NISSAN LEAF Dismantling Guide 2013

2013 LEAF

Dismantling Guide

®  

Foreword

This manual describes dismantling operations and related warnings for this vehicle. This vehicle is an electrically driven car equipped with a high voltage battery pack. Failure to follow

recommended practices during dismantling will cause death or serious personal injury.

Please read this manual in advance in order to understand the features of this vehicle and to help you deal with dismantling operations involving this vehicle. Follow the procedures in order to help assure a safe and successful dismantling operation. This manual is periodically updated. If you are not viewing this manual on the Nissan web site, we urge you to go to www.nissanusa.com or www.nissan-techinfo.com to make sure you have the most recent version of this

manual.

NISSAN EMERGENCY CONTACT INFORMATION

• Nissan EV Customer Support: 1-877-664-2738 (Hours of operation are Monday-Friday 7am - 7pm, Saturday 8am - 4:30pm Central time zone)

• Nissan Consumer Affairs: 1-800-647-7261 (US) or 1-800-387-0122 (Canada) (Hours of operation are 8am - 5pm (Monday-Friday) Eastern, Central and Pacific time zones)

IMPORTANT INFORMATION ABOUT THIS MANUAL

You may see various symbols in this manual. They have the following meanings:

This symbol is used to inform you of an operation which will result in death or serious personal injury if instructions are not followed.

Example: Touching high voltage components without using the appropriate protective equipment will result in electrocution.

This symbol is used to inform you of an operation which may cause death or serious personal injury if instructions are not followed.

This symbol is used to inform you of an operation which may cause personal injury or component damage if instructions are not followed.

Please note that there may be differences between this manual and the vehicle specification due to specification changes.

Table of Contents

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

NISSAN EMERGENCY CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

IMPORTANT INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. ABOUT THE NISSAN LEAF® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1-1 LEAF IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1-1.1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1-1.2. INTERIOR COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-2 VEHICLE IDENTIFICATION NUMBER (VIN) LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1-3 WARNING AND INDICATOR LAMP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2. BASIC HIGH VOLTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-1 HIGH VOLTAGE-RELATED AND 12V-RELATED COMPONENT LOCATIONS AND

DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-1.1. LI-ION BATTERY PACK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-2 HIGH VOLTAGE SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-2.1. WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-3 HIGH VOLTAGE CIRCUIT SHUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2-4 PREVENTING ELECTRICAL SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3. PREPARATION FOR DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3-1 DISCHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3-2 PREPARATION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-3 HIGH VOLTAGE SYSTEM SHUT-DOWN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3-3.1. REMOVING THE CHARGE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3-3.2. INDICATIONS THE HIGH VOLTAGE SYSTEM IS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3-3.3. POWERING DOWN THE HIGH VOLTAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3-3.4. PRIMARY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3-3.5. ALTERNATE PROCEDURE 1 (REMOVE FUSES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3-3.6. ALTERNATE PROCEDURE 2 (REMOVE SERVICE PLUG) . . . . . . . . . . . . . . . . . . . . . . . 23

3-4 CUTTING THE VEHICLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3-4.1. SRS AIR BAG SYSTEM COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3-4.2. VEHICLE CUT SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3-4.3. WATER SUBMERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3-4.4. VEHICLE FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3-5 LI-ION BATTERY DAMAGE AND FLUID LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4. JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4-1 JUMP STARTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4-2 P (PARK) POSITION RELEASE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4-2.1. RESET PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4-3 STORING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5. DISMANTLING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5-1 PRECAUTIONS FOR HANDLING HIGH VOLTAGE LITHIUM ION (LI-ION) BATTERY . . . . . . . . 36

5-2 PERSONAL PROTECTIVE EQUIPMENT (PPE) AND INSULATED TOOLS . . . . . . . . . . . . . . . . 37

5-2.1. PERSONAL PROTECTIVE EQUIPMENT (PPE) PROTECTIVE WEAR CONTROL . . . . . 37

5-2.2. DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5-2.3. INSULATED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5-3 LITHIUM-ION (LI-ION) BATTERY PACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5-3.1. EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5-3.2. REMOVAL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5-4 RECOVERY/RECYCLING OF THE LI-ION HIGH VOLTAGE BATTERY . . . . . . . . . . . . . . . . . . . 43

1. About The Nissan LEAF®

This vehicle uses two types of batteries. One is a 12V battery that is the same as the battery in vehicles powered by internal combustion engines, and the other is the Lithium-ion (Li-ion) battery (high voltage) for the traction motor which propels the vehicle. The Li-ion battery is encased in steel and mounted underneath the vehicle.

