TSB-24-33-001

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).
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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
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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.
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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.
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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".
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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.
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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 .
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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

MB992659: EV battery lifting cart

MB992343: EV battery sling tool kit

MB992327: EV battery guide
Pre-removal Operation
Post-installation Operation
 Floor under cover removal (Refer to Exterior - Under
Cover Removal and Installation).
 Refrigerant charging (Refer to Heater & Air Conditioning
System - Refrigerant Recycle Refrigerant/Charge
Refrigerant) .
 Refrigerant draining (Refer to Heater & Air Conditioning
System - Refrigerant Recycle Refrigerant/Charge
Refrigerant) .
 Floor under cover installation (Refer to Exterior - Under
Cover Removal and Installation).
1
5.5 ± 1.1 N·m
49 ± 9 in-lb
4
2
3
6
1.9 ± 0.2 N·m
17 ± 1 in-lb
5N
105 ± 15 N·m
78 ± 10 ft-lb
30 ± 3 N·m
22 ± 2 ft-lb
105 ± 15 N·m
78 ± 10 ft-lb
105 ± 15 N·m
78 ± 10 ft-lb
30 ± 3 N·m
22 ± 2 ft-lb
5N
DF2000HFAA
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Attached sheet 9
BATTERY MANAGEMENT UNIT (BMU) AND TRACTION BATTERY
DRIVE BATTERY DISASSEMBLY AND ASSEMBLY
4. BMU REMOVAL AND INSTALLATION
4. BMU REMOVAL AND INSTALLATION
DANGER:
When servicing the high voltage components, be sure to wear an insulating protective equipment to measure the high voltage (Refer to PRECAUTIONS
ON HOW TO USE THE HIGH-VOLTAGE VEHICLE).
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)

Required Special Tools:

MB992915: Electric insulation sheet
5.5 ± 1.0 N·m
49 ± 8 in-lb
5.5 ± 1.0 N·m
49 ± 8 in-lb
2N
13 ± 2 N·m →15 ± 1.5 N·m
115 ± 17 in-lb →133 ± 13 in-lb
N
1
5.5 ± 1.0 N·m
49 ± 8 in-lb
5.5 ± 1.0 N·m
49 ± 8 in-lb
9
5.5 ± 1.0 N·m
49 ± 8 in-lb
3
6
7
5
8
5.5 ± 1.0 N·m
49 ± 8 in-lb
5.5 ± 1.0 N·m
49 ± 8 in-lb
4
DF2000X1AA
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Attached sheet 10
)52176863(16,21
FRONT SUSPENSION MEMBER
Removal and Installation
5HPRYDODQG,QVWDOODWLRQ
5(029$/
1.Remove tires. Refer to Suspension - Road Wheels & Tires - Removal and Installation - Road Wheel Tire Assembly - Exploded View.
2.Remove engine room under cover. Refer to Body Exterior, Doors, Roof & Vehicle Security - Exterior - Removal and Installation - Under Cover - Removal And Installation.
3.Remove front bumper fascia assembly. Refer to Body Exterior, Doors, Roof & Vehicle Security - Exterior - Removal And Installation - Front Bumper - Removal And Installation.
4.Remove front bumper reinforcement lower. Refer to Body Exterior, Doors, Roof & Vehicle Security - Exterior - Removal and Installation - Front Bumper - Removal And Installation.

