2011 Nissan LEAF Dismantling Guide

Nissan Emergency Contact Information

• Nissan EV Customer Support: 1-877-664-2738 (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) (Monday-Friday 8am-5pm Eastern, Central and Pacific time zones)

Important Information About This Manual

This manual uses symbols to convey critical safety information:

• DANGER: Indicates an operation that could result in death or serious personal injury if instructions are not followed. Example: Touching high voltage components without appropriate protective equipment can lead to electrocution.
• WARNING: Indicates an operation that may cause death or serious personal injury if instructions are not followed.
• CAUTION: Indicates an operation that may cause personal injury or component damage if instructions are not followed.

Note: Vehicle specifications may differ due to changes.

1. About The Nissan LEAF

The Nissan LEAF is an electric vehicle powered by two batteries: a standard 12V battery and a high-voltage Lithium-ion (Li-ion) battery for the traction motor. The Li-ion battery is located underneath the vehicle. Recharging is done via plugging in, and regenerative charging occurs during deceleration or downhill driving. The LEAF is considered environmentally friendly as it produces no exhaust gases.

1-1 LEAF Identification

1-1.1 Exterior

Exterior identification features include the Nissan logo on the front grille, the "LEAF" badge on the rear, and a "Zero Emission" badge. Notably, the vehicle lacks a tailpipe. The underside is covered by plastic shields, and there are no exhaust system components visible.

1-1.2 Interior Component Location

Key interior components include:

• READY indicator (green) on the instrument cluster.
• Hood release lever.
• Selector lever for gear selection.
• Power switch for vehicle operation.
• Charging indicator lights.
• Air conditioner remote timer indicator.
• Electric parking brake switch with an indicator.

1-2 Vehicle Identification Number (VIN) Layout

The VIN is typically found on a plate visible through the windshield (1) and on the vehicle certification plate on the lower center pillar (2). The 5th alphanumeric character of the VIN identifies the LEAF as an electric vehicle (Z).

1-3 Warning and Indicator Lamp Information

The instrument cluster features several important lamps:

*1: When the READY indicator is ON, the READY lamp will turn OFF.

2. Basic High Voltage Information

2-1 High Voltage-Related and 12V-Related Component Locations and Descriptions

Components marked with a white number on a black background are high voltage components.

2-1.1 Li-ion Battery Pack Specifications

• Li-ion battery voltage: 403.2V
• Number of Li-ion battery modules: 48
• Li-ion battery dimensions: 61.8 x 46.8 x 10.4 in. (1570.5 x 1188 x 264.9 mm)
• Li-ion battery weight: 648 lbs (294 kg)

2-2 High Voltage Safety Measures

• Circuit insulation: High voltage positive (+) and negative (-) circuits are insulated from the metal chassis.
• Reducing the risk of electrocution: High voltage components and harnesses have insulated cases or orange-colored coverings. The high voltage battery case is connected to the vehicle ground for protection.
• Identification: High voltage components are labeled "WARNING". High voltage harnesses are orange.

2-2.1 Warning Label

A multilingual warning label indicates:

• WARNING/AVERTISSEMENT/ACHTUNG/ADVERTENCIA/AVISO
• HIGH VOLTAGE INSIDE: DO NOT remove these covers and/or connectors.
• (German) HOCHSPANNUNGSFÜHRENDE TEILE IM INNEREN: Diese Abdeckungen bzw. Stecker nicht entfernen.
• (French) HAUTE TENSION À L'INTÉRIEUR: NE PAS enlever ces couvercles et connecteurs.
• (Portuguese) Alta Voltagem no interior: Nunca remova esta cobertura e/ou conector.
• (Spanish) Alto voltaje en el interior: Nunca remueva esta tapa y/or conector.

2-3 High Voltage Circuit Shut-Off System

The high voltage can be shut off using the following methods:

• Service plug: Located in the Li-ion battery center, manually removed to shut off high voltage output.
• System main relay: Controlled by the power switch and 12V system, it shuts off high voltage from the Li-ion battery.
• Emergency shut-off system: Activates automatically in collisions (airbag deployment) or system malfunctions to shut off high voltage.
• Charging connector: Removing the charging connector deactivates some high voltage components during charging.

