Mitsubishi Electric OUTLANDER PHEV User manual

OUTLANDER PHEV
Drive Battery Removal Procedure
and Dismantling Guide

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.........4
4. HIGH VOLTAGE COMPONENTS LAYOUT.................................5
TESTER AND SPECIAL TOOLS..................................................5
5. PERSONAL PROTECTIVE EQUIPMENT....................................6
6. PRECAUTIONS ON REMOVING OUTLANDER PHEV MAIN
LITHIUM-ION DRIVE BATTERY FROM VEHICLE ......................7
7. REMOVAL AND DISPOSAL OF THE OUTLANDER PHEV MAIN
DRIVE LITHIUM-ION BATTERY FROM A SCRAP VEHICLE......8
MAIN DRIVE LITHIUM-ION BATTERY REMOVALPROCEDURE
.....................................................................................................9
8. INSPECTION PROCEDURE FOR MAIN DRIVE LITHIUM-ION
BATTERY…………………………..................................................10
9. HIGH VOLTAGE SIGN BOARD....................................................35
10. WARNING SIGN ......................................................................... 36

1
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. Caution
must be used when dismantling the vehicle. This guide provides instructions that must be
followed when the high voltage main drive battery is to be removed from the Outlander
PHEV. Always handle the Outlander PHEV high voltage components by using appropriate
Personal Protective Equipment (PPE) and the methods described in this guide. Failure to
follow the instructions in this guide, including the warnings and cautions, may result in
serious injury or death by electrical shock due to the high voltage battery installed on the
Outlander PHEV. Before dismantling, please read this guide carefully and understand the
identified procedures. It may differ according to the sales classification; refer to the sales
catalog.
Throughout this guide the words DANGER, WARNING and CAUTION appear.
These serve as reminders to be especially careful. Failure to follow instructions may result in personal injury
or damage to the vehicle.
Indicates a hazardous situation which, if not avoided, will results in death or serious injury.
Indicates a strong possibility of severe personal injury or death if instructions are not followed.
indicates hazards or unsafe practices that could cause personal injury or damage to your vehicle.
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.
*NOTE: The contents of this guide maynot match exactly with every vehicle due to changes in vehicle
specification.

2
2. HOW TO IDENTIFY OUTLANDER PHEV
1) Unique features of the Outlander PHEV compared to the gasoline engineOutlander.
- PHEV logo marks
- Charging lid and portal
- Lithium-ion main drive battery(maximum voltage is 336V)
- 60 kW 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.
- Electric transmission gear selector and parking pawl (12V system).
- 12V Battery is located in the left rear cargo area of the vehicle.
- The A/C compressor and interior heater is powered by the 336V Lithium-ionbattery
- Chassis number
2) Exterior features that identify an Outlander PHEV from a gasoline engineOutlander.
①PHEV (PLUG-IN HYBRID EV) logo "PHEV
(PLUG-IN HYBRID EV)" logos are fitted on
the right and left fender panels and the
liftgate.
<On fender>
<On liftgate>
②Charging lid (Right side of vehicle)
1
2
1
2

3
3) Chassis Number and Model Code
The Model code is stamped on the “Vehicle identification number plate” and “Vehicle
information code plate”.
The chassis number is stamped on the passenger side cowl top panel inside the engine compartment.
①VIN plate (at left front of the instrument
panel). When the fifth position (car line) is "2"
on the plate, it means "Outlander PHEV".
②Vehicle information code plate, on
the passenger’s door sill.
When the code in "MODEL" line contains
"GG2W", it means "Outlander PHEV".

