Mitsubishi i-MiEV 2014 Dismantling Manual Download | Manualshive

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© Copyright 2014, Mitsubishi Motors North America, Inc.

MITSUBISHI

2014 i-MiEV Dismantling Guide

Lithium-Ion Battery Electric Vehicle

May 2014

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Summary of Contents for i-MiEV 2014

Page 1: ... Copyright 2014 Mitsubishi Motors North America Inc MITSUBISHI 2014 i MiEV Dismantling Guide Lithium Ion Battery Electric Vehicle May 2014 ...

Page 2: ...GH VOLTAGE COMPONENTS LAYOUT 6 TESTER AND SPECIAL TOOLS 6 PERSONAL PROTECTIVE EQUIPMENT 7 DISMANTLING PROCESS OVERVIEW 8 STEP 1 ASSESSING DAMAGE TO THE MAIN DRIVE LITHIUM ION BATTERY 9 STEP 2A SHUTTING OFF THE HIGH VOLTAGE 10 STEP 2B DISCHARGING THE MAIN DRIVE LITHIUM ION BATTERY 14 STEP 3 REMOVING THE MAIN DRIVE LITHIUM ION BATTERY FROM THE VEHICLE 18 HIGH VOLTAGE SIGNBOARD 24 WARNING SIGN 25 ...

Page 3: ...words WARNING and CAUTION appear These serve as reminders to be especially careful Failure to follow instructions may result in personal injury or damage to your vehicle WARNING Indicates a strong possibility of severe personal injury or death if instructions are not followed CAUTION Means hazards or unsafe practices that could cause minor personal injury or damage to your vehicle indicates option...

Page 4: ...E and the methods described in this guide 1 Unique i MiEV features MiEV logo mark Charging lid and port No exhaust pipe Chassis number 2 Exterior Charging lid and port on the right side of the vehicle MiEV logo mark on right side of tailgate No exhaust pipe i MiEV does not have an exhaust pipe 2 ...

Page 5: ...e left top side of the instrument panel The first 6 digits are JA3215 for i MiEV Ex Model code stamp JA3215H1_CU00001 VEHICLE INFORMATION CODE PLATE The vehicle information code plate is riveted to the face of the driver s door sill i MiEV includes HA3W in the MODEL code Ex MODEL code stamp HA3WGLDDL2M inside of vehicle CHASSIS NUMBER The chassis number is stamped on the body panel quarter trim lo...

Page 6: ... 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 to water If the electrolyte comes...

Page 7: ...ing 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 Mitsubishi i MiEV To prevent accidents your cooperation in the safe collection of Main drive lithium ion batteries is...

Page 8: ...ling special tool MB992345 or equivalent maximum capacity 1200 lbs 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 Main drive lithium ion battery Inverter On board charger DC DC converter Motor electric motor unit Heater A C compressor Regular charging lid Quick charging lid if app...

Page 9: ...le state and local requirements This equipment should include the following Personal Protective Equipment Name Electric insulation helmet with shield a Helmet suspension b Chin strap c Visor d Liner Electric insulation jacket Electric insulation trousers Electric insulation glove Electric insulation boots 7 a b c d ...

Page 10: ...ain drive lithium ion battery Page 9 Is the battery severely damaged Proceed to Step 2B Discharging the Main Drive Lithium Ion Battery Page 14 Step 3 Removing the Main Drive Lithium ion Battery Page 18 Proceed to Step 2A Shutting Off High Voltage Page 10 YES NO 8 ...

Page 11: ... Main drive lithium ion battery place the vehicle in an open space away from any structure or vehicle and continue to monitor the vehicle until the discharging process has been completed and the risk of fire is eliminated If you detect leaking fluids sparks smokes flames increased temperature gurgling popping or hissing noises from the HV compartment notify the Fire Department Ensure area is clear...

Page 12: ...le nose pliers to remove the Power control unit fuse from the fuse box under the hood It is the No 7 15A fuse shown in the figure below If you cannot locate this fuse remove all fuses and relays in the fuse box The hood release is under the instrument panel beside the front passenger s door Pull Fuse No 7 Step 2A Shutting Off the High Voltage WARNING If the Main drive lithium ion battery is severe...

Page 13: ...lithium ion battery can be performed about 5 minutes after disconnecting the 12V battery negative terminal 6 Remove the Service Plug by following the procedure below Adjust the front left side seat to its rear most position and roll up the carpet under the seat Detach the service lid by removing two wing nuts If it is difficult to move the seat remove it WARNING After disconnecting the 12V battery...