2-4 Preventing Electrical Shock

1. If touching high voltage harnesses or components is necessary, wear appropriate PPE and shut down the high voltage system as per section 3-3. Wait at least 10 minutes for capacitor discharge after shutdown.
2. Do not touch the inside of the Li-ion battery unless wearing appropriate PPE, even after the high voltage system is shut down, as the battery retains charge.
3. Cover any damaged high voltage components with insulated tape.

3. Preparation for Dismantling

DANGER: Failure to properly shut down the high voltage electrical system before dismantling will result in serious injury or death from electrical shock. Always wear appropriate PPE and do not touch high voltage harnesses or components without it.

WARNING:

• Never assume the LEAF is OFF just because it is quiet.
• If leaving the vehicle unattended, place a "DANGER" sign to alert others about the high voltage battery.
• If the READY indicator, charging indicator, or air conditioning remote timer indicator is ON, the high voltage system is active.
• Verify that the READY indicator is OFF and the high voltage system is stopped.

3-1 Discharging Procedures

WARNING: Do not perform if the battery is damaged. Use extreme caution and appropriate PPE if unsure.

Li-ion battery discharging is required before dismantling:

1. Place the selector lever in Park (P).
2. Apply the parking brake.
3. Set wheel chocks.
4. Apply the foot brake and press the ignition switch to turn the system ON. Confirm the READY indicator is ON.
5. Check the Li-ion battery available charge gauge:
   • If more than half full (7 of 12 gauge lines lit), continue.
   • If less than half full (6 of 12 gauge lines lit), discharging is not needed.
6. Turn ON electric devices (headlamps, cabin heater at max settings, navigation, rear window defogger) to discharge the battery. Allow approximately 30 minutes per gauge line to drop. Discharge is complete when the gauge shows less than half full (6 lines).
7. Press the power switch to turn the system OFF.

If the Li-ion battery cannot be discharged, contact Nissan EV Customer Support or Nissan Consumer Affairs.

3-2 Preparation Items

Required preparation items and their purpose:

3-3 High Voltage System Shut-Down Procedure

The dismantling operation can only begin after the high voltage system is shut down. If the vehicle is heavily damaged (e.g., deformed Li-ion battery), use appropriate PPE and do not touch the battery or high voltage components.

DANGER: Failure to properly shut down the high voltage system will result in serious injury or death from electrical shock. Do not touch high voltage harnesses or components without appropriate PPE.

WARNING:

• Remove the charge connector if connected.
• The vehicle contains powerful magnets; persons with pacemakers or medical devices should not work on the vehicle.
• Verify the READY indicator is OFF and the high voltage system is stopped.
• Be aware of residual high voltage in the air conditioning system; ensure the air conditioning remote timer indicator is OFF.
• After shutdown, wait at least ten (10) minutes for high voltage capacitor discharge. Do not operate vehicle functions during this time. (Note: Voltage drops below 60V after 5 minutes).
• After shutting down the high voltage system and disconnecting the 12V battery negative terminal, wait at least three (3) minutes to discharge the air bag capacitor, as SRS air bags can deploy unexpectedly.
• Always shut down the high voltage system before disconnecting the 12V battery to prevent electrical shock.
• The 12V system can remain active even after the 12V battery negative terminal is removed if the high voltage system is active (indicated by air conditioning remote timer, charging, or READY indicators being ON). The DC/DC converter supplies power continuously.

3-3.1 Removing the Charge Connector

1. Press the lock release button/lever on the charge connector. (Note: Quick charge connector may not be on all models.)
2. Pull the charge connector to remove it.

3-3.2 Indications the High Voltage System is ON

The high voltage system is active if:

• The charge indicator is ON.
• The air conditioning remote timer indicator (on HVAC controller) is ON.
• The remote controlled climate control system is active (pushing the power switch to ON will turn it OFF).

