Nissan Leaf 2010 User Manual

Page 1

Edition: November 2010 Publication No. SM1E-1ZE0U0

All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, recording or otherwise, without the prior written permission of NISSAN MOTOR CO., LTD.

QUICK REFERENCE INDEX

GENERAL INFORMATION

B ENGINE

C ELECTRIC POWER TRAIN

D TRANSMISSION & DRIVELINE

E SUSPENSION

F BRAKES

G STEERING

H RESTRAINTS

I VENTILATION, HEATER & AIR

CONDITIONER

J BODY INTERIOR

K BODY EXTERIOR, DOORS,

ROOF & VEHICLE SECURITY

L DRIVER CONTROLS

M ELECTRICAL & POWER CON-

TROL

N DRIVER INFORMATION &

MULTIMEDIA

O CRUISE CONTROL &

DRIVER ASSISTANCE

P MAINTENANCE

General Information

Engine Mechanical

Engine Lubrication System

Engine Cooling System

Engine Control System

Fuel System

Exhaust System

STR

Starting System

HBC

Hybrid Control System

HBB

Hybrid Battery System

HBR

Hybrid Brake System

EVC

EV Control System

TMS

Traction Motor System

EVB

EV Battery System

Vehicle Charging System

HCO

High Voltage Cooling System

ACC

Accelerator Control System

Clutch

Transaxle & Transmission

DLN

Driveline

FAX

Front Axle

RAX

Rear Axle

FSU

Front Suspension

RSU

Rear Suspension

SCS

Suspension Control System

Road Wheels & Tires

Brake System

Parking Brake System

BRC

Brake Control System

Steering System

STC

Steering Control System

Seat Belt

SBC

Seat Belt Control System

SRS Airbag

SRC

SRS Airbag Control System

VTL

Ventilation System

Heater & Air Conditioning System

HAC

Heater & Air Conditioning Control System

INT

Interior

Instrument Panel

Seat

ADP

Automatic Drive Positioner

DLK

Door & Lock

SEC

Security Control System

Glass & Window System

PWC

Power Window Control System

Roof

Hood

EXT

Exterior

BRM

Body Repair

MIR

Mirrors

EXL

Exterior Lighting System

INL

Interior Lighting System

Wiper & Washer

DEF

Defogger

HRN

Horn

VSP

Approaching Vehicle Sound for Pedestrians (VSP)

PWO

Power Outlet

BCS

Body Control System

LAN

LAN System

PCS

Power Control System

CHG

Charging System

Power Supply, Ground & Circuit Elements

MWI

Meter, Warning Lamp & Indicator

WCS

Warning Chime System

Sonar System

Audio, Visual & Navigation System

CCS

Cruise Control System

DAS

Driver Assistance System

DMS

Drive Mode System

Maintenance

C D

Page 2

FOREWORD

This manual contains maintenance and repair procedure for the 2011 NISSAN LEAF.

In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.

All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or pa rts which are not specifically recommended by NISSAN must first be completely sat isfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service

method selected.

Page 3

PLEASE HELP MAKE THIS SERVICE MANUAL BETTER!

Your comments are important to NISSAN and will help us to improve our Service Manuals.

Use this form to report any issues or comments you may have regarding our Service Manuals.

Please print this form and type or write your comments below. Mail or fax to:

Nissan North America, Inc. Technical Service Information 39001 Sunrise Drive, P.O. Box 9200 Farmington Hills, MI USA 48331 FAX: (248) 488-3880

SERVICE MANUAL: Model: Year:

PUBLICATION NO. (Refer to Quick Reference Index ):

Please describe any Service Manual issues or problems in detail:

Page number(s)

Note: Please include a copy of each page, marked with your comments.

Are the trouble diagnosis procedures logical and easy to use? (circle your answer) YES NO

If no, what page number(s)?

Note: Please include a copy of each page, marked with your comments.

Please describe the issue or problem in detail:

Is the organization of the manual clear and easy to follow? (circle your answer) YES NO

Please comment:

What information should be included in NISSAN Service Manuals to better support you in servicing or repairing customer vehicles?

DATE: YOUR NAME: POSITION:

DEALER: DEALER NO.: ADDRESS:

CITY: STATE/PROV./COUNTRY: ZIP/POSTAL CODE:

Page 4

QUICK REFERENCE CHART LEAF

2011

QUICK REFERENCE CHART LEAF PFP:00000

TUNE-UP DATA (EM61) ELS0003W

Motor model EM61 Cooling system leakage testing pressure

kPa (kg/cm

, psi)

98 (1.0, 14)

FRONT WHEEL ALIGNMENT ELS0003X

Minimum –1° 10′ (–1.16°)

Camber Degree minute (Decimal degree)

Caster Degree minute (Decimal degree)

Kingpin inclination Degree minute (Decimal degree)

Total toe-in Distance

Toe-in

Toe angle (left wheel or right wheel) Degree minute (Decimal degree)

Measure value under unladen* conditions. *: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

Nominal –0° 25′ (–0.42°) Maximum 0° 20′ (0.33°) Left and right difference –0° 45′ (–0.75°) - 0° 45′ (0.75°) Minimum 4° 05′ (4.09°) Nominal 4° 50′ (4.83°) Maximum 5° 35′ (5.58°) Left and right difference –0° 45′ (–0.75°) - 0° 45′ (0.75°) Minimum 11° 10′ (11.17°) Nominal 11° 55′ (11.92°) Maximum 12° 40′ (12.66°) Minimum In 1 mm (0.04 in) Nominal In 2 mm (0.08 in) Maximum In 3 mm (0.12 in) Minimum In 0° 02′ 46′′ (0.046°) Nominal In 0° 05′ 28′′ (0.091°) Maximum In 0° 08′ 09′′ (0.136°)

REAR WHEEL ALIGNMENT ELS0003Y

Minimum –1° 59′ (–1.98°) Camber Degree minute (Decimal degree)

Total toe-in Distance

Toe-in

Toe angle (left wheel or right wheel) Degree minute (Decimal degree)

Measure value under unladen* conditions. *: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

Nominal –1° 29′ (–1.48°)

Maximum –0° 59′ (–0.99°)

Minimum In 1.5 mm (In 0.06 in)

Nominal In 5.5 mm (In 0.22 in)

Maximum In 9.5 mm (In 0.37 in)

Minimum In 0° 04′ 05′′ (In 0.068°)

Nominal In 0° 14′ 56′′ (In 0.249°)

Maximum In 0° 25′ 48′′ (In 0.43°)

Page 5

QUICK REFERENCE CHART LEAF

BRAKE PEDAL

Brake pedal height 159.9 - 169.9 (6.30 - 6.69) Depressed brake pedal height

[Depressing 490 N (50 kg, 110 lb) while set the vehicle to READY]

93.0 (3.661) or more

FRONT DISC BRAKE

Item Limit Brake pad Wear thickness 2.0 (0.079) Disc rotor Wear thickness 26.0 (1.024)

REAR DISC BRAKE

Item Limit Brake pad Wear thickness 2.0 (0.079) Disc rotor Wear inner diameter 14.0 (0.051)

2011

Unit: mm (in.)

REFILL CAPACITIES ELS00040

UNIT Liter US measure Imp measure Coolant (With reservoir tank at “MAX” level 5.8 6-1/8 qt 5-1/8 qt Reduction gear oil 1.1 2-3/8 pt 1-7/8 pt

Compressor oil 0.15 5.07 fl oz 5.28 fl oz

Air conditioning system

Refrigerant 0.45 kg 1.0 lb 1.0 lb Heater fluid 2.23 2-3/8 qt 2 qt

Page 6

GI-1

GENERAL INFORMATION

SECTION GI

CONTENTS

GENERAL INFORMATION

HOW TO USE THIS MANUAL ......................3

HOW TO USE THIS MANUAL ............................3

Description ................................................................3

Terms ........................................................................3

Units ..........................................................................3

Contents .......................... ..........................................4

Relation between Illustrations and Descriptions .......4

Components .................... ..........................................4

HOW TO FOLLOW TROUBLE DIAGNOSES .....6

Description ................................................................6

How to Follow Test Groups in Trouble Diagnosis ......6

Key to Symbols Signifying Measurements or Pro-

cedures .....................................................................

HOW TO READ WIRING DIAGRAMS ................9

Connector Symbols ...................................................9

Sample/Wiring Diagram -Example- .........................10

Connector Information .............................................12

ABBREVIATIONS ..............................................14

Abbreviation List ......................................................14

TIGHTENING TORQUE OF STANDARD

BOLTS ................................................................

Description ..............................................................19

Tightening Torque Table (New Standard Includ-

ed) ...........................................................................

RECOMMENDED CHEMICAL PRODUCTS

AND SEALANTS ................................................

Recommended Chemical Products and Sealants ....21

VEHICLE INFORMATION ............................22

IDENTIFICATION INFORMATION .....................22

Model Variation .......................................................22

Information About Identification or Model Code ......22

Dimensions .............................................................24

Wheels & Tires ........................................................24

PRECAUTION ..............................................25

PRECAUTIONS .................................................25

Description .......................... ....... ...... ... ....... ...... ........25

Precaution for Technicians Using Medical Electric ....25

Point to Be Checked Before Starting Maintenan ce

Work ........................................................................

Precaution for Supplemental Restraint Syste m (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-

SIONER" .................................................................

Precautions Necessary for Steering Wheel Rota-

tion After Battery Disconnection ..............................

Precaution for Procedure without Cowl Top Cove r ....27

Precaution for Removing 12V Battery .....................27

General Precautions ................................................27

Hoses ......................................................................29

Air Conditioning .......................................................29

CAUTIONS AS TO HIGH VOLTAGE ................31

How to Cut Off High Voltage ...................................31

High Voltage Precautions ........................................32

High Voltage Warning Label ....................................35

Insulated Protective Wear and Insulating Tools ......35

Handling of Damaged Vehicles ...............................36

Cautions for Scrapping Vehicles .............................40

Handling of a Vehicle with a Dead Battery ..............40

LIFTING POINT .................................................41

Commercial Service Tools .......................................41

Garage Jack and Safety Stand and 2-Pole Lift .......41

Board-On Lift ...........................................................42

TOW TRUCK TOWING .....................................43

Tow Truck Towing ...................................................43

Vehicle Recovery (Freeing a Stuck Vehicle) ...........43

PROCEDURE FOR PARK LOCK RELEASE ...45

PROCEDURE FOR PARK LOCK RELEASE ..........45

BASIC INSPECTION ...................................47

Revision: 2010 November LEAF

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GI-2

SERVICE INFORMATION FOR ELECTRICAL

INCIDENT ..........................................................

Work Flow ........ ... .... ... ............................................. 47

Control Units and Electrical Parts ........................... 47

How to Check Terminal .......................................... 48

Intermittent Incident ................................................ 51

Circuit Inspection .................................................... 54

CONSULT/GST CHECKING SYSTEM ..............59

Description ....................... .......................... ............. 59

CONSULT Function and System Application*1 ......59

CONSULT/GST Data Link Connector (DLC) Cir-

cuit ..........................................................................

Wiring Diagram - CONSULT/GST CHECKING

SYSTEM - ...............................................................

INSPECTION AND ADJUSTMENT ................... 67

ADDITIONAL SERVICE WHEN REMOVING BAT-

TERY NEGATIVE TERMINAL ..................................

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Required

Procedure After Battery Disconnection ...................

Revision: 2010 November LEAF

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HOW TO USE THIS MANUAL

GI-3

< HOW TO USE THIS MANUAL >

HOW TO USE THIS MANUAL

Description INFOID:0000000006825117

This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”.

Terms INFOID:0000000006893176

Units INFOID:0000000006825119

• The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about the standard tightening torque.

“Example”

Range

Item Description

DANGER

T o be used to inform an operation which will cause a death or serious personal injury if instructions are not following. Example: Touching high voltage component s without using the appropriate protective equipment will cause electrocution.

WARNING

T o be used to inf orm an operation which may cause a death or serious pers onal injury if instruct ions are not following.

CAUTION

T o be used to inform an operation which may cause personal injury or component damage if instructions are not following.

NOTE To be used to inform you helpful information.

BOLD STATEMENTS except DANGER, WARNING and NOTE

Give you helpful information.

• Standard value: Tolerance at inspection and adjustment.

• Limit value: The maximum or minimum limit value that should not be exceeded at inspection and adjustment.

Symbol Description

Electric shock symbol

It may cause an electric shock if instructions are not following to be used in caution for an operation. To be used to describe the removal of component, connector, etc. where high voltage is/might be present.

Insulated gloves Always wear when inspecting or performing service operation of high voltage component s.

Insulated safety shoes/Insulated rubber sheet

Always wear when inspecting or performing service operation of high voltage components on lift-up vehicle.

Safety glasses

Always wear during under the circumstances

• During removal/installati on or check operation of high voltage terminals and harnessed where spark might terminal appear by short circuit.

• Operation inside battery pack.

Insulated hand tools

Always use when performing hig h voltage prese nts operatio n such as operatio n inside high volt age battery pack.

Outer Socket Lock Nut : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)

Revision: 2010 November LEAF

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GI-4

< HOW TO USE THIS MANUAL >

HOW TO USE THIS MANUAL

Standard

Contents INFOID:0000000006825120

• A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by matching it to the section's black tab.

• THE CONTENTS are listed on the first page of each section.

• THE TITLE is indicated on the upper portion of each page and shows the part or system.

• THE PAGE NUMBER of each section consists of two or three letters which designate the particular section and a number (e.g. “BR-5”).

• THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary.

Relation between Illustrations and Descriptions INFOID:0000000006825121

The following sample explains the relationship between the part description in an illustration, the part name in the text and the service procedures.

Components INFOID:0000000006825122

• THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration.

Drive Shaft Installation Bolt : 44.3 N·m (4.5 kg-m, 33 ft-lb)

SAIA0519E

Revision: 2010 November LEAF

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HOW TO USE THIS MANUAL

GI-5

< HOW TO USE THIS MANUAL >

SYMBOLS

1. Cap 2. Bleeder valve 3. Cylinder body

4. Piston seal 5. Piston 6. Piston boot

7. Sliding pin 8. Sliding pin boot 9. Bushing

10. Torque member : Apply rubber grease.

: Apply brake fluid. : N·m (kg-m, in-lb) : Always replace after every disassembly

JPFIA0511GB

SAIA0749E

Revision: 2010 November LEAF

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GI-6

< HOW TO USE THIS MANUAL >

HOW TO FOLLOW TROUBLE DIAGNOSES

Description INFOID:0000000006825123

NOTICE:

Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing.

• Before performing trouble diagnoses, read the “Work Flow” in each section.

• After repairs, re-check that the problem has been completely eliminated.

• Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors.

• When checking circuit continuity, ignition switch should be OFF.

• Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identification of harness connectors.

• Before checking voltage at connectors, check battery voltage.

• After accomplishing the Diagnosis Procedures and Electrical Components Inspection, check that all harness connectors are reconnected as they were.

How to Follow Test Groups in Trouble Diagnosis INFOID:0000000006825124

1. Test group number and test group title

• Test group number and test group title are shown in the upper portion of each test group.

2. Work and diagnosis procedure

• Start to diagnose a problem using procedures indicated in enclosed test groups.

3. Questions and results

• Questions and required results are indicated in test group.

4. Action

• Next action for each test group is indicated based on result of each question.

JPAIA0021GB

Revision: 2010 November LEAF

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HOW TO FOLLOW TROUBLE DIAGNOSES

GI-7

< HOW TO USE THIS MANUAL >

Key to Symbols Signifying Measurements or Procedures INFOID:0000000006950543

JPAIA0982GB

Revision: 2010 November LEAF

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GI-8

< HOW TO USE THIS MANUAL >

HOW TO FOLLOW TROUBLE DIAGNOSES

JSAIA1461GB

Revision: 2010 November LEAF

Page 14

HOW TO READ WIRING DIAGRAMS

GI-9

< HOW TO USE THIS MANUAL >

HOW TO READ WIRING DIAGRAMS

Connector Symbols INFOID:0000000006825126

Most of connector symbols in wiring diagrams are shown from the terminal side.

• Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark.

• Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark.

• Certain systems and components, especially those related to OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to PG section, “Description”, “HARNESS CONNECTOR”.

• Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

SAIA0257E

SGI363

Revision: 2010 November LEAF

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GI-10

< HOW TO USE THIS MANUAL >

HOW TO READ WIRING DIAGRAMS

Sample/Wiring Diagram -Example-

INFOID:0000000006825127

Each section includes wiring diagrams.

Description

JCAWA0150GB

Number Item Description

1 Power supply • This means the power supply of fusible link or fuse. 2 Fuse • “/” means the fuse.

Current rating of fusible link/fuse

• This means the current rating of the fusible link or fuse.

Number of fusible link/ fuse

• This means the number of fusible link or fuse location. 5 Fusible link • “X” means the fusible link. 6 Connector number

• Alphabetic characters show to which harness the connector is placed.

• Numeric characters show the identification number of connectors. 7Switch

• This shows that continuity exists between terminals 1 and 2 when the switch is in the A

position. Continuity exist s between term inals 1 and 3 when the swi tch is in the B positi on.

8 Circuit (Wiring) • This means the wiring.

Revision: 2010 November LEAF

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HOW TO READ WIRING DIAGRAMS

GI-11

< HOW TO USE THIS MANUAL >

SWITCH POSITIONS

Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when:

• ignition switch is “OFF”,

• doors, hood and trunk lid/back door are closed,

• pedals are not depressed, and

• parking brake is released.

MULTIPLE SWITCH

The continuity of multiple switch is described in two ways as shown below.

• The switch chart is used in schematic diagrams.

9 Shielded line • The line enclosed by broken line circle shows shield wire.

10 Connectors • This means that a transmission line bypasses two connectors or more. 11 Option abbreviation

• This means the vehicle specifications which layouts the circuit between “ ”.

12 Relay • This shows an internal representation of the relay. 13 Optional splice • The open circle shows that the splice is optional depending on vehicle application.

14 Splice

• The shaded circle “ ” means the splice.

15 System branch • This shows that the circuit is branched to other systems. 16 Page crossing • This circuit continues to an adjacent page. 17 Component name • This shows the name of a component . 18 Terminal number • This means the terminal number of a connector. 19 Ground (GND) • This shows the ground connection.

Explation of option description

• This shows a explanation of the option abbreviation used on the same page.

Number Item Description

SGI860

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GI-12

< HOW TO USE THIS MANUAL >

HOW TO READ WIRING DIAGRAMS

• The switch diagram is used in wiring diagrams.

Connector Information INFOID:0000000006825128

Description

JSAIA0017GB

Number Item Description

1 Connector number

• Alphabetic characters show to which harness the connector is placed.

• Numeric characters show the identification number of connectors. 2 Connector type • This means the connector number. 3 Terminal number • This means the terminal number of a connector.

JCAWA0152GB

Revision: 2010 November LEAF

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HOW TO READ WIRING DIAGRAMS

GI-13

< HOW TO USE THIS MANUAL >

4 Wire color

• This shows a code for the color of the wire.

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green BG = Beige

BR = Brown OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green

• When the wire color is striped, the base color is given first, followed by the stripe color as

shown below: Example: L/W = Blue with White Stripe

5 Connector

• This means the connector information.

• This unit-side is described by the connector symbols.

Number Item Description

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GI-14

< HOW TO USE THIS MANUAL >

ABBREVIATIONS

Abbreviation List INFOID:0000000006856139

The following ABBREVIATIONS are used:

ABBREVIATION DESCRIPTION

A/C Air conditioner A/C Air conditioning

A/F sensor Air fuel ratio sensor

A/T Automatic transaxle/transmission

ABS Anti-lock braking system

ACCS Advance climate control system

ACL Air cleaner

AP Accelerator pedal

APP Accelerator pedal position

ATF Automatic transmission fluid

AV Audio visual

AWD All wheel drive

ABBREVIATION DESCRIPTION

BARO Barometric pressure

BCM Body control module

BLSD Brake limited slip differential

BPP Brake pedal position

BSI Blind spot intervention

BSW Blind spot warning

ABBREVIATION DESCRIPTION

CKP Crankshaft position

CL Closed loop

CMP Camshaft position

CPP Clutch pedal position CTP Closed throttle position CVT Continuously variable transaxle/transmission

ABBREVIATION DESCRIPTION

1 Drive range first gear

2 Drive range second gear

3 Drive range third gear

4 Drive range fourth gear

DCA Distance control assist DDS Downhill drive support

DFI Direct fuel injection system DLC Data link connector DTC Diagnostic trouble code

Revision: 2010 November LEAF

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ABBREVIATIONS

GI-15

< HOW TO USE THIS MANUAL >

ABBREVIATION DESCRIPTION

E/T Exhaust temperatu r e

EBD Electric brake force distribution

EC Engine control

ECL Engine coolant level

ECM Engine control module

ECT Engine coolant temperature ECV Electrical control valve

EEPROM Electrically erasable programmable read only memory

EFT Engine fuel temperature EGR Exhaust gas recirculation

EGRT Exhaust gas recirculation temperature

EGT Exhaust gas temperature EOP Engine oil pressure

EP Exhaust pressure EPR Exhaust pressure regulato r EPS Electronically controlled power steering ESP Electronic stability program system

EVAP canister Evaporative emission canister

EXC Exhaust control

ABBREVIATION DESCRIPTION

FC Fan control

FCW Forward collision warning

FIC Fuel injector control

FP Fuel pump

FR Front FRP Fuel rail pressure FRT Fuel rail temperature

FTP Fuel tank pressure FTT Fuel tank temperature

ABBREVIATION DESCRIPTION

GND Ground

GPS Global positioning system GST Generic scan tool

ABBREVIATION DESCRIPTION

HBMC Hydraulic body-motion control system

HDD Hard disk drive

HO2S Heated oxygen sensor

HOC Heated ox ida ti on ca talyst

HPCM HYbrid power train control module

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GI-16

< HOW TO USE THIS MANUAL >

ABBREVIATIONS

ABBREVIATION DESCRIPTION

I/M Inspection and maintenance

IA Intake air

IAC Idle air control

IAT Intake air temperature

IBA Intelligent brake assist

IC Ignition control

ICC Intelligent cruise control

ICM Ignition control module

IPDM E/R Intelligent power distribution module engine room

ISC Idle speed control ISS Input shaft speed

ABBREVIATION DESCRIPTION

KS Knock sensor

ABBREVIATION DESCRIPTION

LBC Li-ion battery controller LCD Liquid crystal display LCU Local control unit LDP Lane departure prevention

LDW Lane departure warning

LED Light emitting diode

LH Left-hand

LIN Local interconnect network

ABBREVIATION DESCRIPTION

M/T Manual transaxle/transmission

MAF Mass airflow

MAP Manifold absolute pressure MDU Multi display unit

MI Malfunction indicator

MIL Malfunction indicator lamp

ABBREVIATION DESCRIPTION

NOX Nitrogen oxides

ABBREVIATION DESCRIPTION

O2 Oxygen O2S Oxygen sensor

OBD On board diagnostic

OC Oxidation catalytic converter

OD Overdrive

OL Open loop OSS Output shaft speed

Revision: 2010 November LEAF

Page 22

ABBREVIATIONS

GI-17

< HOW TO USE THIS MANUAL >

ABBREVIATION DESCRIPTION

P/S Power steering PBR Potentio balance resistor PCV Positive crankcase ventilation PNP Park/Neutral position PSP Power steering pressure PTC Positive temperature coefficient PTO Power takeoff

PWM Pulse width modulation

ABBREVIATION DESCRIPTION

RAM Random access memory

RAS Rear active steer

RH Right-hand ROM Read only memory RPM Engine speed

RR Rear

ABBREVIATION DESCRIPTION

SAE Society of Automotive Engineers, Inc. SCK Serial clock SDS Service Data and Specifications SRT System readiness test SST Special Service Tools

ABBREVIATION DESCRIPTION

TC Turbocharger

TCM Transmission control module TCS Traction control system TCU Telematics communication unit

TP Throttle position

TPMS Tire pressure monitoring system

TSS Turbine shaft speed

TWC Three way catalytic converter

ABBREVIATION DESCRIPTION

USS Uphill start support

ABBREVIATION DESCRIPTION

VCM Vehicle control module

VDC Vehicle dynamics control system

VIN Vehicle identification number

VSS Vehicle speed sensor

Revision: 2010 November LEAF

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GI-18

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ABBREVIATIONS

ABBREVIATION DESCRIPTION

WOT Wide open throttle

ABBREVIATION DESCRIPTION

1 1st range first gear

2 1st range second gear

1GR First gear

ABBREVIATION DESCRIPTION

1 2nd range first gear

2 2nd range second gear

2GR Second gear

2WD 2-wheel drive

ABBREVIATION DESCRIPTION

3GR Third gear

ABBREVIATION DESCRIPTION

4GR Fourth ge ar

4WAS Four wheel active steer

4WD Four wheel drive

ABBREVIATION DESCRIPTION

5GR Fifth gear

ABBREVIATION DESCRIPTION

6GR Sixth ge ar

ABBREVIATION DESCRIPTION

7GR Seven th ge ar

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TIGHTENING TORQUE OF STANDARD BOLTS

GI-19

< HOW TO USE THIS MANUAL >

TIGHTENING TORQUE OF STANDARD BOLTS

Description INFOID:0000000006825130

This vehicle has both new standard based on ISO* and previous standard bolts/nuts. There are some differences between these two types of bolts/ nuts; shape of the head, grade of strength, hexagonal width across flats and the standard tightening torque.

• For guidance in discriminating, refer to GI-19, "

Tightening Torque Table (New Standard Included)".

• The new standard machine screws and tapping screws have a head of ISO standard torx recess.

• If the tightening torque is not described in the description or figure, refer to GI-19, "

Tightening Torque Table

(New Standard Included)".

*ISO: International Organization for Standardization

Tightening Torque Table (New Standard Included) INFOID:0000000006825131

CAUTION:

• The special parts are excluded.

• The bolts/nuts in these tables have a strength (discrimination) number/symbol assigned to the head or the like. As to the relation between the strength grade in these tables and the strength (discrimination) number/symbol, refer to “DISCRIMINATION OF BOLTS AND NUTS”.

PREVIOUS STANDARD

CAUTION:

Grade

(Strength

grade)

Bolt size

Bolt diameter

Hexagonal

width

across flats

Pitch

Tightening torque (Without lubricant)

Hexagon head bolt Hexagon flange bolt

N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb

M66.0 10 1.05.50.564 49 70.715 62

M8 8.0 12

1.25 13.5 1.4 10 — 17 1.7 13 —

1.0 13.5 1.4 10 — 17 1.7 13 —

M10 10.0 14

1.5282.921 —353.626 —

1.25 28 2.9 21 — 35 3.6 26 —

M12 12.0 17

1.75 45 4.6 33 — 55 5.6 41 —

1.25 45 4.6 33 — 65 6.6 48 —

M14 14.0 19 1.5 80 8.2 59 — 100 10 74 —

M6 6.0 10 1.0 9 0.92 7 80 11 1.1 8 97

M8 8.0 12

1.25 22 2.2 16 — 28 2.9 21 —

1.0222.216 —282.921 —

M10 10.0 14

1.5454.633 —555.641 —

1.25 45 4.6 33 — 55 5.6 41 —

M12 12.0 17

1.75 80 8.2 59 — 100 10 74 —

1.25 80 8.2 59 — 100 10 74 —

M1414.0 19 1.513013 96 —17017125—

M6 6.0 10 1.0 11 1.1 8 — 13.5 1.4 10 —

M8 8.0 12

1.25 28 2.9 21 — 35 3.6 26 —

1.0282.921 —353.626 —

M10 10.0 14

1.5555.641 —808.259 —

1.25 55 5.6 41 — 80 8.2 59 —

M12 12.0 17

1.75 100 10 74 — 130 13 96 —

1.25 100 10 74 — 130 13 96 —

M14 14.0 19 1.5 170 17 125 — 210 21 155 —

Revision: 2010 November LEAF

Page 25

GI-20

< HOW TO USE THIS MANUAL >

TIGHTENING TORQUE OF STANDARD BOLTS

The parts with aluminum or the cast iron washer surface/thread surface are excluded.

NEW STANDARD BASED ON ISO

CAUTION:

1. Use tightening torque with lubricant for the new standard bolts/nuts in principle. Friction coefficient stabilizer is applied to the new standard bolts/nuts.

2. However, use tightening torque without lubricant for the following cases. Friction coefficient st abilizer is not applied to the following bolts/nuts.

- Grade 4.8, M6 size bolt, Conical spring washer installed

- Paint removing nut (Size M6 and M8) for fixing with weld bolt

Grade

(Strength

grade)

Bolt

size

Bolt diameter

Hexagonal

width

across flats

Pitch

Tightening torque

Hexagon head bolt Hexagon flange bolt

N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb

4.8 (Without lubricant)

M6 6.0 10 1.0 5.5 0.56 4 49 7 0.71 5 62

M8 8.0 13

1.25 13.5 1.4 10 — 17 1.7 13 —

1.0 13.5 1.4 10 — 17 1.7 13 —

M10 10.0 16

1.5282.921 —353.626 —

1.25 28 2.9 21 — 35 3.6 26 —

M12 12.0 18

1.75 45 4.6 33 — 55 5.6 41 —

1.25 45 4.6 33 — 65 6.6 48 —

M14 14.0 21 1.5 80 8.2 59 — 100 10 74 —

4.8 (With lubricant)

M6 6.0 10 1.0 4 0.41 3 35 5.5 0.56 4 49

M8 8.0 13

1.25 11 1.1 8 — 13.5 1.4 10 —

1.0 11 1.1 8 — 13.5 1.4 10 —

M10 10.0 16

1.5222.216 —282.921 —

1.25 22 2.2 16 — 28 2.9 21 —

M12 12.0 18

1.75 35 3.6 26 — 45 4.6 33 —

1.25 35 3.6 26 — 45 4.6 33 —

M14 14.0 21 1.5 65 6.6 48 — 80 8.2 59 —

8.8 (With lubricant)

M6 6.0 10 1.0 8 0.82 6 71 10 1.0 7 89

M8 8.0 13

1.25 21 2.1 15 — 25 2.6 18 —

1.0212.115 —252.618 —

M10 10.0 16

1.5404.130 —505.137 —

1.25 40 4.1 30 — 50 5.1 37 —

M12 12.0 18

1.75 70 7.1 52 — 85 8.7 63 —

1.25 70 7.1 52 — 85 8.7 63 —

M14 14.0 21 1.5 120 12 89 — 140 14 103 —

10.9 (With lubricant)

M6 6.0 10 1.0 10 1.0 7 89 12 1.2 9 106

M8 8.0 13

1.25 27 2.8 20 — 32 3.3 24 —

1.0272.820 —323.324 —

M10 10.0 16

1.5555.641 —656.648 —

1.25 55 5.6 41 — 65 6.6 48 —

M12 12.0 18

1.75 95 9.7 70 — 110 11 81 —

1.25 95 9.7 70 — 110 11 81 —

M14 14.0 21 1.5 160 16 118 — 180 18 133 —

Revision: 2010 November LEAF

Page 26

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS

GI-21

< HOW TO USE THIS MANUAL >

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS

Recommended Chemical Products and Sealants INFOID:0000000006826362

Refer to the following chart for help in selecting the appropriate chemical product or sealant.

