battery NISSAN LEAF 2013 1.G Dismantling Guide

3-5 Li-ion Battery Damage and Fluid Leaks
The Li-ion battery contains electrolyte solution. To avoid exposure to electrolyte solution
and
serious personal injury, always wear appropriate solvent resistant Personal Protective
Equipment (PPE) and read the following precautions:
• Electrolyte solution is a skin irritant.
• Electrolyte solution is an eye irritant – If contact with eyes, rinse with plenty of water and
see a doctor immediately.
• If electrolyte leak occurs, wear appropriate solvent resistant PPE and use a dry cloth to clean up the spilled electrolyte. Be sure to adequately ventilate the area.
• Electrolyte solution is highly flammable
• Electrolyte liquid or fumes that have come into contact with water vapors in the air will create an oxidized substance. This substance may irritate skin and eyes. In these cases,
rinse with plenty of water and see a doctor immediately.
• Electrolyte fumes (when inhaled) can cause respiratory irritation and acute intoxication. Move to fresh air and wash mouth with water. See a doctor immediately.
In cases of battery case breach or electrolyte leakage, contact the fire department immediately. If you must
walk away from the vehicle, notify an appropriate responder of the fact that the vehicle is an electric car and
contains a high voltage system and warn all others.
Li-ion Battery Electrolyte Solution Characteristics: • Clear in color
• Sweet odor
• Similar viscosity to water
• Since the Li-ion battery is made up of many small sealed battery modules, electrolyte solutionleakage should be minimal.
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4. Jump Starting
T
o start the EV system with a booster battery, the instructions and precautions below must be followed. If done incorrectly, jump starting can lead to a 12V battery explosion, resulting in severe
personal

injury or death. It could also damage your vehicle.
Discharged 12V battery may cause the following issues: • The instrument cluster cannot be displayed while the power switch is turned ON. The start-upsound is not audible. (The electric car system cannot start.)
• The Li-ion battery cannot be charged.
• The vehicle cannot be shifted out of PARK normally. • To avoid electrical shock, the high voltage Li-ion battery CANNOT be jump started.
•

Explosive hydrogen gas is always present in the vicinity of the 12V battery. Keep all
sparks and flames away from the 12V battery.
• Do not allow battery fluid to come into contact with eyes, skin, clothing or painted surfaces. Battery fluid is a corrosive sulfuric acid solution that can cause severe burns. If
the fluid comes into contact with anything, immediately flush the contacted area with
water.
• The booster battery must be rated at 12 volts. Use of an improperly rated battery can damage the vehicle.
• Whenever working on or near a 12V battery, always wear suitable eye protectors (for example, goggles or industrial safety spectacles) and remove rings, metal bands, or any
other jewelry. Do not lean over the 12V battery when jump starting.
• Do not attempt to jump start a frozen battery. It could explode and cause serious injury.
• LEAF is equipped with an automatic cooling fan. It could come on at any time. Keep hands and other objects away from it.
• Always follow the jump starting instructions below. Failure to do so could result in damage to the DC/DC converter and cause personal injury. • Do not use LEAF to jump start another vehicle.
•

Do not attempt to perform a jump start on the 12V battery at the same time that the
Li-ion battery is being charged. Doing so may damage the vehicle or charging
equipment and could cause an injury.
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4-1 Jump Starting Procedures
1. If the booster battery is in another vehicle (B) , position the two vehicles (A and B) to bring their
12V batteries into close proximity to each other.
DO NOT allow the two vehicles to touch.
2. Apply the parking brake.
3. Push the P (Park) position switch to place the vehicle in the P (Park) position.
4. Switch off all unnecessary electrical systems (headlights, heater, air conditioner, etc.) .
5. Place the power switch in the OFF position (if possible) .
If the 12V battery is discharged, the power switch cannot be moved from the OFF
position. Connect the jumper cables to the booster vehicle (B) before pushing
the power switch.
6. Remove the vent caps on the 12V battery (if so equipped) . Cover the battery with a firmly wrung out moist cloth to reduce the hazard of an explosion.
7. Connect jumper cables in the sequence as illustrated (abcd) . • Always connect positive (+) to positive (+) and negative (-) to body ground (for example,
as
illustrated) , not to the 12V battery.
• Make sure the jumper cables do not touch moving parts in the motor compartment and that the cable clamps do not contact any other metal.
8. Start the engine of the booster vehicle (B) .
9. While the booster vehicle (B) engine is running, turn the power switch ON while pressing the brake pedal in order to place the LEAF in READY mode.
If the system does not start right away, push the power switch to the OFF position and wait
at