4
3. 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. If the 12V battery state of charge is depleted or has been disconnected, the vehicle will not
operate even if the 336V drive battery is fully charged. The unlocking mechanism of the rear tail gate is
powered by the 12V battery. This function will be disabled if the 12V battery is dead or disconnected. Refer to
the owner’s manual for instructions on how to jump start the vehicle from the engine compartment.
Proper Handling of the Main Drive Lithium-ion High Voltage Battery (located under vehicle)
If the Main drive lithium-ion battery is damaged during the extraction process due to the use of heavy
machinery or a procedure not described in this guide, collection/recycling of that battery may be denied due to
increased safety concerns in transporting the damaged Main drive lithium-ion battery. Mitsubishi Motors North
America Inc. is not responsible for any accident or damage caused by modification of the Main drive lithium-ion
battery or mounting/installation of the Main drive lithium-ion battery on any vehicle other than the Outlander
PHEV. To prevent accidents, your cooperation in the safe collection/recycling of Main drive lithium-ion
batteries is appreciated. For collection/recycling information, please contact: http://elvsolutions.org/
● 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 followingpages.
● Wear appropriate personal protective equipment where instructed in thisguide.
● Do not assume high voltage components have been shut off simply because the vehicle isquiet.
● Never directly touch any exposed high voltage wiring cables, protective covers detached from high
voltage components, or high voltage components that might bedamaged.
● If fluid leakage is observed under the body, the fluid may be electrolyte leaking from the Main drive
lithium-ion battery. This electrolyte is flammable and poisonous acidic gas will evaporate from the
electrolyte. Wear a mask for organic gas, solvent-resistant gloves (or heavy-duty rubber gloves), and
eye protection. Use an absorption mat or sand to absorb spilled electrolyte. (The electrolyte is clear and
colorless and with a slightly sweet odor. It has similar viscosity towater.)
● If the electrolyte comes into contact with your skin, flush with waterimmediately.
● If the electrolyte gets into your eyes, do not rub your eyes. Immediately flush your eyes with a large
quantity of water and seek medical treatment as soon as possible.
● If the vehicle must be left unattended during the dismantling process, display a sign indicating “HIGH
VOLTAGE WORK IN PROGRESS!! DANGER! DO NOT TOUCH!” Refer to the signboard example at
the end of this guide.
● Advise all dismantlers that an electric vehicle isinvolved.
● If a charge connector is connected to the vehicle, remove it.

5
4. HIGH VOLTAGE COMPONENTS LAYOUT
High voltage (maximum 336V) components and wiring cables are located as shown in the
figure below.
High-voltage components
The high-voltage components are described below. Also, wiring harness and connectors of
high-voltage circuit are (orange in color.)
•Main battery
•Front motor control unit [FPDU (Front Power Drive Unit)] (incorporating
GCU [Generator ControlUnit])
•Rear motor control unit [RMCU (Rear Motor Control Unit)]
•Motor (electric motor unit) <front and rear>
•Generator
•On-board charger/DC-DC converter
•Electric heater <Vehicles with electric heater>
•Main battery cable
•EV charger cable (regular charging)
•EV charger cable <Vehicles compatible with fast charging>
•Service plug (Located under the floor behind the center console)
•Wiring harness and connector
•Main drive lithium-ion battery (maximum 336V)
Tester and special tools (or equivalent)
•High-voltage multimeter (minimum CategoryIV)
•EV battery lifting cart (special tool: MB992659) or equivalent (maximum capacity 1100lbs.)
•EV battery sling (special tool: MB992345) or equivalent (maximum capacity 1200lbs.)
Service plug

6
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
• When you are in contact
with exposed live wiring
of a damaged vehicle
• To prevent the risk of
electric shock
• When you are in contact
with exposed live wiring
of a damaged vehicle
• To prevent the risk of
electric shock
• Service plug
• Working on live wiring
• When you are in contact
with exposed live wiring
of a damaged vehicle
• To prevent the risk of
electric shock
• When you are in contact
with exposed live wiring
of a damaged vehicle
• To prevent the risk of
electric shock

7
6. PRECAUTIONS ON REMOVING OUTLANDER PHEV MAIN DRIVE LITHIUM-ION
BATTERY FROM VEHICLE
1. This vehicle has a high-voltage (maximum 336V) circuit. If the vehicle is handled incorrectly,
electric leakage or shock may occur resulting in serious injury or death. Service
technicians/engineers whoperform inspection and service related to the high-voltage circuit
of the electric vehicles are obligated to observe (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).
When scrapping the Outlander PHEV, removal of these two batteries is required. Dispose of
the lead battery in the same manner as that of a conventional vehicle lead battery.
3. Do not use heavy machinery to remove an Outlander PHEV lithium-ion main drive battery on
a vehicle that is to be scrapped as the battery may still be in a charged state. If the lithium-ion
main drive battery is damaged, using methods to cut it out or use of heavy machinery may
cause sparks, fire or fluid leakage resulting in an accident.
Note: If the Outlander PHEV lithium-ion main drive battery is damaged in any way during the
removal process by heavy machinery (equipment) or other methods not outlined in this guide,
collection/recycling of the battery may be refused due to safety concerns in transporting a
damaged battery.
Mitsubishi Motors Corporation is not responsible for any accident or damage caused by use
(including modification) of the Outlander PHEV drive battery, if it is mounted on or used on any
other vehicle other than the Outlander PHEV.
Never resell or transfer a wrecked or rebuilt Outlander PHEV. A wrecker, salvage yard, body shop,
insurance company, dismantler, private party etc., who conducts the resale or transfer of a wrecked
or rebuilt Outlander PHEV may be liable if an accident occurs.

