Nissan Leaf 2011 User Manual
Dismantling Guide
1
Foreword
This manual describes dismantling operations and related warnings and cautions for this vehicle.
This vehicle is an electrically driven car equipped with a high voltage battery pack. Failure to follow
recommended practices during dismantling will cause death or serious personal injury.
Please read this manual in advance in order to understand the features of this vehicle and to help you deal
with dismantling operations involving this vehicle. Follow the procedures in order to help assure a
successful dismantling operation.
NISSAN EMERGENCY CONTACT INFORMATION
• Nissan EV Customer Support: 1-877-664-2738 (Hours of operation are Monday-Friday 7am 7pm, Saturday 8am - 4:30pm Central time zone)
• Nissan Consumer Affairs: 1-800-647-7261 (US) or 1-800-387-0122 (Canada) (Hours of
operation are 8am - 5pm (Monday-Friday) Eastern, Central and Pacific time zones)
IMPORTANT INFORMATION ABOUT THIS MANUAL
You may see various symbols in this manual. They have the following meanings:
This symbol is used to inform you of an operation which will result in death or serious personal injury if
instructions are not followed.
Example: Touching high voltage components without using the appropriate protective equipment will result
in electrocution.
This symbol is used to inform you of an operation which may cause death or serious personal injury if
instructions are not followed.
This symbol is used to inform you of an operation which may cause personal injury or component damage if
instructions are not followed.
Please note that there may be differences between this manual and the vehicle specification due to
specification changes.
2
Table of Contents
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
NISSAN EMERGENCY CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IMPORTANT INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. ABOUT THE NISSAN LEAF™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-1 LEAF IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-1.1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-1.2. INTERIOR COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-2 VEHICLE IDENTIFICATION NUMBER (VIN) LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-3 WARNING AND INDICATOR LAMP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. BASIC HIGH VOLTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-1 HIGH VOLTAGE-RELATED AND 12V-RELATED COMPONENT LOCATIONS AND
DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-1.1. LI-ION BATTERY PACK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-2 HIGH VOLTAGE SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-2.1. WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-3 HIGH VOLTAGE CIRCUIT SHUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-4 PREVENTING ELECTRICAL SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. PREPARATION FOR DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-1 DISCHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-2 PREPARATION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-3 HIGH VOLTAGE SYSTEM SHUT-DOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-3.1. REMOVING THE CHARGE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-3.2. INDICATIONS THE HIGH VOLTAGE SYSTEM IS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-3.3. POWERING DOWN THE HIGH VOLTAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-3.4. PRIMARY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-3.5. ALTERNATE PROCEDURE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-3.6. ALTERNATE PROCEDURE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-4 CUTTING THE VEHICLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-4.1. SRS AIR BAG SYSTEM COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-4.2. VEHICLE CUT SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3-4.3. WATER SUBMERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-4.4. VEHICLE FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-5 LI-ION BATTERY DAMAGE AND FLUID LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4. JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-1 JUMP STARTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3
4-2 ELECTRIC PARKING BRAKE MECHANICAL RELEASE PROCEDURE . . . . . . . . . . . . . . . . . . 30
4-3 P (PARK) POSITION RELEASE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4-3.1. RESET PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4-4 STORING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5. DISMANTLING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-1 PRECAUTIONS FOR HANDLING HIGH VOLTAGE LITHIUM ION (LI-ION) BATTERY . . . . . . . . 35
5-2 PPE (PERSONAL PROTECTIVE EQUIPMENT) AND INSULATED TOOLS . . . . . . . . . . . . . . . . 36
5-2.1. PPE (PERSONAL PROTECTIVE EQUIPMENT) PROTECTIVE WEAR CONTROL . . . . . 36
5-2.2. DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5-2.3. INSULATED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5-3 LITHIUM-ION (LI-ION) BATTERY PACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5-3.1. EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5-3.2. REMOVAL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6. RECOVERY/RECYCLING OF THE LI-ION HIGH VOLTAGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . 41
4
1. About The Nissan LEAF™
This vehicle uses two types of batteries. One is a 12V battery that is the same as the battery in vehicles
powered by internal combustion engines, and the other is the Lithium-ion (Li-ion) battery (high voltage) for
the traction motor which propels the vehicle. The Li-ion battery is encased in steel and mounted underneath
the vehicle.