Page 14: ...oltage components and wiring cables which retain high voltage for 5 minutes after disconnecting the 12V battery When it is necessary to cut the high voltage components and wiring cables wait at least 5 minutes after cutting before commencing the next action at 7 Measurement of the Main drive lithium ion battery s voltage WARNING Always wear eye protection safety glasses to protect your eyes from f...

Page 15: ... of the Main drive lithium ion battery and carry out the measurement of the battery s voltage as shown below If the voltage is not 0V wait until the voltage shows 0V When the high voltage circuit is successfully shut down the voltage shows 0V 13 ...

Page 16: ...pproximately 180 inch X 80 inch X 30 inch length X width X height Step 2 Use a forklift or similar equipment to place the vehicle in the center of the pool Step 3 Open all windows doors and the tailgate Step 4 Make sure to use water that does not contain salt use tap water well water or pond water to prevent an aggressive chemical reaction and the excessive release of flammable hydrogen gas Requir...

Page 17: ...ng clips Step 3 Drill drain holes in the marked locations on the bottom of the Main drive lithium ion battery see Drain hole locations on Main drive lithium ion battery on next page Then drain water from the Main drive lithium ion battery Step 4 Drained water shall be properly disposed of as an industrial waste according to state and or local regulations Illustration Fixing point of Under cover WA...

Page 18: ...s to drill drain holes in the five marked locations on the front bottom of the Main drive lithium ion battery Then drain the Main drive lithium ion battery Rear end of Main drive lithium ion battery Use a drill diameter size 6mm or less to drill drain holes in the five marked locations on the rear bottom of the Main drive lithium ion battery Then drain the Main drive lithium ion battery Main drive...

Page 19: ...ge while the vehicle is soaking in water Remove the cover of the 12V battery under the hood Turn the plastic nut A counter clockwise and then remove the battery upper cover B Disconnect the negative terminal from the 12V battery WARNING After disconnecting the 12V battery negative terminal to avoid the risk of inadvertent air bag deployment wait at least 1 minute before proceeding to the next step...

Page 20: ... drive lithium ion battery due to body deformation never cut the Main drive lithium ion battery high voltage wiring or other high voltage components The Main drive lithium ion battery is heavy appproximately 507 lbs To remove and move the battery use only equipment with sufficient weight capacity 1 Remove the work hole lid at the bottom of the Main drive lithium ion battery and then remove the Mai...

Page 21: ...com ACA02383AC 1 5 4 2 3 6 Removal steps A 1 Rubber boot connection 2 Service hole lid 3 O ring B 4 Main drive lithium ion battery cable connection 5 O ring 6 Ground cable connection Removal steps Continued ACA02384AC 9 8 7 10 11 11 11 11 Removal steps D 7 Service hole lid 8 O ring C C 9 Quick charging cable connection if applicable 10 O ring 11 Connector connection Removal steps Continued 19 ...

Page 22: ...ACA03978 ACA03978AC 13 12 12 Removal steps 12 Floor frame plate 13 Main drive lithium ion battery assembly 20 D ...

Page 23: ...s 2 locations 3 Pull out the cable from the Main drive lithium ion battery D Main drive lithium ion battery assembly removal 1 Attach the removed work hole lid and O ring to the Main drive li ion battery so that no water foreign material etc can enter the inside of the Main drive li ion battery 2 Use the following special tools and 2 wood blocks 100 x 100 x 1500 mm 1 Remove the handle of the EV ba...

Page 24: ...f the Main drive li ion battery contacts the wood block 6 Remove all the mounting bolts on the Main drive li ion battery CAUTION Be careful not to damage the wiring harness 7 Raise the vehicle with the lift and remove the Main drive li ion battery WARNING Store the Main drive li ion battery in a dry location where it will not get wet Do not bring the Main drive li ion battery close to fire or heat...

Page 25: ...f the EV battery sling belt MB992345 and positions 275 mm right and left from the center NOTE The marking is intended for alignment of the EV battery sling belt and eye bolt 2 Install the eye bolts MB992344 washers MF450156 and nuts MU001480 onto the positions 2 each at the right and left on the Main drive li ion battery as shown in the figure 3 Pass the EV battery sling belt through the eye bolts...

Page 26: ... When doing high voltage work please put up this signboard Fold along the dotted line and place it on top of the i MiEV s roof 24 ...

Page 27: ...It is recommended that a warning sign example provided above is fixed to or on the vehicle during any dismantling work on the vehicle A sign that complies with local regulation should be used 25 ...

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