Before disconnecting the 12V battery terminal, set the parking brake, lower windows, unlock doors, and open the rear hatch if necessary. Power controls will not operate once the 12V battery is disconnected.

3-3.3 Powering Down the High Voltage System

Choose one of the following procedures:

• Turn OFF the power switch and disconnect the 12V battery (Primary Procedure).
• Remove fuses for the high voltage control system and disconnect the 12V battery (Alternate Procedure 1).
• Remove the service plug and disconnect the 12V battery (Alternate Procedure 2).

3-3.4 Primary Procedure

1. Check the READY indicator status; if ON, the high voltage system is active.
2. Place the selector lever in Park (P).
3. Press the power switch once to turn OFF the high voltage system. Verify the READY indicator is OFF.
4. If possible, keep the Nissan Intelligent Key™ at least 5 meters (16 feet) away from the vehicle (not necessary if 12V system is already disabled).
5. Disconnect the negative (-) 12V battery cable and insulate the terminal with tape.
6. Wait at least ten (10) minutes for complete discharge of the high voltage capacitor after the power switch is turned OFF.
7. Perform the dismantling operation.

3-3.5 Alternate Procedure 1

1. Open the hood.
2. Press pawls (A) on the sides of the fuse box and remove the fuse box (1). (Note: The bottom of the fuse box is also its cover.)
3. Remove the following fuses:
   • F15 VCM IGN 10A
   • F24 F/S1 RLY 15A
   • F3 VCM 20A
4. If fuses cannot be identified, remove all fuses in the fuse box.
5. Disconnect the negative (-) 12V battery cable and insulate the terminal with tape.
6. Wait at least ten (10) minutes for complete discharge of the high voltage capacitor after fuses are pulled.
7. Perform the dismantling operation.

WARNING: Carry fuses on your person and cover the fuse box with insulated tape to avoid unintended installation and risk of electrical shock.

3-3.6 Alternate Procedure 2

DANGER: Do not remove the service plug without appropriate PPE. Immediately cover the service plug socket with insulated tape. The Li-ion battery retains high voltage even when the plug is removed. Do not touch terminals inside the socket.

WARNING: Carry the service plug on your person while work is in progress.

1. Locate the carpet flap (1) behind the center console and pull it up at the notched area (A). (Arrow indicates vehicle front direction.)
2. Remove the 10mm access cover bolts (A) and remove the cover (1). (Arrow indicates vehicle front direction.)
3. Remove the service plug by pressing the locking tab (1) and rotating the handle (2) upward. Pull the plug out of its socket.
4. Wait at least ten (10) minutes for complete discharge of the high voltage capacitor after the service plug is removed.
5. Open the hood.
6. Disconnect the negative (-) 12V battery cable (1) and insulate the terminal with tape.
7. Perform the dismantling operation.

3-4 Cutting the Vehicle Body

DANGER:

• 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 high voltage parts or the inside of orange-colored high voltage cables.

WARNING:

• Use appropriate tools (e.g., hydraulic cutter) when cutting the vehicle.
• Do not cut air bag parts to avoid unintended deployment and severe personal injury or death.

Cutting the vehicle is permitted only after the high voltage system has been shut down and at least ten (10) minutes have passed, excluding the Li-ion battery itself.

3-4.1 SRS Air Bag System Components Location

The SRS air bag system must not be cut due to the risk of short circuit and unintentional deployment. Cutting is permitted (except inflators) if air bags have deployed and at least three (3) minutes have passed since the 12V battery negative cable was disconnected and the high voltage system shut down.

Components include:

• Crash zone sensor
• Supplemental front-impact air bag modules
• Front seat-mounted side-impact supplemental air bag modules
• Roof-mounted curtain side-impact supplemental air bag inflators
• Roof-mounted curtain side-impact supplemental air bag modules
• Front door satellite sensors
• Lap outer pretensioner (driver side only)
• Seat belt with pretensioner
• Rear satellite sensors (lower B-pillar)
• Air bag control unit (ACU)

3-4.2 Vehicle Cut Sheet

Diagram shows component locations (12V battery, high voltage battery, traction motor, PTC heater, brake power supply backup unit, high voltage harnesses) and provides emergency contact information. Key indicates high voltage components/harnesses can be cut only after shutdown, and the Li-ion battery should NEVER be cut.