The vehicle must be plugged-in in order for the Li-ion battery to be recharged. Additionally, the vehicle system can recharge the Li-ion battery by converting driving force into electricity while the vehicle is decelerating or being driven downhill. This is called regenerative charging. This vehicle is considered to be an environmentally friendly vehicle because it does not emit exhaust gases.

1-1 LEAF Identification

1-1.1 Exterior

The specific exterior identification features are indicated as follows:

LEAF identification from underside:

1. Plastic shields cover entire underside.

2. No exhaust system components.

No tail pipe

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1-1.2 Interior Component Location

Interior components referenced in this manual are as follows:

Charging indicator lights

READY indicator (green)

Charge connector lock switch

Hood release

Power switch

Selector lever

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1-2 Vehicle Identification Number (VIN) Layout

The vehicle identification number can be located as follows:

Example VIN : 1N4A Z0CPZDC055126

The LEAF is identified by the 5thalphanumeric character: Z

Z = Electric vehicle

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1. VIN plate (visible through windshield) 2. Vehicle certification plate (lower center pillar)

1-3 Warning and Indicator Lamp Information

The following warning and indicator lamps are located in the instrument cluster.

Lamp Name Icon Description

READY Indicator This lamp is on when the EV system is powered up and the

vehicle is ready to drive.

EV System Warning Lamp *1

Master Warning Lamp (RED) This lamp is on when another red warning lamp is displayed in

• Malfunction has occurred in the EV system and/or

• Emergency shut-off system has been activated. The shutoff system activates in the following conditions:

– Front and side collisions in which the air bags are

deployed. – Certain rear collisions. – Certain EV system malfunctions.

the instrument cluster or a warning is displayed on the dot matrix LCD.

Master Warning Lamp (YELLOW)

This lamp is on when:

• Li-ion battery is getting low on charge.

• A yellow warning lamp is displayed in the instrument cluster or a message is displayed on the dot matrix LCD.

*1: When this lamp is ON, the ready lamp will turn OFF.

2. Basic High Voltage Information

2-1 High Voltage-Related and 12V-Related Component Locations and

Descriptions

3 4

Underside View Shown

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NOTE:

Components with white number in black background are high voltage components.

No. Component Location Description

a Charge port Under hood Connecting port for EVSE (Electric Vehicle

Supply Equipment). Two ports are available: Normal charge and quick charge (if so equipped).

b High voltage

cables

Under hood and undercarriage

Orange-colored power cables carry high voltage current between each of the high voltage components.

c Traction Motor Under hood Converts three-phase AC power to drive

power (torque) which propels the vehicle.

Inverter Under hood Converts the DC power stored in the Li-ion

battery to three-phase AC power and controls motor torque (revolution) by regulating the motor current.

Electric air condi-

Under hood Air conditioner compressor

tioner compressor Power Distribution

Module (PDM)

• On Board Charger

• DC/DC Converter

• High voltage junction box (J/B)

Under hood

The PDM includes an On Board Charger, DC/DC converter and high voltage junction box (J/B).

The On Board Charger converts single-phase AC power from a home power outlet to DC power and increases the voltage in order to charge the Li-ion battery. The DC/DC converter reduces the voltage of the Li-ion battery to provide power to the 12V battery in order to operate the vehicle’s electric components (headlights, audio system, etc.). The J/B provides electric power from the Li-ion battery to all high voltage parts of the vehicle.

d 12V Battery Under hood A lead-acid battery that supplies power to the low

voltage devices.

e Cabin heater Interior (This unit is

installed behind the

This is the electric heat source for the cabin heater. It heats the interior of the vehicle.

instrument panel)

f Li-ion (Lithium ion)

battery

g High voltage battery

service disconnect

h Brake power supply

backup unit

Undercarriage Stores and outputs DC power (Maximum voltage

398.4V) needed to propel the vehicle.

Rear seat floor Isolates the battery from the rest of the high volt-

age electrical system.

