Electric Power Train PDF
Electric Power Train PDF
Electric Power Train PDF
EVB
A
B
SECTION
EV BATTERY SYSTEM EVB
E
CONTENTS
PRECAUTION ............................................... 5 LI-ION BATTERY HEATER CONTROL SYSTEM F
: System Description ................................................25
PRECAUTIONS ................................................... 5 Circuit Diagram ........................................................27
Precaution for Technicians Using Medical Electric...... 5 G
Point to Be Checked Before Starting Maintenance HANDLING PRECAUTION ............................... 32
Work .......................................................................... 5 EV Battery System ..................................................32
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
DIAGNOSIS SYSTEM (LBC) ............................ 33 H
CONSULT Function .................................................33
SIONER" ................................................................... 5
Precaution for Procedure without Cowl Top Cover...... 6 ECU DIAGNOSIS INFORMATION .............. 35
Precaution for Removing 12V Battery ....................... 6 I
High Voltage Precautions .......................................... 6 EV BATTERY SYSTEM .................................... 35
Reference Value ......................................................35
PREPARATION ............................................ 9 Fail-safe ...................................................................40 J
PREPARATION ................................................... 9 DTC Index ...............................................................45
Special Service Tools ................................................ 9 WIRING DIAGRAM ...................................... 50
Commercial Service Tools ...................................... 10 K
Sealant or/and Lubricant ......................................... 13 VCM ................................................................... 50
Wiring Diagram ........................................................50
SYSTEM DESCRIPTION ............................. 14 L
BASIC INSPECTION ................................... 82
COMPONENT PARTS .......................................14
Component Parts Location ...................................... 14 DIAGNOSIS AND REPAIR WORK FLOW ....... 82
Li-ion Battery ........................................................... 16 Work Flow ................................................................82 M
Li-ion Battery Controller .......................................... 16 Diagnostic Work Sheet ............................................83
Module .................................................................... 17
Heater Relay Unit .................................................... 18 ADDITIONAL SERVICE WHEN REPLACING N
Li-ion Battery Heater ............................................... 18 LI-ION BATTERY CONTROLLER .................... 85
Battery Current Sensor ........................................... 19 Description ...............................................................85
Battery Temperature Sensor ................................... 19 Work Procedure .......................................................85
Battery Junction Box ............................................... 20 O
Service Plug ............................................................ 20 MODULE CHARGE BALANCE ........................ 86
High Voltage Warning Label ................................... 20 Description ...............................................................86
Work Procedure .......................................................86 P
SYSTEM .............................................................22
DTC/CIRCUIT DIAGNOSIS ......................... 88
LI-ION BATTERY CONTROL SYSTEM .................... 22
LI-ION BATTERY CONTROL SYSTEM : System P0A0D HV SYSTEM INTERLOCK ERROR ..... 88
Description .............................................................. 22 DTC Logic ................................................................88
Diagnosis Procedure ...............................................88
LI-ION BATTERY HEATER CONTROL SYSTEM .... 24 Component Inspection .............................................89
P3030 CELL CONTROLLER LIN ...................... 91 P30FC OVER CURRENT ................................. 111
DTC Logic ............................................................... 91 DTC Logic ............................................................. 111
Diagnosis Procedure .............................................. 91 Diagnosis Procedure ............................................. 111
P3031-P303C CELL CONTROLLER ASIC ....... 92 P318D COMMUNICATION ERROR ................. 112
DTC Logic ............................................................... 92 DTC Logic ............................................................. 112
Diagnosis Procedure .............................................. 92 Diagnosis Procedure ............................................. 112
P303D-P3048 CELL CONTROLLER ASIC ....... 93 P318E COMMUNICATION ERROR ................. 113
DTC Logic ............................................................... 93 DTC Logic ............................................................. 113
Diagnosis Procedure .............................................. 93 Diagnosis Procedure ............................................. 113
P33E1 BAT VOLTAGE ISOLATION SEN ....... 158 LI-ION BATTERY ............................................ 194 O
DTC Logic ............................................................. 158 Exploded View ....................................................... 194
Diagnosis Procedure ............................................. 158 Removal and Installation ....................................... 194
Inspection .............................................................. 201
P33E2 BATT PACK OVER TEMP ................... 159 P
DTC Logic ............................................................. 159 UNIT DISASSEMBLY AND ASSEMBLY . 203
Diagnosis Procedure ............................................. 159
LI-ION BATTERY ............................................ 203
P33E6 CELL CONTROLLER ........................... 160 BATTERY PACK UPPER CASE ............................. 203
DTC Logic ............................................................. 160 BATTERY PACK UPPER CASE : Exploded View.. 203
Diagnosis Procedure ............................................. 160
OPERATION PROHIBITION
WARNING: EVB
• Parts with strong magnet is used in this vehicle.
• Technicians using a medical electric device such as pacemaker must never perform operation on the
vehicle, as magnetic field can affect the device function by approaching to such parts.
D
NORMAL CHARGE PRECAUTION
WARNING:
• If a technician uses a medical electric device such as an implantable cardiac pacemaker or an E
implantable cardioverter defibrillator, the possible effects on the devices must be checked with the
device manufacturer before starting the charge operation.
• As radiated electromagnetic wave generated by PDM (Power Delivery Module) at normal charge
F
operation may affect medical electric devices, a technician using a medical electric device such as
implantable cardiac pacemaker or an implantable cardioverter defibrillator must not approach motor
room [PDM (Power Delivery Module)] at the hood-opened condition during normal charge operation.
G
PRECAUTION AT TELEMATICS SYSTEM OPERATION
WARNING:
• If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), H
avoid the device implanted part from approaching within approximately 220 mm (8.66 in) from inte-
rior/exterior antenna.
• The electromagnetic wave of TCU might affect the function of the implantable cardiac pacemaker or
the implantable cardioverter defibrillator (ICD), when using the service, etc. I
• If a technician uses other medical electric devices than implantable cardiac pacemaker or implant-
able cardioverter defibrillator (ICD), the electromagnetic wave of TCU might affect the function of the
device. The possible effects on the devices must be checked with the device manufacturer before J
TCU use.
PRECAUTION AT INTELLIGENT KEY SYSTEM OPERATION
WARNING: K
• If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD),
avoid the device implanted part from approaching within approximately 220 mm (8.66 in) from inte-
rior/exterior antenna. L
• The electromagnetic wave of Intelligent Key might affect the function of the implantable cardiac
pacemaker or the implantable cardioverter defibrillator (ICD), at door operation, at each request
switch operation, or at engine starting.
• If a technician uses other medical electric devices than implantable cardiac pacemaker or implant- M
able cardioverter defibrillator (ICD), the electromagnetic wave of Intelligent Key might affect the
function of the device. The possible effects on the devices must be checked with the device manu-
facturer before Intelligent Key use. N
Point to Be Checked Before Starting Maintenance Work INFOID:0000000009347449
The high voltage system may starts automatically. It is required to check that the timer air conditioner O
and timer charge (during EVSE connection) are not set before starting maintenance work.
NOTE:
If the timer air conditioner or timer charge (during EVSE connection) is set, the high voltage system starts
P
automatically even when the power switch is in OFF state.
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000009347450
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-5 2013 LEAF
PRECAUTIONS
< PRECAUTION >
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery and wait at least three minutes before performing any service.
Precaution for Procedure without Cowl Top Cover INFOID:0000000009347451
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
CAUTION:
When the 12V battery is removed, plural DTC may be detected.
After installing 12V battery, always perform “All DTC” with CONSULT and delete DTC.
High Voltage Precautions INFOID:0000000009347452
WARNING:
• Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of elec-
tric shock, electric leakage, or similar accidents if the high voltage component and vehicle are han-
dled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• To prevent the removed service plug from being connected by mistake during the procedure, always
carry it in your pocket or put it in the tool box.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield, and glasses
before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or sim-
ilar item to prevent other persons from contacting them.
CAUTION:
JSAIA1600GB
The actual shape of the tools may differ from those illustrated here.
Tool number Description
(TechMate No.) EVB
Tool name
— When removing/installing Li-ion battery.
(J-50583) D
Palette
JPCIA0239ZZ
F
KV99111300 When installing Li-ion battery.
(J-50306) 2 piece/set
Battery location guide pin
G
H
JPCIA0023ZZ
JSCIA0257ZZ
JPCIA0069ZZ
M
— Module voltage adjustment
(J-50346)
Module charge balancer
N
O
JPCIA0070ZZ
JSCIA0726ZZ
JMCIA0149ZZ
JPCIA0066ZZ
JPCIA0011ZZ
JPCIA0012ZZ
JPCIA0167ZZ
JPCIA0013ZZ
B
Insulated rubber sheet Removing and installing high voltage components
EVB
JPCIA0019ZZ
JPCIA0018ZZ
JPCIA0024ZZ
H
I
Stacker Removing and installing Li-ion battery
J
JPCIA0015ZZ
JPCIA0014ZZ
JPCIA0067ZZ
O
P
Insulated torque wrench Removing and installing high voltage components
JPCIA0068ZZ
JPCIA0021ZZ
JPCIA0020ZZ
JPCIA0022ZZ
JSCIA0640ZZ
JSCIA0641ZZ
EVB
JSCIA0643ZZ
D
Tube presser [Gasket material ap- Installing battery pack upper case
plicator] (Apply the adhesive)
E
JSCIA0639ZZ
JSCIA0735ZZ
H
Sealant or/and Lubricant INFOID:0000000009298743
I
Tool name
Description
Tool number
Adhesive J
999MP-57302NP
Dam rubber
KA390-0059U K
Installing battery pack upper case
Primer (Adhesive primer)
999MP-43533PP
Primer sufacer (anti-corrosion praimer) L
—
JSCIA0505ZZ
B
No. Component Function
Li-ion battery EVB-16, "Li-ion Battery"
JSCIA0771ZZ O
: Vehicle front
P
No. Component Function
Li-ion battery heater RH 1 EVB-18, "Li-ion Battery Heater"
JSCIA0701ZZ
• Four cells are integrated into a single module. The Li-ion battery consists of 48 modules placed in series.
JSCIA0702ZZ
JSCIA0071ZZ
• The LBC is the core of battery control. Li-ion battery controller detects the voltage and current of the assem-
bled battery, the temperature of each module, and the voltage of each cell to judge state of charge. LBC also
calculates possible input/output values, meter indication values, and chargeable values, and send this data
to VCM (Vehicle control module). VCM controls the vehicle, according to the battery state.
Main Role of Li-ion Battery Controller
1. Li-ion battery state check
• State of charge
• Possible output value
• Possible input value
• Temperature
2. Optimization of Li-ion battery voltage
JSCIA0703ZZ
F
MODULE INTERNAL CIRCUIT
A module consists of two parallel-connected cells placed in series.
The Li-ion battery has 48 modules placed in series in total. Ninety-six G
parallel-connected cell pairs are connected in series.
