Mitsubishi Outlander PHEV LEV40 Battery Retrofit Project

Client name: European PHEV repair garages & private car owners
Location: Europe
Product: EVE 3.7V 59Ah prismatic cells with custom studs, 3D‑printed brackets and EVA shock‑absorbing foam
Brand: Starmax Energy
Manufacturer: Shenzhen Starmax Energy Technology Co., Ltd.
Application Scenario: Battery replacement & upgrade for Mitsubishi Outlander PHEV, replacing aged GS Yuasa LEV40 original cells。

Executive Summary

Mitsubishi Outlander PHEV original traction battery uses GS Yuasa LEV40 40Ah prismatic cells. After long‑term cycling, capacity declines and pure‑electric EV range shrinks significantly. OEM replacement is very expensive. Starmax Energy provides EVE 59Ah upgrade kit including customized stud terminals, 3D‑printed positioning brackets and EVA foam accessories. New cells fit inside the original 300×175×125 mm module housing. Configured as 8S10P (29.6 V, ~18 kWh), real‑world pure‑electric driving mileage reaches 70‑95 km. It creates an affordable aftermarket option instead of costly dealer OEM battery packages。

Challenges

1. Original LEV40 cell degradation: Capacity loss leads to frequent engine intervention, short EV‑mode driving distance.
2. Dimension & mounting gap: Standard EVE 59Ah cell cannot directly lock into the original plastic module shell due to different terminal position and outer dimension.
3. High official replacement price: 4S OEM new battery packs cost a large amount for most Outlander PHEV owners.
4. Assembly stability risk: Without positioning support, loose cells inside module may bring vibration risk during vehicle driving.
5. System adaptation: Vehicle factory BMS needs local technician adjustment after cell capacity upgrade under 8S10P topology.

Solution

1. Grade‑A EVE 3.7V 59Ah NMC prismatic cells, equipped with custom‑welded M8 stud terminals matching original LEV40 mounting hole distance.
   Specs: 0.86 kg per cell; internal resistance ≤0.7 mΩ; cycle life ≥2000 cycles.

2. Supporting accessories: 3D‑printed insulating brackets and EVA shock‑absorbing foam. Accessories fix cells tightly inside original module shell, eliminate vibration risk during driving for 8S10P
3. Cell sorting: Every cell goes through capacity, voltage and internal‑resistance screening before delivery to guarantee pack consistency. Full‑set module weight after assembly is 7.75 kg, fits original module outer dimension.
4. Technical guidance: Supply assembly reference photos and community retrofit resources. Clarify that BMS / SOC adjustment work shall be finished by local EV repair shops.
5. Provide sea freight DDP logistics option for full‑set orders shipped to European ports.
   
   
   

Implementation & Results

1. Mechanical fitting: With custom studs + 3D brackets + EVA foam, new cells fit perfectly into original Outlander PHEV battery modules for 8S10P build, no casing modification.
2. Range performance: Real‑road test shows pure‑electric EV range 70‑95 km, greatly improving daily zero‑emission commuting capability.
3. Vibration & safety: 3D‑printed brackets and damping foam lock cells firmly inside module housing to resist road vibration.
4. Cost advantage: Complete kit plus local installation cost is substantially cheaper than purchasing OEM brand‑new battery assembly.
5. After‑sale boundary: Starmax supplies cells and mechanical fitting accessories. High‑voltage assembling, BMS parameter matching work relies on local professional EV technicians.
   
   
   
   
   

Conclusion

Starmax Energy’s EVE 59Ah upgrade kit is a cost‑effective aftermarket retrofit solution for ageing Mitsubishi Outlander PHEV. Custom stud terminals plus 3D‑printed fixing accessories solve mechanical compatibility challenge for 8S10P topology, enabling higher‑capacity cells to reuse original battery housing. End‑users get longer pure‑electric driving range without paying premium OEM prices. Professional EV workshop installation is strongly recommended for high‑voltage assembly and vehicle system calibration。

Welcome to contact us:
Shenzhen Starmax Energy Technology Co., Ltd.
WhatsApp/Wechat/Mobile: +86 14704451321
Email: support@szxhbattery.com
Website: www.szxhbattery.com 


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