least 10 seconds before trying again.
10. After starting the EV system, carefully disconnect the negative cable and then the positive cable (dcba) . Keep the EV system on for over twenty (20) minutes to charge the 12V
battery.
11. Replace the vent caps (if so equipped) . Be sure to properly dispose of the cloth used to cover the vent holes because it may be contaminated with corrosive acid. AAYIA0160ZZ
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12. If necessary, connect the vehicle to a charging station or EVSE (Electric Vehicle Supply
Equipment) to charge the Li-ion battery. The vehicle cannot be driven unless the Li-ion battery is
charged.
NOTE:
If it is not possible to turn the LEAF system ON by following this procedure, contact a
NISSAN certified LEAF dealer immediately.
4-2 P (Park) Position Release Procedure
If you need to release the vehicle from the P (Park) position, proceed as follows. When power switch is
turned OFF or 12V battery is low, LEAF automatically shifts to P position.
NOTE: This procedure requires two (2) people.
1. To start the EV system with a booster battery, refer to 4. Jump Starting.
2.

Turn power switch ON by pushing the power switch 2 times without pressing brake pedal.
3. Confirm parking brake is applied.
4. Close all doors and press and hold the brake pedal.
5. Place the selector lever in the N (Neutral) position.
6. Remove the following 2 fuses:
• F/L 40A PBW MTR (under hood fuse and relay box)
• METER 1 10A (in the cabin fuse box)
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Cabin Fuse Box Location
NO
TE:
Insert a screwdriver wrapped with a protective cloth (A) into the slit (1) . Pull to remove the fuse
box cover (2) . Remove the fuse with the fuse puller (3) .
7. Release the parking brake.
8. Turn the power switch OFF.
9. Release brake pedal. To avoid possible personal injury or vehicle damage, use wheel chocks or take appropriate
steps

to prevent the vehicle from rolling freely.
Be sure to firmly position wheel chocks when P (Park) position is manually released.
4-2.1 Reset Procedure 1. Install the 2 fuses removed previously.
2. Turn the power switch ON and wait 5 seconds without pressing the brake pedal. Ensure selectorlever is in the N (neutral) position.
3. If 12V battery is low voltage, please charge with battery charger.
4. Turn the power switch OFF and wait 5 seconds.
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
li-ion battery is severely damaged. There is possibility of delayed fire from a severely
damaged li-ion battery. UP
METER 1
10A
11 3
2
A
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5. Dismantling Information
Removal
or repair of the high voltage battery requires special tools and specific training. NISSAN strongly
recommends that only certified NISSAN dealer technicians perform these operations.
5-1 Precautions for Handling High Voltage Lithium ion (Li-ion) Battery •
Because LEAF contains a high voltage (Li-ion) battery, there is the risk of electric
shock,
electric leakage, or similar accidents if the high voltage components or vehicle is
handled incorrectly. Be sure to follow the correct work procedures when performing
inspection and dismantling.
• If it is necessary to touch any of the high voltage harnesses or components you must
always
wear appropriate Personal Protective Equipment (PPE) and properly shut-down
the high voltage system by removing the service plug.
• The colors of the high voltage harnesses and connectors are all orange. Orange
High
V