3-4.3 Water Submersion

DANGER: Damage to submerged vehicles may not be apparent. Handling without appropriate PPE results in serious injury or death from electrical shock.

WARNING:

• Turn OFF the power switch of a submerged vehicle if possible. Ensure the vehicle is completely out of water and drained to avoid electrical shock.
• Wear appropriate PPE and drain water before removing the service plug.
• Do not touch high voltage components, harnesses, or service plugs if the vehicle is in water.

3-4.4 Vehicle Fire

WARNING:

• Always use full PPE and self-contained breathing apparatus during fire fighting. LEAF fire smoke is similar to conventional vehicle fires.
• Use large amounts of water from a fire hydrant for extinguishing fires. DO NOT use a small amount of water.

CAUTION: A Type ABC fire extinguisher may be used for small electrical fires or oil fires.

In case of vehicle fire, contact the fire department immediately. If evacuating, notify responders that the vehicle is electric with a high voltage system and warn others.

3-5 Li-ion Battery Damage and Fluid Leaks

In case of battery case breach or electrolyte leakage, contact the fire department immediately. If evacuating, notify responders that the vehicle is electric with a high voltage system and warn others.

Li-ion Battery Electrolyte Solution Characteristics:

• Clear in color
• Sweet odor
• Similar viscosity to water
• Skin irritant
• Eye irritant: Rinse eyes with plenty of water and see a doctor immediately.
• If electrolyte leaks, wear solvent-resistant PPE, use a dry cloth to clean up, and ventilate the area.
• Highly flammable.
• Contact with water vapors can create an oxidized substance that may irritate skin and eyes; rinse with water and see a doctor.
• Inhaled electrolyte fumes can cause respiratory irritation and intoxication; move to fresh air, wash mouth with water, and see a doctor.
• Electrolyte leakage should be minimal due to sealed battery modules.

4. Jump Starting

To start the EV system with a booster battery, follow these instructions and precautions.

WARNING: Incorrect jump starting can lead to 12V battery explosion, severe injury, or death, and vehicle damage.

A discharged 12V battery may cause:

• Instrument cluster not displaying, no start-up sound (EV system cannot start).
• Li-ion battery cannot be charged.
• Vehicle cannot be shifted out of PARK.
• Electric parking brake cannot be set or released.

WARNING:

• The high voltage Li-ion battery CANNOT be jump started due to electrical shock risk.
• Explosive hydrogen gas is present near the 12V battery; keep sparks and flames away.
• Battery fluid is corrosive sulfuric acid; avoid contact with eyes, skin, clothing, or painted surfaces. Flush contacted areas with water immediately.
• Use a 12-volt rated booster battery; improper rating can damage the vehicle.
• Always wear eye protection and remove jewelry when working near a 12V battery. Do not lean over the battery.
• Do not attempt to jump start a frozen battery; it could explode.
• Keep hands and objects away from the automatic cooling fan.
• Failure to follow jump starting instructions can result in DC/DC converter damage and personal injury.

CAUTION:

• Do not use the LEAF to jump start another vehicle.
• Do not attempt to jump start the 12V battery while the Li-ion battery is being charged.