8
7. REMOVAL AND DISPOSAL OF THE OUTLANDER PHEV MAIN DRIVE
LITHIUM-ION BATTERY FROM A SCRAP VEHICLE
Recommendations when and after the Outlander PHEV drive battery is removed from a scrap
vehicle.
(1) Before proceeding with the main drive lithium-ion battery removal operation, be sure to
remove the service plug. (For details, refer to the relevant sections on "How to remove
Outlander PHEV main drive battery" in this manual.) Before removal operation, be sure to
remove the service plug first. Do not overhaul the high-voltage portion or remove, disassem-
ble, and/or cut the high-voltage wiring (orange) and its connection with the service plug
connected as serious injury or death may occur.
(2) Never resell, transfer, modify, etc. a main drive lithium-ion battery. Your cooperation in safe
collecting of Outlander PHEV drive battery that has been removed from a scrap vehicle will
be appreciated. Collection/recycling information can be found at:
http://global.ev-life.com/recycle/.
a) Batteries not collected properly pose a safety risk that can result in serious injury or
death.
b) 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,
fire, or explosion may occur, resulting in serious injury or death.

9
OUTLANDER PHEV MAIN DRIVE LITHIUM-ION BATTERY REMOVAL PROCEDURE
1. Mitsubishi Motors Corporation is not responsible for any accident or damage caused by misuse
(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.
3. Inspection/Test of protective equipment, blotter storage. Check and store the protective
equipment in accordance with national legal requirements.
PROTECTIVE EQUIPMENT (REFERENCE ONLY)
Use protective equipment which complies with national
legal requirements.

10
D
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 codesstored.
2) Check if the battery tray and frame is cracked ordamaged.
3) MEASURE THE DISTANCES ON THE SHEETMETAL TRAY (DRIVEBATTERY).
Perform the measurement using the tracking gauge, convex, or other tool. The indicated
numbers are provided for reference.
Front of Vehicle
No.
Measurement Point
Measured distance
Measurement
reference point Measurement end point Dimension (mm)
1
E
A
1208.8
2
E
B
979.8
3
E
C
720.2
4
E
D
678.0
5
E
F
243.0
6
E
G
655.6
7
E
H
964.9
Vehicle inner side
Vehicle inner side
Vehicle inner side

11
Wait two minutes!
9. MAIN DRIVE LITHIUM-ION BATTERY REMOVALPROCEDURE
①Turn off the power supply mode of the electric motor
Cover
Rear bumper
Rear bumper
②
Disconnect the negative terminal of the auxiliary battery.
Wait two minutes after turning off power switch
before proceeding.
Rear hatch lock will be disabled once the 12V
negative battery terminal is disconnected.
●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.
Negative terminal
for 12V battery
Procedure 1
Removing Service Lid Cover
*Please use the check sheet on page 34.
Before starting procedures
Discharge Refrigerant from Battery Cooling Unit (HVAC)

12
③ Remove the battery maintenance lid.
Pull up service lid
cover
Service Plug
Remove the service lid 4 mounting
nuts (10 mm bolt head) and then
remove the service lid
Procedure 2
Remove the Service Lid
*Please use the check sheet on page 34.
Back Side of Lid

13
① Lift the service plug lever and then, pull the service plug.
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.
Lever lock
②Remove the service plug.
Remove the service plug completely as current is being supplied by the main drive
lithium-ion battery during this procedure. Failure to remove the plug completely or use
of personal protective equipment could lead to serious injury or death.
After removing the service plug, keep it in a secure place away from other dismantlers
or technicians to prevent accidental handling/improper reinstallation.

14
Remove the rubber boot from the body after service plug was removed.
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
Rubber boot

15
*Note: Photo below is example of vehicle with fast charger.
Vehicles equipped with fast charger have 3 service lids.
Vehicles NOT equipped with fast charger have 2 service lids.
Front of Vehicle
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.
Main Drive battery
Procedure 5
Remove Front Center Protector

16
Front of Vehicle
Procedure 6
Remove Front Left Side Battery Protector
Procedure 7
Remove Front Right-Side Battery Protector

17
Front of Vehicle
Remove mounting bolt and then pull off pipe form battery.
Pull off pipe from battery
Procedure 8
Remove A/C Pipe (recover A/C refrigerant prior to removal, refrigerant type is R1234YF)

18
＊Note: Removed O-ring will be used in Procedure 25.
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.
Procedure 9
Remove Battery Grounding Bracket
Back side of lid