SUBJECT:

SERVICE PROCEDURE CHANGES AND CORRECTIONS
– SERVICE MANUAL REVISION

No:

TSB-24-33-001

DATE:

April 2024

MODEL: Outlander Plug-in Hybrid

CIRCULATE TO:

[ ] GENERAL MANAGER

[ X ] PARTS MANAGER

[ X ] TECHNICIAN

[ X ] SERVICE ADVISOR

[ X ] SERVICE MANAGER

[ X ] WARRANTY PROCESSOR

[ ] SALES MANAGER

PURPOSE
This TSB provides changes and corrections for the service procedures in the applicable Service
Manual sections.
(1)
(2)

(3)
(4)
(5)
(6)
(7)
(8)

BATTERY MANAGEMENT UNIT (BMU) AND TRACTION BATTERY;
・Correction of description of Removal and Installation procedure about Front
Motor.
BATTERY MANAGEMENT UNIT (BMU) AND TRACTION BATTERY;
・Correction of description of DTC No. P1B12-04 / P1B13-04.
・Correction of description of “CAUTION” when replacing the BMU.
・Correction of description of Check on Insulation Resistance of AC Inverter.
FRONT SUSPENSION;
・Correction of Removal and Installation procedure about Front Suspension
Member.
EXTERIOR;
・Change of Removal and Installation procedure about Fender.
・Change of Removal and Installation procedure about Under Cover.
HEATER & AIR CONDITIONING SYSTEM;
・Correction of description about Perform Lubricant Return Operation.
・Correction of description about Performance Test.
HEATER & AIR CONDITIONING CONTROL SYSTEM;
・Correction of description of “NOTE” about Blow Set.
BODY CONTROL SYSTEM;
・Correction of description of Removal and Installation procedure about BCM.
CIRCUIT DIAGRAM;
・Add the description about “USB cable” and “HDMI cable”.

AFFECTED VEHICLES
2023-2024 Outlander Plug-in Hybrid
AFFECTED SERVICE MANUAL
2023-2024 Outlander Plug-in Hybrid Service Manual
PROCEDURE
Please use the chart below to replace the pages in the affected 2023-2024 Outlander Plug-in
Hybrid Service Manuals.
Note: Content has been removed from areas marked as "deleted" with blank red boxes.

Copyright 2024, 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).
4/17/2024

1 of 34

(5397/MSB24M33_51_54-501)

4/17/2024

2 of 34

(5397/MSB24M33_51_54-501)

4/17/2024

3 of 34

(5397/MSB24M33_51_54-501)

4/17/2024

4 of 34

(5397/MSB24M33_51_54-501)

Attached sheet 2
ELECTRIC MOTOR CONTROL UNIT (EMCU) AND MOTOR (ELECTRIC MOTOR UNIT)
MOTOR (ELECTRIC MOTOR UNIT)
REMOVAL AND INSTALLATION

REMOVAL AND INSTALLATION
DANGER:

When servicing the high-voltage system parts, always wear the protective equipment or armour and always shut off the high-voltage by removing
the service plug (Refer to PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE).
CAUTION:
When the wheel alignment is adjusted, always perform calibration to make ABS actuator and electric unit learn the neutral position of the steering angle sensor (Refer to Brake
Control System - With ABS Actuator and Electric Unit, Adjustment of Steering Angle Sensor Neutral Position ).

Pre-removal and Post-installation Operation

 EV coolant draining and refilling (Refer to EV COOLING
SYSTEM - On-vehicle Service, Coolant Change EV
COOLANT CHANGE).
 Generator (Refer to GENERATOR REMOVAL AND
INSTALLATION)

36 ± 5 N·m
27 ± 3 ft-lb

(MITSUBISHI MOTORS GENUINE ATF SP III)

3

N

2

36 ± 5 N·m
27 ± 3 ft-lb

1
DF2000AJAA
Removal steps
1.

4/17/2024

Front motor & generator harness



EV oil cooler hose F, G, H connection

2.

Front motor

3.