Product Description Purpose

Nissan North America

Part No. (USA)

Nissan Canada Part

No. (Canada)

Aftermarket Cross-

reference Part Nos.

Rear View Mirror Adhesive

Used to permanently remount rear view mirrors to windows.

999MP-AM000P 99998-50505 Permatex 81844

Anaerobic Liquid Gasket

For metal-to-metal flange sealing. Can fill a 0.38 mm (0.015 inch) gap and provide instant sealing for most powertrain applications.

999MP-AM001P 99998-50503

Permatex 51813 and 51817

High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.)

• Do not use on plastic.

999MP-AM002P 999MP-AM002P Permatex 56521

4 Silicone RTV

Gasket Maker

999MP-AM003P (Ultra Grey)

99998-50506 (Ultra Grey)

Permatex Ultra Grey 82194; Three Bond 1207,1215, 1216, 1217F, 1217G and 1217H Nissan RTV Part No. 999MP-A7007

Gasket Maker for Maxima/ Quest 5-speed automatic transmission (RE5F22A)

––

Three Bond 1281B or exact equivalent in its quality

High Temperature, High Strength Thread Locking Sealant (Red)

Threadlocker 999MP-AM004P 999MP-AM004P

Permatex 27200; Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388 Loctite 648

Medium Strength Thread Locking Sealant (Blue)

Threadlocker (service tool removable)

999MP-AM005P 999MP-AM005P

Permatex 24200, 24206, 24240, 24283 and 09178; Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374

Revision: 2010 November LEAF

Page 27

GI-22

< VEHICLE INFORMATION >

IDENTIFICATION INFORMATION

VEHICLE INFORMATION

IDENTIFICATION INFORMATION

Model Variation INFOID:0000000006825132

Model variation code (Prefix and suffix designations)

Information About Identification or Model Code INFOID:0000000006825133

IDENTIFICATION NUMBER

Destination Body Transmission Axle Motor Grade Model

USA 4-door Hachback Reduction gear 2WD EM61 L2 FSDALD9-BUA

JSAIA1454GB

JSAIA1664ZZ

Revision: 2010 November LEAF

Page 28

IDENTIFICATION INFORMATION

GI-23

< VEHICLE INFORMATION >

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

IDENTIFICATION PLATE

MOTOR SERIAL NUMBER

1. Ve hicle identification plate 2. Ve hicle identification number (Chassis number)

3. Air conditioner specification label

4. Tire placard 5. FMVSS certification label

JSAIA1455GB

1. MFR Month/Year 2. Gross vehicle weight rating 3. Gross axle weight rating (Front)

4. Gross axle weight rating (Rear) 5. Guarantee description 6. Vehicle identification number

7. Body color code 8. Trim color code 9. Transmission model

10. Axle model 11. Motor model 12. Vin bar code

JSAIA1665ZZ

: Vehicle front

JSAIA1462ZZ

Revision: 2010 November LEAF

Page 29

GI-24

< VEHICLE INFORMATION >

IDENTIFICATION INFORMATION

Dimensions

INFOID:0000000006856140

Unit: mm (in)

Wheels & Tires INFOID:0000000006856141

Overall length (with license plate bracket) 4,446.8 (175.1) Overall width 1,771.4 (69.7) Overall height 1,549.5 (61.0) Front tread 1,540 (60.6) Rear tread 1,535 (60.4) Wheelbase 2,700 (106.3)

Conventional

Tire 205/55R16 91V Road wheel

(Alminum)

Size 16 × 6-1/2J Offset 40 mm (1.57in)

Spare

Tire T125/90D16 98M Road wheel

(Steel)

Size 16 × 4T Offset 30 mm (1.18 in)

Revision: 2010 November LEAF

Page 30

PRECAUTIONS

GI-25

< PRECAUTION >

PRECAUTION

PRECAUTIONS

Description INFOID:0000000006825136

Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.

Precaution for Technicians Using Medical Electric INFOID:0000000007076757

OPERATION PROHIBITION

WARNING:

• Parts with strong magnet is used in this vehicle.

• Technicians using a medical electric device such as pacemaker must never perform operation on the vehicle, as magnetic field can affect the device function by approaching to such parts.

NORMAL CHARGE PRECAUTION

WARNING:

• If a technician uses a medical electric device such as an implantable cardiac pacemaker or an implantable cardioverter defibrillator, the possible effects on the devices must be checked with the device manufacturer before starting the charge operation.

• As radiated electromagnetic wave generated by on board charger at normal charge operation may effect medical electric devices, a technician using a medical electric device such as implantable cardiac pacemaker or an implantable cardioverter defibrillator must not enter the vehicle compartment (including luggage room) during normal charge operation.

Precaution at telematics system operation

WARNING:

• If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), avoid the device implanted part from approaching within approximately 220 mm (8.66 in) from interior/exterior antenna.

• The electromagnetic wave of TCU might affect the function of the implantable cardiac pacemaker or the implantable cardioverter defibrillator (ICD), when using the service, etc.

• If a technician uses other medical electric devices than implantable cardiac pacemaker or implantable cardioverter defibrillator(ICD), the electromagnetic wave of TCU might affect the function of the device. The possible effects on the devices must be checked with the device manufacturer before TCU use.

Precaution at intelligent key system operation

WARNING:

• The electromagnetic wave of intelligent key might affect the function of the implantable cardiac pacemaker or the implantable cardioverter defibrillator (ICD), at door operation, at each request switch operation, or at engine starting.

• If a technician uses other medical electric devices than implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), the electromagnetic wave of intelligent key might affect the function of the device. The possible effects on the devices must be checked with the device manufacturer before intelligent key use.

Point to Be Checked Before Starting Maintenance Work INFOID:0000000007079500

The high voltage system may starts automatically. It is required to check that the timer air conditioner and timer charge (during EVSE connection) are not set before starting maintenance work. NOTE:

If the timer air conditioner or timer charge (during EVSE connection) is set, the high voltage system starts automatically even when the power switch is in OFF state.

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT

Revision: 2010 November LEAF

Page 31

GI-26

< PRECAUTION >

PRECAUTIONS

PRE-TENSIONER"

INFOID:0000000007037021

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this Service Manual.

WARNING:

Always observe the following items for preventing accidental activation.

• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision that would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.

• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see “SRS AIR BAG”.

• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

Always observe the following items for preventing accidental activation.

• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the power switch ON, never use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury.

• When using air or electric power tools or hammers, always switch the power switch OFF , disconnect the 12V battery, and wait at least 3 minutes before performing any service.

Precautions Necessary for Steering Wheel Rotation After Battery Disconnection

INFOID:0000000006825250

CAUTION:

Comply with the following cautions to prevent any error and malfunction.

• Before removing and installing any control units, first turn the ignition switch to the LOCK position, then disconnect both battery cables.

• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables.

• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.

For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. If turning the steering wheel is required with the battery disconnected or discharged, follow the operation procedure below before starting the repair operation.

OPERATION PROCEDURE

1. Connect both battery cables.

NOTE:

Supply power using jumper cables if battery is discharged.

2. Turn the ignition switch to ACC position.

(At this time, the steering lock will be released.)

3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-

nected and the steering wheel can be turned.

4. Perform the necessary repair operation.

5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn

the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the ignition switch is turned to LOCK position.)

6. Perform self-diagnosis check of all control units using CONSULT.

Revision: 2010 November LEAF

Page 32

PRECAUTIONS

GI-27

< PRECAUTION >

Precaution for Procedure without Cowl Top Cover INFOID:0000000006825251

When performing the procedure after removing cowl top cover , cover the lower end of windshield with urethane, etc to prevent damage to windshield.

Precaution for Removing 12V Battery INFOID:0000000006931587

When removing the 12V battery, turn ON/OFF the power switch and check that the charging status indicator does not blink. The 12V battery must be removed within one hour after checking the indicator lamp.

NOTE:

• The automatic 12V battery charge control may start even when the power switch is in OFF state.

• The automatic 12V battery charge control does not start within approximately one hour when the power switch is turned ON/OFF.

General Precautions INFOID:0000000006825140

• Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle.

• Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle. These operations should be done on a level surface.

• When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.

PIIB3706J

SGI285

SGI231

Revision: 2010 November LEAF

Page 33

GI-28

< PRECAUTION >

PRECAUTIONS

• Before starting repairs which do not require battery power: Turn off power switch. Disconnect the negative battery terminal.

• If the battery terminals are disconnected, recorded memory of radio and each control unit is erased.

• To prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot.

• Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.

• Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow , resulting in fuel spray and possibly a fire.

• Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly.

• Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones.

• Replace inner and outer races of tapered roller bearings and needle bearings as a set.

• Arrange the disassembled parts in accordance with their assembled locations and sequence.

• Do not touch the terminals of electrical components which use microcomputers (such as ECM). Static electricity may damage internal electronic components.

• After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.

• Use only the fluids and lubricants specified in this manual.

• Use approved bonding agent, sealants or their equivalents when required.

• Use hand tools, power tools (disassembly only) and recommended special tools where specified for safe and efficient service repairs.

• When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leakage.

• Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint.

WARNING:

To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and TCM (transmission control module)

SEF289H

SGI233

JPAIA0335ZZ

SGI234

Revision: 2010 November LEAF

Page 34

PRECAUTIONS

GI-29

< PRECAUTION >

system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and TM sections.

Hoses INFOID:0000000006825141

HOSE REMOVAL AND INSTALLATION

• To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

• To reinstall the rubber hose securely, check that hose insertion length and orientation is correct. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

HOSE CLAMPING

• If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position.

• Discard old clamps; replace with new ones.

• After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around.

Air Conditioning INFOID:0000000006825142

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA section “REFRIGERANT” for specific instructions.

SMA019D

SMA020D

SMA021D

SMA022D

Revision: 2010 November LEAF

Page 35

GI-30

< PRECAUTION >

PRECAUTIONS

Revision: 2010 November LEAF

Page 36

CAUTIONS AS TO HIGH VOLTAGE

GI-31

< PRECAUTION >

CAUTIONS AS TO HIGH VOLTAGE

How to Cut Off High Voltage INFOID:0000000006918519

HIGH VOLTAGE SHUT-OFF PROCEDURE

Be sure to follow the procedure below and shut off the high voltage before performing inspection or servicing of the high voltage system.

1. Turn power switch OFF.

CAUTION:

The worker must keep the intelligent key on his/her person.

2. Disconnect 12V battery negative terminal.

3. Remove service plug, following below procedure.

a. Put finger to the notched part (A), and pull of the floor carpet (1).

b. Remove inspection hole cover installation bolt (A) and take the

inspection hole cover (1) off.

c. Remove the service plug.

DANGER:

Touching high voltage components without using the appropriate protective equipment will

cause electrocution.

WARNING:

• Immediately insulate removed high voltage connectors and terminals with insulating tape.

• Be sure to put the removed service plug in your pocket and carry it with you so that another person does not accidentally connect it while work is in progress.

:Vehicle front

JSAIA1611ZZ

:Vehicle front

JSAIA1612ZZ

JPCIA0060ZZ

Revision: 2010 November LEAF

Page 37

GI-32

< PRECAUTION >

CAUTIONS AS TO HIGH VOLTAGE

4. Wait for a minimum of approximately 10 minutes after the service plug is removed.

CONNECTING PROCEDURE

1. Check that 12V battery negative terminal is disconnected.

2. Install service plug as per the following steps.

DANGER:

Touching high voltage components without using the appropriate protective equipment will

cause electrocution.

WARNING:

• Immediately insulate removed high voltage connectors and terminals with insulating tape.

• Be sure to put the removed service plug in your pocket and carry it with you so that another person does not accidentally connect it while work is in progress.

3. Connect 12V battery negative terminal.

High Voltage Precautions INFOID:0000000006918520

WARNING:

• Because hybrid vehicles and electric vehicles contain a high voltage battery , there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.

• Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

• Be sure to put the removed service plug in your pocket and carry it with you so that another person does not accidentally connect it while work is in progress.

• Be sure to wear insulating protective equipment consisting of glove, shoes and face shield before beginning work on the high voltage system.

• Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.

CAUTION:

There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.

HIGH VOLTAGE HARNESS AND EQUIPMENT IDENTIFICATION

The colors of the high voltage harnesses and connectors are all orange. Orange "High Voltage" labels are applied to the Li-ion battery and other high voltage devices. Do not carelessly touch these harnesses and parts.

HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS

Immediately insulate disconnected high voltage connectors and terminals with insulating tape.

REGULATIONS ON WORKERS WITH MEDICAL ELECTRONICS

WARNING:

JPCIA0058ZZ

Revision: 2010 November LEAF

Page 38

CAUTIONS AS TO HIGH VOLTAGE

GI-33

< PRECAUTION >

The vehicle contains parts that contain powerful magnets. If a person who is wearing a pacemaker or other medical device is close to these parts, the medical device may be affected by the magnets. Such persons must not perform work on the vehicle.

PROHIBITED ITEMS TO CARRY DURING THE WORK

Because this vehicle uses components that contain high voltage and powerful magnetism, due not carry any metal products which may cause short circuits, or any magnetic media (cash cards, prepaid cards, etc.) which may be damaged on your person when working.

POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT”

Revision: 2010 November LEAF

Page 39

GI-34

< PRECAUTION >

CAUTIONS AS TO HIGH VOLTAGE

To call the attention of other workers, indicate "High voltage work in progress. Do not touch!" on vehicles where work is being performed on the high voltage systems.

JSAIA1600GB

Revision: 2010 November LEAF

Page 40

CAUTIONS AS TO HIGH VOLTAGE

GI-35

< PRECAUTION >

High V oltage Warning Label INFOID:0000000006918521

LOCATION TO APPLY HIGH VOLTAGE WARNING LABEL

CAUTION:

At times such as when a part was replaced, or whe n a l abel had b ecome peel ed, be sure to apply th e new produ ct lab el in the same position and facing in the same direction.

Insulated Protective Wear and Insulating Tools INFOID:0000000006918522

PROTECTIVE WEAR CONTROL

• Perform an inspection before beginning work, and do not use any items where abnormalities are found.

DAILY INSPECTION

This inspection is performed before and after use, the worker in responsible who will directly use the items inspects them and checks for deterioration and damage.

• Insulated gloves

JSAIA1463ZZ

No. Position to apply Refer to

1Traction motor TMS-13, "

High Voltage Warning Label"

2 Traction motor inverter TMS-13, "High V oltage Warning Label" 3DC/DC-J/B EVC-24, "High Voltage Warning Label" 4 On board charger VC-12, "High Voltage Warning Label" 5 Li-ion battery controller EVB-14, "High Voltage Warning Label" 6 Li-ion battery EVB-14, "High Voltage Warning Label" 7 Service plug EVB-14, "High Voltage Warning Label" 8 PTC elements heater HA-23, "High Voltage Warning Label" 9 Electric co mp res so r HA-23, "High Voltage Warning Label"

Revision: 2010 November LEAF

Page 41

GI-36

< PRECAUTION >

CAUTIONS AS TO HIGH VOLTAGE

Inspect the insulated gloves for scratches, holes, and tears. (Visual check and air leakage test)

• Insulated safety shoes Inspect the insulated safety boots for holes, damage, nails, metal pieces, wear or other problems on the soles. (Visual check)

• Insulated rubber sheet Inspect the insulated rubber sheet for tears. (Visual inspection)

INSULATING TOOLS

When performing work at locations where high voltage is applied (such as terminals), use insulated tools.

HANDLING OF INSULATION RESISTANCE TESTER

CAUTION:

Unlike the ordinary tester, the insulation resistance tester applies 500V when measuring. If used incorrectly, there is the danger of electric shock. If used in the vehicle 12V system, there is the danger of damage to electronic devices. Read the insulation resistance tester instruction manual carefully and be sure to work safely.