The vehicle must be plugged-in in order for the Li-ion battery to be recharged. Additionally, the vehicle
system can recharge the Li-ion battery by converting driving force into electricity while the vehicle is
decelerating or being driven downhill. This is called regenerative charging. This vehicle is considered to be
an environmentally friendly vehicle because it does not emit exhaust gases.
5
1-1 LEAF Identification
1-1.1 Exterior
The specific exterior identification features are indicated as follows:
6
1-1.2 Interior Component Location
Interior components referenced in this manual are as follows:
7
1-2 Vehicle Identification Number (VIN) Layout
The vehicle identification number can be located as follows:
Example VIN : JN1A Z0CP3BT000001
The LEAF is identified by the 5
Z = Electric vehicle
th
alphanumeric character: Z
1. VIN plate (visible through windshield) 2. Vehicle certification plate (lower center pillar)
1-3 Warning and Indicator Lamp Information
The following warning and indicator lamps are located in the instrument cluster.
Lamp Name Icon Description
READY Indicator This lamp is on when the EV system is powered up and the
vehicle is ready to drive.
EV System Warning Lamp *1
Master Warning Lamp (RED)
• Malfunction has occurred in the EV system and/or
• Emergency shut-off system has been activated. The shut-off
system activates in the following conditions:
– Front and side collisions in which the air bags are
deployed.
– Certain rear collisions.
– Certain EV system malfunctions.
This lamp is on when another red warning lamp is displayed in
the instrument cluster or a warning is displayed on the dot matrix
LCD.
Master Warning Lamp (YELLOW)
This lamp is on when:
• Li-ion battery is getting low on charge.
• A yellow warning lamp is displayed in the instrument cluster
or a message is displayed on the dot matrix LCD.
*1: When this lamp is ON, the ready lamp will turn OFF.
8
2. Basic High Voltage Information
2-1 High Voltage-Related and 12V-Related Component Locations and
Descriptions
NOTE:
Components with white number in black background are high voltage components.
9
No. Component Location Description
a Traction Motor Under hood Converts three-phase AC power to drive power
(torque) which propels the vehicle.
b DC/DC Converter –
High voltage junction
box
c Inverter Under hood Converts the DC power stored in the Li-ion bat-
d Electric air condi-
tioner compressor
e Cabin heater Under hood This is the electric heat source for the cabin
f Charge port Under hood Connecting port for EVSE (Electric Vehicle Sup-
7
s
h Li-ion (Lithium ion)
i High voltage cables Undercarriage and
j High voltage battery
k
12
s
12V Battery Under hood A lead-acid battery that supplies power to the low
battery
service disconnect
On Board Charger Cargo area (This unit
Brake power supply
backup unit
Under hood This component includes a DC/DC converter and
high voltage junction box (J/B). The junction box
provides electric power from the Li-ion battery to
all high voltage parts of the vehicle. The DC/DC
converter reduces the voltage of the Li-ion battery
to provide power to the 12V battery in order to
operate the vehicle’s electric components (headlights, audio system, etc.).
tery to three-phase AC power and controls motor
torque (revolution) by regulating the motor current.
Under hood Air conditioner compressor
heater. It heats the interior of the vehicle.
ply Equipment). Two ports are available: Normal
charge and quick charge (if so equipped).
voltage devices.
Undercarriage Stores and outputs DC power (Maximum voltage
400V) needed to propel the vehicle.
Orange-colored power cables carry high voltage
Under hood
Rear seat floor Isolates the battery from the rest of the high volt-
is installed behind a
trim panel to prevent
access)
Cargo area (This unit
is installed behind a
trim panel to prevent
access)
current between each of the high voltage components.
age electrical system.
