3rd party battery for 2014 Outlander

[fresh-milk]

I am well over my skis on this, but I bought a 2014 Outlander and it's in great condition but

• EV range is 20km / 12 miles
• New Zealad has tax based on electric mileage (Road User Charge or RUC)
• Outlander only as an ICE means paying mileage tax twice, once on the petrol/gas and again on the RUC / EV tax.
• Outlander 2014 uses Yuasa LEV40 cells which are now discontinued.
• Based on Yuasa website LEV46 and LEV65 are used in newer models

So my question is, if I look for new batteries what are the key technical specs that I have to match?

1. Am I right that only (1) & (2) below need to be exact?
2. More capacity = more better?
3. Will the BMS "see" more capacity?
4. Can I mix and match cells? ie 50% LEV40 and 50% LEV65
5. Or they all need to be the same type but battery condition can vary based on luck

Yuasa official specs

1. Voltage
   1. LEV40 3.75v
   2. LEV46 3.75v
   3. LEV65 3.70v
   4. Is there a +/- tolerance or does it need to be exactly 3.75v?
2. Connectors
   1. M8 terminal 9-13 NM
3. Dimensions - exact or slightly smaller
   1. LEV40 171 x 34 x 108mm
   2. LEV46 171 x 34 x 108mm
   3. LEV65 171 x 34 x 103mm
   4. X & Y more important that Z height (ie width & depth vs height)
   5. And so long as under it will fit. Any looseness solved with shims.
4. Voltage Range
   1. LEV40 2.75 - 4.1v
   2. LEV46 2.75 - 4.1v
   3. LEV65 2.75 - 4.25v
   4. Is there a +/- tolerance or does it need to be exact?
5. Resistance
   1. LEV40 1.0 mΩ
   2. LEV46 1.0 mΩ
   3. LEV65 0.7 mΩ
   4. Is there a +/- tolerance or does it need to be exact?
6. Capacity
   1. LEV40 40Ah
   2. LEV46 46Ah
   3. LEV65 64Ah
   4. Is the onboard BMS able to recognise and use any extra capacity / range?

 

[crun]

Also in Auckland NZ, and looking at this.
Electrically, the discharge current rating (500A) and the cell resistance (1mohm) may matter.
Since your Itchy can't fast charge, you don't have to worry about that rating.
I'm not sure what the maximum current drawn from the battery is - mine was never especially powerful on full electric. Lets say 50kW, then Ibatt~=170A

If the cells have a higher max voltage, then they will have less capacity than the rating by a little (and irrelevant) bit, as they won't be charged quite as fully.

A questions is how much work you are prepared to do to adequately restrain smaller cells in the same space. Pity you can't just get a new set of LEV46s and do a like for like swap.