O-ring

5 of 34

(5397/MSB24M33_51_54-501)

Attached sheet 3
BATTERY MANAGEMENT UNIT (BMU) AND TRACTION BATTERY
DIAGNOSIS
Required Special Tools:


MB992744: Vehicle communication interface-Lite (V.C.I.-Lite)



MB992745: V.C.I.-Lite main harness A



MB992747: V.C.I.-Lite USB cable short



MB992748: V.C.I.-Lite USB cable long

1. Check of BMU2 DTC
Check whether the BMU2 sets the DTC.
Is the DTC set in the BMU2?
YES >>
Troubleshoot the DTC set in the BMU2. Then,
go to Step 3.
NO >>
Go to Step 2.

2. Check of BMU DTC
(1)

Erase the DTC set in the BMU2.

(2)

Erase the DTC set in the BMU.

(3)

Change the power supply mode of the electric motor switch to OFF, then wait for 3 minutes or more in key lock condition. (Check that the P indicator on the selector lever turns off.)

(4)

Change the power supply mode of the electric motor switch to ON (READY indicator: ON).

(5)

Check whether the DTC No. P1B12-04 / P1B13-04 is set.

Is the DTC No. P1B12-04 / P1B13-04 set?
YES >>
Disassemble the drive battery (Refer to ). After the disassembly, replace the BMU. Then,
go to Step 3.
NO >>
The trouble can be an intermittent malfunction (Refer to General Information - How to Use Troubleshooting/Inspection Service Points, How to Cope with Intermittent Malfunctions ).

3. Test the OBD-II drive cycle.
(1)

Carry out a test drive with the drive cycle pattern. Refer to OBD-II Drive Cycle .

(2)

Check the DTC.

Is the DTC set?
YES >>
Retry the troubleshooting.
NO >>
The procedure is complete.

4/17/2024

6 of 34

(5397/MSB24M33_51_54-501)

Attached sheet 4
BATTERY MANAGEMENT UNIT (BMU) AND TRACTION BATTERY
ON-VEHICLE SERVICE
SAVING AND WRITING BATTERY INFORMATION

SAVING AND WRITING BATTERY INFORMATION
CAUTION:
When replacing the BMU, perform the following operations. If the drive battery is replaced, the battery information is already written in the new battery, so there is no need to take
any steps to write the battery information.


Save the battery information before removing the drive battery.
After replacing the BMU, write the saved battery information.



Vehicle specification writing (Refer to Vehicle specification writing)

Required Special Tools:


MB992744: Vehicle communication interface-Lite (V.C.I.-Lite)



MB992745: V.C.I.-Lite main harness A



MB992747: V.C.I.-Lite USB cable short



MB992748: V.C.I.-Lite USB cable long

SAVING BATTERY INFORMATION
Using the M.U.T.-IIISE, save the battery information stored in the original BMU to the M.U.T.-IIISE by the following procedures.
1.On the "System selection" screen, select "BMU".
2.Select "Special function", then select "SAVING DATA".
3.Save the battery information by following the instructions on the screen.

WRITING BATTERY INFORMATION
Using the M.U.T.-IIISE, write the battery information saved in the M.U.T.-IIISE to the new BMU by the following procedures.
1.On the "System selection" screen, select "BMU".
2.Select "Special function", then select "WRITING DATA".
3.Write the battery information to the new BMU by following the instructions on the screen.

4/17/2024

7 of 34

(5397/MSB24M33_51_54-501)

Attached sheet 5
BATTERY MANAGEMENT UNIT (BMU) AND TRACTION BATTERY
ON-VEHICLE SERVICE
VEHICLE SPECIFICATION WRITING

VEHICLE SPECIFICATION WRITING
CAUTION:
When replacing the BMU, perform the following operations. If the drive battery is replaced, the battery information is already written in the new battery, so there is no need to take
any steps to write the battery information.