5.Secure the radiator and condenser to the vehicle.
6.Separate stabilizer connecting rod (strut side) from strut. Refer to Suspension - Front Suspension - Removal and Installation - Front Stabilizer - Removal And Installation.
7.Remove steering outer socket from steering knuckle. Refer to Transmission & Driveline - Front Axle - Removal and Installation - Front Wheel Hub And Knuckle - Removal And Installation.
8.Remove torque rod. Refer to Engine - Power Plant Mount - Removal And Installation - Power Plant Mount - Removal And Installation.
9.Remove exhaust front pipe. Refer to Engine - Intake and Exhaust - Exhaust Pipe And Main Muffler - Removal And Installation.
10.Separate the connection of steering gear assembly and steering column shaft. Refer to Steering - Steering System - Removal And Installation - Steering Column - Removal And Installation.
11.Separate the transverse link from the steering knuckle while taking care not to damage the ball joint boot. Refer to Suspension - Front Suspension - Removal And Installation - Transverse Link Removal And Installation.
12.Set suitable jack under front suspension member.
&$87,21
x
$WWKLVVWHSWKHMDFNPXVWEHVHWRQO\IRUVXSSRUWLQJWKHUHPRYDOSURFHGXUH)RUGHWDLOVRQMDFNLQJXSWKHYHKLFOHUHIHUWR*HQHUDO,QIRUPDWLRQ*HQHUDO,QIRUPDWLRQ
6XSSRUW/RFDWLRQVIRU/LIWLQJ$QG-DFNLQJ
x
1HYHUGDPDJHWKHIURQWVXVSHQVLRQPHPEHUZLWKDMDFN
x
&KHFNWKHVWDEOHFRQGLWLRQZKHQXVLQJDMDFN
13.Remove member stay.
14.Remove front suspension member mounting bolts.
15.Gradually lower the jack to remove front suspension member from vehicle body.
&$87,21
2SHUDWHZKLOHFKHFNLQJWKDWMDFNVXSSRUWLQJVWDWXVLVVWDEOH
127(
5HPRYHVXVSHQVLRQPHPEHUZLWKVWDELOL]HUEDUDQGWUDQVYHUVHOLQN
16.Remove the following parts.
x
Stabilizer bar: Refer to Suspension - Front Suspension - Removal and Installation - Front Stabilizer - Removal And Installation.
x
Transverse link: Refer to Suspension - Front Suspension - Removal and Installation - Transverse Link - Removal And Installation.
x
Steering gear and linkage. Refer to Steering - Steering System - Removal And Installation - Steering Gear And Linkage - Exploded View.
17.Perform inspection after removal. Refer to Suspension - Front Suspension - Removal And Installation - Front Suspension Member - Inspection .
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Attached sheet 11
SEALANT(S) OR ADHESIVE(S)
Application
Specified adhesive
Plug adhesive surface
Specified primer: 3M™ K-500 or equivalent
LUBRICANT
LUBRICANT
Item
Specified lubricant
Quantity
Degrease agent
Mitsubishi Motors Genuine Parts Cleaner (MZ100387) or
equivalent
As required
Grease and dirt removal from parts surface

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Attached sheet 12 (1/6)
EXTERIOR
REMOVAL AND INSTALLATION
FENDER
REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
• Front fillet molding Removal and Installation (Refer to Fillet molding Removal and Installation)
• Front fender protector Removal and Installation (Refer to Splash shield Removal and Installation)
• Headlight assembly Removal and Installation (Refer to Headlight Removal and Installation)
Cowl top cover Removal and Installation (Refer to Front wiper Removal and Installation)
•
• Front combination light Removal and Installation (Refer to Front combination light Removal and Installation)
NOTE:
There are 3 types of fender. Refer to the illustration and check the type of the fender.
: Vehicle front
Bracket 1
Bracket 1
Bracket 2
Type A
Not existed Not existed
Type B
Not existed
Existed
Type C
Existed
Existed
Bracket 2
N
DF2002FUAP

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Attached sheet 12 (2/6)
EXTERIOR

2
5.0 ± 2.0 N·m
44 ± 17 in-lb
1
5.0 ± 2.0 N·m
44 ± 17 in-lb
7
3
5
6
7
6
5.0 ± 2.0 N·m
44 ± 17 in-lb
5.0 ± 2.0 N·m
44 ± 17 in-lb
5.0 ± 2.0 N·m
44 ± 17 in-lb
4
5.0 ± 2.0 N·m
44 ± 17 in-lb
DF2002FUAQ

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Attached sheet 12 (3/6)
EXTERIOR

2
5.0 ± 2.0 N·m
44 ± 17 in-lb
5.0 ± 2.0 N·m
44 ± 17 in-lb
3
1
8
7
N
11 N
5
7
6
6
5.0 ± 2.0 N·m
44 ± 17 in-lb
5.0 ± 2.0 N·m
44 ± 17 in-lb
5.0 ± 2.0 N·m
44 ± 17 in-lb
5.0 ± 2.0 N·m
44 ± 17 in-lb
9
4
DF2002FUAR

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Attached sheet 12 (4/6)
EXTERIOR

2
5.0 ± 2.0 N·m
44 ± 17 in-lb
5
1
8
N
5.0 ± 2.0 N·m
44 ± 17 in-lb
7
3
10
5.0 ± 2.0 N·m
44 ± 17 in-lb
7
6
6
5.0 ± 2.0 N·m
44 ± 17 in-lb
5.0 ± 2.0 N·m
44 ± 17 in-lb
5.0 ± 2.0 N·m
44 ± 17 in-lb
5.0 ± 2.0 N·m
44 ± 17 in-lb
9
4
DF2002FUAS