NOTE:
Cell voltage displayed on the data monitor of CONSULT means the
potential difference between the upstream and the downstream of H
the parallel circuit.
JPCIA0197GB
J
MODULE LAYOUT
O
JSCIA0704GB
NOTE:
The highest potential is module (MD) 1 and the lowest is module (MD) 48. P
CELL
JSCIA0274ZZ
• The heater relay unit is installed in the battery pack (under the ser-
vice plug).
• When receiving a relay control signal from LBC (Li-ion battery con-
troller), the heater relay unit turns ON the built-in relay and sup-
plies high-voltage power to each Li-ion battery heater.
JSCIA0772ZZ
JPCIA0212ZZ
EVB
JPCIA0213ZZ
D
Battery Current Sensor INFOID:0000000009346493
JSCIA0507ZZ
H
Battery Temperature Sensor INFOID:0000000008745912
L
JSCIA0705ZZ
JPCIA0295GB
• The battery junction box is installed to the front side in the battery
pack.
• The battery junction box includes:
- System main relay to provide/interrupt DC current sent from Li-ion
battery.
- Pre-charge relay to protect the high voltage circuit from a high cur-
rent immediately after power switch ON.
• Installed to both positive side and negative side, the system main
relay provides DC current to each high voltage part. In addition, the
system main relay provides DC current to the Li-ion battery during
motor regeneration or charge.
• When an error occurs in the system, the system main relay is
JSCIA0276ZZ
turned OFF and the Li-ion battery is interrupted for ensuring safety, based on a command from VCM (Vehi-
cle control module).
JSCIA0706ZZ
High voltage warning label is affixed to each of the following component parts.
After replacing a part, check that the part is affixed with a label. If the label is not affixed, be sure to affix the
label in the original position.
Li-ion Battery
• The label is affixed to the rear end of Li-ion battery.
JPCIA0207ZZ
: Vehicle front
EVB
ALCIA0128ZZ
D
Li-ion Battery Controller
The label is affixed to the main body of controller.
G
JSCIA0111ZZ
Service Plug H
The label is affixed to the inspection hole cover .
K
JPCIA0209ZZ
SYSTEM DIAGRAM
JSCIA0731GB
JPCIA0094GB
JSCIA0732GB
A
SYSTEM DIAGRAM
EVB
JSCIA0793GB J
INPUT/OUTPUT SIGNAL ITEM
Input Signal Item K
JSCIA0430ZZ
• When the temperature in the battery pack is low outside the timer charge set time, VCM transmits a keep
SOC request signal to LBC via EV system CAN communication. In this case Li-ion battery is not charged,
and only Li-ion battery heater is activated.
• When timer charge starts at the set time, Li-ion batter is charged, and the Li-ion battery heater is activated.
When EVSE is not connected (normal charge)
JSCIA0431ZZ
• When the charge level of the Li-ion battery is low during the Li-ion battery heater operation, LBC stops the
Li-ion battery heater operation even if the temperature in the battery pack is insufficient.
EVB
JSCIA0805GB
P
JSCIA0795GB
EVB
JSCIA0799GB
K
HARNESS LAYOUT
JSCIA0796ZZ
: Vehicle front
EVB
JSCIA0797GB
P
: Vehicle front
• To improve the Li-ion battery life, never perform quick charge heavily.
• Use the method of nighttime normal charge or timer-controlled charge.
• Never perform rapid acceleration/deceleration.
• Never place EV battery in an area exposed to direct sunlight or under high temperature conditions.
PRECAUTIONS FOR STORAGE OF THE LI-ION BATTERY
• Apply insulating tape to the service plug and high voltage harness connector, and protect the terminals so
that nothing contacts them.
• Store in a well-ventilated location that is not exposed to direct sunlight.
(Storing outdoors or unprotected is prohibited.)
• Never set directly on the floor.
• Lay an anti-static rubber sheet underneath the battery.
• Never invert the battery.
• Never stack batteries.
• Cover with an anti-static cover sheet.
• Put a caution display stating "CAUTION! HIGH VOLTAGE" on the insulated cover sheet.
• Put identification display showing the name of person in charge on the insulated cover sheet.
• Never allow water to contact the battery.
• Prevent other objects from falling onto the battery.
APPLICATION ITEM B
CONSULT performs the following functions via CAN communication with Li-ion battery controller (LBC).
ECU IDENTIFICATION
Part number of LBC can be checked. H
SELF-DIAGNOSTIC RESULTS
Self Diagnostic Item I
Regarding items of DTC, refer to EVB-45, "DTC Index".
How to Erase DTC
1. Select “HV BAT”with CONSULT. J
2. “SELF-DIAGNOSTIC RESULTS”.
3. Touch “ERASE”. (DTC in LBC will be erased.)
FREEZE FRAME DATA (FFD) K
The following vehicle status is recorded when DTC is detected and is displayed on CONSULT.
DATA MONITOR
NOTE:
ACTIVE TEST
Operation
Test item Operation status
item
Turns ON the relay built into the heater relay unit to supply high voltage power to the Li-ion
On
battery heater.
HEATER RELAY UNIT
Turns OFF the relay built into the heater relay unit to stop high voltage power supply to the
Off
Li-ion battery heater.
WORK SUPPORT
When Li-ion Battery Controller (LBC) detects a malfunction of the Li-ion battery, it enters the control mode that
protects the battery by stopping or restricting the output/charging from/to the battery.
The fail-safe mode differs depending on the contents of the detected malfunction.
FAIL-SAFE PATTERN
• Pattern A: No driving, Charge stop, and EV system warning lamp illuminate
• Pattern B: Driving output power limit, Charge stop, and EV system warning lamp illuminate
• Pattern C: Driving output power limit, Charge limit, and EV system warning lamp illuminate
• Pattern D: EV system warning lamp illuminate
FAIL-SAFE LIST
Pattern
DTC CONSULT screen items
A B C D
P0A0D HV SYSTEM INTERLOCK ERROR ×
P0A1F BATTERY ENERGY CONTROL MODULE × × ×
P3030 CELL CONT LIN ×
P3031 CELL CONT ASIC1 ×
P3032 CELL CONT ASIC2 ×
P3033 CELL CONT ASIC3 ×
P3034 CELL CONT ASIC4 ×
P3035 CELL CONT ASIC5 ×
P3036 CELL CONT ASIC6 ×
P3037 CELL CONT ASIC7 ×
P3038 CELL CONT ASIC8 ×
P3039 CELL CONT ASIC9 ×
P303A CELL CONT ASIC10 ×
P303B CELL CONT ASIC11 ×
P303C CELL CONT ASIC12 ×
P303D CELL CONT ASIC13 ×
P303E CELL CONT ASIC14 ×
P303F CELL CONT ASIC15 ×
P3040 CELL CONT ASIC16 ×
P3041 CELL CONT ASIC17 ×
P3042 CELL CONT ASIC18 ×
P3043 CELL CONT ASIC19 ×
P3044 CELL CONT ASIC20 ×
P3045 CELL CONT ASIC21 ×
P3046 CELL CONT ASIC22 ×
P3047 CELL CONT ASIC23 ×
P3048 CELL CONT ASIC24 ×
P3049 CELL CONT ASIC1 VOLT ×
P304A CELL CONT ASIC2 VOLT ×
P304B CELL CONT ASIC3 VOLT ×
P304C CELL CONT ASIC4 VOLT ×
P304D CELL CONT ASIC5 VOLT ×
P304E CELL CONT ASIC6 VOLT ×
A
×: Applicable —: Not applicable
EV system
DTC CONSULT screen items warning Trip Reference B
lamp
P0A0D HV SYSTEM INTERLOCK ERROR × 1 EVB-88
P0A1F BATTERY ENERGY CONTROL MODULE × 1 EVB-90 EVB
P3030 CELL CONT LIN × 1 EVB-91
P3031 CELL CONT ASIC1 × 1 EVB-92
D
P3032 CELL CONT ASIC2 × 1 EVB-92
P3033 CELL CONT ASIC3 × 1 EVB-92
P3034 CELL CONT ASIC4 × 1 EVB-92 E
P3035 CELL CONT ASIC5 × 1 EVB-92
P3036 CELL CONT ASIC6 × 1 EVB-92
F
P3037 CELL CONT ASIC7 × 1 EVB-92
P3038 CELL CONT ASIC8 × 1 EVB-92
P3039 CELL CONT ASIC9 × 1 EVB-92 G
P303A CELL CONT ASIC10 × 1 EVB-92
P303B CELL CONT ASIC11 × 1 EVB-92
P303C CELL CONT ASIC12 × 1 EVB-92
H
P303D CELL CONT ASIC13 × 1 EVB-93
P303E CELL CONT ASIC14 × 1 EVB-93
I
P303F CELL CONT ASIC15 × 1 EVB-93
P3040 CELL CONT ASIC16 × 1 EVB-93
P3041 CELL CONT ASIC17 × 1 EVB-93 J
P3042 CELL CONT ASIC18 × 1 EVB-93
P3043 CELL CONT ASIC19 × 1 EVB-93
K
P3044 CELL CONT ASIC20 × 1 EVB-93
P3045 CELL CONT ASIC21 × 1 EVB-93
P3046 CELL CONT ASIC22 × 1 EVB-93 L
P3047 CELL CONT ASIC23 × 1 EVB-93
P3048 CELL CONT ASIC24 × 1 EVB-93
M
P3049 CELL CONT ASIC1 VOLT × 1 EVB-94
P304A CELL CONT ASIC2 VOLT × 1 EVB-94
P304B CELL CONT ASIC3 VOLT × 1 EVB-94 N
P304C CELL CONT ASIC4 VOLT × 1 EVB-94
P304D CELL CONT ASIC5 VOLT × 1 EVB-94
P304E CELL CONT ASIC6 VOLT × 1 EVB-94
O
P304F CELL CONT ASIC7 VOLT × 1 EVB-94
P3050 CELL CONT ASIC8 VOLT × 1 EVB-94
P
P3051 CELL CONT ASIC9 VOLT × 1 EVB-94
P3052 CELL CONT ASIC10 VOLT × 1 EVB-94
P3053 CELL CONT ASIC11 VOLT × 1 EVB-94
P3054 CELL CONT ASIC12 VOLT × 1 EVB-94
P3055 CELL CONT ASIC13 VOLT × 1 EVB-96
AACWA0009GB
EVB
AACWA0010GB
AACWA0012GB
EVB
AACWA0011GB
AACWA0013GB
EVB
AACIA0085GB
AACIA0086GB
EVB
AACIA0087GB
AACIA0088GB
EVB
AACIA0089GB
AACIA0090GB
EVB
AACIA0091GB
AACIA0092GB
EVB
AACIA0093GB
AACIA0094GB
EVB
AACIA0095GB
AACIA0096GB
EVB
AACIA0124GB
AACIA0125GB
EVB
AACIA0126GB
AACIA0127GB
EVB
AACIA0128GB
AACIA0129GB
EVB
AACIA0130GB
AACIA0131GB
EVB
AACIA0132GB
AACIA0133GB
EVB
AACIA0134GB
AACIA0135GB
EVB
AACIA0136GB
AACIA0137GB
EVB
AACIA0147GB
DETAILED FLOW
1.GET INFORMATION FOR SYMPTOM
Get the detailed information from the customer about the symptom (the condition and the environment when
the incident/malfunction occurred) using the “Question sheet”. (Refer to EVB-83, "Diagnostic Work Sheet".)