Save the battery information before removing the drive battery (Refer to SAVING AND WRITING BATTERY INFORMATION).
After replacing the BMU, write the saved battery information. (Refer to SAVING AND WRITING BATTERY INFORMATION)



Vehicle specification writing

Required Special Tools:


MB992744: Vehicle communication interface-Lite (V.C.I.-Lite)



MB992745: V.C.I.-Lite main harness A



MB992747: V.C.I.-Lite USB cable short



MB992748: V.C.I.-Lite USB cable long

Using the M.U.T.-IIISE, write the vehicle specification in the BMU by the following procedures.
1.On the "System selection" screen, select "BMU".
2.Select "Configuration", then select "Automatic Configuration".
3.Write the vehicle specification by following the instructions on the screen.
NOTE:
For the detailed procedures, refer to "M.U.T.-III SE User's Manual".
4.On the "System selection" screen, select "BMU2".
5.Select "Configuration", then select "Automatic Configuration".
6.Write the vehicle specification by following the instructions on the screen.
NOTE:
For the detailed procedures, refer to "M.U.T.-III SE User's Manual".

4/17/2024

8 of 34

(5397/MSB24M33_51_54-501)

Attached sheet 6
BATTERY MANAGEMENT UNIT (BMU) AND TRACTION BATTERY
ON-VEHICLE SERVICE
CHECK ON INSULATION RESISTANCE OF AC INVERTER

CHECK ON INSULATION RESISTANCE OF AC INVERTER
DANGER:


When servicing the high voltage components, be sure to remove the service plug in order to shut off the high voltage.



When servicing the high voltage components, be sure to wear an insulating protective equipment to measure the high voltage.

CAUTION:
The insulation resistance check must be completed within 10 seconds. (Since DC 1,000 V is applied while checking, parts may be damaged if the check continues for 10 seconds or
more.)

Required Special Tools:


MB991223: Wiring harness set



MB992006: Extra fine probe



MB992355: Electric insulation tester

1.Remove the third seat (Refer to ).
2.Remove the cargo floor cover (Refer to ).
3.Remove the EV control unit cover (LH/RH) (Refer to ).
4.Disconnect the high voltage cable (P, N) from the AC inverter.
5.Disconnect the AC power supply wiring harness from the AC inverter.
6.Use the electric insulation tester (Special tool: MB992355) and set it to the 1,000 V range.
7.Measure the insulation resistance between the AC inverter high voltage terminals (P, N) and AC inverter (body ground).

AC inverter (P, N) terminals
DF2000CEAJ
Standard value: 10 MΩ or more

8.If the measured value is not within the standard value, replace the AC inverter.

4/17/2024

9 of 34

(5397/MSB24M33_51_54-501)

Attached sheet 7
BATTERY MANAGEMENT UNIT (BMU) AND TRACTION BATTERY
BATTERY MANAGEMENT UNIT (BMU)
BATTERY MANAGEMENT UNIT (BMU) REMOVAL AND INSTALLATION

BATTERY MANAGEMENT UNIT (BMU) REMOVAL AND INSTALLATION
CAUTION:
When replacing the BMU, perform the following operations. If the drive battery is replaced, the battery information is already written in the new battery, so there is no need to take
any steps to write the battery information.


Save the battery information before removing the drive battery. (Refer to SAVING AND WRITING BATTERY INFORMATION)
After replacing the BMU, write the saved battery information. (Refer to SAVING AND WRITING BATTERY INFORMATION)



Vehicle specification writing (Refer to Vehicle specification writing)

For the BMU removal and installation, refer to drive battery disassembly and assembly .

4/17/2024

10 of 34

(5397/MSB24M33_51_54-501)

Attached sheet 8
BATTERY MANAGEMENT UNIT (BMU) AND TRACTION BATTERY
DRIVE BATTERY
REMOVAL AND INSTALLATION

REMOVAL AND INSTALLATION
DANGER:


When servicing the high voltage components, be sure to wear an insulating protective equipment and remove the service plug in order to
shut off the high voltage (Refer to PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE).



Do not disassemble any drive battery components other than those described in this manual.

CAUTION:


If the drive battery is replaced, the "preliminary application" is required before replacement. (For the details, contact Mitsubishi Motors dealer.) If the drive battery is
replaced without approval by the "preliminary application", it is excluded from the scope of the warranty. Be careful.



When replacing the drive battery, perform the following operations. If the drive battery is replaced, the battery information is already written in the new battery, so there
is no need to take any steps to write the battery information.


Vehicle specification writing (Refer to Vehicle specification writing)

Required Special Tools:


MB992336: EV battery cart