Removal steps
<>
1.
Front fender inner garnish
2.
Hood rear side weatherstrip
3.
Front fender lid holder
4.
Front fender pad
>>D<<
5.
Front fender
>>C<<
6.
Front fender collar
>>C<<
7.
Front fender washer
>>B<<
8.
Rivets
9.
Reinforcement
10.
Bracket
11.
Plug
>>A<<
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Attached sheet 12 (5/6)
EXTERIOR
6
REMOVAL SERVICE POINT
<> RIVETS REMOVAL
<> RIVETS REMOVAL
Drill
Rivet
Front fender
DF2002IIAJ
Use a drill [φ 4.0 mm (0.16 inch)] to make a hole in the rivet to break it, and remove the rivet.
INSTALLATION SERVICE POINTS
>>A<< PLUG INSTALLATION
>>A<< PLUG INSTALLATION
1.Use Mitsubishi Motors Genuine Parts Cleaner (MZ100387) or equivalent to clean the attachment surface.
2.Apply the 3M™ K-500 primer or equivalent to the surface to which the plug is to be affixed before affixing the plug.
3.Attach the plugs from the inside of the front fender without gaps.
>>B<< RIVETS INSTALLATION

>>B<< RIVETS INSTALLATION
Rivet tool
Reinforcement,
Bracket
Front fender
1
Rivet
Portion A
2
3
Rivet tool
Flange
4
Rivet
DF2002IJAI
Use a rivet tool shown as in the illustration to connect the parts with rivets by the following procedures:
1.Insert the rivet into a corresponding location.
2.Set the rivet tool at a portion A of rivet.
3.While pushing the flange surface of the rivet onto parts to be fixed with the rivet tool, press the handle of the tool.
4.Thin part of portion A of the rivet will be cut off and the part is fixed in position.
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Attached sheet 12 (6/6)
EXTERIOR
>>C<< FRONT FENDER WASHER/FRONT FENDER COLLAR INSTALLATION
>>C<< FRONT FENDER WASHER/FRONT FENDER COLLAR INSTALLATION
Front fender
Front fender washer
Front fender
collar
DF2002FVAI
Fit the front fender collar to the front fender, and install the front fender washer to the front fender.
>>D<< FRONT FENDER INSTALLATION
>>D<< FRONT FENDER INSTALLATION
R-end
Front fender
200 (7.87)
C
200 (7.87)
C
D
D
E
E
F
F
265
(10.43)
215
(8.46)
R-end
Section C - C, D - D, E - E, F - F
Front fender
–
1.0 ± 0.4
(0.039 ± 0.015)
mm (in)
4.5 ± 0.9
(0.177 ± 0.035)
+

DF3000Y3AI
2.Install the front fender so that the gap between the hood and the front fender, and the front door and the front fender fit within the specified value shown in the illustration.
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Attached sheet 13 (1/2)
EXTERIOR
UNDER COVER
Removal and Installation
Removal and Installation
NOTE
1
* : Type A
2
* : Type B

6
4.0 ± 0.6 N·m
36 ± 4 in-lb
View C
Front fender protector
5*2
3
*
1
*
4
1
2
5.0 ± 2.0 N·m
44 ± 17 in-lb

3
2
View B
View A
Front fender protector
8.0 ± 1.2 N·m
71 ± 10 in-lb
DF2002J7AC00USA
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Attached sheet 13 (2/2)
EXTERIOR
View A (Kinds of clips and bolts)
A
A
B
: 63 clips (a)
: 1 clip (b)  or 1 nut 
A : 4 bolts (A)

B : 1 bolt (B)
DF2002J8AE00USA
View B (Kinds of clips)
View C (Kinds of clips)
: 9 Clips (a)
DF2002J8AA
Removal steps
4/17/2024
1.
Engine room under cover front B
2.
Engine room under cover front A
3.
Engine room side cover
4.
Engine room under cover rear
5.
Front floor bracket
6.
Floor under cover
22 of 34

(5397/MSB24M33_51_54-501)
Attached sheet 14
HEATER & AIR CONDITIONING SYSTEM
BASIC INSPECTION
LUBRICANT
Perform Lubricant Return Operation
CAUTION:

When the A/C compressor, condenser, accumulator or liquid tank is replaced, or when the refrigerant is refilled, perform the lubricant return operation before operating air
conditioning.