>> GO TO 2.
2.CHECK DTC IN VCM
1. Check DTC in VCM.
2. Check related service bulletins for information.
Are any DTCs detected?
YES >> Check the DTC. Refer to EVC-102, "DTC Index".
NO >> GO TO 3.
3.CHECK DTC
1. Check DTC.
2. Perform the following procedure if DTC is displayed.
- Record DTC and freeze frame data. (Print them out with CONSULT.)
- Erase DTC.
- Study the relationship between the cause detected by DTC and the symptom described by the customer.
(Symptom Matrix Chart is useful. Refer to EVC-412, "Symptom Index".)
3. Check related service bulletins for information.
Are any symptoms described and any DTCs detected?
Symptom is described, DTC is detected>>GO TO 4.
Symptom is described, DTC is not detected>>GO TO 5.
Symptom is not described, DTC is detected>>GO TO 6.
4.CONFIRM THE SYMPTOM
Try to confirm the symptom described by the customer.
Also study the normal operation and fail-safe related to the symptom. Refer to EVC-412, "Symptom Index"
and EVB-40, "Fail-safe".
Diagnosis Work Sheet is useful to verify the incident.
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 6.
5.CONFIRM THE SYMPTOM
Try to confirm the symptom described by the customer.
Also study the normal operation and fail-safe related to the symptom. Refer to EVC-412, "Symptom Index"
and EVB-40, "Fail-safe".
Diagnosis Work Sheet is useful to verify the incident.
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 7.
6.PERFORM DTC CONFIRMATION PROCEDURE
Perform DTC CONFIRMATION PROCEDURE for the displayed DTC, and then check that DTC is detected
again.
NOTE:
• Freeze frame data is useful if the DTC is not detected.
DESCRIPTION
There are many operating conditions that lead to the malfunction of N
“EV battery system” components. A good grasp of such conditions
can make troubleshooting faster and more accurate.
In general, each customer feels differently about symptoms. It is
important to fully understand the symptoms or conditions for a cus- O
tomer complaint.
Utilize the diagnostic worksheet in order to organize all the informa-
tion for troubleshooting. P
NOTE:
Some conditions may cause a DTC to be detected.
JSCIA0412GB
WORKSHEET SAMPLE
Question Sheet
Incident Date VIN
Customer name
Model & Year In Service Date
MR/MS
Trans. Mileage km/mile
Symptoms Power limitation indicator
Does not to READY EV system warning lamp is on
lamp is on
Water leak* Noise* Vibration* Shock* Gear noise*
Non driving* Poor acceleration* Poor torque* Radio noise*
Does not charge Other* *: If applied, enter in detail
Detailed symptom
Onomatopoeia
>> GO TO 2.
2.REPLACE LI-ION BATTERY OR LBC G
Replace Li-ion battery or LBC. Refer to EVB-194, "Removal and Installation" (Li-ion battery) or EVB-214, "LI-
ION BATTERY CONTROLLER : Removal and Installation" (LBC).
H
>> GO TO 3.
3.WRITE THE LBC INTERNAL INFORMATION I
With CONSULT
1. Select “WRITE BATTERY INFORMATION DATA” in “WORK SUPPOTRT” mode.
2. Write the information that has been read out before LBC replacement. J
>> GO TO 4.
4.WRITE THE LBC INTERNAL INFORMATION TO VCM K
If a malfunction (e.g. abnormal voltage) occurs in a Li-ion battery cell, the module which includes the malfunc-
tioning cell must be replaced. When replacing a module with a new one, its voltage is required to be adjusted
to the adjusting voltage calculated from the maximum cell voltage of normal cells.
Work Procedure INFOID:0000000008745930
NOTE:
Voltage adjustment under low temperature conditions may require a long time. To prevent this from occurring,
it is advisable to adjust voltage under room temperature conditions [20°C ± 10°C (68°F ±18°F)].
1.CHECK ADJUSTMENT VOLTAGE VALUE
With CONSULT
1. Power switch ON.
2. Select “DATA MONITOR”of “HV BAT”.
3. Check “MAXIMUM CELL VOLTAGE”.
4. Double the “MAXIMUM CELL VOLTAGE” and use that value as the module adjustment value.
>> GO TO 2.
2.CHECK MODULE VOLTAGE
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual.
1. Set the new module to the module charge balancer.
2. Measure module voltage and compare it with “adjustment voltage value” confirmed in Step1.
>> GO TO 4.
4.ADJUST VOLTAGE WITH A MODULE CHARGE BALANCER
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual.
1. Enter “adjustment voltage value” into module charge balancer.
>> GO TO 6.
B
6.CHECK CELL VOLTAGE
With CONSULT
1. After adjusting the voltage, install the module to the vehicle. EVB
2. Select “DATA MONITOR” of “HV BAT”.
3. Check “CELL VOLTAGE” of install module.
4. Check that the difference from the “MAXIMUM CELL VOLTAGE” confirmed in Step1 is within the specified
range. D
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.PRECONDITIONING
WARNING:
Disconnect the high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 2.
2.CHECK LI-ION BATTERY INTERLOCK DETECTIONG CIRCUIT FOR SHORT-1
1. Disconnect Li-ion battery controller (LBC) harness connector.
2. Disconnect interlock detecting switch (high voltage harness connector) harness connector.
3. Check the continuity between Li-ion battery controller harness connector and ground.
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-88 2013 LEAF
P0A0D HV SYSTEM INTERLOCK ERROR
< DTC/CIRCUIT DIAGNOSIS >
LBC A
— Continuity
Connector Terminal
LB11 8 Ground Not existed
B
Is the inspection result normal?
YES >> GO TO 3.
NO >> Replace Li-ion battery vehicle communication harness. EVB
3.CHECK LI-ION BATTERY INTERLOCK DETECTIONG CIRCUIT FOR SHORT-2
1. Disconnect interlock detecting switch (service plug) harness connector.
2. Check the continuity between Li-ion battery controller harness connector and ground. D
LBC
— Continuity E
Connector Terminal
LB11 6 Ground Not existed
Is the inspection result normal? F
YES >> GO TO 4.
NO >> Replace Li-ion battery vehicle communication harness.
4.CHECK INTERLOCK DETECTIONG SWITCH (SERVICE PLUG) G
Refer to EVB-89, "Component Inspection".
Is the inspection result normal? H
YES >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
NO >> Replace service plug.
I
Component Inspection INFOID:0000000009346500
Value: Approx. 0 Ω K
Is the inspection result normal?
YES >> INSPECTION END
NO >> Replace service plug. L
M
JPCIA0347ZZ
When this DTC is detected, replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROL-
LER : Removal and Installation".
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”.
2. Check to see if “P3375 - P33A4” is detected simultaneously with “P3030”. I
Is P30F3 detected?
YES >> • When “P3375” - “P3380” are detected simultaneously, perform the diagnosis procedure of
J
“P3375” - “P3380”. Refer to EVB-135, "Diagnosis Procedure".
• When “P3381” - “P338C” are detected simultaneously, perform the diagnosis procedure of
“P3381” - “P338C”. Refer to EVB-139, "Diagnosis Procedure".
• When “P338D” - “P3398” are detected simultaneously, perform the diagnosis procedure of K
“P338D” - “P3398”. Refer to EVB-143, "Diagnosis Procedure".
• When “P3399” - “P33A4” are detected simultaneously, perform the diagnosis procedure of
“P3399” - “P33A4”. Refer to EVB-146, "Diagnosis Procedure". L
NO >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
EVB
EVB
When this DTC is detected, replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROL-
LER : Removal and Installation".
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”.
2. Check to see if “P3375”-“P33A4” is detected simultaneously with “P3062”. I
Is P3375-P33A4 detected?
YES >> • When “P3375” - “P3380” are detected simultaneously, perform the diagnosis procedure of
J
“P3375” - “P3380”. Refer to EVB-135, "Diagnosis Procedure".
• When “P3381” - “P338C” are detected simultaneously, perform the diagnosis procedure of
“P3381” - “P338C”. Refer to EVB-139, "Diagnosis Procedure".
• When “P338D” - “P3398” are detected simultaneously, perform the diagnosis procedure of K
“P338D” - “P3398”. Refer to EVB-143, "Diagnosis Procedure".
• When “P3399” - “P33A4” are detected simultaneously, perform the diagnosis procedure of
“P3399” - “P33A4”. Refer to EVB-146, "Diagnosis Procedure". L
NO >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
When this DTC is detected, replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROL-
LER : Removal and Installation".
DANGER:
L
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and M
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- N
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses O
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- P
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER
>> GO TO 3.
3.CHECK CONNECTION STATUS
1. Power switch OFF.
2. Check connection status of Li-ion battery controller harness connector and module harness connector.
Is the inspection result normal?
YES >> GO TO 4.
NO >> Recover the connection status.
4.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND MODULE
1. Disconnect Li-ion battery controller harness connector and voltage detection terminal of bus bar.
2. Refer to below table and continuity between Li-ion battery controller and voltage detection terminal
of bus bar, according to detected DTC.
JSCIA0813ZZ
A
Module Li-ion battery controller
DTC Continuity
No. Connector Terminal
1 50 B
P308B LB13 Existed
2 51
3 52
P308C LB13 Existed EVB
4 53
5 54
P308D LB13 Existed
6 55 D
7 56
P308E LB13 Existed
8 57
E
9 58
P308F LB13 Existed
10 59
11 Voltage detection terminal of bus 60 F
P3090 LB13 Existed
12 bar 61
13 62
P3091 LB13 Existed G
14 63
15 77
P3092 LB14 Existed
16 78 H
17 80
P3093 LB14 Existed
18 81
19 82 I
P3094 LB14 Existed
20 83
21 84
P3095 LB14 Existed J
22 85
23 86
P3096 LB14 Existed
24 87 K
Is the inspection result normal?
YES >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal
and Installation". L
NO >> Repair harness or connector.
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER
I
>> GO TO 3.
3.CHECK CONNECTION STATUS
1. Power switch OFF. J
2. Check connection status of Li-ion battery controller harness connector and module harness connector.
Is the inspection result normal?
YES >> GO TO 4. K
NO >> Recover the connection status.
4.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND MODULE L
1. Disconnect Li-ion battery controller harness connector and Module harness connector.
2. Refer to below table and continuity between Li-ion battery controller and Module, according to detected
DTC.
M
With CONSULT
1. Perform "All DTC Reading".
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P30E0” is detected. I
Is P30E0 detected?
