NISSAN ALTIMA HYBRID 2009 L32A / 4.G Dismantling Guide

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Nissan Altima Hybrid

























© 2008 NISSAN NORTH AMERICA, INC.
All rights reserved. This document may not be
altered without the written permission of NISSAN NORTH AMERICA, INC.

Pub. No. DG9E-1H32U0

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Foreword .......................................................................\
....................................................... ....................... - 3 -
About the Nissan Altima Hybrid ........................................................................\
....................................... - 4 -
Altima Hybrid Identification ........................................................................\
.............................................. - 5 -
VIN Location ........................................................................\
......................................................................... - 5 -
Engine Compartment ........................................................................\
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Exterior ...............................................................\
....................................................... ................................... - 7 -
Interior ...............................................................\
........................................................................................... - 7 -
Hybrid System .......................................................................\
....................................................... .............. - 8 -
Component Location and Description ........................................................................\
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Battery Information .......................................................................\
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Low Voltage Battery ........................................................................\
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High Voltage Battery ........................................................................\
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Recovery/Recycling of the Ni-MH High Voltage Battery ........................................................................\
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High Voltage Safety .......................................................................\
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High Voltage Safety System ........................................................................\
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Precautions for Dismantling ........................................................................\
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Spills ........................................................................\
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First Aid ........................................................................\
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Vehicle Cut Sheet ........................................................................\
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Dismantling the High Voltage System ........................................................................\
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Service Disconnect ........................................................................\
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Alternative High Voltage System Shut Down Procedure ........................................................................\
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Removal of HV Battery ........................................................................\
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Removal of HV Components ........................................................................\
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Foreword

Nissan released the Altima Hybrid in North America in August of 2007. The Altima Hybrid runs on conventional
gasoline and a traction motor. The basic vehicle systems and features of the Altima Hybrid are the same as
those of the conventional Altima, except where noted in this guide. This Dismantling Guide was published to
help educate and assist the technician in the safe handling of the Altima Hybrid and its technology.

A high voltage battery is used to power the traction motor, generator, electric air conditioning compressor,
voltage converters, and inverter unit. A separate 12 volt battery is used to power other electrical devices such
as the radio, horn, headlamps, and instrument cluste
r gauges. A number of safeguards have been designed to
ensure that the high voltage Nickel Metal Hydride (Ni-MH) battery is kept safe and secure in the event of an
accident.

The Altima Hybrid utilizes both low and high voltage systems:

Low voltage system

• A 12 volt DC negative chassis ground body electrical system

High voltage system

• A 245 volt DC high voltage battery
• A harness that carries high voltage between the high voltage battery, converters, inverter unit, transaxle
and electric air conditioning compressor
• A converter which converts 245 volts DC to 42 volts DC for the electric power steering (EPS) system
• A converter which converts 245 volts DC to 12 volts DC for charging the 12 volt battery
• An inverter unit which delivers up to 650 volts AC to the transaxle
• A transaxle which houses a traction motor and generator
• A 245 volt DC, motor driven electric air conditioning compressor

High voltage electrical safety is an important factor in the dismantling of the Altima Hybrid. It is important to
recognize and understand the disabling procedures and warnings throughout this guide.
Additional topics in this guide include:
• Nissan Altima Hybrid identification
• Hybrid system component locations and descriptions






This Dismantling Guide is intended to assist the technician in the safe handling of a Nissan Altima Hybrid.
The information contained in this guide is somewhat simplified and intended to be used as a technical
reference. Please refer to the Nissan Service Manual for information related to vehicle repair.

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About the Nissan Altima Hybrid

There are two power sources stored on board that are used to drive the vehicle:
• Gasoline is stored in a fuel tank and is used to supply the gasoline engine.
• Electricity is stored in a high voltage battery and is used to power the traction motor.

The result of combining these two power sources is improved fuel economy and reduced emissions. The
gasoline engine also powers an electric generator to recharge the high voltage battery; unlike an entirely
electric vehicle, the Altima Hybrid never needs to be recharged from an external electric power source.

Depending on the driving conditions, one or both sources are used to drive the vehicle. The following
information explains how the Altima Hybrid operates in various driving modes:
1. During light acceleration at low speeds, the vehicle is driven by the traction motor. The gasoline engine
is shut off.

2. During normal driving, the vehicle is driven mainly by the gasoline engine. The gasoline engine also
powers the generator to recharge the high voltage battery.

3. During full acceleration, such as climbing a hill, both the gasoline engine and the traction motor drive
the vehicle.
4. During deceleration, such as when braking, the vehicle converts kinetic energy from the front wheels to
electricity that will recharge the high voltage battery.
5. While the vehicle is stopped, such as at a stoplight, both the gasoline engine and the traction motor are
off, however the vehicle remains operational.

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Altima Hybrid Identification

In appearance, the Nissan Altima Hybrid is nearly identical to the conventional Nissan Altima.

VIN Location


The VIN can be located on either the front windshield cowl (1) or on the driver’s side B-pillar (2).

Example VIN: 1N4CL21E69C051138


An Altima Hybrid is identified by the 4th alphanumeric character: C

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Engine Compartment


The engine compartment of the Altima Hybrid houses an aluminum alloy 2.5 liter gasoline engine, the high
voltage harnesses, fuse/fusible link box, fuse block, inverter unit, transaxle and electric air conditioning
compressor.