Handling of Damaged Vehicles INFOID:0000000007080557

PREPARATION ITEMS

A : Hold glove and fold as shown in the figure. B : Fold three or four more times, preventing air from escaping from the glove. C : Squeeze glove to check that the glove has no holes.

JPCIA0061ZZ

Preparation items Specification Purpose

Insulated gloves

Guaranteed insulation performance for 1000V/ 300A

To protect people from high voltage electrical shock.

Insulated safety shoes — Safety glasses ANSI Z87.1

Wrenches Size: 10mm

To remove the service plug inspection hole cover bolt. To remove the 12V battery terminal bolt.

Heat proof solvent resistance protection gloves Heat proof solvent resistance protection shoes

Heat proof solvent resistance protection tools.

To utilize when the Li-ion battery electrolytic solution leaks.

Absorbent mat and cloth

The same cloth used for internal combustion engine fluids can be used.

To absorb the Li-ion battery electrolytic solution leakage.

Revision: 2010 November LEAF

Page 42

CAUTIONS AS TO HIGH VOLTAGE

GI-37

< PRECAUTION >

HOW TO HANDLE THE DAMAGED VEHICLES AT AN ACCIDENT SCENE

High voltage system shut-down procedure Shut down the high voltage system corresponding to the damage of vehicle. Any of the following procedures can shut down the high voltage system. The first response operation can be done after shutting down the high voltage system. If the vehicle is heavily damaged, for example the Li-ion battery is deformed, broken or cracked, insulating protective gear must be used the Li-ion battery and high voltage cables must not be touched.

WARNING:

• If the EVSE is connected to the vehicle, remove it.

• Failure to disable the high voltage electrical system before the emergency response procedures are performed may result in serious injury or death from electrical shock. To prevent from serious injury or death, do not touch high voltage harnesses and components with bare hands.

• When contact with high voltage parts or high voltage wiring is unavoidable, or when there is risk of such contact, be sure to wear insulating protective gear.

CAUTION:

Extinguisher

Type ABC For electrical fire (Caused by the electrical harness and instrument etc...), and oil fire (Caused by gasoline, oil)

To extinguish a fire.

VAT Tester To measure up to 600V.

T o measure voltage on damaged harness and operated parts.

Plastic tape Insulating.

To cover the damaged harness to protect from electrical shock.

Preparation items Specification Purpose

Revision: 2010 November LEAF

Page 43

GI-38

< PRECAUTION >

CAUTIONS AS TO HIGH VOLTAGE

Before disconnecting the 12V battery terminal, if necessary, lower the windows, unlock the doors, and open the back door as required. Once 12V battery is disconnected, power controls will not operate.

WARNING:

• Be sure to check the READY to drive indicator lamp on the combination meter, and verify that the READY to drive indicator lamp is off and the high voltage system is stopped.

• There is a possibility of remaining high voltage in the air conditioning system by the remote air conditioning system even when the READY to drive indicator lamp is turned OFF and the air conditioning indicator is turned ON. please ensure that the air conditioning indicator lamp is turned OFF and the air conditioning system is inactive.

• After high voltage system shut down, please wait for 10 minutes to complete discharging the high voltage condenser. While waiting, do not operate.

• The high voltage full discharge takes 10 minutes, but after 5 minutes the voltage has dropped below 60 V.

• Remove the 12V battery negative terminal and wait for 3 minutes. Event though the 12V battery negative terminal is disconnected, the supplemental restraint system (SRS) airbag maintains voltage for 3 minutes. There is a possibility of sudden SRS airbag inflation due to harness short circuit or damage and it may cause serious injuries.

Indications the high voltage system is ON

• If the READY to drive indicator is ON, the high voltage system is active.

• If the air conditioning indicator is ON, the high voltage system is active.

Procedure 1: Turn OFF the Power Switch.

1. Check the READY to drive indicator lamp status. If it is ON, the high voltage system active.

2. Press the power switch once to shut OFF the high voltage system. Then verify whether the READY to

drive indicator lamp is OFF.

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GI-39

< PRECAUTION >

3. Keep the intelligent key at least 5 meters (16 feet) away from the vehicle.

4. Disconnect the negative 12V battery cable. Insulate the negative battery terminal with insulated tape.

5. Wait 10 minutes to complete discharging the high voltage condenser after the power switch has been turned OFF.

6. Perform the first response action.

Procedure B: Remove the Fuses. (If Power Switch Cannot Be Turned OFF)

1. Open the hood.

2. Remove the IPDM E/R.

3. Remove the following fuses:

- Power Switch Control Fuse (IGN 10A)

- 12V Main Reply Control Fuse (PBW 15A)

- VCM Electrical Fuse (VCM 20A)

4. If it cannot identify the above fuses, remove all fuses in the fuse box.

5. Disconnect the negative 12V battery cable. Insulate the negative battery terminal with insulated tape.

6. Wait 10 minutes to complete discharging the high voltage condenser after the power switch has been turned OFF.

7. Perform the first response action.

WARNING:

• Do not turn the power switch ON or READY while fuses are being removed.

• To avoid unintended installation and risk of electrical shock, the rescuer should carry the fuses

on his/her person and cover the fuse box with insulated tape.

Procedure 3: Remove the service plug. (When Procedu re 1 and Pr ocedur e 2 are impo ssible, an d the us e of insulat ing rubber gloves is possible)

WARNING:

• Do not remove the service plug without wearing protective gear to prevent the responder from

any serious injury or death by electric shock.

• Do not turn the power switch ON or READY while removing the service plug.

• To avoid unintended installation and risk of electrical shock, the rescuer should carry the ser-

vice plug on his/her person while work is in progress.

• Immediately cover the service plug socket with insulated tape. To avoid electric shock, do not

touch terminals inside the socket.

•

1. Put finger to the notched part (A), and pull of the floor carpet (1).

2. Remove inspection hole cover installation bolt (A) and take the inspection hole cover (1) off.

: Vehicle front

JSAIA1611ZZ

: Vehicle front

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CAUTIONS AS TO HIGH VOLTAGE

3. Remove the service plug.

4. Wait 10 minutes to complete discharging the high voltage condenser after the power switch has been turned OFF.

5. Perform the first response action.

VEHICLE FIRE

WARNING:

In the case of extinguishing the fire with water, large amounts of water from a fire hydrant (it possible) must be used. DO NOT extinguish fire with a small amount of water. Small amounts of water will make toxic gas produced by a chemical reaction between the Li-ion battery electrolyte and water.

LI-ION BATTERY DAMAGE

CAUTION:

Any absorbent mats or cloths used to wipe electrolyte must be disposed of as industrial waste as required by federal law.

1. In case of electrolyte solution leakage, wear insulating protective gear and wipe with a dry cloth. The used cloth must be disposed of in accordance to the same disposal method as other organic solvents.

2. The Li-ion battery electrolyte solution is clear color and the same level of viscosity as water. Also, it has a sweet odor smell. Do not touch the electrolyte solution with bare hands.

3. The Li-ion battery electrolyte solution is flammable. In case of leakage, properly ventilate the accident site.

4. In case electrolyte solution comes in contact with eyes, rinse plenty of running water and see a doctor immediately.

Cautions for Scrapping Vehicles INFOID:0000000006918523

The Li-ion battery must be removed from the vehicle before the vehicle is scrapped.

CAUTION:

Insulate the terminals of the removed Li-ion battery with insulating tape.

Handling of a Vehicle with a Dead Battery INFOID:0000000006918524

For the handling of a vehicle when the battery is dead, refer to GI-43, "Tow Truck Towing".

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LIFTING POINT

GI-41

< PRECAUTION >

LIFTING POINT

Commercial Service Tools INFOID:0000000006825143

CAUTION:

• Every time the vehicle is lifted up, maintain the complete vehicle curb condition.

• Since the vehicle's center of gravity changes when removing main parts on the front side (engine, transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission jack or equivalent.

• Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle, suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equivalent.

• Be careful not to smash or never do anything that would affect piping parts.

Garage Jack and Safety Stand and 2-Pole Lift INFOID:0000000006825144

WARNING:

• Park the vehicle on a level surface when using the jack. Check to avoid damaging pipes, tubes, etc. under the vehicle.

• Never get under the vehicle while it is supported only by the jack. Always use safety stands when you have to get under the vehicle.

• Place wheel chocks at both front and back of the wheels on the ground.

• When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced.

• When setting the lift arm, never allow the arm to contact the brake tubes, brake cable, fuel lines and sill spoiler.

Tool name Description

Board on attachment

Safety stand attachment

S-NT001

S-NT002

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LIFTING POINT

CAUTION:

There is canister just behind Garage jack point rear . Jack up carefully.

Board-On Lift INFOID:0000000006825145

CAUTION:

Check vehicle is empty when lifting.

• The board-on lift attachment (A) set at front end of vehicle should be set on the front of the sill under the front door opening.

• Position attachments at front and rear ends of board-on lift.

1. Safety stand point and lift up point (front) 2. Safety stand point and lift up point (rear)

3. Garage jack point (front)

4. Garage jack point (rear)

JMAIA0096ZZ

: Vehicle front

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TOW TRUCK TOWING

GI-43

< PRECAUTION >

TOW TRUCK TOWING

Tow Truck Towing INFOID:0000000006952958

CAUTION:

• All applicable State or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed.

• It is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing instructions are available from a NISSAN certified LEAF dealer.

• Always attach safety chains before towing.

• When towing, make sure that the axles, steering system and powertrain are in working condition. If any unit is damaged, a flatbed must be used.

• NISSAN recommends that the vehicle be towed with the driving (front) wheels off the ground or that the vehicle be placed on a flatbed truck as illustrated.

Vehicle Recovery (Freeing a Stuck Vehicle) INFOID:0000000006825147

FRONT

Securely install the vehicle recovery hook stored with jacking tools. Check that the hook is properly secured in the stored place after use.

WARNING:

• Stand clear of a stuck vehicle.

• Never spin your tires at high speed. This could cause them to explode and result in serious injury. Parts of your vehicle could also overheat and be damaged.

CAUTION:

• Tow chains or cables must be attached only to the vehicle recovery hooks or main structural members of the vehicle. Otherwise, the vehicle body will be damaged.

• Never use the vehicle tie downs to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehicle using the vehicle tie downs or recovery hooks.

• Always pull the cable straight out from the front of the vehicle. Never pull on the hook at an angle.

• Pulling devices should be routed so they never touch any part of the suspension, steering, brake or cooling systems.

• Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or recovery.

REAR

JMAIA0305ZZ

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TOW TRUCK TOWING

Rear hook is designed as the recovery hook.

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PROCEDURE FOR PARK LOCK RELEASE

GI-45

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PROCEDURE FOR PARK LOCK RELEASE

PROCEDURE FOR PARK LOCK RELEASE INFOID:0000000007027273

CAUTION:

If the vehicle must be unavoidably moved with front wheel on the ground or four wheel on the ground, release the park lock and hold the park lock in the released status (N position). The park lock is activated when power switch is OFF or when 12V battery voltage is low. Always perform the following work so that the N position status is maintained. If the vehicle is moved without performing the fo llowing work, serious accident may be caused. Steering lock does not operate after performing this work. Be careful that the brake effectiveness is reduced and steering operation becomes heavy.

1. Turn power switch ON (Press power switch twice without depressing brake pedal). At this moment, check

that electric parking brake is operated.

2. Shift selector lever from the P position to the N position (Depress brake pedal while all doors are closed,

and then release the P position).

3. Remove the following fuse.

•PBW MTR-1

•PBW MTR-2

1. Fuse holder 2. Fuse holder cover

3. PBW MTR-2 fuse 4. PBW MTR-1 fuse

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PROCEDURE FOR PARK LOCK RELEASE

• METER 1

4. Release electric parking brake.

5. Turn power switch OFF. (Release brake pedal)

6. Move the vehicle while power switch is OFF.

7. Fix the vehicle after moving. (Using electric parking brake or tire stopper)

8. Install fuse that is removed.

9. Turn power switch ON (Press switch twice without depressing brake pedal) and wait for 5 seconds at this moment, maintain the shift position to the N position. (Charge 12V battery if its voltage is low)

10. Turn power switch OFF. (Wait for 5 seconds)

1. Fuse block 2. Installment mask LH

3. METER 1 fuse

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

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BASIC INSPECTION

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

Work Flow INFOID:0000000006825148

WORK FLOW

Control Units and Electrical Parts INFOID:0000000006825149

PRECAUTIONS

• Never reverse polarity of battery terminals.

• Install only parts specified for a vehicle.

• Before replacing the control unit, check the input and output and functions of the component parts.

• Do not apply excessive force when disconnecting a connector.

SGI838

STEP DESCRIPTION

STEP 1

Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis:

WHAT Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio). WHEN Date, Time of Day, Weather Conditions, Frequency. WHERE Road Conditions, Altitude and Traffic Situation.

HOW

System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed.

STEP 2

Operate the system, road test if necessary. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulation Tests”.

STEP 3

Get the proper diagnosis materials together including:

• Power Supply Routing

• System Operation Descriptions

• Applicable Service Manual Sections

• Check for any Service Bulletins Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.

STEP 4

Inspect the system for mechanical binding, loose connectors or wiring damage. Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Layouts.

STEP 5 Repair or replace the incident circuit or component. STEP 6

Operate the system in all modes. Verify the system works properly under all conditions. Check you have not inadvertently created a new incident during your diagnosis or repair steps.

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

• Do not apply excessive shock to the control unit by dropping or hit-

ting it.

• Be careful to prevent condensation in the control unit due to rapid

temperature changes and do not let water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle.

• Be careful not to let oil to get on the control unit connector.

• Avoid cleaning the control unit with volatile oil.

• Do not disassemble the control unit, and do not remove the upper

and lower covers.

• When using a DMM, be careful not to let test probes get close to

each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting.

• When checking input and output signals of the control unit, use the

specified check adapter.

How to Check Terminal INFOID:0000000006825614

CONNECTOR AND TERMINAL PIN KIT

• Use the connector and terminal pin kits listed below when replacing connectors or terminals.

• The connector and terminal pin kits contain some of the most commonly used NISSAN/INFINITI connectors

and terminals. For detailed connector and terminal pin replacement procedures, refer to the latest NISSAN/ INFINITI CONNECTOR AND TERMINAL PIN SERVICE MANUAL.

SAIA0255E

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HOW TO PROBE CONNECTORS

• Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks.

• The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip.

Probing from Harness Side

Standard type (not waterproof type) connector should be probed from harness side with “T” pin.

• If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal.

• Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.

Probing from Terminal Side

FEMALE TERMINAL

• There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch. Do not insert any object other than the same type male terminal into female terminal.

Tool number

(Kent-Moore No.)

Tool na me

Description

(J38751-95NI) Connector and terminal pin kit (NISSAN)

(J38751-95INF) Connector and terminal pin kit (INFINITI)

(J42992-98KIT) OBD and terminal repair kit

(J42992-2000UPD) OBD-II Connector Kit Update

WAIA0004E WAIA0005E

SGI841

SEL265V

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

• Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.

MALE TERMINAL

• Carefully probe the contact surface of each terminal using a “T” pin.

CAUTION:

Never bend terminal.

How to Check Enlarged Contact Spring of Terminal

• An enlarged contact spring of a terminal may create intermittent signals in the circuit.

• If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal.

1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire.

NOTE: Use a male terminal which matches the female terminal.

2. Disconnect the suspected faulty connector and hold it terminal

side up.

3. While holding the wire of the male terminal, try to insert the male

terminal into the female terminal.

CAUTION:

Never force the male terminal into the female terminal with your hands.

SEL266V

SEL267V

SEL270V

SEL271V

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< BASIC INSPECTION >

4. While moving the connector, check whether the male terminal can be easily inserted or not.

• If the male terminal can be easily inserted into the female ter-

minal, replace the female terminal.