Converts single-phase AC power from a home
power outlet to DC power and increases the voltage in order to charge the Li-ion battery.
Power supply backup unit for the brake system. It
supplies power to the brake system if a malfunction occurs in the 12V battery.
2-1.1 Li-ion Battery Pack Specifications
Li-ion battery voltage 403.2V
Number of Li-ion battery modules in the pack 48
Li-ion battery dimensions 61.8 x 46.8 x 10.4 in. (1570.5 x 1188 x 264.9 mm)
Li-ion battery weight 648 lbs (294 kg)
10
2-2 High Voltage Safety Measures
Circuit insulation The high voltage positive (+) and negative (-) circuits are insulated
from the metal chassis.
Reducing the risk of electrocution The high voltage components and harnesses have insulated cases or
orange-colored coverings which provide insulation and easy identification.
The high voltage battery case is electrically connected to the vehicle
ground. This connection helps protect the vehicle occupants and
emergency responders from high voltage electrical shock.
Identification The high voltage components are labeled “WARNING” similar to label
shown below. All high voltage harnesses are coated in orange.
2-2.1 Warning Label
11
2-3 High Voltage Circuit Shut-Off System
The high voltage can be shut off by the following methods:
Service plug Positioned in the center area of the Li-ion battery, this shuts off output high
voltage when manually removed.
System main relay Controlled by the power switch, this relay, which is controlled by the 12V
system, shuts off the high voltage from the Li-ion battery.
Emergency shut-off system
Charging connector Some of the high voltage components are activated during charging. Remove
In the case of a collision (front and side collisions in which the air bags are
deployed, certain rear collisions) or certain system malfunctions this system
may shut off the high voltage from the Li-ion battery.
the charging connector to deactivate these components.
2-4 Preventing Electrical Shock
1. If it is necessary to touch any of the high voltage harnesses or components, you must wear
appropriate PPE (refer to 3-2 Preparation Items) and shut off the high voltage system by referring
to 3-3 High Voltage System Shut-Down Procedure.
2. To avoid the risk of electrocution, do not touch the inside of the Li-ion battery unless appropriate
PPE
is worn even after shutting off the high voltage system. The Li-ion battery maintains charge
even though the high voltage system is shut down.
3. Cover any damaged high voltage components with insulated tape.
12
3. Preparation for Dismantling
• Failure to properly shut down the high voltage electrical system before the
Dismantling Procedures are performed will result in serious injury or death from
electrical shock. To prevent serious injury or death, DO NOT touch high voltage
harnesses or components without wearing appropriate PPE.
• If it is necessary to touch any of the high voltage harnesses or components you
must wear appropriate PPE to avoid electrical shock. Shut down the high voltage system
by following the steps outlined in
at least ten (10) minutes for complete discharge of the high voltage capacitor after the
high voltage system has been shut down.
• NEVER assume the LEAF is shut OFF simply because it is quiet.
• If it becomes necessary for the dismantler to leave the vehicle, place a “DANGER”
sign (for example, refer to 4-4 Storing the Vehicle) on the vehicle to alert other people
that the vehicle contains a high voltage battery.
•
indicator are ON the high voltage system is active.
• If possible, be sure to verify that the READY indicator on the instrument
cluster is OFF and the high voltage system is stopped.
If the READY indicator, charging indicator or air conditioning remote timer
3-3 High Voltage System Shut-Down Procedure. Wait
3-1 Discharging Procedures
Do not perform this procedure if the battery is damaged. If you are unsure of battery
damage, use extreme caution and wear appropriate PPE.
Li-ion battery discharging must take place before dismantling. Sufficient discharging can be achieved by
following these steps.
1. Place the selector lever into the Park (P) position
2. Apply the parking brake.
3. Set wheel chocks to ensure the vehicle is completely stopped.
13
Loading...