SUBJECT:

MAIN DRIVE LITHIUM-ION BATTERY PROCEDURE
CHANGE – SERVICE MANUAL REVISION

No:

TSB-23-54-008

DATE:

October 2023

MODEL:

See below

CIRCULATE TO:

[ ] GENERAL MANAGER

[ X ] PARTS MANAGER

[ X ] TECHNICIAN

[ X ] SERVICE ADVISOR

[ X ] SERVICE MANAGER

[ X ] WARRANTY PROCESSOR

[ ] SALES MANAGER

PURPOSE

This TSB provides revisions to the procedure for disassembly and reassembly procedure of the
Main Drive Lithium-Ion Battery section in the applicable Service Manual.

AFFECTED VEHICLES
2021 Outlander Plug-in Hybrid

AFFECTED SERVICE MANUAL
• 2021 Outlander Plug-in Hybrid Service Manual

PROCEDURE

Please use the chart below to replace the pages found in the affected Service Manual:

2021 Outlander Plug-in Hybrid: Group 54, Battery Management Unit (BMU) and Main Drive
Lithium-Ion Battery Main Drive Lithium-Ion Battery Disassembly/Assembly
Applicable Manual
2021 OUTLANDER
PHEV Service
Manual

Pub. No.
MSCD-027B-2021

Applicable Title
Battery tray cover and plug hole cover removal and installation
Air leak check

Contents
Attached
sheet 5, 6
Attached
sheet 7, 8

Copyright 2023, Mitsubishi Motors North America, Inc.

The information contained in this bulletin is subject to change. For the latest version of this document, go to the
Mitsubishi Dealer Link, MEDIC, or the Mitsubishi Service Information website (www.mitsubishitechinfo.com).
10/23/2023

1 of 21

(5005/MSB20EXML54002)

Attached sheet 5 (1/9)

54Dc-344

BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY
MAIN DRIVE LITHIUM-ION BATTERY DISASSEMBLY AND ASSEMBLY

Battery tray cover removal
1. Remove the bolts.
2. Using glass adhesive knife. [Blade length: 48 mm (1.89
inches)]
NOTE: Prepare the blade spare due to the possibility that
the blade of the glass adhesive knife will break during work.

BC002060AA

3. While holding the glass adhesive knife and the end of
battery tray cover at right angle, pull the blade of the glass
adhesive knife parallel to the end of the battery tray cover to
detach the adhesive and remove the battery tray cover.

CAUTION

Glass adhesive knife

BCI00262AA

• Do not scrape away the remaining adhesive more than
necessary to prevent adhesion failure.
• Smoothly form the surface of the adhesive left on the
flange. If there is a step on the surface of the adhesive,
there is a possibility of leakage from the step after reapplying the adhesive.
• When battery tray cover and battery tray assembly are
damage with a knife etc, apply repair paint to the damaged part.
4. Scrape away the remaining adhesive on the flange of the
battery tray cover and battery tray assembly with a sharp
knife etc. around the whole circumference so that the
thickness is about 1 mm (0.039 inch).
5. Remove the chip of adhesive cleanly.
6. Remove the cover pads.
7. Remove the breather caps.

Attached sheet 6

10/23/2023

2 of 21

(5005/MSB20EXML54002)

Attached sheet 5 (2/9)
BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY

MAIN DRIVE LITHIUM-ION BATTERY DISASSEMBLY AND ASSEMBLY

54Dc-345

Plug hole cover removal
1.
2.
3.
4.

Remove the battery tray cover.
Remove the plug hole plate.
Remove the upper plug hole plate.
Remove the plug hole cover.

Plug hole cover installation
CAUTION

Plug hole cover

A

• Butyl rubber tape 3M ATD Part No.8625 or equivalent:
Application surface should be free of oil, grease or foreign materials.
• First, tighten all the bolts by hand until they are seated.
Then after final tightening, check that all the bolts are
tightened to the specified torque.
1. Apply the butyl rubber tape 3M ATD Part No.8625 or
equivalent to the plug hole cover as shown. Then install it to
the battery tray cover.
2. Install the upper plug hole plate.
3. Install the plug hole plate.
4. Install the battery tray cover.

A

Battery
tray cover

Butyl
rubber tape

Plug
hole
cover

BCD02659AA

Attached sheet 6

10/23/2023

3 of 21

(5005/MSB20EXML54002)

Attached sheet 5 (3/9)
BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY
MAIN DRIVE LITHIUM-ION BATTERY DISASSEMBLY AND ASSEMBLY

54Dc-346

Battery tray cover installation
1. Install the breather cap.

