MITSUBISHI 2012 i-MiEV Dismantling Guide Lithium-Ion Battery Electric Vehicle June 2013 © Copyright 201 , Mitsubishi Motors North America, Inc.
TABLE OF CONTENTS INTRODUCTION ............................................................................... 1 HOW TO IDENTIFY I-MIEV .............................................................. 2 UNIQUE I-MIEV FEATURES ............................................................................ 2 EXTERIOR......................................................................................................... 2 CHASSIS NUMBER AND MODEL CODE .........................................................
Introduction Since the i-MiEV is an 100% electric vehicle equipped with a high voltage (370V) Main drive lithium-ion battery, caution must be used when dismantling the vehicle. This guide provides instructions that must be followed when the high voltage Main drive lithium-ion battery is to be removed from the i-MiEV.
How to Identify i-MiEV Always handle i-MiEV using appropriate Personal Protective Equipment (PPE) 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 ① Charging lid and port on the right side of the vehicle. ② ② MiEV logo mark on right side of tailgate. ② ① ③ ③ No exhaust pipe i-MiEV does not have an exhaust pipe.
(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 “Quarter Trim”. ① VEHICLE IDENTIFICATION NUMBER PLATE The vehicle identification number (VIN) plate is located on a plate attached to the left top side of the instrument panel. The first 6 digits are “JA3215” for i-MiEV.
Safety Precautions WARNING; ● 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 is quiet.
Proper Handling of the High Voltage Battery 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 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.
High Voltage Components Layout High voltage (maximum 370V) components and wiring cables are located as shown in the figure below. Main drive lithium-ion battery (maximum 370V) 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.
Personal Protective Equipment (Reference Only) CAUTION; Use personal protective equipment that complies with applicable 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.
Dismantling Process Overview Step 1: Assessing damage to the Main drive lithium-ion battery - Page 9 Is the battery severely damaged? NO YES Proceed to Step 2A: Shutting Off High Voltage – Page 10 Proceed to Step 2B: Discharging the Main Drive Lithium-Ion Battery – Page 14 Step 3: Removing the Main Drive Lithium-ion Battery – Page 18 8
Step 1: Assessing Damage to the Main Drive Lithium-ion Battery Immediately after receiving the vehicle, and prior to any dismantling work, check for damage to the Main drive lithium-ion battery. If the Main drive lithium-ion battery is severely damaged, the Main drive lithium-ion battery must be discharged by soaking in water prior to any dismantling work in order to reduce the risk of electric shock and/or fire.
Step 2A: Shutting Off the High Voltage WARNING; If the Main drive lithium-ion battery is severely damaged, do not carry out the procedures described in this section. Instead, discharge the Main drive lithium-ion battery in accordance with Step 2B. 1) Shut down the vehicle’s high voltage system using one of the following two methods. This will disconnect the high voltage electricity current supplied from the Main drive lithium-ion battery.
2) Wait at least 1 minute before proceeding to the next step. High voltage system shut down is performed during this waiting time. 3) Disconnect the 12V battery negative terminal. This will disconnect the power supply to the SRS airbag system and the EV ECU. Disconnect the 12V battery negative terminal by using a 10mm wrench as follows: ① 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).
② Pull up the lever of the Service Plug and then remove the Service Plug by pulling upward on the lever. WARNING; After removing the Service Plug, keep it in a secure place away from other dismantlers to prevent accidental handling/improper re-installation. There are some high voltage components and wiring cables which retain high voltage for 5 minutes after disconnecting the 12V battery.
② Remove the service hole lids on the bottom 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.
Step 2B: Discharging the Main Drive Lithium-ion Battery WARNING; - Do not use salt water to discharge the Main drive lithium-ion battery. Using water containing salt can generate a large volume of flammable hydrogen and increases the risk of fire or explosion. - Hydrogen gas is generated during the discharging process, even when fresh water is used and proper discharging procedures are followed. To reduce the risk of fire; ● The discharging must be done in a well-ventilated area located outside.
2) Draining the Main drive lithium-ion battery Step 1. After 72 hours have elapsed, remove the vehicle from the water. Step 2. Remove the Under cover (2 pieces) from bottom of vehicle. (see illustration below.) - Use Socket wrench (size 10mm) for removing the fixing bolts. - Use Flat head screwdriver for removing of the fixing clips. Step 3.
Drain hole locations on Main drive lithium-ion battery Service hole lid: Remove the service hole lids on the bottom of the Main drive lithium-ion battery and drain the Main drive lithium-ion battery. Main drive lithium-ion battery Front 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 front bottom of the Main drive lithium-ion battery. Then drain the Main drive lithium-ion battery.
3) Disconnect 12V battery under the front hood. WARNING; Disconnect 12V battery to avoid inadvertent airbag deployment during the dismantling process, since the 12V battery may not have discharged while the vehicle was soaking for 72 hours in water. Since the 12V battery will not discharge while the vehicle is soaking in water; The hood release is under the instrument panel beside the front passenger’s door. ① Remove the cover of the 12V battery under the hood.
Step 3: Removing the Main Drive Lithium-ion Battery From the Vehicle WARNING; Before removing the Main drive lithium-ion battery, be sure that the procedure for shutting off the high voltage or discharging the Main drive lithium-ion battery has been completed. Only use procedures described in this guide to remove the Main drive lithium-ion battery. Using different procedures increase the risk of injury and may cause damage to the battery.
*Pre-removal operation • Removal of Under cover A, B (Refer to Pg.12 illustration) • Floor duct removal if applicable (Refer to GROUP 55 − Duct) *For additional assistance, visit http://www.mitsubishitechinfo.com 1 5 4 3 6 2 ACA02383AC <> 1. 2. 3. Removal steps Rubber boot connection Service hole lid O-ring <> Removal steps (Continued) Main drive lithium-ion battery cable connection O-ring Ground cable connection 4. 5. 6. 11 10 9 11 11 8 7 11 ACA02384AC >>D<< <> >>C<< 7. 8. 9.
13 12 12 ACA03978AC ACA03978 <> Removal steps 12. Floor frame plate 13.
Removal service points 1. Remove the inner cable mounting bolts (2 locations). 2. Remove the outer cable mounting bolts (2 locations). 3. Pull out the cable from the Main drive lithium-ion battery. <> Rubber boot discussion <> Quick charging cable disconnection (if applicable) Outer cable mounting bolt ACA02499AB Inner cable mounting bolt AC902206AB 1. Remove the inner cable mounting bolts (2 locations). 2.
CAUTION Be careful not to damage the wiring harness. Wood block MB992659 AC902360AB (2) When the vehicle is lowered with the lift using the special tool (MB992336), if the lower stopper lock does not work, use the EV battery lifting cart (special tool: MB992659) instead. NOTE: For instructions how to use the EV battery lifting cart, refer to the provided "Operation Manual". 3.
9. When moving the removed Main drive li-ion battery with a crane or other machine, 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) NOTE: For instructions how to use the EV battery sling belt, refer to the provided "Operation Manual".
*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.
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.
