Mitsubishi Electric OUTLANDER PHEV Dismantling Manual Download Page 1 | Manualshive

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OUTLANDER PHEV

Drive Battery Removal Procedure

and Dismantling Guide

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Summary of Contents for OUTLANDER PHEV

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

Page 2: ...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 REMOVAL PROCEDURE 9 8 INSPECTION PROCEDURE FOR MAIN DRIVE LITHIUM ION BATTERY 10 9 HIGH...

Page 3: ...ue 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 pers...

Page 4: ...ngine 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 ion battery Chassis number 2 Exterior features that identify an Outlander PHEV from a gasoline engine Outlander PHEV PLUG IN HYBRID EV logo PHEV PLUG IN HYBRID EV logos ar...

Page 5: ... chassis number is stamped on the passenger side cowl top panel inside the engine compartment VIN plate at left front of the instrument panel When the fifth position car line is 2 on the plate it means Outlander PHEV Vehicle information code plate on the passenger s door sill When the code in MODEL line contains GG2W it means Outlander PHEV ...

Page 6: ...hium 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 following pages Wear appr...

Page 7: ...nit 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 to...

Page 8: ...lectric 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 wi...

Page 9: ... 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 ...

Page 10: ...sem 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...

Page 11: ...on 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 REFERE...

Page 12: ...cked or damaged 3 MEASURE THE DISTANCES ON THE SHEETMETAL TRAY DRIVE BATTERY 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 ...

Page 13: ...ed 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 u...

Page 14: ...tenance 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 ...

Page 15: ...lug Wear protective electric insulation gloves when removing the service plug Lever lock Remove 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 se...

Page 16: ...vice 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 ...

Page 17: ...ids 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 ...

Page 18: ...16 Front of Vehicle Procedure 6 Remove Front Left Side Battery Protector Procedure 7 Remove Front Right Side Battery Protector ...

Page 19: ...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 ...

Page 20: ...cedure 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 ...

Page 21: ...cuit 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 Procedure 11 Remove Cable Protector ...

Page 22: ...cle Remove 2 inner cable mounting bolts Remove 2 outer cable mounting bolts Remove battery front cable positive and negative from drive battery assembly Procedure 12 Remove Inner and Outer Cable from Main Drive Battery ...

Page 23: ...21 Front of Vehicle Procedure 14 Remove 3 12V Connectors Procedure 13 Remove Battery Side Protector ...

Page 24: ...will be used in Procedure 25 Procedure 15 Remove Battery Grounding Bracket Procedure 16 Remove Rear Service Lid Always wear Personal Protective Equipment PPE electric insulator gloves and use insulated tools when measuring voltage ring O ring ...

Page 25: ...nd use insulated tools when measuring voltage 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 ...

Page 26: ...s remove 2 inner cable mounting bolts Using insulated tools remove 2 outer mounting bolts Remove drive battery rear cable Procedure 17 Remove Main Drive Battery Rear Cable Positive and Negative Outer Mounting Bolts Inner Cable Mounting Bolts ...

Page 27: ...ocedure 18 Remove Battery Grounding Bracket vehicles with fast charger only 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 O ring ...

Page 28: ...nd use insulated tools when measuring voltage 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 ...

Page 29: ... Front of Vehicle Using insulated tools remove 2 inner cable mounting bolts Using insulated remove 2 outer cable bolts Remove EV charge cable from main drive battery Procedure 20 Remove EV Charge Cable from Main Drive Battery vehicles with fast charger only ...

Page 30: ...28 Procedure 21 Remove Grounding Bracket Front of Vehicle Remove Grounding Bracket ...

Page 31: ...29 Procedure 23 Remove left side battery grounding bracket Front of Vehicle ...

Page 32: ... 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 Service access lid Front of Vehicle Front of Vehicle O ring must be assembled onto service lid before installing service lid to drive battery Step 1 Assemble an O ring and service lid Step 2 Attach the assembled service lid and O ring to drive battery O ring ...

Page 33: ...0mm i Special tool EV battery cart MB992336 Remove the cart handle and set the 2 wood blocks ii Special tool EV battery lifting car MB992659 and2woodblocks Check owner s manual for details about how to use battery cart Remove 2 mounting bolts in both front and rear Front of Vehicle Front of Vehicle Mounting Bolt ...

Page 34: ...bolts Loosen 4 remaining bolts Front of Vehicle Lower the vehicle with the lift until the bottom of the drive battery just makes contact with the wood blocks Remove all 4 of the mounting bolts on the drive battery Main battery ...

Page 35: ...he main drive battery with a plastic sheet or other material so that no water foreign material etc may enter the inside of the drive battery Store the drive battery in a dry safe place Do not expose the drive battery to fire or heat of 140 F 60 or more Be careful not to damage the wiring harness ...

Page 36: ...ers MF450156 x 8 Hexagon nuts MU001480 x 4 NOTE For how to use the EV battery sling belt refer to the provided Operation Manual i Mark center of the EV battery sling belt and positions 210 mm right and left from center Remarks The marking is intended for alignment of battery sling belt and eye bolt ii Install the eye bolts washers and nuts onto positions 2 eachattherightandleft onthedrivebattery i...

Page 37: ...move service lid nut and service lid Wait for 5 minutes to allow voltage to lower Voltage of condenser must be sufficiently lowered Wait for 5 minutes 3 Pull up service plug lever Wear insulated gloves and use insulated tools when unplugging the service plug Pull out service plug completely as the plug is energized while removing 3 Remove service plug Be sure to carry out preliminary inspection wh...

Page 38: ...35 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: ...36 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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