
  • Page 13 15. When removing and installing each high-voltage part, be sure to perform the following inspection beforehand. 16. Check the drive battery front cable connector and drive battery rear cable (junction box) connector by the following procedure below. 17. Remove the engine room under cover rear.
  • Page 14 18. Remove the front floor heat protector (rear). When servicing the high-voltage components, be sure to disconnect the service plug. When unlocking the connector lock, do not use tools etc. otherwise the connector lock may be damaged. Be sure to unlock the connector lock by hand. 19.
  • Page 15 21. Pull the connector to the direction of the arrow until it stops while pushing the lock (B). 22. Pull the connector to the direction of the arrow while pushing the lock (C) to disconnect the connector. 23. Disconnect the drive battery rear cable (junction box) from the drive battery.
  • Page 16 25. Pull down the connector to the direction of the arrow until it stops while pushing the lock (B). 26. Pull the connector to the direction of the arrow while pushing the lock (C) to disconnect the connector.
  • Page 17 27. Measure the voltages between the terminals as shown in the illustration using a high-voltage multi-meter. Normal voltage: Approximately 0 V 28. Remove the A/C pipes from the drive battery.
  • Page 18 29. Use the following special tools and 2 wood blocks (RH: 90 x 90 x 1,500 mm, LH: 90 x 90 x 1,650 When the vehicle is lowered with the lift using the above special tool (MB992336), if the lower stopper lock does not work, use the EV battery lifting cart (special tool: MB992659) instead.
  • Page 19 32. Lower the vehicle with the lift until just before the bottom of the drive battery contacts the wood block. 33. Remove all the mounting bolts on the drive battery. Be careful of damage due to wiring harness caught or hooked. 34.
  • Page 20 36. When moving the removed drive battery with a crane or others, 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 21 c) Pass the EV battery sling belt through the eye bolts and align the marks on the EV battery sling belt to the eye bolt positions. d) Bind the 2 EV battery sling belts together and sling up the drive battery with a crane or others.

  • Page 22: Service Plug Removal Check Sheet

    9. SERVICE PLUG REMOVAL CHECK SHEET Check Procedure Notes Disconnect charging cable if it is connected. Turn the power switch OFF. Open the hood and tail-gate. Turn the power switch ON, then press and hold for more than 5 seconds. Close driver side door.

  • Page 23: High Voltage Sign Board

    10. HIGH VOLTAGE SIGN BOARD *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 24: Warning Sign

    11. WARNING SIGN 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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