Waterproof Connector Inspection

If water enters the connector, it can short interior circuits. This may lead to intermittent problems. Check the following items to maintain the original waterproof characteristics.

RUBBER SEAL INSPECTION

• Most waterproof connectors are provided with a rubber seal

between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications.

• The rubber seal may come off when connectors are disconnected.

Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector.

WIRE SEAL INSPECTION

• The wire seal must be installed on the wire insertion area of a

waterproof connector. Be sure that the seal is installed properly.

Terminal Lock Inspection

Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.

Intermittent Incident INFOID:0000000006825150

DESCRIPTION

Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditions present at the time of the incident. Doing so may help avoid a No T rouble Found Di agnosis. The fol-

SEL272V

SEL273V

SEL275V

SEL330V

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident.

The section is broken into the six following topics:

• Vehicle vibration

• Heat sensitive

• Freezing

• Water intrusion

• Electrical load

• Cold or hot start up Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem.

VEHICLE VIBRATION

The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration.

Connector & Harness

Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This test may indicate a loose or poor electrical connection.

Hint

Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system.

Sensor & Relay

Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay.

Engine Compartment

There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are:

• Connectors not fully seated.

• Wiring harness not long enough and is being stressed due to engine vibrations or rocking.

• Wires laying across brackets or moving components.

• Loose, dirty or corroded ground wires.

• Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground Inspection described later.) First check that the system is properly grounded. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity.

Behind the Instrument Panel

An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw.

Under Seating Areas

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< BASIC INSPECTION >

An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or pinching.

HEAT SENSITIVE

• The customer's concern may occur during hot weather or after car

has sat for a short time. In such cases you will want to check for a heat sensitive condition.

• To determine if an electrical component is heat sensitive, heat the

component with a heat gun or equivalent.

CAUTION:

Never heat components above 60°C (140°F).

• If incident occurs while heating the unit, either replace or properly

insulate the component.

FREEZING

• The customer may indicate the incident goes away after the car

warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system.

• There are two methods to check for this. The first is to arrange for

the owner to leave his car overnight. Check it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected.

• The second method is to put the suspect component into a freezer

long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

WATER INTRUSION

The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash.

CAUTION:

Never spray water directly on any electrical components.

ELECTRICAL LOAD

The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.

COLD OR HOT START UP

On some occasions an electrical incident may occur only when the car is started cold, or it may occur when the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis.

SGI842

SGI843

SGI844

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

Circuit Inspection

INFOID:0000000006825151

DESCRIPTION

• In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure.

• You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this.

TESTING FOR “OPENS” IN THE CIRCUIT

Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

Continuity Check Method

The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Check to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits, please refer to the previous schematic.

• Disconnect the battery negative cable.

• Start at one end of the circuit and work your way to the other end. (At the fuse block in this example)

• Connect one probe of the DMM to the fuse block terminal on the load side.

• Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A)

• Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity . If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B)

• Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C)

Any circuit can be diagnosed using the approach in the previous example.

Voltage Check Method

To help in understanding the diagnosis of open circuits please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function.

• Connect one probe of the DMM to a known good ground.

• Begin probing at one end of the circuit and work your way to the other end.

• With SW1 open, probe at SW1 to check for voltage. voltage: open is further down the circuit than SW1. no voltage: open is between fuse block and SW1 (point A).

• Close SW1 and probe at relay.

OPEN A circuit is open when there is no continuity through a section of the circuit.

SHORT

There are two types of shorts.

• SHORT CIRCUIT

When a circuit contacts another circuit and causes the normal resistance to change.

• SHORT TO GROUND When a circuit contacts a ground source and grounds the circuit.

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voltage: open is further down the circuit than the relay. no voltage: open is between SW1 and relay (point B).

• Close the relay and probe at the solenoid. voltage: open is further down the circuit than the solenoid. no voltage: open is between relay and solenoid (point C).

Any powered circuit can be diagnosed using the approach in the previous example.

TESTING FOR “SHORTS” IN THE CIRCUIT

To simplify the discussion of shorts in the system, please refer to the following schematic.

Resistance Check Method

• Disconnect the battery negative cable and remove the blown fuse.

• Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.

• Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known good ground.

• With SW1 open, check for continuity. continuity: short is between fuse terminal and SW1 (point A). no continuity: short is further down the circuit than SW1.

• Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity: short is between SW1 and the relay (point B). no continuity: short is further down the circuit than the relay.

• Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity: short is between relay and solenoid (point C). no continuity: check solenoid, retrace steps.

Voltage Check Method

• Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.

• Turn the power switch to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground).

• With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage: short is between fuse block and SW1 (point A). no voltage: short is further down the circuit than SW1.

• With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for voltage. voltage: short is between SW1 and the relay (point B). no voltage: short is further down the circuit than the relay.

• With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage: short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage: retrace steps and check power to fuse block.

GROUND INSPECTION

• Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works.

• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface.

• When inspecting a ground connection follow these rules:

- Remove the ground bolt or screw.

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

- Inspect all mating surfaces for tarnish, dirt, rust, etc.

- Clean as required to assure good contact.

- Reinstall bolt or screw securely.

- Inspect for “add-on” accessories which may be interfering with the ground circuit.

- If several wires are crimped into one ground eyelet terminal, check for proper crimps. Check all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet check no ground wires have excess wire insulation.

• For detailed ground distribution information, refer to “Ground Distribution” in PG section.

VOLTAGE DROP TESTS

• Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation.

• Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop.

• Unwanted resistance can be caused by many situations as follows:

- Undersized wiring (single strand example)

- Corrosion on switch contacts

- Loose wire connections or splices.

• If repairs are needed always use wire that is of the same or larger gauge.

Measuring Voltage Drop — Accumulated Method

• Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the DMM should be closer to power and the negative lead closer to ground.

• Operate the circuit.

• The DMM will indicate how many volts are being used to “push” current through that part of the circuit.

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< BASIC INSPECTION >

Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

Measuring Voltage Drop — Step-by-Step

• The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”).

• Circuits in the “Computer Controlled System” operate on very low amperage.

• The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the system. Such resistance variation may be caused by poor connection, improper installation, improper wire gauge or corrosion.

• The step by step voltage drop test can identify a component or wire with too much resistance.

CONTROL UNIT CIRCUIT TEST

System Description

• When the switch is ON, the control unit lights up the lamp.

CASE 1

SGI974

SAIA0258E

MGI034A

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GI-58

< BASIC INSPECTION >

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

INPUT-OUTPUT VOLTAGE CHART

• The voltage value is ba sed on the body ground.

• *: If high resistance exist s in the swi t ch sid e circ ui t (cau se d by a single stra nd), termi nal 1 d oe s not d etec t batt ery vol tage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp.

CASE 2

INPUT-OUTPUT VOLTAGE CHART

• The voltage value is ba sed on the body ground.

• *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not dete ct approx. 0 V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.

Terminal No. Description

Condition Value (Approx.)

In case of high resistance such as single strand (V) *

+ − Signal name

Input/

Output

Body ground

Switch Input

Switch ON Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF 0 V Approx. 0

Body ground

Lamp Output

Switch ON Battery voltage Approx. 0 (Inoperative lamp) Switch OFF 0 V Approx. 0

Terminal No. Description

Condition Value (Approx.)

In case of high resistance such as single strand (V) *

+ − Signal name

Input/

Output

Body ground

Lamp Output

Switch ON 0 V Battery voltage (Inoperative lamp) Switch OFF Battery voltage Battery voltage

Body ground

Switch Input

Switch ON 0 V Higher than 0 Approx. 4 (Example) Switch OFF 5 V Approx. 5

MGI035A

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Page 64

CONSULT/GST CHECKING SYSTEM

GI-59

< BASIC INSPECTION >

CONSULT/GST CHECKING SYSTEM

Description INFOID:0000000006856142

• When CONSULT/GST is connected with a data link connector (A) equipped on the vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various kinds of diagnostic tests.

• Refer to CONSULT Software Operation Manual for more information.

CONSULT Function and System Application*1 INFOID:0000000006918515

FUNCTION

SYSTEM APPLICATION

1 : Instrument lower panel LH

JSAIA1464ZZ

Mode Function All DTC Reading Display all DTCs or diagnostic items that all ECUs are recording and judging. Work Support This mode enables a technician to adjust some devices faster and more accurately. Self Diagnostic Results Retrieve DTC from ECU and display diagnostic items. Data Monitor Monitor the input/output signal of the control unit in rea l time . CAN Diagnosis This mode displays a network diagnosis result about CAN by diagram. CAN Diagnosis Support Monitor It monitors the status of CAN communication. Active Test Send the drive signal from CONSULT to the actuator.The operation check can be performed. DTC & SRT confirmation The status of system monitoring tests and the self-diagnosis status/result can be confirmed. ECU Identification Display the ECU identification number (part number etc.) of the selected system. Configuration Function to READ/WRITE vehicle config uration. Special Function Other results or histories, etc. that are recorded in ECU are displayed.

System

All DTC Reading

Work Support

Self Diagnostic Results

Data Monitor

CAN Diagnosis

CAN Diagnosis Support Monitor

Active Test

DTC & SRT confirmation

ECU Identification

Configuration

AIR BAG x-x-x---xMETER / M&A x-xxxx---BCM xxxxxxx-xx IPDM E/R x -xxxxx-xEPS x-xxxx- -xMULTI AV - -xxxxx - -HVAC -xxxxxx-x-

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GI-60

< BASIC INSPECTION >

CONSULT/GST CHECKING SYSTEM

x: Applicable *1 : If GST application is equipped, functions in accordance with SAE J1979 and ISO 15031-5 can be used.

CONSULT/GST Data Link Connector (DLC) Circuit INFOID:0000000006856144

INSPECTION PROCEDURE

If the CONSULT/GST cannot diagnose the system properly, check the following items.

NOTE:

The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system. A short in a DDL circuit connected to a control unit in one system may affect CONSULT access to other systems. If the GST cannot operate properly, check the circuit based on the information of SAE J1962 and ISO 15031-

ABS xxxxxxx-xTCU xxxxxx--xHV BAT xxxxx-x-xEV/HEV xxxxxxx-xCHARGER x-xxxx- -xMOTOR CONTROL xxxxxx--xSHIFT xxxxxx--xHEADLAMP LEVELIZER - xxxxxxxxBRAKE xxxxxx--xEHS/PKB xxxxxx--xVSP x-xx--x-x-

System

All DTC Reading

Work Support

Self Diagnostic Results

Data Monitor

CAN Diagnosis

CAN Diagnosis Support Monitor

Active Test

DTC & SRT confirmation

ECU Identification

Configuration

Symptom Check item

CONSULT/GST cannot access any system.

• CONSUL T/GST DLC power su pply circuit (Terminal 8 and 16) and grou nd circuit (Terminal 4 and 5)

CONSULT cannot access individual system. (Other systems can be accessed.)

• Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.)

• Open or short circuit between the system and CONSULT DLC (For detailed circuit, refer to wiring diagram for each system.)

• Open or short circuit CAN communication line. Refer to LAN-15, "

Trouble Diagnosis Flow Chart".

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CONSULT/GST CHECKING SYSTEM

GI-61

< BASIC INSPECTION >

Wiring Diagram - CONSULT/GST CHECKING SYSTEM - INFOID:0000000006856145

JCAWA0254GB

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GI-62

< BASIC INSPECTION >

CONSULT/GST CHECKING SYSTEM

JCAWA0255GB

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CONSULT/GST CHECKING SYSTEM

GI-63

< BASIC INSPECTION >

JCAWA0256GB

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GI-64

< BASIC INSPECTION >

CONSULT/GST CHECKING SYSTEM

JCAWA0257GB

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CONSULT/GST CHECKING SYSTEM

GI-65

< BASIC INSPECTION >

JCAWA0258GB

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GI-66

< BASIC INSPECTION >

CONSULT/GST CHECKING SYSTEM

JCAWA0259GB

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INSPECTION AND ADJUSTMENT

GI-67

< BASIC INSPECTION >

INSPECTION AND ADJUSTMENT

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Required Procedure After Battery Disconnection

INFOID:0000000006918518

*: Not equipped.

SYSTEM ITEM REFERENCE

Automatic temperature control

Temperature setting trimmer HAC-55, "

Tempe r atu r e Set tin g Trimmer"

Foot position setting trimmer HAC-56, "Foot Position Setting Trimmer" Inlet port memory function —

Inlet port Memory function (FRE)

HAC-56, "Inlet Port Memory Function

(FRE)"

Inlet port Memory Function (REC)

HAC-55, "

Inlet Port Memory Function

(REC)"

Gas Sensor Sensitivity Adjustment Function — Auto Intake Switch Interlocking Movement Change — Clean Switch Interlocking Movement Change —

Automatic drive positioner Automatic drive positioner syst em — Power window control Power window control system PWC-26, "

Description"

Sunroof system Sunroof system — Sunshade system Sunshade system —

Rear view monitor

Rear view monitor predictive course line center position adjustment

—

Around view monitor* Predictive conurse line center position adjustment — Automatic back door system Automatic back door system — Engine oil level read Engine oil level read — VCM timer set VCM timer set EVC-99, "

Description"

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EVC-1

ELECTRIC POWER TRAIN

SECTION EVC

EVC

CONTENTS

EV CONTROL SYSTEM

PRECAUTION ...............................................7

PRECAUTIONS ...................................................7

Precaution for Technicians Using Medical Electric ......7

Point to Be Checked Before Starting Maintenance

Work ................................ ..........................................

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-

SIONER" ...................................................................

Precaution for Procedure without Cowl Top Cover ......8

Precaution for Removing 12V Battery .......................8

High Voltage Precautions ..........................................8

General Precautions ...............................................10

PREPARATION ...........................................13

PREPARATION ..................................................13

Commercial Service Tools ......................................13

SYSTEM DESCRIPTION .............................14

COMPONENT PARTS .......................................14

Component Parts Location . .... .................................14

VCM ........................................................................16

M/C Relay ...............................................................16

F/S Relay ..... ... ... .... .......................................... .......16

F/S CHG Relay ............................................ .... .......16

SSOFF Relay ..........................................................17

A/C Relay ................................................................17

System Main Relay 1 ..............................................17

System Main Relay 2 ..............................................17

Pre-charge Relay ....................................................17

Reverse Lamp Relay .... ... ........................................17

Accelerator Pedal Position Sensor ..........................17

Refrigerant Pressure Sensor ...................................17

Stop Lamp Switch ...................................................18

ASCD Steering Switch ............................................18

ASCD Brake Switch ................................................18

DC/DC Junction Box ...............................................18

Battery Current Sensor (With Battery Tempera-

ture Sensor) .................................... .... ... ... ..............

Coolant Temperature Sensor ..................................19

Electric Water Pump ................................................20

Cooling Fan Control Module ....................................20

Combination Meter ..................................................20

Warning/Indicator Lamp ..........................................21

ECO Indicator .. ... .......................................... ... ... .....23

Information Display ..................................................23

Approaching Vehicle Sound for Pedestrian s

(VSP) .......................................................................

High Voltage Warning Label ....................................24

SYSTEM ............................................................25

ELECTRIC POWER TRAIN SYSTEM .......................25

ELECTRIC POWER TRAIN SYSTEM : System

Description .......................... ....... ...... ... ....... ...... ........

ELECTRIC POWER TRAIN SYSTEM : Schematic

....

EV SYSTEM START UP CONTROL .........................30

EV SYSTEM START UP CONTROL : System De-

scription ...................................................................

HIGH VOLTAGE POWER SUPPLY CONTROL .......33

HIGH VOLTAGE POWER SUPPLY CONTROL :

System Description ..................................................

MOTOR POWER CONTROL .....................................34

MOTOR POWER CONTROL : System Descrip-

tion ................................... ................................... .....

