service NISSAN LEAF 2013 1.G Dismantling Guide

Table of Contents
FOREWORD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
NISSAN EMERGENCY CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IMPORTANT INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. ABOUT THE NISSAN LEAF® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1-1 LEAF IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-1.1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-1.2. INTERIOR COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-2 VEHICLE IDENTIFICATION NUMBER (VIN) LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-3 WARNING AND INDICATOR LAMP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. BASIC HIGH VOLTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2-1 HIGH VOLTAGE-RELATED AND 12V-RELATED COMPONENT LOCATIONS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-1.1. LI-ION BATTERY PACK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-2 HIGH VOLTAGE SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2-2.1. WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-3 HIGH VOLTAGE CIRCUIT SHUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-4 PREVENTING ELECTRICAL SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. PREPARATION FOR DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3-1 DISCHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-2 PREPARATION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-3 HIGH VOLTAGE SYSTEM SHUT-DOWN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163-3.1. REMOVING THE CHARGE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-3.2. INDICATIONS THE HIGH VOLTAGE SYSTEM IS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-3.3. POWERING DOWN THE HIGH VOLTAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-3.4. PRIMARY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-3.5. ALTERNATE PROCEDURE 1 (REMOVE FUSES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-3.6. ALTERNATE PROCEDURE 2 (REMOVE SERVICE PLUG) . . . . . . . . . . . . . . . . . . . . . . . 23
3-4 CUTTING THE VEHICLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3-4.1. SRS AIR BAG SYSTEM COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-4.2. VEHICLE CUT SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3-4.3. WATER SUBMERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-4.4. VEHICLE FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-5 LI-ION BATTERY DAMAGE AND FLUID LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4. JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4-1 JUMP STARTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3

NOTE:
Components with white number in black background are high voltage components.No. Component
LocationDescription
a Charge

port Under hood Connecting port for EVSE (Electric Vehicle
Supply Equipment) . Two ports are available:
Normal charge and quick charge (if so
equipped) .
b High voltage
cables Under hood and
undercarriage Orange-colored power cables carry high volt-
age current between each of the high voltage
components.
c 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 Li-ion
battery to three-phase AC power and controls
motor torque (revolution) by regulating the
motor current.
Electric air condi-
tioner compressor Under hood
Air conditioner compressor
Power Distribution
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 Li-ion
battery.
The DC/DC converter reduces the voltage of the Li-ion
battery to provide power to the 12V battery in order to
operate the vehicle’s electric components (headlights,
audio system, etc.) .
The J/B provides electric power from the Li-ion battery
to all high voltage parts of the vehicle.
d 12V Battery Under hood A lead-acid battery that supplies power to the low
voltage devices.
e 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.
f Li-ion (Lithium ion)
battery Undercarriage Stores and outputs DC power (Maximum voltage
398.4V) needed to propel the vehicle.
g High voltage battery
service disconnect Rear seat floor Isolates the battery from the rest of the high volt-
age electrical system.
h 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 malfunc-
tion occurs in the 12V battery.
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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 Li-ion battery, this shuts off output high
voltage
when manually removed.
System main relay Controlled by the power switch, this relay, which is controlled by the 12V system, shuts off the high voltage from the Li-ion battery.
Emergency shut-off sys-
tem 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
may shut off the high voltage from the Li-ion battery.
Charging connector Some of the high voltage components are activated during charging. Remove the charging connector to deactivate these components.
2-4 Preventing Electrical Shock 1. If it is necessary to touch any of the high voltage harnesses or components, you must alwayswear appropriate Personal Protective Equipment (PPE) (refer to 3-2 Preparation Items) and shut
off

the high voltage system by referring to 3-3 High Voltage System Shut-Down Procedures.
2.

To avoid the risk of electrocution, do not touch the inside of the Li-ion battery unless appropriate
PPE is worn even after shutting off the high voltage system. The Li-ion battery maintains charge
even though the high voltage system is shut down.
3. Cover any damaged high voltage components with insulated tape.
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Please contact following number if the Li-ion battery cannot be discharged.
• Nissan EV Customer Support: 1-877-664-2738 (Hours of operation are Monday - Friday 7am -
7pm, Saturday 8am - 4:30pm Central time zone)
• Nissan Consumer Affairs: 1-800-647-7261 (US) or 1-800-387-0122 (Canada) (Hours of operation are 8am - 5pm (Monday - Friday) Eastern, Central and Pacific time zones)
3-2 Preparation Items Preparation Items
Specification Purpose
Personal
Protective Equip-
ment (PPE):
Insulated gloves Up to 1,000V
For
protection from high voltage elec-
trical shock
Insulated shoes –
Safety

shield –
W

renches Size:10mm
T
o remove the service plug access
cover bolts.
To remove the 12V battery terminal bolt.
Solvent resistant protection
gloves –
To utilize in the event of a Li-ion bat-
tery electrolytic solution leak.
Solvent resistant protection
shoes –
Absorbent pad The same pad used for internal
combustion engine fluids can be
used. To absorb any Li-ion battery electro-
lytic solution leakage.
Standard fire fighting equip-
ment 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.
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3-3.2 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 12V battery terminal, if necessary, lower the windows, unlock the doors, and open
the rear hatch as required. Once 12V battery is disconnected, power controls will not operate.
3-3.3 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 12V battery. Refer to
3-3.4 Primary Procedure.
•

Remove the fuses for the high voltage control system and disconnect the 12V battery. Refer to
3-3.5 Alternate Procedure 1 (Remove Fuses).
•

Remove the service plug and disconnect the 12V battery. Refer to 3-3.6 Alternate Procedure 2
(Remove

Service Plug) .
3-3.4

Primary Procedure
1. Check the READY indicator status. If it is ON, the high voltage system is active.
2.

Place the selector lever in the Park (P) position.
3. Press the power switch once to turn OFF the high voltage system. Then verify whether the READY indicator is OFF.
4.
If possible, keep the Nissan Intelligent Key® at least 5
meters (16 feet) away from the vehicle.
NOTE:
This step is not necessary if the 12V system is
already disabled. AAYIA0155ZZ
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3-3.6 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 Li-ion battery
retains
high voltage power even when the service plug is removed. To avoid electric
shock, DO NOT 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
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1
2
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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 ten (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 (-) 12V battery cable (1) . Insulate the negative (-) battery cable terminal with
insulated tape.
NOTE: : Arrow in illustration depicts vehicle front
direction. 1
2
3
Pull up Rotate
Push to
release Pull up
and
remove
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1
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7. Perform the dismantling operation.
3-4
Cutting the Vehicle Body • Do not cut into high voltage related areas to avoid severe personal injury or death.
• Do not cut into the Li-ion battery to avoid severe personal injury or death.
• When removing parts, DO NOT touch the high voltage parts or the insides of the
exposed
orange-colored high voltage cables to avoid severe personal injury or death. • 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
3-3 High Voltage System Shut-Down Procedures) , then the dismantler can cut the vehicle except for the Li-ion battery.
DO

NOT cut the Li-ion battery due to possible electrocution risk and electrolyte solution
leakage.
25

3-4.3 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 do not touch the high voltage
components,
harnesses or service plug.
3-4.4 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.
28

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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