YES >> Replace VCM. Refer to EVC-426, "Removal and Installation".
J
NO >> GO TO 2.
2.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER
With CONSULT K
1. Select “Self Diagnostic Result” of “HV BAT”.
2. Check to see if “U1000” is detected simultaneously with “P30E0”.
Is U1000 detected? L
YES >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
NO >> INSPECTION END M
With CONSULT
1. Perform "All DTC Reading".
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P30E3” is detected. I
Is P30E3 detected?
YES >> Replace traction motor inverter. Refer to TMS-108, "Removal and Installation".
J
NO >> GO TO 2.
2.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER
With CONSULT K
1. Select “Self Diagnostic Result” of “HV BAT”.
2. Check to see if “U1000” is detected simultaneously with “P30E3”.
Is U1000 detected? L
YES >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
NO >> INSPECTION END M
For the diagnosis procedure, refer to LAN-16, "Trouble Diagnosis Flow Chart".
J
1.PERFORM THE SELF-DIAGNOSIS
With CONSULT
1. Perform "All DTC Reading". K
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P318E” is detected.
Is P318E detected?
YES >> Replace VCM. Refer to EVC-426, "Removal and Installation". L
NO >> GO TO 2.
2.PREFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER M
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”.
2. Check to see if “U1000” is detected simultaneously with “P318E”. N
Is U1000 detected?
YES >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal
and Installation". O
NO >> INSPECTION END
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”.
N
2. Check to see if “U1000” is detected simultaneously with “P3196”.
Is U1000 detected?
YES >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal O
and Installation".
NO >> INSPECTION END
When this DTC is detected, replace VCM. Refer to EVC-426, "Removal and Installation".
H
When this DTC is detected, replace traction motor inverter. Refer to TMS-108, "Exploded View".
When this DTC is detected, replace VCM. Refer to EVC-426, "Removal and Installation".
H
When this DTC is detected, replace traction motor inverter. Refer to TMS-108, "Exploded View".
DANGER:
L
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and M
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
N
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses O
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- P
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-121 2013 LEAF
P3302-P330D CELL OVER VOLTAGE
< DTC/CIRCUIT DIAGNOSIS >
1. Perform “All DTC Reading” with CONSULT.
2. Check systems other than “HV BAT” if any DTC is detected.
Is any DTC detected?
YES >> After performing trouble diagnosis of detected DTC, GO TO 2.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 3.
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
1. Disconnect voltage detection terminal of bus bar and Li-ion battery controller harness connector.
2. Refer to below table and check the continuity between Li-ion battery controller and corresponding bus
bar .
JSCIA0812GB
Terminals
Voltage
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V
Is the inspection result normal?
YES >> INSPECTION END
NO >> Replace module. Refer to EVB-246, "FRONT MODULE
STACK : Disassembly and Assembly" (Front module) or
EVB-261, "REAR MODULE STACK : Disassembly and
Assembly" (Rear module).
JSCIA0338ZZ
DANGER:
L
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and M
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
N
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses O
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- P
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-125 2013 LEAF
P330E-P3319 CELL OVER VOLTAGE
< DTC/CIRCUIT DIAGNOSIS >
1. Perform “All DTC Reading” with CONSULT.
2. Check systems other than “HV BAT” if any DTC is detected.
Is any DTC detected?
YES >> After performing trouble diagnosis of detected DTC, GO TO 2.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 3.
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
1. Disconnect voltage detection terminal of bus bar and Li-ion battery controller harness connector.
2. Refer to below table and check the continuity between Li-ion battery controller and corresponding bus
bar .
JSCIA0812GB
Terminals
Voltage
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V
Is the inspection result normal?
YES >> INSPECTION END
NO >> Replace module. Refer to EVB-261, "REAR MODULE
STACK : Disassembly and Assembly".
JSCIA0338ZZ
DANGER:
L
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and M
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
N
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses O
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- P
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-129 2013 LEAF
P331A-P3325 CELL OVER VOLTAGE
< DTC/CIRCUIT DIAGNOSIS >
1. Perform “All DTC Reading” with CONSULT.
2. Check “Self Diagnostic Result” of systems other than “HV BAT” if any DTC is detected.
Is any DTC detected?
YES >> After performing trouble diagnosis of detected DTC, GO TO 2.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 3.
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
With CONSULT
1. Power switch OFF.
2. Identify the malfunctioning module based on detected DTC.
3. Disconnect module harness connector and Li-ion battery controller harness connector.
4. Refer to below table and check the continuity between corresponding module and Li-ion battery controller.
Terminals
Voltage M
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V N
Is the inspection result normal?
YES >> INSPECTION END
NO >> Replace module. Refer to EVB-246, "FRONT MODULE O
STACK : Disassembly and Assembly".
JSCIA0338ZZ
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-132 2013 LEAF
P3326-P3331 CELL OVER VOLTAGE
< DTC/CIRCUIT DIAGNOSIS >
1. Perform “All DTC Reading” with CONSULT.
2. Check “Self Diagnostic Result” of systems other than “HV BAT” if any DTC is detected. A
Is any DTC detected?
YES >> After performing trouble diagnosis of detected DTC, GO TO 2.
NO >> GO TO 2. B
2.PRECONDITIONING
WARNING: EVB
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation". D
>> GO TO 3.
E
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
With CONSULT
1. Power switch OFF. F
2. Identify the malfunctioning module based on detected DTC.
3. Disconnect module harness connector and Li-ion battery controller harness connector.
4. Refer to below table and check the continuity between corresponding module and Li-ion battery controller. G
Terminals
Voltage
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V
Is the inspection result normal?
YES >> INSPECTION END
NO >> Replace module. Refer to EVB-246, "FRONT MODULE
STACK : Disassembly and Assembly".
JSCIA0338ZZ
DANGER:
L
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and M
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
N
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses O
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- P
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-135 2013 LEAF
P3375-P3380 CELL OVER DISCHARGE
< DTC/CIRCUIT DIAGNOSIS >
1. Perform “All DTC Reading” with CONSULT.
2. Check systems other than “HV BAT” if any DTC is detected.
Is any DTC detected?
YES >> After performing trouble diagnosis of detected DTC, GO TO 2.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 3.
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
1. Disconnect voltage detection terminal of bus bar and Li-ion battery controller harness connector.
2. Refer to below table and check the continuity between Li-ion battery controller and corresponding bus
bar .
JSCIA0812GB
Terminals
Voltage
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V
Is the inspection result normal?
YES >> INSPECTION END
NO >> Replace module. Refer to EVB-261, "REAR MODULE
STACK : Disassembly and Assembly".
JSCIA0338ZZ
DANGER:
L
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and M
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
N
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses O
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- P
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-139 2013 LEAF
P3381-P338C CELL OVER DISCHARGE
< DTC/CIRCUIT DIAGNOSIS >
1. Perform “All DTC Reading” with CONSULT.
2. Check systems other than “HV BAT” if any DTC is detected.
Is any DTC detected?
YES >> After performing trouble diagnosis of detected DTC, GO TO 2.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Disconnect high voltage circuit. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation",
>> GO TO 3.
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
1. Disconnect voltage detection terminal of bus bar and Li-ion battery controller harness connector.
2. Refer to below table and check the continuity between Li-ion battery controller and corresponding bus
bar .
JSCIA0812GB
Terminals
Voltage
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V
Is the inspection result normal?
YES >> INSPECTION END
NO >> Replace module. Refer to EVB-261, "REAR MODULE
STACK : Disassembly and Assembly".
JSCIA0338ZZ
DANGER:
L
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and M
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
N
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses O
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- P
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
Revision: October 2013
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EVB-143 2013 LEAF
P338D-P3398 CELL OVER DISCHARGE
< DTC/CIRCUIT DIAGNOSIS >
1. Perform “All DTC Reading” with CONSULT.
2. Check “Self Diagnostic Result” of systems other than “” if any DTC is detected.
Is any DTC detected?
YES >> After performing trouble diagnosis of detected DTC, GO TO 2.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation",
>> GO TO 3.
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
With CONSULT
1. Select “Self Diagnostic Result” mode of “HV BAT” using CONSULT.
2. Identify the malfunctioning module based on detected DTC.
3. Disconnect module harness connector and Li-ion battery controller harness connector.
4. Refer to below table and check the continuity between corresponding module and Li-ion battery controller.
Terminals
Voltage M
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V N
Is the inspection result normal?
YES >> INSPECTION END
NO >> Replace module. Refer to EVB-246, "FRONT MODULE O
STACK : Disassembly and Assembly".
JSCIA0338ZZ
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
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EVB-146 2013 LEAF
P3399-P33A4 CELL OVER DISCHARGE
< DTC/CIRCUIT DIAGNOSIS >
1. Perform “All DTC Reading” with CONSULT.
2. Check “Self Diagnostic Result” of systems other than “” if any DTC is detected. A
Is any DTC detected?
YES >> After performing trouble diagnosis of detected DTC, GO TO 2.
NO >> GO TO 2. B
2.PRECONDITIONING
WARNING: EVB
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation", D
>> GO TO 3.
E
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
With CONSULT
1. Select “Self Diagnostic Result” mode of “HV BAT” using CONSULT. F
2. Identify the malfunctioning module based on detected DTC.
3. Disconnect module harness connector and Li-ion battery controller harness connector.
4. Refer to below table and check the continuity between corresponding module and Li-ion battery controller. G
Terminals
Voltage
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V
Is the inspection result normal?
YES >> INSPECTION END
NO >> Replace module. Refer to EVB-246, "FRONT MODULE
STACK : Disassembly and Assembly".
JSCIA0338ZZ
When this DTC is detected, replace Li-ion battery. Refer to EVB-194, "Removal and Installation".
H
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS OF VCM
With CONSULT
1. Select “Self Diagnostic Result” mode of “EV/HEV” using CONSULT.
2. Check to see if “P0AA0”, “P0AA1” or “P0AA4” is detected.
Is any DTC detected?
YES >> Perform diagnosis on the detected DTC. Refer to EVB-45, "DTC Index".
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
>> GO TO 3.
3.CHECK CONNECTION STATUS B
Check connection status of Li-ion battery controller harness connector and current sensor harness connector.
Is the inspection result normal? EVB
YES >> GO TO 4.
NO >> Recover the connection status.
4.CHECK HARNESS BETWEEN CURRENT SENSOR AND LI-ION BATTERY CONTROLLER D
Check continuity between current sensor harness connector and Li-ion battery controller harness connector.
E
Current sensor Li-ion battery controller
Continuity
Connector Terminal Connector Terminal
S 10 F
LB5 V LB11 9 Exited
G 15
G
Is the inspection result normal?
YES >> GO TO 5.
NO >> Repair Harness or connector.
H
5.CHECK CURRENT SENSOR
Check resistance of current sensor.