Cargo area (This unit is installed behind a trim panel to prevent

Power supply backup unit for the brake system. It supplies power to the brake system if a malfunction occurs in the 12V battery.

access)

2-1.1 Li-ion Battery Pack Specifications

Li-ion battery voltage

(240V - 398.4V usable range)

360V nominal

Number of Li-ion battery modules in the pack 48 Li-ion battery dimensions 60.91 x 46.77 x 10.39 in. (1547 x 1188 x 264 mm) Li-ion battery weight 606 lbs (275 kg)

2-2 High Voltage Safety Measures

Circuit insulation The high voltage positive (+) and negative (-) circuits are insulated

from the metal chassis.

Reducing the risk of electrocution The high voltage components and harnesses have insulated cases or

orange-colored coverings which provide insulation and easy identification.

The high voltage battery case is electrically connected to the vehicle ground. This connection helps protect the vehicle occupants and vehicle dismantlers from high voltage electrical shock.

Identification The high voltage components are labeled “WARNING” similar to label

shown below. All high voltage harnesses are coated in orange.

2-2.1 Warning Label

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2-3 High Voltage Circuit Shut-Off System

The high voltage can be shut off by the following methods:

Service plug Positioned in the center area of the Li-ion battery, this shuts off output high

voltage when manually removed.

System main relay Controlled by the power switch, this relay, which is controlled by the 12V

system, shuts off the high voltage from the Li-ion battery.

Emergency shut-off system

Charging connector Some of the high voltage components are activated during charging. Remove

In the case of a collision (front and side collisions in which the air bags are deployed, certain rear collisions) or certain system malfunctions this system may shut off the high voltage from the Li-ion battery.

the charging connector to deactivate these components.

2-4 Preventing Electrical Shock

1. If it is necessary to touch any of the high voltage harnesses or components, you must always wear appropriate Personal Protective Equipment (PPE) (refer to 3-2 Preparation Items) and shut off

the high voltage system by referring to 3-3 High Voltage System Shut-Down Procedures.

2. To avoid the risk of electrocution, do not touch the inside of the Li-ion battery unless appropriate PPE is worn even after shutting off the high voltage system. The Li-ion battery maintains charge even though the high voltage system is shut down.

3. Cover any damaged high voltage components with insulated tape.

3. Preparation for Dismantling

• Failure to properly shut down the high voltage electrical system before the Dismantling Procedures are performed will result in serious injury or death from electrical shock. To prevent serious injury or death, DO NOT touch high voltage harnesses or components without always wearing appropriate Personal Protective Equipment (PPE).

• If it is necessary to touch any of the high voltage harnesses or components you must always wear appropriate PPE to avoid electrical shock. Shut down the high voltage system by following the steps outlined in 3-3 High Voltage System Shut-Down

Procedures. Wait at least ten (10) minutes for complete discharge of the high voltage

capacitor after the high voltage system has been shut down.

• NEVER assume the LEAF is shut OFF simply because it is quiet.

• If it becomes necessary for the dismantler to leave the vehicle, place a “DANGER” sign (for example, refer to vehicle contains a high voltage battery.

• If the READY indicator or charging indicator are ON, the high voltage system is active.

• If possible, be sure to verify that the READY indicator on the instrument cluster is OFF and the high voltage system is stopped.

4-3 Storing the Vehicle) on the vehicle to alert other people that the

3-1 Discharging Procedures

Do not perform this procedure if the battery is damaged. If you are unsure of battery damage, use extreme caution and wear appropriate Personal Protective Equipment (PPE).

Li-ion battery discharging must take place before dismantling. Sufficient discharging can be achieved by following these steps.

1. Place the selector lever into the Park (P) position

2. Apply the parking brake.

3. Set wheel chocks to ensure the vehicle is completely immobilized.

4. Apply foot brake and press the ignition switch to turn the system ON. Confirm READY indicator in instrument cluster turns ON.

LOCK

Acc

(OFF)

5. Check Li-ion battery available charge gauge:

Brake

MPH

POWER

120miles

0.0miles

miles

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1 2

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a. If remaining energy (1) shows higher than half full (7 of 12 gauge lines lit up), continue to

next step.

b. If remaining energy (2) shows lower than half full (6 of 12 gauge lines lit up), discharging is

not needed.

6. Turn ON electric devices such as headlamps, cabin heater (set to the highest temperature and maximum fan speed; do not use AUTO A/C setting), navigation system and rear window defogger to discharge the Li-ion battery. Allow approximately 30 minutes for each line on the available charge gauge to drop. Discharge is complete when the available charge gauge drops to lower than half full (6 of 12 gauge lines lit up).

7. Press the power switch to turn the system OFF.

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