MOTOR REGENERATION CONTROL .....................36

MOTOR REGENERATION CONTROL : System

Description .......................... ....... ...... ... ....... ...... ........

LI-ION BATTERY CHARGE CONTROL ...................36

LI-ION BATTERY CHARGE CONTROL : System

Description .......................... ....... ...... ... ....... ...... ........

LI-ION BATTERY CHARGE CONTROL : Normal

Charge Control ........................................................

LI-ION BATTERY CHARGE CONTROL : Quick

Charge Control ........................................................

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EVC-2

HIGH VOLTAGE SYSTEM COOLING CONTROL ... 39

HIGH VOLTAGE SYSTEM COOLING CONTROL

: System Description ...............................................

AIR CONDITIONER CONTROL ................................ 43

AIR CONDITIONER CONTROL : System De-

scription ..................................................................

POWER VOLTAGE VARIABLE CONTROL SYS-

TEM ...........................................................................

POWER VOLTAGE VARIABLE CONTROL SYS-

TEM : System Description ......................................

AUTOMATIC 12V BATTERY CHARGE CONTROL

...

AUTOMATIC 12V BATTERY CHARGE CON-

TROL : System Description ....................................

POWER CUT OFF CONTROL .................................. 45

POWER CUT OFF CONTROL : System Descrip-

tion ................................... .......................................

AUTOMATIC SPEED CONTROL DEVICE (ASCD) ... 46

AUTOMATIC SPEED CONTROL DEVICE (AS-

CD) : System Description .......................................

ECO INDICATOR CONTROL ...................................46

ECO INDICATOR CONTROL : System Descrip-

tion ................................... .......................................

CAN COMMUNICATION ........................................... 47

CAN COMMUNICATION : System Description ...... 48

OPERATION ......................................................49

AUTOMATIC SPEED CONTROL DEVICE (ASCD) ... 49

AUTOMATIC SPEED CONTROL DEVICE (AS-

CD) : Switch Name and Function ...........................

ON BOARD DIAGNOSTIC (OBD) SYSTEM .....50

Diagnosis Description ............................................. 50

Counter System ......... ... ... ....................................... 50

DTC and Freeze Frame Data ................................. 50

DIAGNOSIS SYSTEM (VCM) ............................51

CONSULT Function ................................................ 51

ECU DIAGNOSIS INFORMATION .............. 60

VCM ...................................................................60

Reference Value ........ ... ... ....................................... 60

Fail-Safe ................................................................. 73

DTC Inspection Priority Chart ................................. 76

DTC I ndex ................. ...................... ....................... 78

WIRING DIAGRAM ..................................... 82

VCM ...................................................................82

Wiring Diagram ....................................................... 82

BASIC INSPECTION ................................... 94

DIAGNOSIS AND REPAIR WORK FLOW ........94

Work Flow ...............................................................94

Diagnostic Work Sheet ...........................................96

ADDITIONAL SERVICE WHEN REMOVING

12V BATTERY NEGATIVE TERMINAL ............

Description .............................................................. 99

Work Procedure ...................................................... 99

ADDITIONAL SERVICE WHEN REPLACING

VCM ..................................................................

100

Description ............................................................ 100

Work Procedure .................................................... 100

ACCELERATOR PEDAL RELEASED POSI-

TION LEARNING ..............................................

102

Description ............................................................ 102

Work Procedure .................................................... 102

LI-ION BATTERY GRADUAL CAPACITY

LOSS DATA CLEAR ........................................

103

Description ............................................................ 103

Work Procedure .................................................... 103

LI-ION BATTERY JUNCTION BOX DATA

CLEAR ..............................................................

104

Description ............................................................ 104

Work Procedure .................................................... 104

WRITE VEHICLE IDENTIFICATION NUMBER

DATA ................................................................

105

Description ............................................................ 105

Work Procedure .................................................... 105

LOAD BATTERY IDENTIFICATION DATA .....106

Description ............................................................ 106

Work Procedure .................................................... 106

DTC/CIRCUIT DIAGNOSIS .......................107

POWER SUPPLY AND GROUND CIRCUIT ....107

VCM ......................................................................... 107

VCM : Diagnosis Procedure ... .... ... ... ... ... ............... 107

U1000 CAN COMM CIRCUIT ...........................109

Description ............................................................ 109

DTC Logic ............................................................. 109

Diagnosis Procedure ..... ... ... ... ............................... 109

U1010 CONTROL MODULE (CAN) .................110

DTC Logic ............................................................. 110

Diagnosis Procedure ..... ... ... ... ............................... 110

P0603 VCM .......................................................111

DTC Logic ............................................................. 111

Diagnosis Procedure ..... ... ... ... ............................... 111

P0616 READY SIGNAL ....................................112

DTC Logic ............................................................. 112

Diagnosis Procedure ..... ... ... ... ............................... 112

P0643 SENSOR POWER SUPPLY ..................114

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EVC-3

EVC

DTC Logic .............................................................

114

Diagnosis Procedure .............. ...............................114

P0A00 COOLANT TEMPERATURE S ENSOR

116

DTC Logic .............................................................116

Diagnosis Procedure .............. ...............................116

Component Inspection .............. ... ... .... ... ...............118

P0A08 DC/DC CONVERTER ...........................119

DTC Logic .............................................................119

Diagnosis Procedure .............. ...............................119

P0A0B HIGH VOLTAGE CONNECTOR IN-

TERLOCK DETECT CIRCUIT ..........................

120

Description ............................................................120

DTC Logic .............................................................120

Diagnosis Procedure .............. ...............................120

P0A8D, P0A8E 12V BATTERY POWER SUP-

PLY ...................................................................

123

DTC Logic .............................................................123

Diagnosis Procedure .............. ...............................123

P0A8F 12V BATTERY POWER SUPPLY .......124

DTC Logic .............................................................124

Diagnosis Procedure .............. ...............................124

P0A94 DC/DC CONVERTER ...........................125

DTC Logic .............................................................125

Diagnosis Procedure .............. ...............................125

P0AA0 SYSTEM MAIN RELAY + ....................126

DTC Logic .............................................................126

Diagnosis Procedure .............. ...............................126

P0AA1 SYSTEM MAIN RELAY + ....................128

DTC Logic .............................................................128

Diagnosis Procedure .............. ...............................128

P0AA2 SYSTEM MAIN RELAY + ....................130

DTC Logic .............................................................130

Diagnosis Procedure .............. ...............................130

P0AA4 SYSTEM MAIN RELAY - .....................132

DTC Logic .............................................................132

Diagnosis Procedure .............. ...............................132

P0AA5 SYSTEM MAIN RELAY - .....................134

DTC Logic .............................................................134

Diagnosis Procedure .............. ...............................134

P0AA6 HIGH VOLTAGE SYSTEM ISOLA-

TION .................................................................

136

Description ............................................................136

DTC Logic .............................................................136

Diagnosis Procedure .............. ...............................136

P1550, P1551, P1552 BATTERY CURRENT

SENSOR ...........................................................

141

DTC Logic .............................................................141

Diagnosis Procedure .............. ...............................141

Component Inspection ...........................................143

P1554 BATTERY CURRENT SENSOR .......... 145

DTC Logic ..............................................................145

Component Function Check ..................................145

Diagnosis Procedure .............................................145

Component Inspection ...........................................147

P1556, P1557 BATTERY TEMPERATURE

SENSOR ..........................................................

149

DTC Logic ..............................................................149

Diagnosis Procedure .............................................149

Component Inspection ...........................................150

P155A BATTERY TEMPERATURE SENSOR .151

DTC Logic ..............................................................151

Diagnosis Procedure .............................................151

Component Inspection ...........................................152

P1564 ASCD STEERING SWITCH .................153

DTC Logic ..............................................................153

Diagnosis Procedure .............................................153

Component Inspection (ASCD STEERING

SWITCH) ...............................................................

154

P1572 ASCD BRAKE SWITCH ......................156

DTC Logic ..............................................................156

Diagnosis Procedure .............................................157

Component Inspection (ASCD Brake Switch) .......160

Component Inspection (Stop Lamp Switch) ..........160

P1574 ASCD VEHICLE SPEED SENSOR .....161

Description .......................... ....... ...... ... ....... ...... ......161

DTC Logic ..............................................................161

Diagnosis Procedure .............................................161

P1805 BRAKE SWITCH .................................162

DTC Logic ..............................................................162

Component Function Check ..................................162

Diagnosis Procedure .............................................162

Component Inspection (Stop Lamp Switch) ..........163

P2122, P2123 APP SENSOR ......................... 165

DTC Logic ..............................................................165

Diagnosis Procedure .............................................165

Component Inspection (Accelerator Pedal Posi-

tion Sensor) ...........................................................

167

P2127, P2128 APP SENSOR ......................... 168

DTC Logic ..............................................................168

Diagnosis Procedure .............................................168

Component Inspection (Accelerator Pedal Posi-

tion Sensor) ...........................................................

170

P2138 APP SENSOR ......................................171

DTC Logic ..............................................................171

Diagnosis Procedure .............................................171

Component Inspection (Accelerator Pedal Posi-

tion Sensor) ...........................................................

172

P3100 EV SYSTEM CAN COMMUNICATION . 173

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EVC-4

Description ....................... .......................... ............173

DTC Logic ..............................................................173

Diagnosis Procedure .............................................173

P3101 VCM ...................................................... 175

DTC Logic ..............................................................175

Diagnosis Procedure .............................................175

P3102 LI-ION BATTERY ................................. 176

Description ....................... .......................... ............176

DTC Logic ..............................................................176

Diagnosis Procedure .............................................176

P311C HIGH VOLTAGE CIRCUIT .................. 177

DTC Logic ..............................................................177

Diagnosis Procedure .............................................177

P312A EV SYSTEM CAN COMMUNICATION . 180

Description ....................... .......................... ............180

DTC Logic ..............................................................180

Diagnosis Procedure .............................................181

P312B EV SYSTEM RESTART ERROR ......... 182

DTC Logic ..............................................................182

Diagnosis Procedure .............................................182

P312C, P3130 TRACTION MOTOR INVERT-

ER CONDENSER DISCHARGE ERROR ........

184

DTC Logic ..............................................................184

Diagnosis Procedure .............................................184

P312D QUICK CHARGE ERROR ................... 186

DTC Logic ..............................................................186

Diagnosis Procedure .............................................186

P312E READY OFF ERROR ........................... 187

DTC Logic ..............................................................187

Diagnosis Procedure .............................................187

P312F CHARGE OFF ERROR ........................ 189

DTC Logic ..............................................................189

Diagnosis Procedure .............................................189

P3131 SYSTEM SHUTOFF ERROR ............... 191

DTC Logic ..............................................................191

Diagnosis Procedure .............................................191

P3137 AIR BAG INFLATION ........................... 193

DTC Logic ..............................................................193

Diagnosis Procedure .............................................193

P315C CHARGE RELAY ................................. 194

DTC Logic ..............................................................194

Diagnosis Procedure .............................................194

P315E ABS/VDC ............................................. 195

DTC Logic ..............................................................195

Diagnosis Procedure .............................................195

P316A MOTOR SPEED ................................... 196

DTC Logic ..............................................................196

Diagnosis Procedure .............................................196

P316F ON-BOARD CHARGER ........................197

DTC Logic ............................................................. 197

Diagnosis Procedure ..... ... ... ... ............................... 197

P3172, P3173 ON-BOARD CHARGER ...........198

DTC Logic ............................................................. 198

Diagnosis Procedure ..... ... ... ... ............................... 198

P3175 VCM .......................................................199

DTC Logic ............................................................. 199

Diagnosis Procedure ..... ... ... ... ............................... 199

P3176 TRACTION MOTOR INVERTER CON-

DENSER ...........................................................

200

DTC Logic ............................................................. 200

Diagnosis Procedure ..... ... ... ... ............................... 200

P3177 ECU ACTIVATION ERROR ..................202

DTC Logic ............................................................. 202

TYPE 1 ..................................................................... 202

TYPE 1 : Diagnosis Procedure ............................. 202

TYPE 2 ..................................................................... 203

TYPE 2 : Diagnosis Procedure ............................. 203

TYPE 3 ..................................................................... 203

TYPE 3 : Diagnosis Procedure ............................. 203

P3178 ECU ACTIVATION ERROR ..................205

DTC Logic ............................................................. 205

Diagnosis Procedure ..... ... ... ... ............................... 205

P3179, P317A, P317B TRACTION MOTOR

INVERTER ........................................................

207

DTC Logic ............................................................. 207

Diagnosis Procedure ..... ... ... ... ............................... 207

P317D TRACTION MOTOR INVERTER ..........208

DTC Logic ............................................................. 208

Diagnosis Procedure ..... ... ... ... ............................... 208

P317E, P3180, P3182 LI-ION BATTERY .........209

DTC Logic ............................................................. 209

Diagnosis Procedure ..... ... ... ... ............................... 209

P3183 LI-ION BATTERY ..................................210

DTC Logic ............................................................. 210

Diagnosis Procedure ..... ... ... ... ............................... 210

P3188 ELECTRIC SHIFT .................................211

DTC Logic ............................................................. 211

Diagnosis Procedure ..... ... ... ... ............................... 211

P318A ELECTRIC SHIFT .................................212

DTC Logic ............................................................. 212

Diagnosis Procedure ..... ... ... ... ............................... 212

P318B ELECTRIC SHIFT .................................213

DTC Logic ............................................................. 213

Diagnosis Procedure ..... ... ... ... ............................... 213

P318D CAN COMMUNICATION ......................214

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EVC-5

EVC

DTC Logic .............................................................

214

Diagnosis Procedure .............. ...............................214

P3191, P319C, P31A7 EV SYSTEM CAN

COMMUNICATION ...........................................

215

DTC Logic .............................................................215

Diagnosis Procedure .............. ...............................215

P3193, P319E, P31A9 EV SYSTEM CAN

COMMUNICATION ...........................................

216

DTC Logic .............................................................216

Diagnosis Procedure .............. ...............................216

P3194, P319F, P31AA CAN COMMUNICA-

TION .................................................................

217

DTC Logic .............................................................217

Diagnosis Procedure .............. ...............................217

P3195, P31A0, P31AB CAN COMMUNICA-

TION .................................................................

218

DTC Logic .............................................................218

Diagnosis Procedure .............. ...............................218

P3196, P31A1, P31AE EV SYSTEM CAN

COMMUNICATION ...........................................

219

DTC Logic .............................................................219

Diagnosis Procedure .............. ...............................219

P3197, P31A2, P31AD EV SYSTEM CAN

COMMUNICATION ...........................................

220

DTC Logic .............................................................220

Diagnosis Procedure .............. ...............................220

P31AF, P31B3 EV SYSTEM CAN COMMUNI-

CATION ............................................................