I
Current sensor Resistance val-
Connector Terminal Terminal ue
J
S G
LB5 1 kΩ–10 MΩ
V G
Is the inspection result normal? K
YES >> GO TO 6.
NO >> Replace current sensor.
6.CHECK LI-ION BATTERY CONTROLLER L
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 2.
2.CHECK CURRENT SENSOR
1. Disconnect Li-ion battery controller harness connector.
2. Check the resistance of current sensor from Li-ion battery controller side.
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 2.
2.CHECK HARNESS
Revision: October 2013
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EVB-154 2013 LEAF
P33D7, P33D9, P33DD TEMPERATURE SENSOR
< DTC/CIRCUIT DIAGNOSIS >
1. Power switch OFF.
2. Check a connection state of harness connector of Li-ion battery controller. A
Is the inspection result normal?
YES >> GO TO 3.
NO >> Recover the connection status. B
3.CHECK BATTERY TEMPERATURE SENSOR
Refer to EVB-155, "Component Inspection".
EVB
Is the inspection result normal?
YES >> GO TO 4.
NO >> Replace battery temperature sensor. D
4.CHECK HARNESS BETWEEN BATTERY TEMPERATURE SENSOR AND GROUND
1. Disconnect Li-ion battery controller harness connector.
2. Check continuity between battery temperature sensor harness connector and ground. E
Battery tem-
perature sen- Connector Terminal — Continuity F
sor
1 LB9 1
2 LB10 4 Ground No existed G
4 LB10 2
Is the inspection result normal? H
YES >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
NO >> Repair harness or connector.
I
Component Inspection INFOID:0000000008746020
When this DTC is detected, replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROL-
LER : Removal and Installation".
When this DTC is detected, replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROL-
LER : Removal and Installation". H
When this DTC is detected, perform Li-ion battery insulation resistance loss check. Refer to EVB-176, "Com-
ponent Inspection".
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK SELF-DIAGNOSIS RESULTS OF LI-ION BATTERY CONTROLLER
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”.
2. Check to see if “P0A1F”, “P3062” or “P33ED” is detected simultaneously with “P33E6”.
Is P0A1F, P3062 or P33ED detected?
YES-1 >> When “P0A1F” or “P3062” are detected simultaneously, Replace Li-ion battery controller. Refer to
EVB-214, "LI-ION BATTERY CONTROLLER : Removal and Installation".
YES-2 >> When “P33ED” is detected simultaneously, perform the diagnosis procedure of “P33ED”. Refer to
EVB-169, "Diagnosis Procedure".
NO >> GO TO 2.
2.CHECK FREEZE FRAME DATA (FFD)
With CONSULT
1. Check “FFD” when DTC is detected.
Revision: October 2013
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EVB-160 2013 LEAF
P33E6 CELL CONTROLLER
< DTC/CIRCUIT DIAGNOSIS >
2. Calculate the average value of cell voltage by dividing “TOTAL BATTERY VOLTAGE” by 96 (the number
of cells). A
>> GO TO 5.
5.CHECK CELL OF VOLTAGE LOSS
With CONSULT
1. Check that “MINIMUM CELL VOLTAGE” is 3,712 mV or less. Touch “START.”
2. Check to see if a cell of which voltage is less than or equal to “CELL VOLTAGE LOSS JUDGMENT
VALUE” is displayed.
Is a cell displayed?
YES >> Record applicable cell No. and then GO TO 6.
NO >> Check the minimum cell voltage on the data monitor and replace a module which includes the
minimum cell voltage. Refer to EVB-235, "FRONT MODULE STACK : Exploded View" (Front
module stack) or EVB-251, "REAR MODULE STACK : Exploded View" (Rear module stack).
6.PRECONDITIONING
WARNING:
Disconnect high voltage circuit. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-203, "BATTERY PACK UPPER CASE : Exploded View".
>> GO TO 7.
7.CHECK CONDENSATION
Check condensation in battery pack.
Is the inspection result normal?
YES >> GO TO 8.
NO >> Replace Li-ion battery. Refer to EVB-194, "Removal and Installation".
8.CHECK CONNECTORS AND FIXING BOLTS
Check connection state, damage and dust of following;
• Li-ion battery controller (LBC) harness connector
• Module harness connector
• Module terminal fixing bolt
Is the inspection result normal?
YES >> GO TO 9
NO >> Repair or replace error-detected parts.
9.CHECK MODULE VOLTAGE
Check module voltage within determined cell at step 3 and check the divergence of the voltage and cell volt-
age with “DATA MONITOR”.
DANGER:
When check module voltage, be careful not to short.
Is Divergence within 40mV?
YES-1 >> When the determined cell at step 3 is in front module stack.: GO TO 10.
YES-2 >> When the determined cell at step 3 is in rear module stack.: GO TO 12.
NO >> Replace Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
10.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND MODULE HARNESS CONNEC-
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-162 2013 LEAF
P33E6 CELL CONTROLLER
< DTC/CIRCUIT DIAGNOSIS >
TOR
1. Disconnect Li-ion battery controller harness connector and module harness connector. A
2. Check the resistance Li-ion battery controller harness connector and module harness connector of the
determined cell at step 3.
B
Resistance val-
Terminal
ue
Li-ion battery control- Module harness EVB
Approx. 0 Ω
ler harness connector connector
3. Check the divergence of the resistance and the resistance of other cell harness.
Is the inspection result normal? D
YES >> GO TO 11
NO >> Repair or replace harness or connectors.
11.CHECK HARNESS BETWEEN MODULE HARNESS CONNECTOR AND BUS BAR E
1. Check the resistance module harness connector and bus bar of the determined cell at step 3.
F
JSCIA0811GB
M
Resistance val-
Terminal N
ue
Module harness con-
Bus bar Approx. 0 Ω
nector
2. Check the divergence of the resistance and the resistance of other cell harness. O
Is the inspection result normal?
YES >> Replace module within the determined cell at step 5.
NO >> Repair or replace harness or connectors. P
JSCIA0812GB
Resistance val-
Terminal
ue
Li-ion battery control-
Bus bar Approx. 0 Ω
ler harness connector
2. Check the divergence of the resistance and the resistance of other cell harness.
Is the inspection result normal?
YES >> Replace module within the determined cell at step 5.
NO >> Repair or replace harness or connectors.
DANGER: L
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are M
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- N
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake. O
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
P
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.PRECONDITIONING
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-165 2013 LEAF
P33EA BATTERY HEATER RELAY
< DTC/CIRCUIT DIAGNOSIS >
WARNING:
Shut off high voltage circuit. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 2.
2.CHECK CONTINUITY LI-ION BATTERY CONTROLLER AND HEATER RELAY UNIT
1. Remove service plug switch bracket. Refer to EVB-217, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Exploded View".
2. Disconnect Li-ion battery controller harness connector and heater relay unit harness connector.
3. Check continuity Li-ion battery controller harness connector and heater relay unit harness connector.
DANGER:
H
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and I
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- J
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses K
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- L
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise M
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.PRECONDITIONING N
WARNING:
Disconnect the high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation". O
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
P
>> GO TO 2.
2.CHECK BATTERY TEMPERATURE SENSOR
Refer to EVB-168, "Component Inspection".
Is the inspection result normal?
YES >> Replace all battery temperature sensor.
NO >> Replace applicable battery temperature sensor.
>> GO TO 3.
3.CHARGE OF LI-ION BATTERY K
1. Charge the Li-ion battery by normal charge until the level reaches full charge.
2. After the completion of normal charge, check that the indication of the Li-ion battery available charge
gauge shows 12 segments. L
>> GO TO 4.
M
4.PERFORM DTC CONFIRMATION PROCEDURE
With CONSULT
1. Power switch ON and wait for 10 seconds or more. N
2. Select “Self Diagnostic Result” of “HV BAT”.
3. Check DTC.
Is P33ED detected? O
YES >> Refer to EVB-169, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000008746039
P
>> Replace corresponding Module. Refer to EVB-235, "FRONT MODULE STACK : Exploded View".
DANGER: E
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and F
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- G
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake. H
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- I
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION: J
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.PRECONDITIONING K
WARNING:
Disconnect the high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation". L
2. Remove battery pack upper case. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
M
>> GO TO 2.
2.CHECK INSTALLATION CONDITION OF LI-ION BATTERY HEATER N
Check the main body of Li-ion battery heater for installation condition.
Is the inspection result normal?
YES >> GO TO 3. O
NO >> Tighten the mounting nut of the Li-ion battery heater to the specified torque. Refer to EVB-227,
"LI-ION BATTERY HEATER : Exploded view".
3.CHECK CONNECTION STATUS OF LI-ION BATTERY HEATER CONNECTOR P
Check the connection status of the Li-ion battery heater connector.
Is the inspection result normal?
YES >> GO TO 4.
NO >> Restore the connection status of the Li-ion battery heater connector.
4.CHECK RESISTANCE OF LI-ION BATTERY HEATER
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-171 2013 LEAF
P33EE BATTERY HEATER CONTROL SYSTEM
< DTC/CIRCUIT DIAGNOSIS >
Check resistance of Li-ion battery heater.
CAN (Controller Area Network) is a serial communication line for real time applications. It is an on-vehicle mul- B
tiplexcommunication line with high data communication speed and excellent error detection ability. Modern
vehicle is equipped with many electronic control units, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected
with 2 communication lines (CAN-H, CAN-L) allowing a high rate of information transmission with less wiring. EVB
Each control unit transmits/receives data but selectively reads the required data only.
CAN communication signal chart. Refer to LAN-36, "CAN COMMUNICATION SYSTEM : CAN Communica-
tion Signal Chart". D
DTC Logic INFOID:0000000008746043
For the diagnosis procedure, refer to LAN-16, "Trouble Diagnosis Flow Chart".
H
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK HIGH VOLTAGE FUSE
Check the continuity between and .
Is the inspection result normal?
YES >> GO TO 2
NO >> Replace the service plug (with high voltage fuse) after
repairing the applicable circuit. Refer to EVB-219, "BAT-
TERY JUNCTION BOX AND BATTERY HARNESS :
Disassembly and Assembly".
JSCIA0745ZZ
2.PRECONDITIONING
WARNING:
Disconnect the high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 3.
3.CHECK CONNECTION STATUS
Check connection status of each bus bar in high voltage circuit
Is the inspection result normal?
YES >> GO TO 4
NO >> Recover the connection status.
4.CHECK HIGH VOLTAGE HARNESS
CAUTION:
Check that high voltage harness and harness shield have no scratches and cracks. If any damage is
found, replace damaged parts.
1. Remove high voltage harness from battery junction box.
2. Disconnect Li-ion battery controller harness connector.
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
The following diagnosis procedure must be performed when “P0AA6 or P33E1” are detected and Li-ion
battery is judged that its insulation resistance is dropping.
1.CHECK MAXIMUM CELL VOLTAGE
With CONSULT
1. Power switch ON.
2. Select “DATA MONITOR” of “HV BAT”.
3. Record “MAXIMUM CELL VOLTAGE”.
NOTE:
It is used, when replace a malfunction module.
>> GO TO 2
2.CHECK INSULATION OF FRONT MODULE STACK LH-1
CAUTION:
Check that high voltage harness and harness shield have no scratches and cracks. If any damage is
found, replace damaged parts.
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
3. Remove bus bar that connects front module stack LH and front module stack RH.
4. Measure voltages between positive terminal of front module stack LH and battery pack ground, and
between positive terminal of front module stack LH and battery pack ground.
JSCIA0739ZZ
+
B
Front module stack LH − Voltage
Terminal
JSCIA0739ZZ
I
: Battery pack front
J
+
Front module stack LH − Voltage
K
Terminal
1. Remove bus bar that connects service plug and front module stack LH.
2. Measure voltages between positive terminal of front module stack LH and battery pack ground, and N
between positive terminal of front module stack LH and battery pack ground.
JSCIA0739ZZ
+
Front module stack LH − Voltage
Terminal
+ — Resistance
Service plug switch terminal Service plug switch bracket 1000 MΩ or more
Is the inspection result normal?
YES >> Replace bus bar that connects service plug and front module stack LH and GO TO 8.
NO >> Replace service plug switch (Refer to EVB-217, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Exploded View".) and GO TO 8.
6.CHECK MODULE-1
1. Remove front module stack LH. Refer to EVB-239, "FRONT MODULE STACK : Removal and Installa-
tion".
NOTE:
Do not disassemble module stack.
2. Measure voltages between terminal / of all modules in front
module stack LH and module body.
JSCIA0740ZZ
+
Module − Voltage
Terminal
+
G
Module − resistance
Terminal
H
Module body 100 MΩ or more
JSCIA0741ZZ
O
: Battery pack front
+ P
Front module stack RH − Voltage
Terminal
JSCIA0741ZZ
+
Front module stack RH − Voltage
Terminal
JSCIA0741ZZ
+
Front module stack RH − Voltage
Terminal
WARNING: EVB
Unlike the ordinary tester, the insulation resistance tester
applies 500 V when measuring. If used incorrectly, there is
the danger of electric shock. If used in the vehicle 12V sys-
tem, there is the danger of damage to electronic devices. D
Read the insulation resistance tester instruction manual JSCIA0453ZZ
JSCIA0740ZZ N
+ O
Module − Voltage
Terminal
P
Module body Approx. 0 V
+
Module − resistance
Terminal
JSCIA0744ZZ
+
Rear module stack − Voltage
Terminal
EVB
JSCIA0146ZZ
D
2. Measure voltages between positive terminal of rear module stack and battery pack ground, and
between positive terminal of rear module stack and battery pack ground.
E
JSCIA0744ZZ H
+
Front module stack RH − Voltage I
Terminal
JSCIA0743ZZ
O
2. Measure voltages between positive terminal of rear module stack and battery pack ground, and
between positive terminal of rear module stack and battery pack ground.
JSCIA0744ZZ
+
Rear module stack − Voltage
Terminal
JSCIA0740ZZ
+
Module − Voltage
Terminal
+ E
Module − resistance
Terminal
F
Module body 100 MΩ or more
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.PRECONDITIONING
WARNING:
Disconnect the high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-194, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
>> GO TO 2.
2.CHECK HIGH VOLTAGE HARNESS
Check the harness shield between the heater relay unit and the Li-ion battery heater for scratches and cracks.
Is the inspection result normal?
YES >> GO TO 3.
NO >> Repair or replace error-detected parts and Li-ion battery controller.
3.CHECK HEATER RELAY UNIT INSULATION RESISTANCE
WARNING:
Unlike the ordinary tester, the insulation resistance tester applies 500 V when measuring. If used
incorrectly, there is the danger of electric shock. If used in the vehicle 12 V system, there is the danger
of damage to electronic devices. Read the insulation resistance tester instruction manual carefully
and be sure to work safely.
1. Disconnect high voltage harness connector from heater relay unit.
NOTE:
Check the heater relay with it installed on the battery pack.
2. Use 500 V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until
the value becomes stable.
CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting
higher than 500 V can result in damage to the component being inspected.
WARNING:
Unlike the ordinary tester, the insulation resistance tester applies 500 V when measuring. If used
incorrectly, there is the danger of electric shock. If used in the vehicle 12 V system, there is the danger P
of damage to electronic devices. Read the insulation resistance tester instruction manual carefully
and be sure to work safely.
1. Use 500 V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until
the value becomes stable.
CAUTION:
Be sure to set the insulation resistance tester to 500V when performing this test. Using a setting
higher than 500 V can result in damage to the component being inspected.
DANGER: B
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and EVB
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- D
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake. E
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- F
lating sheet except when using them.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION: G
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed.
1.CHECK FUSE H
Check that the following fuse is not fusing.
Battery 79
57 J
Power switch ON
74
Is the fuse fusing?
YES >> Replace the fuse after repairing the applicable circuit. K
NO >> GO TO 2.
2.CHECK LI-ION BATTERY CONTROLLER GROUND CIRCUIT L
1. Turn power switch OFF.
2. Disconnect Li-ion battery vehicle communication harness connector.
3. Check the continuity between Li-ion battery vehicle communication harness connector and ground.
M
+
Li-ion battery − Continuity N
Connector Terminal
6
B24 7 Ground Existed O
8
Is the inspection result normal? P
YES >> GO TO 3.
NO >> Repair or replace error-detected parts.
3.CHECK BATTERY POWER SUPPLY
Check the voltage between Li-ion battery vehicle communication harness connector and ground.
+
Li-ion battery − Voltage
Connector Terminal
12V battery power
B24 5 Ground
supply
Is the inspection result normal?
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK BATTERY POWER SUPPLY CIRCUIT
1. Check the continuity between Li-ion battery vehicle communication harness connector and fuse terminal.
+
Li-ion battery − Continuity
Connector Terminal
No.79 fuse ter-
B24 5 Existed
minal
2. Also check harness for short to ground.
Is the inspection result normal?
YES >> Check power supply circuit for battery power supply.
NO >> Repair or replace error-detected parts.
5.CHECK POWER SWITCH ON POWER SUPPLY
1. Turn power switch ON.
2. Check the voltage between Li-ion battery vehicle communication harness and ground.
+
Voltage
Li-ion battery −
(Approx.)
Connector Terminal
4
B24 Ground 11 – 14 V
31
Is the inspection result normal?
YES >> GO TO 8.
NO >> GO TO 6.
6.CHECK POWER SWITCH ON POWER SUPPLY CIRCUIT-1
1. Turn power switch OFF.
2. Disconnect IPDM E/R harness connector.
3. Check the continuity between Li-ion battery vehicle communication harness and IPDM E/R harness con-
nector.
Li-ion battery A
— Continuity
Connector Terminal
No.74 fuse ter-
B24 31
minal
Existed B
>> GO TO 3.
3.CHARGE OF LI-ION BATTERY
1. Charge the Li-ion battery by normal charge until the level reaches full charge.
2. After the completion of normal charge, check that the indication of the Li-ion battery available charge
gauge shows 12 segments.
>> GO TO 4.
4.PERFORM DTC CONFIRMATION PROCEDURE
With CONSULT
1. Power switch ON and wait for 10 seconds or more.
2. Select “Self Diagnostic Result” of “HV BAT”.
3. Check DTC.
Is any DTC detected?
YES >> Perform diagnosis on the detected DTC. Refer to EVB-45, "DTC Index".
NO >> INSPECTION END
JSCIA0554GB
Li-ion battery Bonding plate (stamped No. 4.) Li-ion battery undercover (front)
Li-ion battery undercover (center) Li-ion battery undercover (rear) Clip
Battery mounting bracket (left) Battery mounting bracket (right)
: N-m (kg-m ft-lb)
DANGER:
Because hybrid vehicles and electric vehicles contain a high voltage battery, there is a risk of A
electric shock, electric leakage, or similar accidents if the vehicle is handled incorrectly. Be sure to fol-
low the correct work procedures when performing inspection and maintenance.
WARNING: B
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress. EVB
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet D
or similar item to prevent contact with other persons.
• Refer to EVB-6, "High Voltage Precautions".
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the E
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
REMOVAL F
WARNING:
Prepare for work on the high-voltage system. Refer to GI-33, "How to Disconnect High Voltage".
G
1. Lift up the vehicle and remove the Li-ion battery undercover. EVB-194, "Exploded View".
2. Remove the harness clamp and disconnect the Li-ion battery
high-voltage harness connector . H
DANGER:
JSCIA0555ZZ
JPCIA0035ZZ
O
3. Disconnect the Li-ion battery heater harness connector .
DANGER:
JSCIA0556ZZ
• Because there is the danger of electric shock, immediately insulate disconnected high volt-
age connectors and terminals with insulating tape.
• Follow the procedure below to disconnect the PTC heater harness connector.
JSCIA0557ZZ
JSCIA0558ZZ
JSCIA0559ZZ
CAUTION:
Do not remove the 4 bolts shown by in the figure.
JSCIA0560ZZ
Front
Side B
EVB
G
JSCIA0178ZZ
JSCIA0179ZZ
K
9. Remove the Li-ion battery mounting bolts (4 bolts) .
N
JSCIA0561ZZ
WARNING:
O
To prevent electric shock, wear insulated protective gear.
JSCIA0181ZZ
11. Lower the Li-ion battery from the lift table together with the pallet.
JPCIA0196ZZ
CAUTION:
Because there is the danger of tipping over, do not move the stacker while the Li-ion battery is
lifted up.
INSTALLATION
1. When replacing the Li-ion battery with a new battery, perform the work listed below.
a. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged
together with the new part.
b. Cut the EV battery tracking identification seal into 2 pieces and apply them to the body of the replaced
(old) Li-ion battery and to the “Li-ion battery replacement history record”.
c. Enter the necessary information in the “Li-ion battery replacement history record”.
2. Install the locating pin [SST: KV99111300 (J-50306)] in the position on the body as shown in the figure.
JSCIA0182ZZ
: Vehicle front A
JSCIA0183ZZ
E
4. Tighten the Li-ion battery mounting bolts (4 bolts) , then remove the pallet.
H
JSCIA0561ZZ
WARNING:
I
To prevent electric shock, wear insulated protective gear.
JSCIA0185ZZ
N
JSCIA0560ZZ
JSCIA0559ZZ
8. After installing the bonding plate, perform an electric equipotential test. EVB-201, "Inspection".
9. Rotate the vehicle communications connector clockwise to
connect it.
WARNING:
JSCIA0562ZZ
JSCIA0556ZZ
JSCIA0563ZZ
EVB
JSCIA0555ZZ
D
• Connect the high-voltage harness connector by the following procedure.
G
JPCIA0036ZZ
Inspection INFOID:0000000009298672
I
ELECTRIC EQUIPOTENTIAL TEST
After installing the Li-ion battery, measure the resistance between the battery pack ground bolt and the body
ground. J
O
JSCIA0707ZZ
WARNING:
EVB
JSCIA0565GB
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress.
