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

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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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• 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 high voltage ECU will illuminate the hybrid system
warning light in the instrument cluster.

• The high voltage battery relays (SMR1 and SMR2) will automatically open to stop the electrical flow in a
frontal collision that is sufficient enough to activate the supplemental restraint system (SRS).

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Precautions for Dismantling


Dismantling the Altima Hybrid may be performed like conventional Nissan vehicles, except as noted in these
guidelines.

Spills

The Altima Hybrid contains the same common automotive fluids used in other non-hybrid Nissan vehicles, with
the exception of the Ni-MH electrolyte used in the high voltage battery. The Ni-MH battery electrolyte is a
caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however, is absorbed in the cell
plates and should not normally spill or leak out even if a battery module is cracked. Both the metal battery case
and the plastic battery modules could be breached if a catastrophic crash occurred.

A diluted boric acid solution or vinegar can be used to neutralize a Ni-MH battery electrolyte spill, similar to the
use of baking soda to neutralize a lead-acid battery electrolyte spill.

NOTE:
Electrolyte leakage from the high voltage battery is unlikely due to the battery construction and the amount of
available electrolyte contained within the Ni-MH modules. Any spillage would not warrant a declaration as a
hazardous material incident. The technician should follow the recommendations as outlined in this dismantling
guide.

In an emergency, Nissan Material Safety Data Sheets (MSDS) are available by contacting:
United States: CHEMTREC at 1-800-424-9300
Canada: CANUTEC at *666 or 1-613-996-6666 (collect)

• Handle Ni-MH electrolyte spills using the following personal protective equipment:
¾Splash shield or safety goggles (fold down helmet shields are not acceptable for acid or alkaline
electrolyte spills)
¾ Insulated rubber gloves
¾ Acid-resistant apron
¾ Insulated rubber boots
¾ Insulated rubber mats (for connect/disconnect of high voltage battery)
DANGER:
•
Failure to disable the high voltage electrical system before emergency response procedures are
performed may result in serious injury or death from electrical shock.
• Failure to disable the low and high voltage electrical systems before emergency response procedures are
performed may result in serious injury or death from the unintentional deployment of the SRS.
• The Ni-MH battery electrolyte is a caustic alkaline (p H 13.5) that is damaging to human tissues. To avoid
injury by coming in contact with the electrolyte, wear proper personal protective equipment.
WARNING:
• Never assume that the Altima Hybrid is shut off simply because it is quiet.
• Always observe the instrument cluster for the READY operation indicator light (green) status to verify
whether the vehicle is on or shut off. The vehicle is shut off when the READY operation indicator light
(green) is off.
• The use of personal protective equipment (PPE) such as insulated rubber gloves, insulated rubber boots,
and insulated rubber mats must be used when disabling the high voltage electrical system.

DANGER:
• The Ni-MH battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. To
avoid injury by coming in contact with the electrolyte, wear proper personal protective equipment.

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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.