Mitsubishi MOTORS OUTLANDER PHEV 2023 User manual

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

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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. HIGH-VOLTAGE COMPONENTS ......................................................................................8
8. MAIN DRIVE LITHIUM-ION BATTERY REMOVAL PROCEDURE.........................................9
9. SERVICE PLUG REMOVAL CHECK SHEET......................................................................21
10.HIGH VOLTAGE SIGN BOARD........................................................................................22
11. WARNING SIGN ...........................................................................................................23

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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 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 result 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 may not match exactly with every vehicle due to changes in vehicle
specification.

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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.
- 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 350V Lithium-ion battery
- Chassis number
2) Exterior features that identify an Outlander PHEV from a gasoline engine Outlander.
(1) “PLUG-IN HYBRID EV” logo mark on the left and right sides of the door panel
(2) “PHEV” logo mark on the liftgate
(3) “Battery charging lid” on the right rear panel
*NOTE : The left rear panel is the “Fuel filler lid”.
(1)
(2)
(3)
Battery Charging lid

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3) Chassis Number and Model Code
(1) “Chassis number” shown in the engine compartment
(2) “Model code” shown in the Vehicle information code plate
(3) “PLUG-IN HYBRID EV” logo mark on the “PDU cover” in the engine compartment
Chassis number
PDU Cover
Model code
GN0WPZ*******
(1)
(2)
(3)
GN0WXD*******

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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.
●Wear appropriate personal protective equipment where instructed in this guide.
●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 be damaged.
●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 water immediately.
●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 is involved.
●If a charge connector is connected to the vehicle, remove it.
Information on the 12V Auxiliary Battery (located in rear cargo area)
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 350V 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/

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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.
Protective equipment
Name
Use
Electric insulation
helmet (with shield)
•When you may contact with the exposed
live wirings while handling the damaged
vehicle
•Alternatively, when you prevent the
electric shock according to need
Electric insulation
jacket
•When you may contact with the exposed
live wirings while handling the damaged
vehicle
•Alternatively, when you prevent the
electric shock according to need
Electric insulation
trousers
•When you may contact with the exposed
live wirings while handling the damaged
vehicle
•Alternatively, when you prevent the
electric shock according to need
Electric insulation
glove
•Service plug removal and installation
•Work on live wirings when there is a
problem
•When you may contact with the exposed
live wirings while handling the damaged
vehicle

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•Alternatively, when you prevent the
electric shock according to need
Electric insulation
boots
•When you may contact with the exposed
live wirings while handling the damaged
vehicle
•Alternatively, when you prevent the
electric shock according to need
6. TESTER AND SPECIAL TOOL
Be sure to use the tester and special tools specified in this manual.

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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
Control Unit (GCU)]
•Front motor
•Rear motor [with built-in Rear Electric Motor Control Unit (REMCU)]
•Generator
•On Board Charger (OBC)/DC-DC converter
•AC inverter <Some models>
•Drive battery cable
•EV home & Quick charger cable*
•Service plug
•Wiring harness and connector
•A/C compressor
•Junction box
•High voltage sensor (for quick charging)
Generator cable
Drive battery front cable
Front motor cable
EV home & Quick charger cable*
g
Drive battery rear cable
(junction box)
A/C compressor
cable
*: Quick charger cable is only equipped on
models with quick charging system.
AC inverter cable
Drive battery
rear cable
rear cable
(rear motor)
converter cable
On board charger/DC-DC

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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. Press the power switch for more than 5 seconds.
7. Close the driver side door and wait for more than 5 minutes.
8. Check if illumination of combination meter and “P” indicator of electrical parking brake switch are
OFF.
9. Disconnect the negative terminal of 12V battery and wait for more than 5 minutes.
Do not remove the negative terminal of 12V battery for 5 minutes after turning OFF the
power switch. It may cause of damage of power unit components.
Do not remove the service plug within 5 minutes after disconnecting negative terminal of 12V
battery to decrease voltage of smooth condenser inside of inverter.
10. Remove service lid cover.

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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.
Therefore, do not remove the service plug 5 minutes after the negative terminal of the 12 V
battery is disconnected.
12. Pull up the service plug lever a little,
then pull up the lever more while
pushing the tab, then pull out the
service plug.
After removing the service plug, insulate the plug installed part of the drive battery side
securely.

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13. Remove the service plug.
14. Remove the floor under cover.
During inspection, wear the electric insulation gloves.
Service plug
Floor under cover

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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.

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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. Disconnect the drive battery front
cable from the drive battery.
20. Move the lock (A) of the connector to
the direction of the arrow.
DF2000W4AA
Lock (A)
High-voltage connector

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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.
24. Move the lock (A) of the connector to
the direction of the arrow (UNLOCK
position).

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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.

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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.

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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
mm)
a
b
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.
30. Remove the 2 ground bolts and 3
mounting bolts shown in the
illustration with the drive battery
mounted.
31. Loosen the remaining mounting bolts (6 locations).

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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. Raise the vehicle with the lift and remove the drive battery.
Store the drive battery on a place with no risk of wetting.
Do not bring the drive battery close to fire or heat it to 60℃(140℉) or more.
35. Cover around the service plug of the
drive battery with a vinyl sheet or
others so that no water, foreign
material, etc. enter the inside of the
drive battery.

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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)
oEye bolts (MB992344 x 4)
oEV battery sling belts (MB992345 x 2)
oWashers (MF450156 x 8)
oHexagon nuts (MU001480 x 4)
a) Mark the center of the EV battery
sling belt (MB992345) and
positions 256.5 mm right and left
from the center.
b) Install the eye bolts (MB992344),
washers (MF450156) and nuts
(MU001480) onto the positions (2
each at the right and left) on the
drive battery as shown in the
figure.