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet
or similar item to prevent contact with other persons.
• Refer to EVB-6, "High Voltage Precautions".
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent-
ing electric shock, fire, and damage to parts.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK
1. Must be an indoor environment.
• The environment must utilize a shutter or other means to shut out the outside environment and prevent
rain, snow, dust, or other substances from entering.
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur
due to high temperature or humidity.
2. Metal powder, grease, and other foreign substances must not enter.
• The indoor environment must also prevent metal powder, grease, and other foreign substances from
entering due to maintenance performed on other vehicles and other sources during disassembly work.
• If there is a risk of the above substances entering, take appropriate countermeasures, such as use of a
vinyl curtain or an equivalent to shut out the outside environment.
3. The floor must be dry.
• The floor must not be wet as a result of factors such as vehicle entry during rain or snow.
4. Work space
• The work space must be approximately the size of one entire vehicle.
• Take appropriate countermeasures so that persons other than the operator do not enter the work space,
such as by placing signs indicating that disassembly work is in progress.
5. Standard fire fighting equipment
• Always place a standard fire fighting equipment in the disassembly work area.
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin-
guisher).
REMOVAL
Revision: October 2013
Downloaded from www.Manualslib.com manuals search engine
EVB-204 2013 LEAF
LI-ION BATTERY
< UNIT DISASSEMBLY AND ASSEMBLY >
1. Clean any dust or dirt adhered to the battery pack.
2. Remove the service plug retainer . A
WARNING:
EVB
JSCIA0143ZZ
D
3. Remove the battery pack upper case mounting bolts and ground bolts .
E
JSCIA0571GB J
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
K
L
4. Cut the battery pack upper case adhesive according to the following procedure.
WARNING:
M
To prevent electric shock, wear insulated protective gear.
N
a. Prepare a windshield cutter.
NOTE:
• Sharpen the blade of the windshield cutter . O
• Apply a tape for preventing damage to the battery pack.
: 38 mm (1.50 in) P
JSCIA0572ZZ
JSCIA0655ZZ
JSCIA0699ZZ
CAUTION:
• When cutting the adhesive, be careful to avoid scratching the battery pack coating to the maxi-
mum extent possible.
• The paint sealant is set between the paint sealant marks stamped on the battery pack upper case
(between to ). Therefore be careful not to damage the paint sealant when cutting the adhe-
sive.
• Because the paint sealant functions to release pressure from inside the battery pack, if the paint
sealant is damaged beyond the limit, the battery pack lower case must be replaced. If the paint
sealant damage is less than the limit, repair by applying primer (adhesive primer: 999MP-
43533PP).
EVB
JSCIA0678ZZ
D
• Hold the windshield cutter facing toward the grip, and cut the adhesive while holding the blade level.
c. Use piano wire (A) to cut the adhesive at the battery pack cor-
ners. E
CAUTION:
When cutting the adhesive, be careful to avoid scratching
the battery pack coating and paint sealant to the maximum F
extent possible.
NOTE:
Press the piano wire against the adhesive at the battery pack
G
corner, and pull it in alternate directions for cutting of adhesive.
H
JSCIA0574ZZ
d. Use the windshield cutter (A) for cutting adhesive at the embossed locations.
K
JSCIA0679ZZ
i. Insert a plastic remover tool (B) into the embossed locations to open a clearance.
CAUTION: L
Do not press the remover tool farther in than necessary. Doing so may deform the battery pack
upper case.
ii. Tilt the windshield cutter blade at an angle and cut the adhesive at the embossed locations. M
CAUTION:
When cutting the adhesive, be careful to avoid scratching the battery pack coating to the maxi-
mum extent possible.
N
5. Remove the battery pack upper case.
WARNING:
P
CAUTION:
• Check that the adhesive is fully cut before removing. Use of excessive force during removal may
deform the battery pack upper case.
• When removing the battery pack upper case, be careful that cutting particles do not enter the
battery pack.
JSCIA0576ZZ
CAUTION:
• Because airtightness leakage is likely to occur, cut the seal in such a way that burrs are not pro-
duced.
• Be careful not to damage the paint sealant.
- If the paint sealant on a straight section is damaged in excess of the limit, the battery pack lower
case must be replaced. If the paint sealant damage is less than the limit, repair by applying
primer (adhesive primer: 999MP-43533PP).
JSCIA0577ZZ
EVB
JSCIA0634ZZ
D
4. Apply dam rubber (KA390-0059U) on the inside of the old adhesive on the battery pack lower case.
G
JSCIA0578ZZ
C : 10 mm (0.39 in)
H
WARNING:
CAUTION: J
If dam rubber is already applied there, replace it with new dam rubber.
NOTE:
Apply the dam rubber so that adhesive does not enter the inner side. If the adhesive enters the inner side,
K
then the next time the battery pack is disassembled, the windshield cutter may not be able to reach the
adhesive and removing the battery pack upper case may be difficult.
5. Apply adhesive (999MP-57302NP) to the battery pack lower case as shown in the figure. L
WARNING:
JSCIA0580ZZ
CAUTION:
• Because there is a risk of airtightness leakage, apply the adhesive so that there are no seams or
overlaps.
• Complete installation of the battery pack upper case before the adhesive surface hardens. The
adhesive begins to harden in as little as 12 minutes. [Humidity: 80%, Temperature: 35°C (95°F)]
• Before installing the battery pack upper case, check that there are no locations of insufficient
adhesive. If there is insufficient adhesive, correct the location. (If the adhesive height is lower
than the height of the dam rubber, then the amount of adhesive is insufficient.)
• Do not apply too much adhesive as doing so may make work difficult the next time the battery
pack upper case is removed.
NOTE:
EVB
JSCIA0642ZZ
D
Nozzle inner diameter (A) : Approx. 5 mm (0.20 in)
6. Grasp the carabiner installed in Step 3, and install the battery pack upper case while visually aligning the
alignment holes on the battery pack upper case and battery pack lower case . E
JSCIA0680ZZ
H
WARNING:
J
CAUTION:
• Operation must be performed by 2 persons. Be careful
that the battery pack upper case does not contact the bat-
tery module. K
• Moving the upper case after it is installed makes airtight-
ness leakage more likely. Therefore, position the upper
case carefully. L
M
JSCIA0581ZZ
JSCIA0582ZZ
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
JSCIA0583ZZ
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
EVB
JSCIA0143ZZ
D
10. Perform a battery pack air leak inspection. Refer to EVB-269, "Inspection".
CAUTION:
If air leakage occurs, remove the battery pack upper case and wipe off the adhesive, then apply
E
new dam rubber and apply adhesive again. (Proceed to Step 4.)
11. Spray primer surfacer (anti-corrosion primer) (A) into cracks in
the periphery of the battery pack adhesive.
F
WARNING:
JSCIA0584ZZ
CAUTION: I
• After the battery pack is assembled, it can be installed into the vehicle. However the battery pack
must not be subjected to any external force (such as high-pressure washing or parking in a location
which strains the vehicle body) for approximately 3 hours after installation. J
• Be sure to reinstall the high voltage harness clips in their original positions. If a clip is damaged,
replace it with a new clip before installing.
• After assembling the battery pack, perform an electric equipotential test.
• Check the following items after installing battery pack: Refer to EVB-269, "Inspection". K
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST
L
LI-ION BATTERY CONTROLLER
JSCIA0760GB
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress.
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet
or similar item to prevent contact with other persons.
• Refer to EVB-6, "High Voltage Precautions".
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent-
ing electric shock, fire, and damage to parts.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK
1. Must be an indoor environment.
JSCIA0145ZZ
K
3. Remove the Li-ion battery controller mounting nuts , then
remove the mounting bolts .
WARNING: L
N
JPCIA0192ZZ
WARNING:
• Because there is a risk of electric shock, immediately protect the terminals of the discon-
nected high-voltage harness connector with insulating tape so that they are not exposed.
INSTALLATION
1. Install the Li-ion battery controller.
WARNING:
• To prevent electric shock, wear insulated protective gear and use insulated tools.
: Battery front
JPCIA0204ZZ
2. Install the battery pack upper case. EVB-204, "BATTERY PACK UPPER CASE : Removal and Installa-
tion".
CAUTION:
• Be sure to reinstall the high voltage harness clips in their original positions. If a clip is damaged,
replace it with a new clip before installing.
• Check the following items after installing battery pack: Refer to EVB-269, "Inspection".
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST
BATTERY JUNCTION BOX AND BATTERY HARNESS
EVB
P
JSCIA0761GB
Service plug switch Service plug switch bracket High-voltage battery harness
Bus bar nut cap Bus bar Bus bar nut cap
Bus bar (integrated with noise filter) Battery junction box Harness bracket
Vehicle communications harness Snap ring PTC heater harness connector
Because there is a danger of electric shock and fire, never contact bus bar in a wrong terminal. A
EVB
JSCIA0874ZZ P
: Battery front
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress.
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet
or similar item to prevent contact with other persons.
• Refer to EVB-6, "High Voltage Precautions".
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent-
ing electric shock, fire, and damage to parts.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK
1. Must be an indoor environment.
• The environment must utilize a shutter or other means to shut out the outside environment and prevent
rain, snow, dust, or other substances from entering.
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur
due to high temperature or humidity.
2. Metal powder, grease, and other foreign substances must not enter.
• The indoor environment must also prevent metal powder, grease, and other foreign substances from
entering due to maintenance performed on other vehicles and other sources during disassembly work.
• If there is a risk of the above substances entering, take appropriate countermeasures, such as use of a
vinyl curtain or an equivalent to shut out the outside environment.
3. The floor must be dry.
• The floor must not be wet as a result of factors such as vehicle entry during rain or snow.
4. Work space
• The work space must be approximately the size of one entire vehicle.
• Take appropriate countermeasures so that persons other than the operator do not enter the work space,
such as by placing signs indicating that disassembly work is in progress.
5. Standard fire fighting equipment
• Always place a standard fire fighting equipment in the disassembly work area.
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin-
guisher).
DISASSEMBLY
1. Remove the battery pack upper case. EVB-204, "BATTERY PACK UPPER CASE : Removal and Installa-
tion".
2. Remove Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
EVB
JSCIA0708ZZ
D
4. Open the bus bar cover and remove the high-voltage harness
connector terminal mounting bolt .
DANGER: E
G
JSCIA0709ZZ
• Because of the danger of electric shock, be sure to
close the bus bar cover after removing the bus bar.
H
5. Remove the mounting bolt and disconnect the high-voltage
harness connector from the connector flange.
WARNING: I
K
JSCIA0590ZZ
JSCIA0710ZZ O
JSCIA0592ZZ
JSCIA0762ZZ
JSCIA0727ZZ
10. Remove the bus bar mounting nuts and , and remove the
bus bar (integrated with noise filter) .