Engine Compartment Components and Locations



1. Fuse/Fusible link box 2. Fuse block 3.
Inverter unit
4. High voltage harness (orange) 5. Transaxle 6.
Electric air conditioning
compressor
7. Gasoline engine A. HV electrical connector :
Vehicle front

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Exterior


• A Hybrid logo is located on the right side of the trunk.












• A Hybrid logo is located on each front door above the
body side molding.










Interior


• In place of a tachometer, a power meter (1) is used.
• In place of a temperature gauge, a high voltage
battery status meter (2) is used.

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Hybrid System

Component Location and Description

Component Location Description
1. Electric Air
Conditioning
Compressor
Engine compartment, front
passenger side
Motor driven electric air conditioning compressor supplied
with 245 volts DC.
2. Electric Power
Steering Engine compartment, on
steering rack A 42 volt DC assist motor is used for the electric power
steering (EPS) system.
3. EPS DC/DC
Converter Trunk area, mounted to top
of high voltage battery Converts 245 volts DC (high voltage) to 42 volts DC (low
voltage) for the EPS.
4. High Voltage
Battery Trunk area, mounted to
cross member and behind
rear seat 245 volt DC Nickel Metal Hydride (Ni-MH) battery
consisting of 34 low voltage (7.2 volt) modules connected
in series.
5. DC/DC
Converter
Trunk area, under front left
cover of the high voltage
battery Converts 245 volts DC (high voltage) to 12 volts DC (low
voltage) for charging the 12 volt battery.
6. Service
Disconnect
Trunk area, on the
passenger side of the high
voltage battery Used to disable the high voltage system.
7. High Voltage
Harnesses
•
Trunk area, on high
voltage battery and EPS
DC/DC converter
• Under passenger side
rear seat and floor pan
• Engine compartment, on
rear, driver side and front Orange colored power cables carry high voltage direct
current (DC) between the high voltage battery, EPS
DC/DC converter, inverter unit, and electric air
conditioning compressor. There are two cables which also
carry 3-phase alternating current (AC) between the
inverter unit and transaxle.
NOTE:
High voltage cables under the vehicle floor are encased in
a black plastic protector.
8. Transaxle

Engine compartment, on
driver side Contains a traction motor and generator used to drive the
front wheels and recharge the high voltage battery.
9. Inverter Unit Engine compartment, front
driver side Changes the 245 volts DC from the high voltage battery to
3-phase 650 volts AC to power the transaxle. The inverter
unit also changes AC electricity from the transaxle to DC
that recharges the high voltage battery.

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Battery Information

The Altima Hybrid utilizes two batteries in order to supply both low and high voltage.

Low Voltage Battery


The Altima Hybrid contains a lead-acid 12 volt DC low voltage
battery. The low voltage battery is located in the passenger rear
quarter panel well of the trunk and is concealed by a trim cover.
The negative (-) 12 volt battery cable can be accessed through
an access panel in the trim cover.

The 12 volt battery powers the vehicle’s 12 volt electrical
system, similar to a conventional vehicle. As with conventional
vehicles, the 12 volt battery is grounded to the metal chassis of
the vehicle. However, the 12 volt battery is charged by the high
voltage battery through the DC/DC converter.

High Voltage Battery


The Altima Hybrid contains a Ni-MH 245 volt DC high voltage
battery. The high voltage battery is enclosed in a metal case,
which is isolated from high voltage, and is securely mounted in
the trunk area behind the rear seat and is concealed by a trim
cover. The service disconnect can be accessed through an
access panel in the trim cover.

The 245 volt battery powers the vehicle’s high voltage electrical
system. The high voltage battery consists of 34 low voltage (7.2
volt) Ni-MH battery modules connected in series to produce
approximately 245 volts DC. Each Ni-MH battery module is
sealed in a non-spillable plastic case. The electrolyte used in
the Ni-MH battery module is an alkaline mixture of potassium and sodium hydroxide. The electrolyte is
absorbed into the battery cell plates and forms a gel that should not normally leak, even in a collision. In the
unlikely event that the high voltage battery is overcharged, the modules vent gases directly outside the vehicle
through a vent hose.


The high voltage battery supplies power to the following:
• Power cables
• EPS DC/DC converter
• DC/DC converter
• Inverter unit
• Transaxle
• Electric air conditioning compressor

High Voltage Battery Specifications
High voltage battery voltage 245 V
Number of Ni-MH battery modules in the pack 34
Ni-MH battery module voltage 7.2 V
Ni-MH battery module dimensions 5 x 1 x 11 in. (125.5 x 25.1 x 276.1 mm)
Ni-MH module weight 2.2 lbs (1.0 kg)
Ni-MH high voltage battery dimensions 8 x 34 x 19 in. (200.8 x 853.4 x 476.9 mm)
Ni-MH high voltage battery weight 114.6 lbs (52 kg)

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Recovery/Recycling of the Ni-MH High Voltage Battery

The high voltage battery is recyclable. For information regarding recycling of the high voltage battery, contact
the nearest Nissan dealer or Nissan customer assist ance at: United States: 1-800-NISSAN-1 (1-800-647-7261)
or in Canada: 1-800-387-0122.