221

DTC Logic .............................................................221

Diagnosis Procedure .............. ...............................221

P31B0, P31B4 CAN COMMUNICATION .........222

DTC Logic .............................................................222

Diagnosis Procedure .............. ...............................222

P31B5 CAN COMMUNICATION ......................223

DTC Logic .............................................................223

Diagnosis Procedure .............. ...............................223

P31B6 CAN COMMUNICATION ......................224

DTC Logic .............................................................224

Diagnosis Procedure .............. ...............................224

P31B7 CAN COMMUNICATION ......................225

DTC Logic .............................................................225

Diagnosis Procedure .............. ...............................225

P31B8 EV SYSTEM CAN COMMUNICATION ..226

DTC Logic .............................................................226

Diagnosis Procedure .............. ...............................226

P31B9 CAN COMMUNICATION ......................227

DTC Logic .............................................................227

Diagnosis Procedure .............. ...............................227

P31C0 ON-BOARD CHARGER ...................... 228

DTC Logic ..............................................................228

Diagnosis Procedure .............................................228

P31C1, P31C2 TCU ........................................230

DTC Logic ..............................................................230

Diagnosis Procedure .............................................230

P31C4 VCM TIMER .........................................231

DTC Logic ..............................................................231

Diagnosis Procedure .............................................231

P31C5, P31C6, P31C7 VCM ...........................232

DTC Logic ..............................................................232

Diagnosis Procedure .............................................232

P31C8. P31C9 NORMAL CHARGE RELAY .. 233

DTC Logic ..............................................................233

Diagnosis Procedure .............................................233

P31CA. P31CB QUICK CHARGE RELAY ..... 236

DTC Logic ..............................................................236

Diagnosis Procedure .............................................236

P31D4 PRE-CHARGE RELAY .......................238

DTC Logic ..............................................................238

Diagnosis Procedure .............................................238

P31D5 PRE-CHARGE RELAY .......................239

DTC Logic ..............................................................239

Diagnosis Procedure .............................................239

P31D6 F/S RELAY ..........................................241

DTC Logic ..............................................................241

Diagnosis Procedure .............................................241

P31D7 F/S RELAY ..........................................242

DTC Logic ..............................................................242

Diagnosis Procedure .............................................242

P31DB SYSTEM MAIN RELAY + ................... 244

DTC Logic ..............................................................244

Diagnosis Procedure .............................................244

P31DC SYSTEM MAIN RELAY - ....................246

DTC Logic ..............................................................246

Diagnosis Procedure .............................................246

P31DD PRE-CHARGE RELAY .......................248

DTC Logic ..............................................................248

Diagnosis Procedure .............................................248

P31DE SYSTEM MAIN RELAY ......................249

DTC Logic ..............................................................249

Diagnosis Procedure .............................................249

P31E0 HIGH VOLTAGE CIRCUIT INTER-

LOCK ERROR .................................................

251

Description .......................... ....... ...... ... ....... ...... ......251

DTC Logic ..............................................................251

Diagnosis Procedure .............................................251

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EVC-6

P31E1 HIGH VOLTAGE CIRCUIT INTER-

LOCK ERROR .................................................

256

Description ....................... .......................... ............256

DTC Logic ..............................................................256

Diagnosis Procedure .............................................256

P31E2 HIGH VOLTAGE CIRCUIT INTER-

LOCK ERROR .................................................

259

Description ....................... .......................... ............259

DTC Logic ..............................................................259

Diagnosis Procedure .............................................259

P31E7 RESTART INHIBITION ........................ 261

Description ....................... .......................... ............261

P31E8 WATER PUMP 1 .................................. 262

DTC Logic ..............................................................262

Diagnosis Procedure .............................................262

P31E9 WATER PUMP 1 .................................. 264

DTC Logic ..............................................................264

Diagnosis Procedure .............................................264

P31EA WATER PUMP 2 ................................. 265

DTC Logic ..............................................................265

Diagnosis Procedure .............................................265

P31EB WATER PUMP 2 ................................. 267

DTC Logic ..............................................................267

Diagnosis Procedure .............................................267

P31EC WATER PUMP 1 ................................. 268

DTC Logic ..............................................................268

Diagnosis Procedure .............................................268

P31ED WATER PUMP 2 ................................. 269

DTC Logic ..............................................................269

Diagnosis Procedure .............................................269

P31EE REFRIGERANT PRESSURE SEN-

SOR ..................................................................

270

DTC Logic ..............................................................270

Diagnosis Procedure .............................................270

P31F0 DC/DC CONVERTER ........................... 273

DTC Logic ..............................................................273

Diagnosis Procedure .............................................273

P31F2 AV INFORMATION MISMATCH .......... 275

DTC Logic ..............................................................275

Diagnosis Procedure .............................................275

COOLING FAN .................................................277

Component Function Check ................................. 277

Diagnosis Procedure ..... ... ... ... ............................... 277

Component Inspection (Cooling Fan Motor) ......... 279

Component Inspection (Cooling Fan Relay) ......... 280

M/C RELAY ......................................................281

Diagnosis Procedure ..... ... ... ... ............................... 281

Component Inspection (M/C Relay) ...................... 283

F/S CHG RELAY ..............................................284

Diagnosis Procedure ..... ... ... ... ............................... 284

Component Inspection (F/S CHG Relay) .............. 286

SSOFF RELAY .................................................287

Diagnosis Procedure ..... ... ... ... ............................... 287

Component Inspection (SSOFF Relay) ................ 289

REVERSE LAMP RELAY .................................290

Component Function Check ................................. 290

Diagnosis Procedure ..... ... ... ... ............................... 290

Component Inspection (Reverse Lamp Relay) ..... 292

A/C RELAY .......................................................294

Diagnosis Procedure ..... ... ... ... ............................... 294

Component Inspection (A/C Relay) ...................... 296

CHARGING STATUS INDICATOR ..................297

Component Function Check ................................. 297

Diagnosis Procedure ..... ... ... ... ............................... 297

IMMEDIATE CHARGING SWITCH ..................300

Diagnosis Procedure ..... ... ... ... ............................... 300

Component Inspection (Immediate Char ging

Switch) ..................................................................

302

SYMPTOM DIAGNOSIS ...........................303

EV CONTROL SYSTEM ...................................303

Symptom Table ..................................................... 303

REMOVAL AND INSTALLATION ............. 307

DC/DC-J/B ........................................................307

Exploded View ...................................................... 307

Removal and Installation .. ... .................................. 307

Inspection ............................ ................ ............. ..... 314

VCM ..................................................................315

Exploded View ...................................................... 315

Removal and Installation .. ... .................................. 315

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PRECAUTIONS

EVC-7

< PRECAUTION >

EVC

PRECAUTION

PRECAUTIONS

Precaution for Technicians Using Medical Electric INFOID:0000000007071848

OPERATION PROHIBITION

WARNING:

• Parts with strong magnet is used in this vehicle.

• Technicians using a medical electric device such as pacemaker must never perform operation on the vehicle, as magnetic field can affect the device function by approaching to such parts.

NORMAL CHARGE PRECAUTION

WARNING:

Precaution at telematics system operation

WARNING:

• The electromagnetic wave of TCU might affect the function of the implantable cardiac pacemaker or the implantable cardioverter defibrillator (ICD), when using the service, etc.

Precaution at intelligent key system operation

WARNING:

Point to Be Checked Before Starting Maintenance Work INFOID:0000000007079401

The high voltage system may starts automatically. It is required to check that the timer air conditioner and timer charge (during EVSE connection) are not set before starting maintenance work. NOTE:

If the timer air conditioner or timer charge (during EVSE connection) is set, the high voltage system starts automatically even when the power switch is in OFF state.

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" INFOID:0000000007080038

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EVC-8

< PRECAUTION >

PRECAUTIONS

system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this Service Manual.

WARNING:

Always observe the following items for preventing accidental activation.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

Always observe the following items for preventing accidental activation.

• When using air or electric power tools or hammers, always switch the power switch OFF , disconnect the 12V battery, and wait at least 3 minutes before performing any service.

Precaution for Procedure without Cowl Top Cover INFOID:0000000006977077

When performing the procedure after removing cowl top cover , cover the lower end of windshield with urethane, etc to prevent damage to windshield.

Precaution for Removing 12V Battery INFOID:0000000006977078

NOTE:

• The automatic 12V battery charge control may start even when the power switch is in OFF state.

• The automatic 12V battery charge control does not start within approximately one hour when the power switch is turned ON/OFF.

High Voltage Precautions INFOID:0000000006977079

WARNING:

• Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

• Be sure to put the removed service plug in your pocket and carry it with you so that another person does not accidentally connect it while work is in progress.

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PRECAUTIONS

EVC-9

< PRECAUTION >

EVC

• Be sure to wear insulating protective equipment consisting of glove, shoes and face shield before beginning work on the high voltage system.

• Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage part s with an insulating cover sheet or similar item to prevent other persons from contacting them.

CAUTION:

HIGH VOLTAGE HARNESS AND EQUIPMENT IDENTIFICATION

HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS

Immediately insulate disconnected high voltage connectors and terminals with insulating tape.

REGULATIONS ON WORKERS WITH MEDICAL ELECTRONICS

WARNING:

PROHIBITED ITEMS TO CARRY DURING THE WORK

POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT”

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EVC-10

< PRECAUTION >

PRECAUTIONS

To call the attention of other workers, indicate "High voltage work in progress. Do not touch!" on vehicles where work is being performed on the high voltage systems.

General Precautions INFOID:0000000006977080

• Never disassemble VCM and DC/DC junction box.

• If the 12V battery is disconnected, the diagnostic information will be lost within 3 minutes.

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PRECAUTIONS

EVC-11

< PRECAUTION >

EVC

• When connecting or disconnecting harness connectors into

or from VCM, take care not to damage pin terminals (bend or break). Check that there are not any bends or breaks on VCM pin terminal, when connecting harness connectors.

• After performing each TROUBLE DIAGNOSIS, perform DTC confirmation procedure or Component Function Check. The DTC should not be displayed in the DTC Confirmation Procedure if the repair is completed. The Component Function Check should be a good result if the repair is completed.

• When measuring ECU signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECU power transistor.

PBIB0090E

JSCIA0026ZZ

JMCIA0152GB

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EVC-12

< PRECAUTION >

PRECAUTIONS

• When installing C.B. ham radio or a mobile phone, be sure to

observe the following as it may adversely affect electronic control systems depending on installation location.

- Keep the antenna as far as possible from the electronic con-

trol units.

- Keep the antenna feeder line more than 20 cm (8 in) away

from the harness of electronic controls. Do not let them run parallel for a long distance.

- Adjust the antenna and feeder line so that the standing-wave

radio can be kept smaller.

- Be sure to ground the radio to vehicle body.

SEF708Y

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PREPARATION

EVC-13

< PREPARATION >

EVC

PREPARATION

Commercial Service Tools INFOID:0000000006977081

Tool name Description

Insulated gloves [Guaranteed insulation per formance for 1000V/300A]

Removing and installin g high vo ltage components

Leather gloves [Use leather gloves that can fasten the wrist tight]

• Removing and installing high voltage components

• Protect insulated gloves

Insulated safety shoes

Removing and installin g high vo ltage components

Safety glasses [ANSI Z87.1]

• Removing and installing high voltage components

• To protect eye from the spatter on the work to electric line

Insulated helmet

Removing and installin g high vo ltage components

Insulation resistance tester (Multi tester)

Measuring voltage and insulation resistance

JMCIA0149ZZ

JPCIA0066ZZ

JPCIA0011ZZ

JPCIA0012ZZ

JPCIA0013ZZ

JPCIA0014ZZ

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EVC-14

< SYSTEM DESCRIPTION >

COMPONENT PARTS

SYSTEM DESCRIPTION

COMPONENT PARTS

Component Parts Location INFOID:0000000006977082

MOTOR ROOM COMPARTMENT

Component Parts Description

A. Radiator assembly B. Cooling fan assembly C: Front fender protector LH remove

condition

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No. Component p arts Function

1 F/S relay (IPDM E/R) EVC-16, "

F/S Relay"

2 Battery Current Sensor (With Battery Temperature Sensor)

EVC-19, "

Battery Current Sensor (With Battery Tempera-

ture Sensor)"

3 M/C relay EVC-16, "M/C Relay" 4 Reverse lamp relay EVC-17, "Reverse Lamp Relay" 5 Electrically-driven intelligent brake unit BR-10, "Electrically-driven Intelligent Brake" 6 DC/DC-J/B EVC-18, "DC/DC Junction Box"

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COMPONENT PARTS

EVC-15

< SYSTEM DESCRIPTION >

EVC

BODY COMPARTMENT

7 Traction Motor Inverter TMS-12, "Traction Motor Inverter" 8 Electric water pump 1 EVC-20, "Electric Water Pump"

9 F/S CHG relay EVC-16, "F/S CHG Relay" 10 A/C relay EVC-17, "A/C Relay" 11 12V battery PG-8, "12V Battery" 12 Refrigerant pressure sensor EVC-17, "Refrigerant Pressure Sensor" 13 SSOFF relay (IPDM E/R) EVC-17, "SSOFF Relay" 14 Water temperature sensor EVC-19, "Coolant Temperature Sensor" 15 Cooling fan control module EVC-20, "Cooling Fan Control Module" 16 Electric water pump 2 EVC-20, "Electric Water Pump"

No. Component parts Function

A. Li-ion battery junction box B. Grove box cover is removed. C: Brake pedal upper part D. Accelerator pedal upper part

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EVC-16

< SYSTEM DESCRIPTION >

COMPONENT PARTS

Component Parts Description

VCM INFOID:0000000006977083

VCM (Vehicle control module) judges the vehicle status according to signals from various sensors and ECUs, and VCM controls EV system in a comprehensive manner. VCM also has a gateway function for EV system CAN communication and CAN communication, which enables communication between an ECU performing EV system CAN communication and an ECU performing CAN communication.

M/C Relay INFOID:0000000006977084

The M/C (motor control) relay supplies the main power to the EV system. VCM activates the M/C relay and supplies power to the EV system when the EV system needs to be started.

F/S Relay INFOID:0000000006977085

The F/S (fail-safe) relay supplies the driving power for the system main relay inside the Li-ion battery. VCM activates the F/S relay to make the system main relay controllable when the system is set to READY or when the battery is charged. When VCM detects a malfunction in the EV system and judges that the system main relay must be deactivated, VCM deactivates the F/S relay to shut off the system main relay driving power.

F/S CHG Relay INFOID:0000000006977086

The F/S CHG (fail-safe charge) relay supplies the driving power for the quick charge relay inside the DC/DC junction box. When VCM recognizes a quick charge start, VCM activates the F/S CHG relay to make the quick charge relay operable. During driving, F/S CHG relay remains OFF so that the quick charge relay is not activated.

No. Component parts Function

1 On-board charger VC-9, "

On-board Charger"

2 Li-ion battery controller EVB-12, "Li-ion Battery Controller" 3 TCU (telematics communication unit) AV-143, "TCU"

4 VSP control unit

VSP-8, "

Approaching Vehicle Sound For Pedestrians

(VSP) Control Unit"

5 Charging status indicator VC-11, "Charging Status Indicator" 6 ASCD steering switch EVC-18, "ASCD Steering Switch" 7 Combination meter EVC-20, "Combination Meter" 8 Immediate ch arg in g switc h VC-10, "Immediate Charging Switch" 9 Electric shift control modu le TM-27, "Electric Shift Control Module"

10 A/C auto amp. HAC-12, "A/C Auto Amp." 11 System main relay 2 EVC-17, "System Main Relay 2" 12 Pre-charge relay EVC-17, "Pre-charge Relay" 13 System main relay 1 EVC-17, "System Main Relay 1" 14 VCM (vehicle control module) EVC-16, "VCM" 15 Stop lamp switch EVC-18, "Stop Lamp Switch" 16 ASCD brake switch EVC-18, "ASCD Brake Switch" 17 Accelerator pedal position sensor EVC-17, "Accel erator Pedal Positi on Sensor"

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COMPONENT PARTS

EVC-17

< SYSTEM DESCRIPTION >

EVC

SSOFF Relay INFOID:0000000006977087

The SSOFF (self shutoff) relay supplies power to VCM and the coil of the A/C relay. The SSOFF relay is controlled by VCM so that VCM can shut off VCM power (self shutoff).

A/C Relay INFOID:0000000006977088

The A/C (air conditioner) relay supplies power to the air conditioner system. VCM activates the A/C relay to supply power to the air conditioner system when the power is turned on or an air conditioner operation request signal is received.

System Main Relay 1 INFOID:0000000006977089

The system main relay 1 is integrated in the Li-ion battery and controlled by VCM. The system main relay 1 connects and disconnects the high-voltage circuit (+) side and Li-ion battery. If the pre-charge to the inverter condenser is complete while high voltage power is supplied, VCM activates the system main relay 1 to supply power from the Li-ion battery to the EV system. Also when charging, VCM activates the system main relay 1 to supply power from an external charger to the Li-ion battery.