WARNING:
JSCIA0728ZZ
11. Remove the harness clips, then remove the battery member
pipe .
WARNING:
NOTE:
JSCIA0715ZZ
12. Remove the bus bar nut cap and remove the high-voltage
harness nut cap , then open the bus bar cover . B
WARNING:
JSCIA0712ZZ
E
13. Remove the mounting nuts , and remove the bus bar and
high-voltage harness .
DANGER:
F
• There is the danger of electric shock caused by
contact with the terminals. Be sure to wear insulated pro-
tective gear and use insulated tools. G
H
JSCIA0713ZZ
• Because of the danger of electric shock, be sure to close the bus bar cover after removing
the bus bar. J
14. Remove the mounting nuts and remove the junction box .
WARNING:
K
To prevent electric shock, wear insulated protective
gear and use insulated tools.
L
M
JSCIA0595ZZ
JSCIA0657ZZ
JSCIA0596ZZ
• Because of the danger of electric shock, be sure to
close the bus bar cover after removing the bus bar.
JSCIA0597ZZ
18. Invert the service plug switch bracket and remove the high-volt-
age harness mounting bolt , current sensor mounting bolt ,
and the connector , then remove the service plug switch
bracket .
DANGER:
JSCIA0598ZZ
• Because there is a risk of electric shock, immediately protect the terminals of the discon-
nected high-voltage harness connector (high-voltage terminals) with insulating tape so that they
are not exposed.
19. Remove the mounting nuts , then remove high-voltage harness and .
EVB
JSCIA0764ZZ F
: Harness clip
DANGER: G
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools. H
I
• Because of the danger of electric shock, be sure to close the bus bar cover after removing
the bus bar.
J
20. Remove the vehicle communications harness and voltage detection harness.
JSCIA0765ZZ
P
Vehicle communications harness Voltage detection harness Snap ring
: Harness clip
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
ASSEMBLY
Note the following items, and disassembly in the reverse order of disassembly.
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools.
• Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong ter-
minal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.
- Since the correct installation position for the bus bar connected to both front module stacks is com-
monly-confused with the wrong position , install the bus bar to the correct position with extreme
caution.
JSCIA0873ZZ
WARNING:
Install the Li-ion battery controller immediately before installing the battery pack upper case. Refer to
EVB-214, "LI-ION BATTERY CONTROLLER : Removal and Installation".
CAUTION:
• Perform the “LI-ION BATTERY JUNCTION BOX DATA CLEAR” when battery junction box is replaced.
Refer to EVC-148, "Work Procedure".
• Be sure to reinstall the high voltage harness clips in their original positions. If a clip is damaged,
replace it with a new clip before installing.
• Check the following items after installing battery pack: Refer to EVB-269, "Inspection".
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST
LI-ION BATTERY HEATER
EVB
P
JSCIA0750GB
Li-ion battery heater RR2 Li-ion battery heater RH2 Li-ion battery heater RH1
Li-ion battery heater LH1 Li-ion battery heater LH2 Li-ion battery heater relay unit
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• To prevent the removed service plug from being connected by mistake during the procedure, always
carry it in your pocket or put it in the tool box.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Refer to EVB-6, "High Voltage Precautions".
• To prevent electric shock hazards, ignition, and damage to parts, always remove Li-ion battery con-
troller before disassembling battery pack.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
WORK ENVIRONMENT FOR DISASSEMBLY OF LI-ION BATTERY
1. Must be an indoor environment.
• The work environment must be able to be isolated from the outside by shutters or other means to pre-
vent the intrusion of rain, snow, sand, and other substances.
• The environment must prevent the entry of sweat during work, and also prevent condensation from
occurring as a result of high temperature and humidity.
2. No entry of foreign materials.
• In addition to being indoors, the environment must not permit the entry during disassembly work of
metal powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.
• If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take
other necessary steps.
3. The floor must be dry.
• The floor must not become wet as a result of causes such as vehicles entering when it is raining or
snowing.
4. Work space
• Space approximately the size of one vehicle must be secured as the disassembly space.
• A sign indicating that disassembly is in progress or other measures must be taken so that persons other
than the workers do not enter the work space.
5. Standard fire fighting equipment
• Always place a standard fire fighting equipment in the disassembly work area.
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin-
guisher).
REMOVAL
Li-Ion Battery Heater RR1 & RR2
1. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
2. Remove Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
EVB
JSCIA0751ZZ
WARNING: D
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu-
lated tools. E
F
4. Remove mounting nuts and then remove Li-ion battery heaters.
JSCIA0752ZZ L
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu- N
lated tools.
: Battery front
WARNING:
JSCIA0753ZZ
5. Remove mounting nuts and then remove Li-ion battery heater
LH1 .
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu-
lated tools.
: Battery front
WARNING:
JSCIA0755ZZ
4. Remove mounting nuts and then remove Li-ion battery heater
RH1 .
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu-
lated tools.
NOTE: EVB
The right-side mounting hole is larger for facilitating removal of
the battery member pipe. Lifting up the left side first makes JSCIA0715ZZ
removal easier. D
WARNING:
F
To prevent electric shock hazards, be sure to put on
insulated protective gear and use insulated tools.
G
JSCIA0754ZZ
6. Remove mounting nuts and then remove Li-ion battery heater
LH2 . H
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu- I
lated tools.
NOTE: P
The right-side mounting hole is larger for facilitating removal of
the battery member pipe. Lifting up the left side first makes JSCIA0715ZZ
removal easier.
: Battery front
WARNING:
JSCIA0756ZZ
6. Remove mounting nuts and then remove Li-ion battery heater
RH2 .
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu-
lated tools.
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated
tools.
CAUTION:
• Install Li-ion battery controller immediately before installing battery pack upper case. Refer to EVB-
214, "LI-ION BATTERY CONTROLLER : Removal and Installation".
• Be sure to reinstall the high voltage harness clips in their original positions. If a clip is damaged,
replace it with a new clip before installing.
• Check the following items after installing battery pack: Refer to EVB-269, "Inspection".
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST
LI-ION BATTERY HEATER RELAY UNIT
EVB
P
JSCIA0750GB
Li-ion battery heater RR2 Li-ion battery heater RH2 Li-ion battery heater RH1
Li-ion battery heater LH1 Li-ion battery heater LH2 Li-ion battery heater relay unit
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• To prevent the removed service plug from being connected by mistake during the procedure, always
carry it in your pocket or put it in the tool box.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Refer to EVB-6, "High Voltage Precautions".
• To prevent electric shock hazards, ignition, and damage to parts, always remove Li-ion battery con-
troller before disassembling battery pack.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
WORK ENVIRONMENT FOR DISASSEMBLY OF LI-ION BATTERY
1. Must be an indoor environment.
• The work environment must be able to be isolated from the outside by shutters or other means to pre-
vent the intrusion of rain, snow, sand, and other substances.
• The environment must prevent the entry of sweat during work, and also prevent condensation from
occurring as a result of high temperature and humidity.
2. No entry of foreign materials.
• In addition to being indoors, the environment must not permit the entry during disassembly work of
metal powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.
• If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take
other necessary steps.
3. The floor must be dry.
• The floor must not become wet as a result of causes such as vehicles entering when it is raining or
snowing.
4. Work space
• Space approximately the size of one vehicle must be secured as the disassembly space.
• A sign indicating that disassembly is in progress or other measures must be taken so that persons other
than the workers do not enter the work space.
5. Standard fire fighting equipment
• Always place a standard fire fighting equipment in the disassembly work area.
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin-
guisher).
DISASSEMBLY
1. Remove battery pack upper case. Refer to EVB-204, "BATTERY PACK UPPER CASE : Removal and
Installation".
2. Remove Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
3. Remove the following; Refer to EVB-219, "BATTERY JUNCTION BOX AND BATTERY HARNESS : Dis-
assembly and Assembly".
• Battery current sensor (integrated with bus bar)
• Service plug switch bracket
EVB
ASSEMBLY
Assemble in the reverse order of disassembly. E
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated
tools. F
G
CAUTION:
• Check the following items after installing battery pack: Refer to EVB-269, "Inspection".
AIR LEAK INSPECTION
H
ELECTRIC EQUIPOTENTIAL TEST
• Install Li-ion battery controller immediately before installing battery pack upper case.
FRONT MODULE STACK
I
FRONT MODULE STACK : Exploded View INFOID:0000000009298683
JSCIA0568GB
EVB
JSCIA0569GB
P
JSCIA0704GB
Because there is a danger of electric shock and fire, never contact bus bar in a wrong terminal. A
EVB
JSCIA0874ZZ P
: Battery front
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress.
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet
or similar item to prevent contact with other persons.
• Refer to EVB-6, "High Voltage Precautions".
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent-
ing electric shock, fire, and damage to parts.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK
1. Must be an indoor environment.
• The environment must utilize a shutter or other means to shut out the outside environment and prevent
rain, snow, dust, or other substances from entering.
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur
due to high temperature or humidity.
2. Metal powder, grease, and other foreign substances must not enter.
• The indoor environment must also prevent metal powder, grease, and other foreign substances from
entering due to maintenance performed on other vehicles and other sources during disassembly work.
• If there is a risk of the above substances entering, take appropriate countermeasures, such as use of a
vinyl curtain or an equivalent to shut out the outside environment.
3. The floor must be dry.
• The floor must not be wet as a result of factors such as vehicle entry during rain or snow.
4. Work space
• The work space must be approximately the size of one entire vehicle.
• Take appropriate countermeasures so that persons other than the operator do not enter the work space,
such as by placing signs indicating that disassembly work is in progress.
5. Standard fire fighting equipment
• Always place a standard fire fighting equipment in the disassembly work area.
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin-
guisher).
REMOVAL
1. Remove the battery pack upper case. EVB-204, "BATTERY PACK UPPER CASE : Removal and Installa-
tion".
2. Remove Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
3. Remove the following parts. Refer to EVB-219, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
Disassembly and Assembly".
• Battery junction box
• Service plug switch bracket
• High-voltage battery harnesses
• Vehicle communications harness
• Voltage detection harness
• Harness brackets
JSCIA0658ZZ
D
5. Remove the battery temperature sensor harness (front) from the front module stack RH.
JSCIA0631ZZ
H
: Harness clip
WARNING:
I
To prevent electric shock, wear insulated protective gear and use insulated tools.
M
NOTE:
The right-side mounting hole is larger for facilitating removal of
the battery member pipe. Lifting up the left side first makes JSCIA0715ZZ
removal easier. N
: Battery front
DANGER: P
• Because there is a danger of electric shock, be sure to close the bus bar cover after remov-
ing the bus bar.
8. Remove the following parts. Refer to EVB-228, "LI-ION BATTERY HEATER : Disassembly and Assem-
bly".
• Li-ion battery heater RH1
• Li-ion battery heater RH2
• Li-ion battery heater LH1
• Li-ion battery heater LH2
9. