service NISSAN LEAF 2017 1.G Dismantling Guide

Table of Contents
FOREWORD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
NISSAN EMERGENCY CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
IMPORTANT INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
1. ABOUT THE NISSAN LEAF® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–5
1-1 LEAF IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–6 1-1.1 EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–6
1-1.2 INTERIOR COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–7
1-2 VEHICLE IDENTIFICATION NUMBER (VIN) LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–8
1-3 WARNING AND INDICATOR LAMP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–8
2. BASIC HIGH-VOLTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–9 2-1 HIGH-VOLTAGE-RELATED AND 12-VOLT-RELATED COMPONENT LOCATIONS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–9
2-1.1 HIGH-VOLTAGE BATTERY PACK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-2 HIGH-VOLTAGE SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11 2-2.1 WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-3 HIGH-VOLTAGE CIRCUIT SHUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-4 PREVENTING ELECTRICAL SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–12
3. PREPARATION FOR DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–13
3-1 DISCHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–13
3-2 PREPARATION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–15
3-3 PERSONAL PROTECTIVE EQUIPMENT (PPE) AND INSULATED TOOLS . . . . . . . . . . . . . DG–163-3.1 PERSONAL PROTECTIVE EQUIPMENT (PPE) PROTECTIVE WEAR CONTROL . . DG–16
3-3.2 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–16
3-3.3 INSULATED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–16
3-4 HIGH-VOLTAGE SYSTEM SHUT-DOWN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . DG–16 3-4.1 REMOVING THE CHARGE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–18
3-4.2 INDICATIONS THE HIGH-VOLTAGE SYSTEM IS ON . . . . . . . . . . . . . . . . . . . . . . . DG–20
3-4.3 POWERING DOWN THE HIGH-VOLTAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . DG–20
3-4.4 PRIMARY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–21
3-4.5 ALTERNATE PROCEDURE 1 (REMOVE FUSES) . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–22
3-4.6 ALTERNATE PROCEDURE 2 (REMOVE SERVICE PLUG) . . . . . . . . . . . . . . . . . . . . DG–25
DG–3

No. Component
LocationDescription
Charge
port Under hood Connecting port for EVSE (Electric Vehicle
Supply Equipment) . Two ports are available:
Normal charge and quick charge (if so equipped) .
High-voltage cables Under hood and
undercarriage Orange-colored power cables carry high-voltage
current between each of the high-voltage
components.
Traction Motor Under hood Converts three-phase AC power to drive power
(torque) which propels the vehicle.
Inverter Under hood Converts the DC power stored in the high-voltage
battery to three-phase AC power and controls
motor torque (revolution) by regulating the motor
current.
Electric air
conditioner
compressor Under hood
Air conditioner compressor
Power Delivery
Module (PDM)
• On Board Charger
• DC/DC Converter
• High-voltage junction box (J/B) Under hood
The PDM includes an On Board Charger, DC/DC
converter and high-voltage junction box (J/B) .
The On Board Charger converts single-phase AC
power from a home power outlet to DC power
and increases the voltage in order to charge the
high-voltage battery.
The DC/DC converter reduces the voltage of the
high-voltage battery to provide power to the
12-volt battery in order to operate the vehicle’s
electric components (headlights, audio system,
etc.) .
The J/B provides electric power from the
high-voltage battery to all high-voltage parts of
the vehicle.
12-volt Battery Under hood A lead-acid battery that supplies power to the
low voltage devices.
Cabin heater Interior (This unit is
installed behind the
instrument panel) This is the electric heat source for the cabin
heater. It heats the interior of the vehicle.
High-voltage battery Undercarriage Stores and outputs DC power (Maximum voltage
398.4V) needed to propel the vehicle.
High-voltage battery
service disconnect Rear seat floor Isolates the battery from the rest of the
high-voltage electrical system.
Brake power supply
backup unit Cargo area (This unit
is installed behind a
trim panel to prevent
access) Power supply backup unit for the brake system.
It supplies power to the brake system if a
malfunction occurs in the 12-volt battery.
DG–10