oltage labels are applied to the Li-ion battery and other high voltage devices. Do not
touch the Li-ion battery or other high voltage devices without always wearing appropriate
PPE.
• Clearly identify the persons responsible for high voltage work and ensure that other
persons
do not touch the vehicle. When not working, cover high voltage parts with an
insulating cover sheet and sign or similar item to prevent other persons from contacting
them.
• The high voltage battery retains high voltage at all times.
• Be sure to always wear appropriate PPE before beginning work on the high voltage
system.
• Be sure to remove the service plug in order to shut-down the high voltage system
before
performing inspection or dismantling of high voltage system harnesses and parts.
• Be sure to put the removed service plug in your pocket and carry it with you so another
person
does not accidentally reinstall it while work is in progress.
• Immediately insulate disconnected high voltage connectors and terminals with
insulated
tape.
• The vehicle contains parts that contain powerful magnets. If a person who is wearing a
pacemaker
or other medical device is close to these parts, the medical device may be
affected by the magnets. Such persons must not perform work on the vehicle.
• Because this vehicle uses components that contain high voltage and powerful
magnetism,
do not carry any metal products which may cause short circuits, or any
magnetic media (cash cards, credit cards, etc.) which may be damaged when working on
the vehicle.
• Keep removed Li-ion battery packs away from rain to avoid electric shock.
• If the vehicle is heavily damaged, for example the Li-ion battery is deformed, broken, or
cracked;
appropriate PPE must always be used at all times to avoid electrical shock.
• Do not heat removed battery packs higher than 158° F (70° C) .
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5-3 Lithium-ion (Li-ion) Battery Pack Removal
5-3.1
Exploded View
NOTE: : Arrow in illustration depicts vehicle front direction.
1.

Li-ion battery pack 2. Bonding plates 3. Li-ion battery under cover
(front)
4. Li-ion battery under cover
(center) 5. Li-ion battery under cover (rear) 6. Bolts and clips
7. Battery mounting bracket (left) 8. Battery mounting bracket (right) 1
2
2 8
7
6
6
63 4 5
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5-3.2 Removal Procedure
DO NOT disassemble or open the Li-ion battery to avoid severe personal injury or death by
electrical
shock.
1. Discharge the high voltage battery. Refer to 3-1 Discharging Procedures.
2.

Raise the vehicle and remove the Li-ion battery under covers (front, center and rear) .
3. Remove the harness clamp (A) and disconnect the high voltage harness connector (B) from the Li-ion battery. Touching high voltage components without wearing
appropriate

Personal Protective Equipment (PPE) will
cause electrocution.
a. Use the following instructions to disconnect thehigh voltage harness connector. To prevent electrocution, cover battery side of high
voltage

connector with insulated tape (A) . : Insulated tape A
B
AAYIA0165ZZ AAYIA0049GB
AAYIA0166ZZ
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4. Disconnect the cabin heater harness connector (A) from
the Li-ion battery. Touching high voltage components without wearing
appropriate

Personal Protective Equipment (PPE) will
cause electrocution.
a. Use the following instructions to disconnect thecabin heater harness connector. To prevent electrocution, cover battery side of high
voltage

connector with insulated tape (A) . : Insulated tape
5.
Disconnect the Li-ion battery vehicle communications
connector (A) while turning it counterclockwise. Touching high voltage components without wearing
appropriate

Personal Protective Equipment (PPE) will
cause electrocution.
A
AAYIA0171ZZ 1
3 4
2
Pull back lock tab
Press release and
pull connector

Disconnect connector
AAYIA0050GB AAYIA0172ZZ
A
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6. Remove the bonding plates (1) .
Touching high voltage components without wearing
appropriate
Personal Protective Equipment (PPE) will
cause electrocution.
7. Remove ONLYthe Li-ion battery mounting bolts (A) (6
bolts) . At this stage of disassembly, NEVER remove the 4 bolts
(B)

shown in the illustration. These remaining 4 bolts
will retain the Li-ion battery to the vehicle body
while the lifter table can be set up in the next step. Touching high voltage components without wearing
appropriate

Personal Protective Equipment (PPE) will
cause electrocution.
8. Set the pallet (1) onto the lift table (2) .• Align the pallet center mark (A) and the lifter centermark (B) (white line) . Touching high voltage components without wearing
appropriate

Personal Protective Equipment (PPE) will
cause electrocution. 1
AAYIA0168ZZ A A
A
BB
BB
AA
AAYIA0169ZZ 1
12
2B
B A A
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