4-1 Jump Starting Procedures

1. Position vehicles (A and B) to bring their 12V batteries close together. DO NOT allow vehicles to touch.
2. If the electric parking brake is not applied and the selector lever is not in P (Park), immobilize the vehicle with wheel chocks.
3. Switch off all unnecessary electrical systems.
4. Place the power switch in the OFF position (if possible). If the 12V battery is discharged, connect jumper cables to the booster vehicle before engaging the power switch.
5. Remove 12V battery vent caps (if equipped). Cover the battery with a moist cloth to reduce explosion hazard.
6. Connect jumper cables in the sequence: positive (+) to positive (+), negative (-) to body ground. Ensure cables do not touch moving parts or metal.
7. Start the engine of the booster vehicle (B).
8. While the booster vehicle's engine is running, place the LEAF in READY mode. If the system does not start, turn the power switch OFF and wait 10 seconds before retrying.
9. After starting the EV system, disconnect cables in reverse sequence. Keep the EV system ON for over 20 minutes to charge the 12V battery.
10. Replace vent caps (if equipped) and dispose of the cloth properly.
11. If necessary, connect the vehicle to a charging station or EVSE to charge the Li-ion battery. The vehicle cannot be driven unless the Li-ion battery is charged.

4-2 Electric Parking Brake Mechanical Release Procedure

If the electric parking brake cannot be released via the switch, it can be mechanically released.

WARNING: Always confirm the vehicle is in P (Park) position before mechanical release. Failure to do so may cause unexpected movement and serious injury or death. Contact a NISSAN certified LEAF dealer if the vehicle cannot be placed in Park.

CAUTION:

• Perform this procedure only after the parking brake switch indicator turns OFF.
• To release mechanically, turn the power switch OFF and ensure the parking brake switch indicator is OFF.
• Driving with the parking brake applied may cause overheating and reduced effectiveness.
• The mechanical release tool is for emergency use only.

NOTE: The mechanical release tool can only release, not apply, the parking brake. The parking brake switch indicator may turn OFF 1 minute after the power switch is OFF.

To release the parking brake mechanically:

1. Confirm the vehicle is in P (Park) position.
2. Check that the parking brake switch operation indicator is OFF.
3. Place the power switch in the OFF position.
4. Open the rear hatch.
5. Remove the electric parking brake mechanical release tool from the cargo area tool set.
6. Remove the luggage floor board from the cargo area.
7. Remove the cap by turning it counterclockwise.
8. Insert the tool and turn it counterclockwise while pushing it in. Continue turning until it stops, then release. Do not turn past the stopping point.
9. Return the tool set and interior parts to their original locations.

4-3 P (Park) Position Release Procedure

This procedure is for releasing the vehicle from P (Park) position when the power switch is OFF or the 12V battery is low. It requires two people.

1. To start the EV system with a booster battery, refer to Section 4. Jump Starting.
2. Turn the power switch ON twice without pressing the brake pedal.
3. Confirm the parking brake is ON (indicator will be ON).
4. Place the selector lever in N (Neutral).
5. Close all doors and press the brake pedal.
6. Remove the following fuses:
   • PBW MTR-1 20A (under hood fuse box)
   • PBW MTR-2 20A (under hood fuse box)
   • METER 1 10A (cabin fuse box)
7. Release the electrical parking brake.
8. Turn the power switch OFF.
9. Release the brake pedal.

Ensure wheel chocks are firmly positioned when P (Park) is manually released.

4-3.1 Reset Procedure

1. Install the 3 removed fuses.
2. Turn the power switch ON and wait 5 seconds without pressing the brake pedal. Ensure the selector lever is in N (Neutral).
3. If the 12V battery is low, charge it.
4. Turn the power switch OFF and wait 5 seconds.

4-4 Storing the Vehicle

If the LEAF needs to be stored or left unattended, the high voltage system must be shut down by removing the service plug (refer to 3-3.6 Alternate Procedure 2). Place a sign on the vehicle indicating "DANGER: HIGH VOLTAGE REPAIR IN PROGRESS. DO NOT TOUCH!" with the person in charge noted.

5. Dismantling Information

Removal or repair of the high voltage battery requires special tools and training. NISSAN recommends only certified dealer technicians perform these operations.