2-1.1 High-Voltage Battery Pack Specifications
High-voltage battery voltage
360V nominal
(240V - 398.4V usable range)
Number of high-voltage battery modules in the pack 48
High-voltage battery dimensions 60.91 x 46.77 x 10.39 in. (1547 x 1188 x 264 mm)
High-voltage battery weight US: 648 lbs (294 kg)
Canada: 653 lbs (296 kg)
2-2 High-Voltage Safety Measures Circuit insulation
The high-voltage positive (+) and negative (-) circuits are insulated from
the
metal chassis.
Reducing the risk of
electrocution
The high-voltage components and harnesses have insulated cases or
orange-colored coverings which provide insulation and easy identification.
The high-voltage battery case is electrically connected to the vehicle
ground. This connection helps protect the vehicle occupants and vehicle
dismantlers from high-voltage electrical shock.
Identification The high-voltage components are labeled “WARNING” similar to label shown below. All high-voltage harnesses are coated in orange.
2-2.1 Warning Label
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 high-voltage battery, this shuts off output
high-voltage
when manually removed.
System main relay (located
in high-voltage battery) Controlled by the power switch, this relay, which is controlled by the 12-volt
system, shuts off the high-voltage from the high-voltage battery.
Emergency shut-off
system 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
is designed to shut off the high-voltage from the high-voltage battery.
Charging connector Some of the high-voltage components are activated during charging. Remove the charging connector to deactivate these components. AAYIA0147ZZ
DG–11

3-2 Preparation Items
Preparation Items
Specification Purpose
Personal Protective
Equipment (PPE):
Insulated gloves Up to 1,000V
For protection from high-voltage
electrical
shock
Insulated shoes –
Safety

shield –
Leather

gloves Must be able to fasten tight
around

the wrist (worn over
insulated gloves) . To protect insulated gloves
Wrenches Size:10mm
T
o remove the service plug access
cover bolts.
To remove the 12-volt battery terminal
bolt.
Solvent resistant protection
gloves –
To utilize in the event of a high-
voltage battery electrolytic solution
leak.
Solvent resistant protection
shoes –
Absorbent pad The same pad used for internal
combustion engine fluids can be
used. To absorb any high-voltage battery
electrolytic solution leakage.
Standard fire fighting
equipment Standard fire fighting equipment
Depending on type of fire (vehicle
or battery) use standard fire
fighting equipment (water or
extinguisher) . To extinguish a fire.
Insulated tape Insulating
To cover any damaged harnesses to
protect from and prevent electrical
shock. Tape should cover all bare or
damaged wire.
DG–15

3-4.2 Indications the High-voltage System is ON
1. If the READY indicator is ON, the high-voltage system is active.
2.

The high-voltage system is active if any charge indicator
is ON (blue LEDs on top of the instrument panel) .
Before disconnecting the 12-volt battery terminal, if necessary, lower the windows, unlock the doors, and
open the rear hatch as required. Once 12-volt battery is disconnected, power controls will not operate.
3-4.3 Powering Down the High-voltage System
The high-voltage system can be shut down with any 1 of the following procedures: • Turn OFF the power switch anddisconnect the 12-volt battery.
Refer to 3-4.4 Primary Procedure (DG–21) .
•

Remove the fuses for the high-voltage control system and disconnect the 12-volt battery.
Refer to 3-4.5 Alternate Procedure 1 (Remove Fuses) (DG–22).
•

Remove the service plug and disconnect the 12-volt battery.
Refer to 3-4.6 Alternate Procedure 2 (Remove Service Plug) (DG–25). AAYIA0155ZZ
DG–20

3-4.6 Alternate Procedure 2 (Remove Service Plug)
• Do not remove the service plug without always wearing appropriate Personal
Protective Equipment (PPE) to help protect the dismantler from serious injury or death
by electrical shock.
• Immediately cover the service plug socket with insulated tape. The high-voltage
battery
retains high-voltage power even when the service plug is removed. To avoid
electric shock, NEVER touch the terminals inside the socket. To avoid unintended reinstallation and risk of electrical shock and severe personal injury
or

death, the dismantler should carry the service plug on his/her person while work is in
progress.
1. Insert a suitable tool (1) under the RH rear corner of theaccess trim cover located on the floor behind the center
console. Pry up (2) and remove.
NOTE: : Arrow in illustration depicts vehicle front
direction.
2.

