NISSAN LEAF 2016 1.G Dismantling Guide

2-1.1 High Voltage Battery Pack Specifications
24kWh
Battery High voltage battery voltage
360V
nominal
(240V - 398.4V usable range)
Number of high voltage battery modules in the pack 48
High voltage battery dimensions 60.91 x 46.77 x 10.39 in. (1547 x 1188 x 264 mm)
High voltage battery weight US: 602 lbs (273 kg)
Canada: 606 lbs (275 kg)
30kWh Battery High voltage battery voltage
360V
nominal
(240V - 398.4V usable range)
Number of high voltage battery modules in the pack 48
High voltage battery dimensions 60.91 x 46.77 x 10.39 in. (1547 x 1188 x 264 mm)
High voltage battery weight US: 648 lbs (294 kg)
Canada: 653 lbs (296 kg)
2-2 High Voltage Safety Measures Circuit insulation
The high voltage positive (+) and negative (-) circuits are insulated
from
the metal chassis.
Reducing the risk of electrocution The high voltage components and harnesses have insulated cases or orange-colored coverings which provide insulation and easy
identification.
The high voltage battery case is electrically connected to the vehicle
ground. This connection helps protect the vehicle occupants and
vehicle dismantlers from high voltage electrical shock.
Identification The high voltage components are labeled “WARNING” similar to label
shown below. All high voltage harnesses are coated in orange.
2-2.1 Warning Label AAYIA0147ZZ
DG–11

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 high voltage battery, this shuts off output
high
voltage when manually removed.
System main relay (located
in high voltage battery) Controlled by the power switch, this relay, which is controlled by the 12-volt
system, shuts off the high voltage from the high voltage battery.
Emergency shut-off
system 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
is designed to shut off the high voltage from the high voltage 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
(DG–15) ) and shut off the high voltage system by referring to 3-4 High Voltage System
Shut-Down

Procedures (DG–16) .
2.

To avoid the risk of electrocution, NEVER touch the inside of the high voltage battery unless
appropriate PPE is worn even after shutting off the high voltage system. The high voltage battery
maintains charge even though the high voltage system is shut down.
3. Cover any damaged high voltage components with insulated tape.
DG–12

3. Preparation for Dismantling
• Failure to properly shut down the high voltage electrical system before the
Dismantling Procedures are performed will result in serious injury or death from
electrical shock. To prevent serious injury or death, NEVER touch high voltage
harnesses or components without always wearing appropriate Personal Protective
Equipment (PPE) .
• If it is necessary to touch any of the high voltage harnesses or components you
must
always wear appropriate PPE to avoid electrical shock. Shut down the high
voltage system by following the steps outlined in 3-4 High Voltage System Shut-Down
Procedures

(DG–16) . Wait at least ten (10) minutes for complete discharge of the high
voltage

capacitor after the high voltage system has been shut down. • NEVER assume the LEAF is shut OFF simply because it is quiet.
• If it becomes necessary for the dismantler to leave the vehicle, place a “DANGER” sign
(for
example, refer to 4-3 Storing the Vehicle (DG–36)) on the vehicle to alert other
people

that the vehicle contains a high voltage battery.
• If the READY indicator or charging indicator are ON, the high voltage system is
active.
• If possible, be sure to verify that the READY indicator on the instrument cluster
is

OFF and the high voltage system is stopped.
3-1 Discharging Procedures Do not perform this procedure if the high voltage battery is damaged. If you are unsure of
battery

damage, use extreme caution and always wear appropriate Personal Protective
Equipment (PPE) when working on high voltage components.
High voltage battery discharging must take place before dismantling. Sufficient discharging can be achieved
by following these steps. 1. Place the selector lever into the Park (P) position
2. Apply the parking brake.
3. Set wheel chocks to ensure the vehicle is completely immobilized.
DG–13

4. Apply foot brake and press the power switch to turn the system ON. Confirm READY
indicator in instrument cluster turns ON.
5. Check high voltage battery available charge gauge: a. If remaining energy (1) shows higher than half full (7 of 12 gauge lines lit up) , continue to next step.
b. If remaining energy (2) shows lower than half full (6 of 12 gauge lines lit up) , discharging is not needed.
6. Turn ON electric devices such as headlamps, cabin heater (set to the highest temperature and maximum fan speed; do not use AUTO A/C setting) , navigation system and rear window defroster
to discharge the high voltage battery. Allow approximately 30 minutes for each line on the
available charge gauge to drop. Discharge is complete when the available charge gauge drops to
lower than half full (6 of 12 gauge lines lit up) .
7. Press the power switch to turn the system OFF. LOCK Acc
(OFF) ON AAYIA0036GB
0
1 POWER
Brake
P A 120miles
0.0miles MPH
PM
F miles 1 2
AAYIA0148ZZ
DG–14

Please contact following number if the high voltage 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
Equipment (PPE):
Insulated gloves Up to 1,000V
For
protection from high voltage
electrical shock
Insulated shoes –
Safety

shield –
Leather

gloves Must be able to fasten tight
around

the wrist (worn over
insulated gloves) . To protect insulated gloves
Wrenches Size: 10mm
T
o remove the service plug access
cover bolts.
To remove the 12-volt battery terminal
bolt.
Solvent resistant protection
gloves –
To utilize in the event of a high voltage
battery electrolytic solution leak.
Solvent resistant protection
shoes –
Absorbent pad The same pad used for internal
combustion engine fluids can be
used. To absorb any high voltage battery
electrolytic solution leakage.
Standard fire fighting
equipment 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.
DG–15

3-3 Personal Protective Equipment (PPE) and Insulated Tools
3-3.1
Personal Protective Equipment (PPE) Protective Wear Control
Perform an inspection of the Personal Protective Equipment (PPE) items before beginning work. Do not use
any damaged PPE items.
3-3.2 Daily Inspection
This inspection is performed before and after use. The worker who will be using the items should perform
the inspection and check for deterioration and damage. • Insulated rubber gloves should be inspected for scratches, holes and tears. (Visual check and airleakage test)
• Insulated safety boots should be inspected for holes, damage, nails, metal pieces, wear or other problems on the soles. (Visual check)
• Insulated rubber sheet should be inspected for tears. (Visual check)
3-3.3 Insulated Tools
When performing work at locations where high voltage is applied (such as terminals) , use insulated tools
meeting 1,000V/300A specifications.
3-4 High Voltage System Shut-Down Procedures
Once the high voltage battery is properly discharged, any of the following procedures can shut down and
isolate the high voltage system. The dismantling operation can only begin after shutting down the high
voltage system. If the vehicle is heavily damaged, for example the high voltage battery is deformed, broken
or cracked, appropriate Personal Protective Equipment (PPE) must always be used and the high voltage
battery and high voltage components must not be touched. • Failure to properly shut down the high voltage system before the dismantling
procedures
are performed will result in serious injury or death from electrical shock.
To prevent serious injury or death, NEVER touch high voltage harnesses or
components without always wearing appropriate Personal Protective Equipment
(PPE) . PPE must always be worn when touching or working on high voltage
components
• When contact with high voltage components or high voltage harnesses is
unavoidable,
or when there is risk of such contact, you must always wear appropriate
PPE. PPE must always be worn when touching or working on high voltage
components.
DG–16

• If the charge connector is connected to the vehicle, remove it. Refer to
3-4.1 Removing the Charge Connector (DG–18).
• 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.
• Be sure to verify that the READY indicator is off and the high voltage system is
stopped.
•

After the high voltage system is shut down, please wait at least ten (10) minutes for
complete discharge of the high voltage capacitor. While waiting, do not operate any
vehicle functions.
• After shutting down the high voltage system and removing the 12-volt battery negative (-) terminal, wait at least three (3) minutes to discharge the air bag capacitor. Even
though the 12-volt battery negative (-) is disconnected, the Supplemental
Restraint System (SRS) air bag maintains voltage at least three (3) minutes. During
this time, there is a possibility of sudden SRS air bag inflation due to harness
short circuit or damage and it may cause serious injuries.
• Always shut down the high voltage system before disconnecting the 12-volt battery. Not doing so may result in serious injury or death from electrical shock.
• The 12V system will remain active even after the 12-volt battery negative (-) terminal is removed while the high voltage system is active. The high voltage system is active
during any of the following conditions:
• charging indicator is turned ON
• READY indicator is turned ON
Refer to 1-1.2 Interior Component Location (DG–7)
for location of these indicators.
This

is because DC/DC converter will not shut down and power will be supplied
to the 12V system and high voltage system continuously.
DG–17

3-4.1 Removing the Charge Connector
NO
TE:
Use the illustration to identify the type of charge connector and follow the appropriate procedure.
1.Quick Charge Connector (If So Equipped)
NOTE:
The quick charger must be OFF to release the charge connector lock.
Release the quick connector lock and pull to remove. Refer to the quick charger label or
instructions.
2. Trickle and Normal Charge Connectors
a. Press the charge connector release button on the charge connector and pull to remove.
NOTE:
If the charge connector cannot be removed, the electric lock is engaged. Follow the next
steps to disengage.
b. To disengage the electric charge connector lock, place the charge connector lock switch in the
UNLOCK mode (center level position) . Trickle and Normal Charge Connector
T

ypical Quick Charge Connector
AAYIA0047GB
LOCKAUTO AAYIA0152ZZ
DG–18

c. The charge connector can be unlocked by
pushing the charge connector unlock button on
the Nissan Intelligent Key® for more than
1 second. The charge connector will temporarily
unlock for 30 seconds.
d. Press the charge connector release button and pull the charge connector to remove it.
3. If the Trickle or Normal Charge Connector Cannot Unlock
a. Place power switch in OFF position.
b. Open the hood.
c. Using a flat head screwdriver (or suitable tool) , insert into the screw located through the access
hole near the front of the hood lock.
d. Rotate screw clockwise to release the charge connector lock.
e. Press the charge connector release button and pull the charge connector to remove it. HOLD
NISSAN
AAYIA0153ZZ
AAYIA0091ZZ
AAYIA0145ZZ
AAYIA0353ZZ
DG–19

3-4.2 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 12-volt battery terminal, if necessary, lower the windows, unlock the doors, and
open the rear hatch as required. Once 12-volt battery is disconnected, power controls will not operate.
3-4.3 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 12-volt battery. Refer to
3-4.4 Primary Procedure
(DG–20) .
•

Remove the fuses for the high voltage control system and disconnect the 12-volt battery. Refer to
3-4.5 Alternate Procedure 1 (Remove Fuses) (DG–22).
•

Remove the service plug and disconnect the 12-volt battery. Refer to 3-4.6 Alternate Procedure 2
(Remove

Service Plug) (DG–24) .
3-4.4

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 and continue to the next steps to
open

the hood for 12-volt battery negative cable access.
If the READY indicator does not turn off, refer to
3-4.5 Alternate Procedure 1 (Remove Fuses)
(DG–22)
4. If possible, keep the Nissan Intelligent Key® at least 5
meters (16 feet) away from the vehicle. AAYIA0155ZZ
AAYIA0091ZZ
HOLD
AAYIA0144ZZ
DG–20