CAUTION
Application surface should be free of oil, grease or foreign
materials.
2. Position the cover pads as shown.

A

Cover pad
E

A

B

Cover pad

D

C

B

C

D

E

Battery tray cover
Attach to the
flat surface of
the bead.

Cover pad

F

F

F
F

Cover pad

Battery tray cover

Attach according
to the shape.
Cover pad
BCI00263AA

Attached sheet 6
10/23/2023

4 of 21

(5005/MSB20EXML54002)

Attached sheet 5 (4/9)
BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY

54Dc-347

MAIN DRIVE LITHIUM-ION BATTERY DISASSEMBLY AND ASSEMBLY

unit: mm (inch)

Adhesive left
on the flange

27 (1.06)

27 (1.06)

27 (1.06)

27 (1.06)

Adhesive left on the flange

31 (1.22)
28 (1.10)

29 (1.14)
22 (0.86)

27 (1.06)
27 (1.06)
27 (1.06)

28 (1.10)

30 (1.18)
28 (1.10)
27 (1.06)

27 (1.06)

27 (1.06)

27 (1.06)

31 (1.22)
BCI00264AA

3. Measure the position where the adhesive flow prevention
dam (inner pad) is attached to the adhesive left on the flange
portion of the battery tray assembly with a vernier caliper
etc. and mark it.

Attached sheet 6

10/23/2023

5 of 21

(5005/MSB20EXML54002)

Attached sheet 5 (5/9)

54Dc-348

BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY
MAIN DRIVE LITHIUM-ION BATTERY DISASSEMBLY AND ASSEMBLY

Adhesive flow prevention
dam (inner pad): 2nd
10 10 mm (0.39 × 0.39 inch)
length: 980 mm (38.6 inches)

4. 2nd (end point)

5. 3rd (starting point)
Confirm that there is
no gap when attaching.

Adhesive flow prevention
dam (inner pad): 3rd
10 10 mm (0.39 × 0.39 inch)
length: 980 mm (38.6 inches)

3. 2nd (starting point)
Confirm that there is
no gap when attaching.
6. 3rd (end point)
2. 1st (end point)
7. 4th (starting point)
Confirm that there is
no gap when attaching.
Adhesive flow prevention
dam (inner pad): 1st
10 10 mm (0.39 × 0.39 inch)
length: 980 mm (38.6 inches)

1. 1st (starting point)

8. 4th (end point)
Confirm that there is no gap
when butting.
Cut the remaining part against
the first one.

Adhesive flow prevention
dam (inner pad): 4th
10 10 mm (0.39 × 0.39 inch)
length: 980 mm (38.6 inches)

BCI00265AA

4. Attach four adhesive flow prevention dam (inner pad) inside
the marking.

Attached sheet 6

10/23/2023

6 of 21

(5005/MSB20EXML54002)

Attached sheet 5 (6/9)
BATTERY MANAGEMENT UNIT (BMU) AND MAIN DRIVE LITHIUM-ION BATTERY

MAIN DRIVE LITHIUM-ION BATTERY DISASSEMBLY AND ASSEMBLY

54Dc-349

A
A

A
A

Adhesive flow prevention
dam (inner pad)

A

Adhesive flow prevention
dam (outer pad): 11
5 5 mm (0.197 × 0.197 inch),
length: 35 mm (1.38 inches)

3 mm (0.118 inch)

Mounting bolt hole
35 mm (1.38 inches)

5 mm
(0.197 inch)
8 mm
(0.315
inch)

About 3 mm
(0.118 inch)
About
3 mm
(0.118
inch)

BCI00270AA

BCI00266AA

5. Attach 11 adhesive flow prevention dams (outer pads) to the
inside of the bolt hole.
6. Cut the nozzle tip of the sealant gun in the following
procedure.
(1) Cut so that the inner diameter of the nozzle tip becomes
5 mm (0.197 inch).
(2) Cut it obliquely so that the nozzle tip height is 8 mm
(0.315 inch).
(3) In order to make it easier to apply the adhesive, cut the
opposite side that cut to 8 mm (0.315 inch) so that the
inside diameter is about 3 mm (0.118 inch) and the height
is about 3 mm (0.118 inch).
(4) Whether the adhesive can be applied with the standard
dimension [5 × 8 mm (0.197 × 0.315 inch)] is trial applied,
and if it is less than standard, perform the cutting
operation again.

Attached sheet 6

10/23/2023

7 of 21

(5005/MSB20EXML54002)

54Dc-350