Remove the 10 mm access cover bolts (1) and remove
the cover (2) .
NOTE: : Arrow in illustration depicts vehicle front
direction. 12
AAYIA0159ZZ
1
2
AAYIA0158ZZ
DG–25

3. Remove the service plug using the following steps: (1) pull up and release the green lever, (2)
press the locking tab to release and rotate fully upward, (3) pull the service plug completely out of
its socket.
4. Wait at least (10) minutes for complete discharge of the high-voltage capacitor after the
service plug has been removed.
5. Open the hood.
6. Disconnect the negative (-) 12-volt battery cable (1) . Insulate the negative (-) battery cable terminal with
insulated tape.
NOTE: : Arrow in illustration depicts vehicle front
direction.
7.

Perform the dismantling operation. 1
2
3
Pull up Rotate
Push to
release Pull up
and
remove
AAYIA0048GB AAYIA0145ZZ
1
AAYIA0149ZZ
DG–26

3-5 Cutting the Vehicle Body
• Do not cut into high-voltage related areas to avoid severe personal injury or death.
• Do not cut into the high-voltage battery to avoid severe personal injury or death.
• When removing parts, NEVER touch the high-voltage parts or the insides of the
exposed orange-colored high-voltage cables to avoid severe personal injury or death.
Personal Protective Equipment (PPE) must always be worn when touching or
working on high-voltage components. • To avoid unintended reinstallation and risk of electrical shock and severe personal injury
or
death, the dismantler should carry the fuses or service plug on his/her person while
work is in progress.
• Do not cut air bag parts to avoid unintended deployment of the air bags and the risk of severe personal injury or death.
If at least ten (10) minutes have passed since the dismantler shut down the high-voltage system (refer to
3-4 High-voltage System Shut-Down Procedures (DG–16)) , then the dismantler can cut the vehicle
except

for the high-voltage battery. DO NOT cut the high-voltage battery due to possible electrocution risk and electrolyte solution
leakage.
DG–27

3-5.3 Water Submersion
Damage level of submerged vehicle may not be apparent. Handling a submerged
vehicle without appropriate Personal Protective Equipment (PPE) will result in serious
injury or death from electrical shock. • The power switch of the submerged vehicle must be turned OFF first, if possible.
Then
the vehicle must be completely out of the water and drained to avoid electrical
shock.
• Always wear appropriate Personal Protective Equipment (PPE) and remove/drain
water
before removing the service plug when working on a vehicle after a fire or
submersion to avoid electrical shock.
• If the vehicle is in the water, to avoid electrical shock NEVER touch the high-
voltage
components, harnesses or service plug. PPE must always be worn when
touching or working on high-voltage components.
3-5.4 Vehicle Fire • Always utilize full Personal Protective Equipment (PPE) and self-contained breathing
apparatus
during fire fighting operations. Smoke from a LEAF vehicle fire is similar to
smoke from a conventional vehicle fire.
• In the case of extinguishing a fire with water, large amounts of water from a fire hydrant (if possible) must be used. DO NOT extinguish fire with a small amount of
water. In the event of a small fire, a Type ABC fire extinguisher may be used for an electrical fire
caused

by wiring harnesses, electrical components, etc. or oil fire.
In case of vehicle fire, contact fire department immediately and extinguish the fire if possible. If you must
walk away from the vehicle, notify an appropriate responder or a rescue person of the fact that the vehicle is
an electric car and contains a high-voltage system and warn all others.
DG–31

4-3 Storing the Vehicle
The service plug must be removed to shut down the high-voltage system for storage.
Do
not store a vehicle inside a structure. Keep the vehicle away from other vehicles if the
high-voltage battery is severely damaged. There is possibility of delayed fire from a
severely damaged high-voltage battery.
If LEAF needs to be stored or left unattended, the high-voltage system must be shut down by removing the
service plug [refer to 3-4.6 Alternate Procedure 2 (Remove Service Plug) (DG–25)] and a sign put on the
vehicle

indicating it is an electric vehicle with high-voltage dangers. For example:
DG–38