NISSAN Pathfinder Hybrid Dismantling Guide 2014
2014 Pathfinder HYBRID
Dismantling Guide
Foreword
This manual describes dismantling operations and important safety related warnings and cautions for this
vehicle.
This vehicle is equipped with a high voltage Lithium-ion (Li-ion) battery pack. Failure to follow
recommended practices during dismantling will cause death or serious personal injury.
Please read this manual in advance of any dismantling activities in order to understand the features of this
vehicle and to help you deal with dismantling operations involving this vehicle. Follow the procedures in
order to help assure a safe and successful dismantling operation.
This manual is periodically updated. If you are not viewing this manual on the Nissan web site, we urge you
to go to
this manual.
NISSAN EMERGENCY CONTACT INFORMATION
IMPORTANT INFORMATION ABOUT THIS MANUAL
You may see various symbols in this manual. They have the following meanings:
www.nissanusa.com or www.nissan-techinfo.com to make sure you have the most recent version of
• 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
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. PPE must always be worn when touching or
working on high voltage components.
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.
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Table of Contents
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
NISSAN EMERGENCY CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
IMPORTANT INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
1. ABOUT THE PATHFINDER HYBRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–5
1-1 PATHFINDER HYBRID IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–6
1-1.1. EXTERIOR AND ENGINE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–6
1-1.2. INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–7
1-2 VEHICLE IDENTIFICATION NUMBER (VIN) LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–8
1-3 WARNING AND INDICATOR LAMP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–9
2. BASIC HIGH VOLTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-1 BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-1.1. 12V BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-1.2. LI-ION BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-2 HIGH VOLTAGE-RELATED AND 12V-RELATED COMPONENT LOCATIONS AND
DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–12
2-3 LI-ION BATTERY PACK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–13
2-4 HIGH VOLTAGE SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–14
2-4.1. WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–14
2-5 HIGH VOLTAGE SAFETY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–15
2-6 HIGH VOLTAGE CIRCUIT SHUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–16
2-7 PREVENTING ELECTRICAL SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–16
3. PREPARATION FOR DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–17
3-1 PREPARATION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–18
3-2 PERSONAL PROTECTIVE EQUIPMENT (PPE) AND INSULATED TOOLS . . . . . . . . . . . . . DG–18
3-2.1. PERSONAL PROTECTIVE EQUIPMENT (PPE) PROTECTIVE WEAR CONTROL . DG–18
3-2.2. DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–19
3-2.3. INSULATED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–19
3-3 DISCHARGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–19
3-4 HOW TO HANDLE A DAMAGED VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–21
3-4.1. HIGH VOLTAGE SYSTEM SHUT-DOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . DG–21
3-4.2. CUTTING THE VEHICLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–31
3-4.3. WATER SUBMERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–34
3-4.4. VEHICLE FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–34
3-4.5. LI-ION BATTERY DAMAGE AND FLUID LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–35
DG–3
4. JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–36
4-1 JUMP STARTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–37
4-2 SHIFT SELECTOR LEVER LOCK RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–38
5. STORING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–39
6. DISMANTLING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–41
6-1 PRECAUTIONS FOR HANDLING HIGH VOLTAGE LITHIUM-ION (LI-ION) BATTERY . . . . DG–41
6-2 LITHIUM-ION (LI-ION) BATTERY PACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–43
6-2.1. EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–43
6-2.2. REMOVAL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–45
6-3 LI-ION BATTERY RECYCLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–49
DG–4
1. About the Pathfinder HYBRID
This hybrid electric vehicle (HEV) uses two types of batteries. One is a 12V battery that is the same as the
battery in vehicles powered by internal combustion engines. The 12V battery is located under the hood near
the driver side headlamp. The other is the Lithium-ion (Li-ion) battery (high voltage) for the traction motor
which propels the vehicle. The Li-ion battery is located under the third row seating with service plug access
through the cargo area storage bin.
The high voltage Li-ion battery is recharged with an on-board DC/DC converter and generator powered by
the engine. 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.
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1-1 PATHFINDER HYBRID IDENTIFICATION
1-1.1 Exterior and Engine Compartment
DG–6
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1-1.2 Interior
Interior components referenced in this manual are as follows:
A
B C D
E
F
G
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A. Assist charge gauge B. READY indicator (green) C. Energy flow display *1
D. Energy flow display *1 E. Liftgate switch (if equipped) F. Hood release handle
G. START/STOP switch and
ON indicator lamp (orange)
*1: This screen may not be displayed due to customer settings. Only one of these screens will display
energy flow depending on vehicle optional equipment.
DG–7
1-2 Vehicle Identification Number (VIN) Layout
In exterior appearance the Pathfinder HYBRID is nearly identical to the conventional Nissan Pathfinder
series vehicles.
The vehicle identification number can be located as follows:
Example VIN : 5N1 CR2MN0EC056087
The Pathfinder HYBRID is identified by the 4th alphanumeric character: C
C = Pathfinder HYBRID
1 2
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1. VIN plate (visible through windshield) 2. Vehicle certification plate (lower center pillar)
DG–8
1-3 Warning and Indicator Lamp Information
1 2 3 4
Hybrid System
Overheated
4
3
5
2
1
PWR
6
7
8
1
1/2
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1. Hybrid System Warning Lamp (Orange) 2. READY Indicator (Green)
3. Master Warning Lamp (Orange or Red) 4. Hybrid System Overheated Stop Vehicle Warning
(Vehicle Information Display)
DG–9
Lamp Name Icon Description
READY Indicator
(Green)
This lamp is on when the high voltage system is powered
up and the vehicle is ready to drive.
Master Warning Lamp
(Orange or Red)
Hybrid System Warning
Lamp *1
(Orange)
This lamp is on when another warning lamp or message is
displayed in the instrument cluster.
This lamp is on or blinking when:
• Malfunction has occurred in the high voltage system
and/or
• High voltage leak to vehicle chassis 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 high voltage system malfunctions.
*1: When this lamp is ON, the READY Indicator will turn OFF.
DG–10
2. Basic High Voltage Information
2-1 Battery Information
The Pathfinder HYBRID utilizes two batteries in order to supply both high and low voltage.
2-1.1 12V Battery
• The Pathfinder HYBRID contains a conventional lead-acid
12 volt battery.
• The 12V battery is located in the front of the vehicle on the
left side of the engine compartment, under a trim cover.
• The 12V battery is charged by the Li-ion battery through
the DC/DC converter.
: Vehicle front
2-1.2 Li-ion Battery
• The Pathfinder HYBRID contains a Li-ion high voltage
battery.
• The high voltage battery is mounted in the cargo area
under the 3rd row seating, enclosed in a metal case
and concealed by trim cover.
• The high voltage battery stores approximately 144 volts
DC.
• A vent hose is provided to exhaust gasses outside the
vehicle, if necessary.
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• Air vents (A) are located on the cargo area trim panels for
battery cooling.
The high voltage battery supplies power to the following:
• High voltage harnesses
• DC/DC converter
• Traction motor inverter
• Traction motor
A
A
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DG–11
2-2 High Voltage-Related and 12V-Related Component Locations and
Descriptions
=
1 3
2
4 5 7
6
NOTE:
Components with white number in black background are high voltage components.
DG–12
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No. Component Location Description
➊ DC/DC Converter Cargo area floor
(mounted right of
Li-ion battery)
➋ Service Plug Cargo area floor
(inside storage bin
behind access door)
➌ Lithium-ion (Li-ion)
Battery
➍ Traction Motor Engine compart-
➎ Traction Motor
Inverter
➅ 12V Battery Engine compart-
➐ High Voltage Har-
ness
Cargo area floor
(under 3rd row
seating floor trim)
ment (built-into the
transmission)
Engine compartment (front driver
side)
ment (front driver
side)
Cargo area (on
Li-ion battery),
under floor, engine
compartment
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.).
This is used to disable the high voltage system.
The Li-ion battery stores and outputs DC
power (Maximum voltage 144V) needed to
propel the vehicle.
Converts three-phase alternating current (AC)
power to drive power (torque) which propels
the vehicle.
Converts the DC power stored in the Li-ion
battery to three-phase AC power and controls
motor torque (revolution) by regulating the
motor current. The inverter has a built in high
voltage capacitor.
A lead-acid battery that supplies power to the
low voltage devices.
Orange-colored power cables carry high DC
voltage between each of the high voltage components.
2-3 Li-ion Battery Pack Specifications
Li-ion Battery Specifications
Li-ion battery voltage 144V
Number of Li-ion battery modules in the pack 3 modules (40 cells)
Li-ion battery module voltage 48V each
Li-ion battery dimensions 36.31 x 22.07 x 6.52 in. (922.3 x 560.5 x 165.6
mm)
Li-ion battery weight 62.4 lbs (28.3 kg)
DG–13
2-4 High Voltage Safety Measures
Circuit insulation The high voltage positive (+) and negative (-) circuits are insulated
from the metal chassis.
Reducing the risk of electrocution The high voltage components and harnesses have insulated cases or
orange-colored coverings which provide insulation and easy
identification.
The high voltage battery case is electrically connected to the vehicle ground.
This connection helps protect the vehicle occupants and vehicle dismantlers
from high voltage electrical shock.
Identification The high voltage components are labeled “WARNING” similar to label
shown below. All high voltage harnesses are coated in orange.
2-4.1 Warning Label
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2-5 High Voltage Safety System
The high voltage safety system is intended to help keep vehicle occupants and emergency responders safe
from high voltage electricity.
• A high voltage fuse provides short circuit protection inside the high voltage battery.
• The high voltage safety system is insulated from the metal chassis.
• Positive and negative high voltage power cables are connected to the high voltage battery and are
controlled by normally open system main relays (SMR1 and SMR2). When the vehicle is shut off,
the relays stop electrical flow from leaving the high voltage battery. However, it can take
approximately ten (10) minutes for the high voltage capacitor to fully discharge.
Engine Compartment
Transmission
Traction
Motor
Traction
Motor Inverter
(With built in high
voltage capacitor)
HPCM
(Hybrid Powertrain
Control Module)
DC/DC
Converter
Cargo Area
Junction Box
System main relay 1
System main relay 2
Li-ion Battery
Service Plug
(With Fuse)
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• The high voltage system and high voltage capacitor may remain powered for up to
approximately 10 minutes after the vehicle is shut off. Personal Protective Equipment
(PPE) must always be worn when touching or working on high voltage components
to avoid risk of electrical shock and severe personal injury or death.
• The high voltage battery retains high voltage at all times. PPE must always be worn when
touching or working on high voltage components to avoid risk of electrical shock and
severe personal injury or death.
• A ground fault monitor continuously monitors for high voltage leakage to the metal chassis while the
vehicle is running. If a malfunction is detected, the HPCM (hybrid powertrain control module) will
illuminate the hybrid system warning lamp
in the instrument cluster.
DG–15
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