service NISSAN PATHFINDER HYBRID 2014 R52 / 4.G Dismantling Guide

1. About the Pathfinder HYBRID
This hybrid electric vehicle (HEV) uses two types of batteries. One is a 12V battery that is the same as the
battery in vehicles powered by internal combustion engines. The 12V battery is located under the hood near
the driver side headlamp. The other is the Lithium-ion (Li-ion) battery (high voltage) for the traction motor
which propels the vehicle. The Li-ion battery is located under the third row seating with service plug access
through the cargo area storage bin.
The high voltage Li-ion battery is recharged with an on-board DC/DC converter and generator powered by
the engine. Additionally, the vehicle system can recharge the Li-ion battery by converting driving force
into electricity while the vehicle is decelerating or being driven downhill. This is called regenerative charging.DG–5

No. Component Location Description DC/DC Converter Cargo area floor
(mounted right of
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.) .
Service Plug Cargo area floor
(inside storage bin
behind access door) This is used to disable the high voltage system.
Lithium-ion (Li-ion)Battery Cargo area floor
(under 3rd row
seating floor trim) The Li-ion battery stores and outputs DC
power (Maximum voltage 144V) needed to
propel the vehicle.
Traction Motor Engine compart-
ment (built-into thetransmission) Converts three-phase alternating current (AC)
power to drive power (torque) which propels
the vehicle.
Traction MotorInverter Engine compart-
ment (front driverside) 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. The inverter has a built in high
voltage capacitor.
12V Battery Engine compart-
ment (front driverside) A lead-acid battery that supplies power to the
low voltage devices.
High Voltage Har-ness Cargo area (on
Li-ion battery) ,
under floor, enginecompartment Orange-colored power cables carry high DC
voltage between each of the high voltage com-ponents.
2-3 Li-ion Battery Pack Specifications
Li-ion Battery Specifications
Li-ion battery voltage 144V
Number of Li-ion battery modules in the pack 3 modules (40 cells)
Li-ion battery module voltage 48V each
Li-ion battery dimensions 36.31 x 22.07 x 6.52 in. (922.3 x 560.5 x 165.6 mm)
Li-ion battery weight 62.4 lbs (28.3 kg)
DG–13

2-5 High Voltage Safety System
The high voltage safety system is intended to help keep vehicle occupants and emergency responders safe
from high voltage electricity.• A high voltage fuse provides short circuit protection inside the high voltage battery.
• The high voltage safety system is insulated from the metal chassis.
• Positive and negative high voltage power cables are connected to the high voltage battery and arecontrolled by normally open system main relays (SMR1 and SMR2) . When the vehicle is shut off,
the relays stop electrical flow from leaving the high voltage battery. However, it can take
approximately ten (10) minutes for the high voltage capacitor to fully discharge.
• The high voltage system and high voltage capacitor may remain powered for up to
approximately 10 minutes after the vehicle is shut off. Personal Protective Equipment
(PPE) must always be worn when touching or working on high voltage components
to avoid risk of electrical shock and severe personal injury or death.
• The high voltage battery retains high voltage at all times. PPE must always be worn when touching or working on high voltage components to avoid risk of electrical shock and
severe personal injury or death.
• 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 HPCM (hybrid powertrain control module) will
illuminate the hybrid system warning lamp
in the instrument cluster.
Cargo Area
Junction Box Li-ion Battery
System main relay 1
Service Plug (With Fuse)
System main relay 2
Transmission
Traction Motor Traction
Motor Inverter
(With built in high
voltage capacitor) DC/DC
Converter
HPCM
(Hybrid Powertrain Control Module)
Engine Compartment
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DG–15

• The high voltage battery relays (SMR1 and SMR2) will automatically open to stop the electrical flowin a front, side or certain rear collisions that are sufficient enough to activate the supplemental
restraint system (SRS) .
2-6 High Voltage Circuit Shut-Off System
This vehicle is equipped with a system to shut off the current from the Li-ion battery by the following methods:
Service plug Positioned in the right rear area of the Li-ion battery, this plug shuts off the output of high voltage when manually removed.
System main relays
(located in the high voltagebattery) Controlled by the ignition switch, these relays are powered by the 12V sys-
tem and shut off 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
is designed to shut off the high voltage from the Li-ion battery.
2-7 Preventing Electrical Shock 1. If it is necessary to touch any of the high voltage harnesses or components, always wearappropriate Personal Protective Equipment (PPE) [refer to
3-1 Preparation Items (DG–18)].
Shut off the high voltage system by referring to
3-4.1 High Voltage System Shut-Down
Procedure (DG–21)
.
2. To avoid the risk of electrocution, NEVER touch the inside of the Li-ion battery with bare hands after shutting off the high voltage system. The Li-ion battery maintains charge even though the
high voltage system is shut down. PPE must always be worn when touching or working on high
voltage components.
3. Cover damaged high voltage components with insulated tape.
DG–16

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 and disconnect the 12V battery. Refer to
Primary Procedure (DG–23).
• Remove the underhood fuse for the high voltage control system and disconnect the 12V battery. Refer to
Alternate Procedure 1 (Removing Fuses) (DG–25).
• Remove the service plug and disconnect the 12V battery. Refer to
Alternate Procedure 2 (Remove
Service Plug) (DG–27)
.
DG–22

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, NEVER 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.
NOTE: Before disconnecting the 12V battery terminal, if necessary, lower the windows, adjust the
steering column, adjust the seats, unlock the doors, etc. Once 12V battery is disconnected,
power controls will not operate.
1. If possible, check the READY
indicator status in the instrument cluster. If it is on, the high
voltage system is active.
2. Place the shift selector in the Park (P) position.
3. Push the ignition switch once to turn OFF the high voltage system. Then verify whether the READY indicator
is off.
If the READY indicator does not turn off, continue to the
next steps.
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ACC
LOCK
(OFF)
ON
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DG–27

7. Open service plug access cover.
8. Remove the service plug (A) by pulling the locking lever (B) , then pressing the locking tab (C)and rotating the handle (D) fully outward. Using the handle, pull the service plug (E) completely
out of its socket.
9. Cover the service plug socket with insulated tape.
10. Wait approximately ten (10) minutes for complete discharge of the high voltage capacitor
after the service plug has been removed.
11. Pull release handle (1) and pull up release lever (2) to open hood.
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A
B
C
DE
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1
2
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DG–30

12. Remove traction motor inverter cover (1) .
13. Disconnect negative (-) battery cable and cover it withinsulated tape.
14. Perform the dismantling operation. Refer to
Dismantling Information (DG–41).
3-4.2 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, NEVER touch the high voltage parts or the insides of the
exposed orange-colored high voltage cables to avoid severe personal injury or death.
Personal Protective Equipment (PPE) must always be worn when touching or
working on high voltage components.
• 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 approximately (10) minutes have passed since the rescuer shut down the high voltage system [refer to
3-4.1 High Voltage System Shut-Down Procedure (DG–21)], then the dismantler can cut the vehicle except
for the Li-ion battery.
1
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DG–31

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 ignition 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 NEVER touch the high voltage
components, harnesses or service plug. PPE must always be worn when touching or
working on high voltage components.
3-4.4 Vehicle Fire
• Always utilize full Personal Protective Equipment (PPE) and self-contained breathing apparatus during fire fighting operations. Smoke from a Pathfinder HYBRID 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
a hybrid vehicle that contains a high voltage system and warn all others. DG–34

5. 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.
If the Pathfinder HYBRID needs to be stored or left unattended, the high voltage system must be shut down
by removing the service plug [refer to
Alternate Procedure 2 (Remove Service Plug) (DG–27)] and a sign
put on the vehicle indicating it is a hybrid vehicle with high voltage dangers. For example:
DG–39