Honda CR-VVehicle Fitting Instructions

MHFK409Please pay particular attention to pages 2 & 3 when

Working on Electric or Hybrid Vehicles

Rev. E Aug 2021

ICE (Internal Combustion Engine - Petrol/Diesel)

EV (Electric Vehicle)

PHEV (Plug-In Hybrid Electric Vehicle)

HEV (Hybrid Electric Vehicle)

mHEV (Mild Hybrid Electric Vehicle)

2

Introduction• Electric and Hybrid vehicles introduce hazards into the workplace

in addition to those normally associated with vehicle adaptation activities.

These include:• The presence of high voltage components and cabling capable of

delivering a fatal electric shock.• The storage of electrical energy with the potential to cause

explosionorfire.• Components that may retain a dangerous voltage even when a vehicle is

switchedoff.• Electric motors or the vehicle itself that may move unexpectedly due to

magnetic forces within the motors.• The potential for the release of explosive gases and harmful liquids if batteries

aredamagedorincorrectlymodified.• The possibility of people being unaware of vehicles moving as when

electrically driven they are silent in operation.• Thepotentialfortheelectricalsystemsonthevehicletoaffectmedical

devices such as pacemakers.

DO NOT work on vehicle if any of these Warning signs are showing

Essential requirements• YoumustbequalifiedtoworkonElectric/HybridvehiclestoIMIlevel3or

equivalent.• YoumustusethelatestadaptationinstallationinstructionsandOEMvehicle

model information.• You must use appropriate Tools.• Drill depth limiters.• No sharp tools used when routing the adaptation power line.

Before you start1. Identifywherethevehiclewillbeplacedbeforeyoustartanywork,sothatyou

do not have to move it once you have started work.2. Visually inspect the vehicle for any signs of damage. Do not work on a

damaged vehicle as there may be damage to the High Voltage lines.3. Checkthedashforwarningsymbols.Agenericexampleisshownalthough

you should check the vehicle manual for exact information:

Procedure for working on Electric/Hybrid Vehicles (dedicated adaptation kits) Procedure for working on Electric/Hybrid Vehicles (dedicated adaptation kits)

This means any vehicle with a High Voltage system (50-1000v DC) and Mild Hybrids (Typically 48v DC but can vary)

InsulationFail

InsulationFail

High Voltage Fault

3

4. Open the boot or other doors you need to install the adaptation.5. Turnthevehicleoff.Removetheignitionfobtoalocationatleast6maway ensuring the vehicle cannot activate at that distance. Place in a locked keybox. Remove any jewellery prior to commencing work.6. Disconnectthe12Vbatterynegative.Securethenegativeleadsoitcannot accidentally reconnect. Wait 10 minutes. 7. Before you start any work identify the vehicle model and check the location of the high voltage (HV) cable runs and components. ABC mobility Group providehighvoltagediagramsinmodelspecificinstallationinstructions. IfyoudonothavethediagramsthenAppssuchas“Eurorescue”and“Crash recoverysystem”canhelp,otherwiseemail: electricvehiclecheck@abcmobilitygroup.co.uk who will provide a diagram showing the HV layout (A maximum of 24 hour working day turnaround). BeawaretheOEMvehiclemanufacturerscanchangetheirspecificationat anytimewithoutnotice.Ifyouareinanydoubt,contacttheOEMvehicle manufacturer directly.

Do not try to feed a power cable through a grommet which contains HV cables.

IntheeventyouareworkingadjacenttoHighVoltage(HV)components, includingcabling,youmusttakegreatcarenottodamageanyelements of the HV system. The adaptation must always be clear of any HV component.

MildHybridvehiclestypicallyuseblackelectriccablingasopposedto coloured conduit cabling used for high voltage Electric vehicles. Electric cable routing diagrams are not available for these models from ABC mobility group.

8. The adaptation can now be safely installed as detailed.

Procedure for working on Electric/Hybrid Vehicles (dedicated adaptation kits)

Emergency procedures• Intheeventyoudamagethebatterythereisthepossibilityoffireandyou shouldcontactthefireservice.Stayatleast6mawayfromthevehicleastoxic fumes may be emitted.• IntheeventyoudamageanotherHVcomponentorcablethencontactthe vehicle manufacturer directly for advice. Do not use the vehicle or reconnect the HV system as there is the risk of electric shock.

4

Honda CR-V ICE

Electro

High Voltage Electro Greater than 60v

Electric or Electronic (SRS) Components

High Voltage Electric or Electronic Components Greater than 60v

Right Hand Drive Vehicle Left Hand Drive Vehicle

Procedure for working on Electric/Hybrid Vehicles (dedicated adaptation kits)

Electro

High Voltage Electro Greater than 60v

Electric or Electronic (SRS) Components

High Voltage Electric or Electronic Components Greater than 60v

Honda CR-V HEV

Electro

High Voltage Electro Greater than 60v

Electric or Electronic (SRS) Components

High Voltage Electric or Electronic Components Greater than 60v

Right Hand Drive Vehicle Left Hand Drive Vehicle

Electro

High Voltage Electro Greater than 60v

Electric or Electronic (SRS) Components

High Voltage Electric or Electronic Components Greater than 60v

All Vehicle schematics provided by:

All images correct at the date of issue. You must verify the diagrams are as the vehicle model you are installing into

5

Prior to installation. Fold the rear seats down.

Remove the two tie down lugs located at the frontoftheboot/trunkandremovethefalsefloorpanel.

Remove the plastic cover from the Rear seats. Plastic cover shown removed.

Removetheboot/trunksilltrim. The right hand rear seat mounting point will beusedfortheFrontMounting.

WARNING: The HEV version will have a cover over the High Voltage Battery as shown.

HEV Model

6

AligntheTopMountingwiththesidepaneland mark the hole location.

TopMountingassembly(looseparts). TopMountingassembly(assembled).

Remove the right rear door sill trim. Remove the rear quarter panel trim.

Screwthethreadedhexwiththespreaderplate and fully tighten.

Place the spreader plate with captive nut behind the panel.

Remove the A-frame and drill a 10mm hole.

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AligntheA-frameFrontMountingwiththeexisting hole.

StandtheA-frameinplace.MarktheRearFoot tab outline on the side panel trim as this will need trimming.

Remove the A-frame and trim the side panel trim.View after trimming.

StandtheA-framebackinposition.Notethatthe highlighted section of the Rear foot sits underneaththetrim.Marktheholeposition.

Drill a 10mm hole as marked.

AligntheTopMountingwiththerearquarterpanel trim and mark the hole location.

RemovetheA-frameanddrilla30mm(11/8”)cut out in the marked hole location.

FrontMountingfixing.

8

Refittherightreardoorsilltrim.

Refittherearquarterpaneltrim. Place the A-frame in position. Loosely tighten theFrontandTopMountings.

Rear mounting assembly (loose parts).

Refittheboot/trunksilltrim.

Rear mounting assembly (assembled).

Place the spreader plate underneath the car and seal with silicone. Fully tighten the screws.

Fully tighten all mounting points.

9

SmartLifterLPRange.

SmartLifterLCRange.

TrimthefalseflooraroundtheRearMounting.Finished A-frame installation.

10

There is a wiring grommet behind the brake fluidreservoir.

Wire up using the in-line fuse to the positive terminal of the battery.

Guide to routing the power cable

There is a wiring grommet behind the brake fluidreservoir.WARNING: The Highlighted orange conduit is high voltage.

Wire up using the in-line fuse to the positive terminal of the battery.WARNING: The Highlighted orange conduit is high voltage.

HEV Guide to routing the power cable