charging NISSAN LEAF 2016 1.G Dismantling Guide

Table of Contents
FOREWORD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
NISSAN EMERGENCY CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
IMPORTANT INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–2
1. ABOUT THE NISSAN LEAF® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–5
1-1 LEAF IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–6 1-1.1 EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–6
1-1.2 INTERIOR COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–7
1-2 VEHICLE IDENTIFICATION NUMBER (VIN) LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–8
1-3 WARNING AND INDICATOR LAMP INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–8
2. BASIC HIGH VOLTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–9 2-1 HIGH VOLTAGE-RELATED AND 12-VOLT-RELATED COMPONENT LOCATIONS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–9
2-1.1 HIGH VOLTAGE BATTERY PACK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-2 HIGH VOLTAGE SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11 2-2.1 WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–11
2-3 HIGH VOLTAGE CIRCUIT SHUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–12
2-4 PREVENTING ELECTRICAL SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–12
3. PREPARATION FOR DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–13
3-1 DISCHARGING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–13
3-2 PREPARATION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–15
3-3 PERSONAL PROTECTIVE EQUIPMENT (PPE) AND INSULATED TOOLS . . . . . . . . . . . . . DG–163-3.1
PERSONAL PROTECTIVE EQUIPMENT (PPE) PROTECTIVE WEAR CONTROL. . . DG–16
3-3.2 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–16
3-3.3 INSULATED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–16
3-4 HIGH VOLTAGE SYSTEM SHUT-DOWN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . DG–16 3-4.1 REMOVING THE CHARGE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–18
3-4.2 INDICATIONS THE HIGH VOLTAGE SYSTEM IS ON . . . . . . . . . . . . . . . . . . . . . . . . DG–20
3-4.3 POWERING DOWN THE HIGH VOLTAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . DG–20
3-4.4 PRIMARY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–20
3-4.5 ALTERNATE PROCEDURE 1 (REMOVE FUSES) . . . . . . . . . . . . . . . . . . . . . . . . . . . DG–22
3-4.6 ALTERNATE PROCEDURE 2 (REMOVE SERVICE PLUG) . . . . . . . . . . . . . . . . . . . . DG–24
DG–3

1. About The Nissan LEAF®
This
vehicle uses two types of batteries. One is a 12-volt battery that is the same as the battery in vehicles
powered by internal combustion engines, and the other is the high voltage battery for the traction motor
which propels the vehicle. The high voltage battery is encased in steel and mounted underneath the vehicle.
The vehicle must be plugged-in in order for the high voltage battery to be recharged. Additionally, the
vehicle system can recharge the high voltage battery by converting driving force into electricity while the
vehicle is decelerating or being driven downhill. This is called regenerative charging. This vehicle is
considered to be an environmentally friendly vehicle because it does not emit exhaust gases.
DG–5

1-1.2 Interior Component Location
Interior
components referenced in this manual are as follows: Charging indicator lights
Power switch
Hood r

elease Selector lever
READY indicator (green)
Charge connector
lock switch
AAYIA0044GBDG–7

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

• 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

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 12-volt battery explosion, resulting in severe
personal

injury or death. It could also damage your vehicle.
Discharged 12-volt 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 high voltage battery cannot be charged.
• The vehicle cannot be shifted out of PARK normally. • To avoid electrical shock, the high voltage battery CANNOT be jump started.
•

Explosive hydrogen gas is always present in the vicinity of the 12-volt battery. Keep all
sparks and flames away from the 12-volt battery. Make sure the vent tube is correctly
installed.
• 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 12-volt 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 12-volt 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 charging system and cause personal injury. • Do not use LEAF to jump start another vehicle.
•

Do not attempt to perform a jump start on the 12-volt battery at the same time that the
high voltage battery is being charged. Doing so may damage the vehicle or charging
equipment and could cause an injury.
DG–31

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.
12. If necessary, connect the vehicle to a charging station or EVSE (Electric Vehicle Supply Equipment) to charge the high voltage battery. The vehicle cannot be driven unless the high
voltage battery is charged.
NOTE:
If it is not possible to turn the LEAF system ON by following this procedure, it is
recommended you 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 12-volt 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 (DG–31).
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)
DG–33

5-2.2 Removal Procedure
NEVER disassemble or open the high voltage battery to avoid severe personal injury or
death
by electrical shock.
1. Discharge the high voltage battery. Refer to 3-1 Discharging Procedures (DG–13).
2.

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

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

connector with insulated tape. : Insulated tape A
B
AAYIA0165ZZ AAYIA0049GB
AAYIA0166ZZ
DG–41