5-1 Precautions for Handling High Voltage Lithium ion (Li-ion) Battery

WARNING:

• The LEAF contains a high voltage (Li-ion) battery, posing risks of electric shock, leakage, or accidents if handled incorrectly. Follow correct work procedures.
• High voltage harnesses and connectors are orange. "High Voltage" labels are present. Do not touch the Li-ion battery or other high voltage devices without appropriate PPE.
• Clearly identify personnel responsible for high voltage work and prevent others from touching the vehicle. Cover high voltage parts when not working.
• The high voltage battery retains high voltage at all times.
• Always wear appropriate PPE before working on the high voltage system.
• If touching high voltage harnesses or components is necessary, wear appropriate PPE and shut down the system by removing the service plug.
• Ensure the service plug is removed to shut down the system before inspection or dismantling. Keep the removed plug with you.
• Immediately insulate disconnected high voltage connectors and terminals with insulated tape.
• The vehicle contains powerful magnets; persons with pacemakers or medical devices should not work on the vehicle.
• Do not carry metal products or magnetic media that could cause short circuits or damage.
• Keep removed Li-ion battery packs away from rain to avoid electric shock.
• If the Li-ion battery is heavily damaged (deformed, broken, cracked), use appropriate PPE at all times.
• Do not heat removed battery packs above 158° F (70° C).

CAUTION: A malfunction may occur if the vehicle is changed to READY status while the service plug is removed.

5-2 PPE (Personal Protective Equipment) and Insulated Tools

5-2.1 PPE (Personal Protective Equipment) Protective Wear Control

Inspect all PPE items before use. Do not use damaged PPE.

5-2.2 Daily Inspection

Inspect PPE before and after use for deterioration and damage:

• Insulated rubber gloves: Check for scratches, holes, tears (visual check and air leakage test).
• Insulated safety boots: Check soles for holes, damage, nails, metal pieces, wear (visual check).
• Insulated rubber sheet: Check for tears (visual check).

5-2.3 Insulated Tools

Use insulated tools meeting 1,000V/300A specifications for work involving high voltage.

5-3 Lithium-ion (Li-ion) Battery Pack Removal

5-3.1 Exploded View

Diagram shows the Li-ion battery pack and its mounting components, including bonding plates, battery under covers, clips, and mounting brackets.

5-3.2 Removal Procedure

1. Raise the vehicle and remove the battery under covers (front, center, and rear).
2. Disconnect the high voltage connector (A) from the Li-ion battery. DANGER: Touching high voltage components without appropriate PPE will cause electrocution.
3. Follow the procedure to disconnect the high voltage connector. Cover the battery side of the high voltage connector with insulated tape (A).
4. Disconnect the Li-ion battery vehicle communications connector (A) by turning it counterclockwise. DANGER: Touching high voltage components without appropriate PPE will cause electrocution.
5. Remove the bonding plates (3 locations). Note that bonding plate shapes may differ. DANGER: Touching high voltage components without appropriate PPE will cause electrocution.
6. Remove ONLY the Li-ion battery mounting bolts (A) (6 bolts). Do NOT remove the 4 bolts (B) shown in the illustration at this stage, as they retain the battery for lifter table setup. DANGER: Touching high voltage components without appropriate PPE will cause electrocution.
7. Set the pallet (1) onto the lifter table (2), aligning center marks (A and B). DANGER: Touching high voltage components without appropriate PPE will cause electrocution.
8. Set the pallet (1) under the Li-ion battery. DANGER: Touching high voltage components without appropriate PPE will cause electrocution.
9. Remove the remaining 4 Li-ion battery mounting bolts (A). DANGER: Touching high voltage components without appropriate PPE will cause electrocution.
10. Carefully lower the pallet and remove the Li-ion battery (1) from the vehicle. DANGER: Touching high voltage components without appropriate PPE will cause electrocution.
11. Ensure the service plug socket and high voltage connector (battery side) are covered with insulated tape.
12. Dismantling the remainder of the LEAF can proceed like conventional vehicles once the high voltage system is properly shut down and discharged.

6. Recovery/Recycling of the Li-ion High Voltage Battery

The Li-ion high voltage battery is fully recyclable. For information regarding safe recovery and recycling, contact the nearest NISSAN dealer or call NISSAN Customer Assistance.

• Nissan EV Customer Support: 1-877-664-2738
• Nissan Consumer Affairs: 1-800-647-7261 (US) or 1-800-387-0122 (Canada)