If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return operation.
1.Turn ON the IGN power supply.
2.Change the power supply mode to ON (READY indicator: OFF), then set the vehicle as follows.

A/C switch: ON

Blower air volume: 1/7

Temperature setting: 25C

3.Change the power supply mode to ON (READY indicator: ON), then operate the air conditioner for at least 2 minute.
4.Change the power supply mode of the electric motor switch to OFF.
5.Lubricant return operation is complete.
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Attached sheet 15
HEATER & AIR CONDITIONING SYSTEM
BASIC INSPECTION
PERFORMANCE TEST
Inspection
INSPECTION PROCEDURE
1. Connect recovery/recycling/recharging equipment (for HFC134a  or HFO-1234yf ) or manifold gauge.
2. Set the vehicle to the continuous idling mode, and set to the following condition. Refer to General Information - General Information - Precautions CONTINUOUS IDLING MODE.
Test condition

Surrounding condition
Indoors or in the shade (in a well-ventilated place)
Vehicle condition
A/C condition
Door
Open
Door glass
Full open
Hood
Open
Temperature control switch or dial
Full cold
A/C switch
ON
Air outlet
VENT (ventilation)
Intake door position
Recirculation
Fan (blower) speed
Maximum speed set

3. Maintain test condition until A/C system becomes stable. (Approximately 10 minutes)
4. Check that test results of “recirculating-to-discharge air temperature” and “ambient air temperature-to-operating pressure” are within the specified value.
5. When test results are within the specified value, inspection is complete.
If any of test result is out of the specified value, perform diagnosis by gauge pressure. Refer to LUBRICANT.
RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE TABLE
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature from center ventilator
Relative humidity
Air temperature
%
C (F)
30 – 80
C (F)
20 (68)
0 – 13 (32 – 55)
30 (86)
10 - 23 (50 – 73)
40 (104)
19 - 32 (66 – 90)
50 (122)
28 - 42 (82 – 108)
AMBIENT AIR TEMPERATURE-TO-OPERATING PRESSURE TABLE
Fresh air
Relative humidity
Air temperature
%
C (F)
Low-pressure (Suction side)
kPa (bar, kg/cm2, psi)
kPa (bar, kg/cm2, psi)
20 (68)
1,255 – 1,593 (12.55 – 15.93, 12.8 - 16.2, 182 231)
111 – 349 (1.11 – 3.49, 1.1 - 3.6, 16.1 - 50.6)
30 (86)
1,783 – 2,121 (17.83 - 21.21, 18.2 - 21.6, 258.6 307.6)
246 – 484 (2.46 – 4.84, 2.5 - 4.9, 35.7 - 70.2)
40 (104)
2,311 – 2,649 (23.11 – 26.49, 23.6 - 27.0, 335.2 384.2)
381 – 619 (3.81 – 6.19, 3.9 - 6.3, 55.3 - 89.8)
50 (122)
2,839 – 3,177 (28.39 – 31.77, 28.9 - 32.4, 411.7 460.8)
516 – 754 (5.16 – 7.54, 5.3 - 7.7, 74.8 - 109.4)
30 – 80
4/17/2024
High-pressure (Discharge side)
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Attached sheet 16
HEATER & AIR CONDITIONING CONTROL SYSTEM
SPECIAL FUNCTION
Setting change of each setting functions can be performed.
Function
name
Work support items
Description
Display
Setting
ECU
Information
–
Displays the part number of A/C amp.
–
–
Actuator Test
–
The signals used to activate each device are
forcibly supplied from A/C amp.
–
–
A/C amp. control temperature against set temperature can be set (-3.0)C/(-6)F
– (+3.0)C/(+6)F at a rate of 0.5C/1F per adjustment.
TEMP SET CORRECT
If the temperature felt by the customer is
different from the air flow temperature
controlled by the temperature setting, the A/C
amp. control temperature can be adjusted to
compensate for the temperature setting.
This item displayed, but cannot be used.
NOTE:
FRE MEMORY SET
This item displayed, but cannot be used.
When the FOOT mode is selected in the AUTO
control/MANUAL control of the A/C, the
activation/deactivation of the air blown from the
defroster can be changed.
AUTO control: Air blown from the defroster
O/A C/M*
MANUAL control: No air blown from the defroster
NOTE:
AUTO control: Air blown from the defroster
The values displayed on the M.U.T.III SE indicate the following
conditions.
BLOW SET
O/A O/M
MANUAL control: Air blown from the defroster
e.g.:
AUTO control: No air blown from the defroster
O/A C/M
C/A O/M
MANUAL control
Setting
change
MANUAL control: Air blown from the defroster
CLOSE: No air blown from the
defroster
AUTO control: No air blown from the defroster
AUTO control
C/A C/M
OPEN: Air blown from the defroster
MANUAL control: No air blown from the defroster
DF100C7PAE
TARGET EVAPORATOR
TEMP UPPER LIMIT
SETTING
STOP/START SYSTEM
OPERATION COND
SETTING
NOTE:
When −3.0C (−6F) is corrected on the temperature setting set as
25.0C (77F) the temperature controlled by A/C amp. is 25.0C
(77F) −3.0C (−6F) = 22.0C (72F) and the temperature becomes
lower than the temperature setting.
NOTE:
REC MEMORY SET