System Main Relay 2 INFOID:0000000006977090

The system main relay 2 is integrated in the Li-ion battery and controlled by VCM. The system main relay 2 connects and disconnects the high-voltage circuit (-) side and Li-ion battery. When high voltage power is supplied, VCM activates the system main relay 2 to supply power from the Li-ion battery to the EV system. When charging, power from an external charger is supplied from the system main relay 2 to the Li-ion battery.

Pre-charge Relay INFOID:0000000006977091

The pre-charge relay is integrated in the Li-ion battery and controlled by VCM. When high voltage power is required, VCM activates the pre-charge relay before activating the system main relay to prevent abrupt application of high voltage.

Reverse Lamp Relay INFOID:0000000006977092

When VCM receives a reverse range information from the electric shift control module, VCM activates the reverse lamp relay to turn on the reverse lamp.

Accelerator Pedal Position Sensor INFOID:0000000006977093

The accelerator pedal sensor is integrated with the accelerator pedal. This sensor is a potentiometer that detects the acceleration pedal stroke, converts it to a voltage signal, and transmits the signal to VCM. The sensor transmits its signals through dual lines, providing a minimum driving function even if either line malfunctions. Upon a POWER ON cycle, VCM learns the full close position of the acceleration pedal from the accelerator pedal position sensor signal.

Refrigerant Pressure Sensor INFOID:0000000006977094

The refrigerant pressure sensor is installed at the liquid tank of the air conditioner system. The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. VCM calculates refrigerant

PBIB1741E

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Page 90

EVC-18

< SYSTEM DESCRIPTION >

COMPONENT PARTS

pressure based on the voltage and sends a refrigerant pressure signal to the A/C amp. Furthermore, VCM uses the voltage signal to the cooling fan control.

Stop Lamp Switch INFOID:0000000006977095

The stop lamp switch is installed to the brake pedal bracket. The switch detects state of the brake pedal and transmits an ON/OFF signal to VCM. The contact of the stop lamp switch is usually open. When the brake pedal is depressed, it closes and the stop lamp switch signal is transmitted as a voltage signal.

ASCD Steering Switch INFOID:0000000006977096

ASCD steering switch has various values of electrical resistance for each button. VCM reads voltage variation of switch, and determines which button is operated.

ASCD Brake Switch INFOID:0000000006977097

The ASCD brake switch is installed to the brake pedal bracket. The switch detects state of the brake pedal and transmits an ON/OFF signal to VCM. The contact of the ASCD brake switch is usually closed. When the brake pedal is depressed, it opens to disconnect the circuit, and shut off the output voltage. This constitutes an ASCD brake switch signal.

DC/DC Junction Box INFOID:0000000006977098

The DC/DC junction box integrates a DC/DC converter to supply electric power to the 12 V power system and charge the 12V battery in addition to distributing high voltage power from the Li-ion battery to systems. The DC/DC junction box has a normal charge relay and a quick charge relay so that the circuits are changed over according to the charge mode. The DC/DC junction box has an internal cooling fin used to cool the DC/DC converter by water cooling.

DC/DC CONVERTER

PBIB2657E

JSBIA0308ZZ

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COMPONENT PARTS

EVC-19

< SYSTEM DESCRIPTION >

EVC

The DC/DC converter steps down the high voltage DC current of the Li-ion battery to a 12 V DC current, which is used to supply power to the 12 V electrical system and charge the 12V battery. In addition, the DC/DC converter changes the output voltage according to VCM signals so that appropriate voltage is supplied depending on the vehicle condition.

Battery Current Sensor (With Battery Temperature Sensor) INFOID:0000000006977099

BATTERY CURRENT SENSOR

The battery current sensor is installed to the negative cable of the battery. The battery current sensor detects the battery charge/discharge current and transmits signals to VCM. VCM judges the battery load based on these signals and controls the power generation by converting the target generation voltage to a power generation command signal and transmitting it to the DC/DC converter.

CAUTION:

Never connect the electrical component or the ground wire directly to the battery terminal. The connection causes the malfunction of the power voltage variable control, and may cause the battery discharge.

BATTERY TEMPERATURE SENSOR

Battery temperature sensor is integrated in battery current sensor. The sensor measures temperature around the battery. This sensor uses a thermistor and its electrical resistance varies as the temperature varies. VCM detects a voltage change caused by the change in electrical resistance.

Coolant Temperature Sensor INFOID:0000000006977100

The coolant temperature sensor is detects the coolant temperature. This sensor uses a thermistor that changes its electrical resistance according to the temperature. VCM detects a voltage change according to electrical resistance change.

JPBIA3262ZZ

Temperature [°C (°F)] Voltage (V) Resistance (kΩ)

25 (77) 3.333 1.9 - 2.1

90 (194) 0.969 0.222 - 0.258

SEF012P

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EVC-20

< SYSTEM DESCRIPTION >

COMPONENT PARTS

Electric Water Pump INFOID:0000000006977101

The electric water pump (1) feeds coolant by pressure, which circulates in the high voltage system cooling circuit. The high voltage system cooling circuit includes two cooling pumps. They are controlled by VCM independently so that the amount of pressure feed is adjusted according to the vehicle speed and water temperature. The electric water pump also integrates an interface circuit that monitors the pump function for any malfunction, and it transmits a malfunction signal to VCM if necessary.

Cooling Fan Control Module INFOID:0000000006977102

The cooling fan control module is mounted on top of the cooling fan and drives the cooling fan motor. The cooling fan control module conducts communication between VCM via the PWM communication. The cooling fan control module drives the cooling fan motor so that the cooling fan speed is controlled in accordance with the control signal from VCM.

Combination Meter INFOID:0000000006977103

Coolant temperature [°C (°F)] Voltage (V) Resistance (kΩ)

–10 (14) 4.4 7.0 - 11.4

20 (68) 3.5 2.35 - 2.73 50 (122) 2.2 0.68 - 1.00 90 (194) 0.9 0.236 - 0.260

SEF012P

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COMPONENT PARTS

EVC-21

< SYSTEM DESCRIPTION >

EVC

VCM controls the following items inside the combination meter in addition to the warning lamps and indicator lamps.

LI-ION BATTERY INFORMATION

Li-ion Battery Capacity Level G auge (1)

VCM receives the Li-ion battery capacity signal from the Li-ion battery controller, and VCM transmits the signal to the combination meter to display the maximum capacity of the Li-ion battery. When the capacity of the Li-ion battery decreases with age and usage, the level of the gauge will also decrease.

Li-ion Battery Available Charge Gauge (2)

VCM receives the Li-ion battery available charge signal from the Li-ion battery controller, and VCM transmits the signal to the combination meter to display the available Li-ion battery charge to run the vehicle.

Li-ion Battery Temperature Gauge (3)

VCM receives the Li-ion battery temperature signal from the Li-ion battery controller, and VCM transmits the signal to the combination meter to display the Li-ion battery temperature.

Distance Range (4)

The driving range (km or miles) provides an estimated distance that the vehicle can be driven before recharging is necessary . The driving range is const antly being calculated, based on the amount of available Li-ion battery charge and the actual power consumption average. VCM calculates average electricity consumption at a specified travel distance, according to total power consumption of the vehicle. Based on the average electricity consumption and a Li-ion battery available charge signal received from the LI-ion battery, VCM calculates driving range and transmits a driving range signal to the combination meter.

POWER METER

Maximum Power (5)

VCM receives a maximum motor output power signal from the traction motor inverter and a maximum regenerative power signal from the Li-ion battery controller. VCM transmits these signals to the combination meter and displays the upper limit of available output power and regenerative electric power.

Current Motor Power (6)

VCM receives the current motor power signal from the traction motor inverter, and VCM transmits the signal to the combination meter to display the power currently being output.

Warning/Indicator Lamp INFOID:0000000006977104

VCM controls the following warning lamps and indicator lamps.

READY TO DRIVE INDICATOR LAMP

The READY to drive indicator lamp indicates that the vehicle is in a state allowing vehicle travel. VCM transmits a READY to drive indicator lamp request signal to the combination meter via CAN communication to turn ON the READY to drive indicator lamp. The READY to drive indicator lamp operates as follows.

EV SYSTEM WARNING LAMP

Condition Illumination status

A few seconds after operation of POWER ON to READY.

Blink

READY ON Except above OFF

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EVC-22

< SYSTEM DESCRIPTION >

COMPONENT PARTS

The EV system warning lamp turns ON if a malfunction occurs with the EV system. If VCM detects a malfunction or receives an EV system warning lamp request signal from any of other ECUs, it transmits an EV system warning lamp request signal to the combination meter via CAN communication. The EV system warning lamp operates as per the following.

*1: When the EV system warning lamp tu rns ON, it re mains ON u ntil the po wer switch is turne d OFF. (Depending on diagnosis, the EV system warning lamp may turns OFF soon after the system returns to normal.)

*2: Because the EV system warning lamp cannot turn ON during charging (POWER OFF), it turns ON at a next POWER ON cycle.

POWER LIMITATION INDICATOR LAMP

The output limit indicator turns on when the vehicle output is limited. When the vehicle output is limited, VCM sends an output limit indicator ON request signal to the combination meter via CAN communication. The power limitation indicator lamp operates as per the following.

LOW BATTERY CHARGE WARNING LAMP

The low battery charge warning lamp turns ON when the Li-ion battery remaining energy is lowered. When VCM detects that Li-ion battery remaining energy is approximately 4kWh or less, VCM transmits a low battery charge warning lamp request signal to the combination meter via CAN communication. The low battery charge warning lamp operates as per the following.

PLUG IN INDICATOR LAMP

Condition Illumination status

2 seconds after turn power switch ON

(bulb check)

If malfunction is present in EV system

POWER ON just after occurrence of malfuncti on in EV system during charging (POWER OFF)

Except above OFF

JSCIA0026ZZ

Condition Illumination status

2 seconds after POWER ON

(bulb check) When vehicle power is lowered ON Except above OFF

JSCIA0027ZZ

Condition Illumination status

When Li-ion battery remaining energy is Approx. 4kWh or less.

When Li-ion battery remaining energy recovers to

4.5 kWh or more while warning lamp is illuminating

ON ⇒ OFF

Except above OFF

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COMPONENT PARTS

EVC-23

< SYSTEM DESCRIPTION >

EVC

The plug in indicator lamp turns ON when a charge connector is connected to the normal charge port or the quick charge port. VCM supplies power to the plug in indicator lamp in the combination meter to turn on the lamp when VCM receives the EVSE connecting signal or the quick charger connecting signal from on-board charger. The plug in indicator lamp operates as per the following.

NOTE:

• When the quick charge connector is connected, the indicator lamp is turned ON by turning ON the quick charger start switch.

• When EVSE is connected, the indicator lamp turns ON immediately. The indicator lamp turns OFF after the lapse of 10 seconds with non-operating state.

12V BATTERY CHARGE WARNING LAMP

When DC/DC converter is malfunctioning, the 12V battery charge warning lamp turns ON.

NOTE:

• If the 12V battery voltage lowers during READY, the READY state is also canceled.

• If VCM judges that the vehicle is running (transmission in a position except P range and parking brake released) when the 12V battery voltage lowers, it turns on the 12V battery charge warning lamp and alerts the driver by sounding a buzzer.

The 12V battery charge warning lamp operates as per the following.

ECO Indicator INFOID:0000000006977105

The ECO indicator shows the instantaneous ECO drivability in the instant ECO indicator (1) and the cumulative ECO drivability during 1 trip in the ECO tree (2). For information regarding control, refer to EVC-47, "

ECO INDICA-

TOR CONTROL : System Description".

Information Display INFOID:0000000006977106

Information necessary to control the information display is transmitted from each relevant control unit and entered into the combination meter. Based on this information, warnings or information appears on the information display. VCM displays the following items.

Condition Illumination status

2 seconds after POWER ON

(bulb check) When charge connector is connected ON Charging Blink Except above OFF

JSCIA0029ZZ

Condition Illumination status

When turn power switch ON

ON (bulb

check)⇒OFF⇒ON When 12V battery voltage lowers ON Except above OFF

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EVC-24

< SYSTEM DESCRIPTION >

COMPONENT PARTS

Approaching Vehicle Sound for Pedestrians (VSP)

INFOID:0000000006977107

VSP informs the user of various information by electronic sounds. In the following cases, VCM transmits a operation signal to VSP.

High Voltage Warning Label INFOID:0000000006977108

• The high voltage warning label is stuck on the rear side (A) of DC/ DC-J/B.

• When replacing DC/DC-J/B, make sure to stick it on original position.

Display item Display content Cruise set indicator Displays the setting status of ASCD. Shift position indicator Displays the current shift position.

Remove charge connector warning

If a plug is connected to a char ge port when a READY operatio n is performed, a warning is issued.

DC/DC converter warning Displays the voltage of 12V battery becomes lower. Timer setting status

Displays the setting status of timer charge/timer air conditioner stored in VCM.

Charging time

Displays the expected time till the target charge level is achieved in VCM timer.

Charging timer setting confirmation

This shows the next scheduled time when timer charging will be conducted.

A/C heater timer (Climate Ctrl. Timer) setting confirmation This shows the next scheduled timer air conditioner time.

Condition Operation status EVSE is connected to the normal charge port Short beep (once) When normal charging starts Short beeps in sequence (twice)

: Direction of the label

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SYSTEM

EVC-25

< SYSTEM DESCRIPTION >

EVC

SYSTEM

ELECTRIC POWER TRAIN SYSTEM

ELECTRIC POWER TRAIN SYSTEM : System Description INFOID:0000000006977109

CONTROL OUTLINE

EV depends on electric power as the only source of power for system operation. The power stored in the lithium-ion battery is supplied as high-voltage direct current to the high-voltage system while also being converted to 13-15 V by the DC/DC converter and supplied to the 12 V power system. VCM judges the vehicle status from various information and performs various EV system controls in a comprehensive manner.

Main Control Contents of EV

Control Reference

EV system start-up control

EVC-31, "

EV SYSTEM START UP CONTROL : System Descrip-

tion"

High voltage power supply control

EVC-34, "

HIGH VOLT AGE POWER SUPPL Y CONTROL : System

Description"

Motor power control EVC-35, "MOTOR POWER CONTROL : System Description" Motor regeneration control

EVC-36, "

MOTOR REGENERATION CONTROL : System De-

scription"

Li-ion battery charge control

EVC-36, "

LI-ION BATTERY CHARGE CONTROL : System De-

scription"

Cooperative Regenerative brake control BR-12, "System Description" High voltage system cooling control

EVC-39, "

HIGH VOLTAGE SYSTEM COOLING CONTROL : Sys-

tem Description"

Air conditioner control EVC-43, "AIR CONDITIONER CONTROL : System Description" Power voltage variable control

EVC-44, "

POWER VOLTAGE VARIABLE CONTROL SYSTEM :

System Description"

Automatic 12V battery charge control

EVC-45, "

AUTOMATIC 12V BATTERY CHARGE CONTROL :

System Description"

Power cut off control EVC-45, "POWER CUT OFF CONTROL : System Description" ASCD (automatic speed control device)

EVC-46, "

AUTOMATIC SPEED CONTROL DEVICE (ASCD) :

System Description"

ECO indicator control EVC-47, "ECO INDICATOR CONTROL : System Description"

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EVC-26

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SYSTEM

ELECTRIC POWER TRAIN SYSTEM : Schematic

INFOID:0000000006977110

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SYSTEM

EVC-27

< SYSTEM DESCRIPTION >

EVC

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EVC-28

< SYSTEM DESCRIPTION >

SYSTEM

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Nissan Leaf 2010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual