service NISSAN ALTIMA HYBRID 2009 L32A / 4.G Dismantling Guide

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Foreword .......................................................................\
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About the Nissan Altima Hybrid ........................................................................\
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Altima Hybrid Identification ........................................................................\
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VIN Location ........................................................................\
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Engine Compartment ........................................................................\
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Exterior ...............................................................\
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Interior ...............................................................\
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Hybrid System .......................................................................\
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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 ........................................................................\
............................................................ - 16 -
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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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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Dismantling the High Voltage System

Dismantling of the Altima Hybrid may be performed like conventional Niss\
an vehicles, except as noted in these
guidelines.

Service Disconnect


1. Immobilize the vehicle a. Move the shift lever to the P (Park) position.

b. Shut the vehicle OFF by pressing the push-button
ignition switch.
c. Chock the wheels.
d. Set the parking brake.




4. Open the trunk using one of the following methods:
• Intelligent Key button:
Push and hold the trunk release button for longer than
0.5 second to open the trunk.

NOTE:
The trunk release button on the Intelligent Key will not
operate when the ignition switch is in the ON position or
when the trunk cancel switch (located in the glove box)
is in the OFF position.





• Trunk release switch:
The trunk switch is located on the left side of the
instrument panel. To open the trunk, push the switch
downward.

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DANGER:
•
The high voltage system may remain powered for up to 10 minutes after the vehicle is disabled.
•
To prevent serious injury or death from electrical shock avoid touching, cutting, or breaching any
orange high voltage power cable or high voltage component while the system discharges.
WARNING:
• The SRS may remain powered for up to 3 minutes after the vehicle is disabled.
• To prevent serious injury or death from unintentional SRS deployment, avoid crushing, cutting, or
breaching the SRS components.
• If the disabling procedures cannot be performed completely, proceed with caution as there is no
assurance that the high voltage electrical system, SRS, or fuel pump are disabled.
4. Remove the service disconnect by performing the following as shown:

a. Open the access panel inside the trunk to access the service disconnect.

b. Pull upward (1) on the service disconnect handle and then rotate the handle downward (2).
c. Pull outward (3) on the service disconnect handle to remove the service disconnect from the
battery.
d. Wait 3 minutes before handling SRS system components and 10 minutes before handling high
voltage system components while the system discharges

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DANGER:
•
The high voltage system may remain powered for up to 10 minutes after the vehicle is disabled.
•
To prevent serious injury or death from electrical shock avoid touching, cutting, or breaching any
orange high voltage power cable or high voltage component while the system discharges.
WARNING:
• The SRS may remain powered for up to 3 minutes after the vehicle is disabled.
• To prevent serious injury or death from unintentional SRS deployment, avoid crushing, cutting, or
breaching the SRS components.
• If the disabling procedures cannot be performed completely, proceed with caution as there is no
assurance that the high voltage electrical system, SRS, or fuel pump are disabled.
Alternative High Voltage System Shut Down Procedure

NOTE:
If the service disconnect procedure cannot be performed, the following alternative shut down procedure is
acceptable.
1. Locate the fuse/fusible link box (1) under the hood near
the driver side strut tower (2).
• : Vehicle Front










2. Remove the fuse/fusible link box cover and remove the
IGCT 50 amp fusible link (1) from the fuse/fusible link
box (2). If the correct fuse cannot be recognized, pull all
the fuses in the fuse/fusible link box.

11. Remove the outlet duct bolts (1), then remove the outlet
duct (2) from the HV battery (3).










12. Disconnect the HV battery blower motor connector (1)
from the HV battery blower (2).
13. Remove the HV battery blower motor harness clips and
HV battery blower motor harness from the HV battery.








14. Remove the lock (1) from the RH cover (6) on the HV
battery (7) using the service plug grip (2).
15. Remove the nuts (3), bolts (4) and ground wires (5) from
the RH cover (6).
16. Remove the RH cover (6) from the HV battery (7).







17. Remove the terminal cover and 12 volt terminal nut (1),
then remove the terminal cable (2) and 12 volt harness
from the HV battery.
18. Remove the battery shield contact (4), HV wire nuts (6)
and HV wires (5) from the HV battery.
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rom
19. Disconnect the body harness connector (3) from the HV
battery.
20. Disconnect the EPS DC/DC converter connector (7) f
the HV battery.
21. Remove the harnesses from the HV battery.