0.0C/0F*
Setting of upper limit value of target evaporator
temperature can be changed. Control
characteristic of A/C compressor control
(freezing protection control and refrigerant
discharge amount control) changes according
to change of the setting, and then operation
ratio of A/C compressor and refrigerant
discharge amount are changed. According to
change of the setting, control characteristic
focusing on the fuel consumption can be
adjusted to control characteristic focusing on
the cooling capacity.
DEFAULT*
Target evaporator temperature upper limit value: 10C (50F)
3C/37F
Target evaporator temperature upper limit value: 3C (37F)
5C/41F
Target evaporator temperature upper limit value: 5C (41F)
7C/45F
Target evaporator temperature upper limit value: 7C (45F)
NOTE:
This item displayed, but cannot be used.
NOTE:
AIR INLET CHANGE
SETTING
This item displayed, but cannot be used.
AIR FLOW REDUCTION
SETTING
This item displayed, but cannot be used.
NOTE:
*: Initial status
NOTE:
When the battery cable is disconnected from the negative terminal or when the battery voltage is 10 V or less, the setting for the work support item is set to the value stored 1 minute
after most recent electric motor switch OFF status.
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Attached sheet 17
BODY CONTROL SYSTEM
REMOVAL AND INSTALLATION
BCM
Removal and Installation
CAUTION:
When the BCM is replaced, perform the additional service procedures. Refer to ADDITIONAL SERVICE WHEN REPLACING BCM.

Pre-removal and Post-installation Operation
Instrument Lower Panel Assembly Removal and Installation (Refer to Instrument Panel
Driver's Side ).

Steering member
1
DF2002P4AA
Removal steps
4/17/2024

Slide fuse block (J/B) to the back to remove it.
1.
BCM
26 of 34
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Attached sheet 18 (1/3)
CIRCUIT DIAGRAM
SMARTPHONE LINK DISPLAY AUDIO 
SMARTPHONE LINK DISPLAY AUDIO 
FRONT DOOR
SPEAKER LH
FUSIBLE LINK
(12V BATTERY)
FRONT
SQUAWKER LH
FRONT
SQUAWKER RH
FRONT DOOR
SPEAKER RH
REAR DOOR
SPEAKER RH
REAR DOOR
SPEAKER LH
CUT OFF
SWITCH
FUSE
BLOCK
(J/B)
J/C-M03
USB
ADAPTER
AV CONTROL
UNIT
8CH CAN GATEWAY

MICROPHONE

DF3000KHAB
4/17/2024
27 of 34
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Attached sheet 18 (2/3)
CIRCUIT DIAGRAM
SMARTPHONE LINK DISPLAY AUDIO  (CONTINUED)
FUSE
BLOCK
(J/B)
NOTE
*: INDICATES A WIRING CONNECTOR
WHICH IS INSIDE THE EQUIPMENT AND
WHICH IS NOT SHOWN IN THE WIRING
HARNESS CONFIGURATION DIAGRAM.
ACC
RELAY
J/C-M04
ANTENNA BASE
SATELLITE
ANTENNA
ANTENNA
AMP.
*
GPS
ANTENNA
*
*
AV CONTROL
UNIT
COMBINATION
METER
Indicator light/Warning light
·Information display
·Master warning light
*
$ *
$ *
USB CABLE
LVDS CABLE
SPIRAL
CABLE
*
USB CABLE
$
CPU
$ *
AROUND VIEW
MONITOR
CONTROL UNIT
STEERING SWITCH
$ *
$ *
USB ADAPTER
TCU


4/17/2024
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DF4001ZTAC
Attached sheet 18 (3/3)
CIRCUIT DIAGRAM
SMARTPHONE LINK DISPLAY AUDIO  (CONTINUED)


DF3000KKAB
4/17/2024
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Attached sheet 19 (1/3)
CIRCUIT DIAGRAM
SMARTPHONE LINK DISPLAY AUDIO 
SMARTPHONE LINK DISPLAY AUDIO 
FRONT DOOR
SPEAKER LH
FUSIBLE LINK
(12V BATTERY)
FRONT
SQUAWKER LH
FRONT
SQUAWKER RH
FRONT DOOR
SPEAKER RH
REAR DOOR
SPEAKER RH
REAR DOOR
SPEAKER LH
CUT OFF
SWITCH
FUSE
BLOCK
(J/B)
J/C-M03
USB
ADAPTER
AV CONTROL
UNIT
8CH CAN GATEWAY
MICROPHONE


DF3000KHAB
4/17/2024
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(5397/MSB24M33_51_54-501)
Attached sheet 19 (2/3)
CIRCUIT DIAGRAM
SMARTPHONE LINK DISPLAY AUDIO  (CONTINUED)
FUSE
BLOCK
(J/B)
NOTE
*: INDICATES A WIRING CONNECTOR
WHICH IS INSIDE THE EQUIPMENT AND
WHICH IS NOT SHOWN IN THE WIRING
HARNESS CONFIGURATION DIAGRAM.
ACC
RELAY
J/C-M04
ANTENNA BASE
SATELLITE
ANTENNA
ANTENNA
AMP.
*
GPS
ANTENNA
*
*
AV CONTROL
UNIT
COMBINATION
METER
Indicator light/Warning light
·Information display
·Master warning light
*
$ *
$ *
USB CABLE
LVDS CABLE
SPIRAL
CABLE
*
USB CABLE
$
CPU
$ *
AROUND VIEW
MONITOR
CONTROL UNIT
STEERING SWITCH
$ *
$ *
USB ADAPTER
TCU


4/17/2024
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(5397/MSB24M33_51_54-501)
DF4001ZTAC
Attached sheet 19 (3/3)
CIRCUIT DIAGRAM
SMARTPHONE LINK DISPLAY AUDIO  (CONTINUED)


DF3000KKAB
4/17/2024
32 of 34
(5397/MSB24M33_51_54-501)
Attached sheet 20
CIRCUIT DIAGRAM
SMARTPHONE LINK DISPLAY AUDIO  (CONTINUED)
FUSE
BLOCK
(J/B)
NOTE
*: INDICATES A WIRING CONNECTOR
WHICH IS INSIDE THE EQUIPMENT AND
WHICH IS NOT SHOWN IN THE WIRING
HARNESS CONFIGURATION DIAGRAM.
ACC
RELAY
J/C-M04
ANTENNA BASE
SATELLITE
ANTENNA
*
ANTENNA
AMP.
*
GPS
ANTENNA
*
AV CONTROL
UNIT
Indicator light/Warning light
·Information display
·Master warning light
$ *
*
USB CABLE
LVDS CABLE
SPIRAL
CABLE
$ *
$ *
USB CABLE
COMBINATION
METER
CPU
$ *
AROUND VIEW
MONITOR
CONTROL UNIT
STEERING SWITCH
$ *
USB ADAPTER
$ *
TCU


4/17/2024
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DF4001ZXAB
Attached sheet 21
CIRCUIT DIAGRAM
MULTI AROUND VIEW MONITOR
MULTI AROUND VIEW MONITOR
FUSE
BLOCK
(J/B)
SONAR CONTROL UNIT
ACC
RELAY
CALIBRATION CONNECTOR
J/C-B02
J/B-B07
J/C-B04A
·ADAS
CONTROL
UNIT 2
·CHASSIS
CONTROL
MODULE
AROUND VIEW
MONITOR
CONTROL UNIT
$
AV CONTROL UNIT

*
*
FRONT
CAMERA
DOOR
MIRROR LH
*
*
DOOR
MIRROR RH
REAR
CAMERA
NOTE
*: INDICATES A WIRING CONNECTOR
WHICH IS INSIDE THE EQUIPMENT AND
WHICH IS NOT SHOWN IN THE WIRING
HARNESS CONFIGURATION DIAGRAM.
DF4001ZZAD
4/17/2024
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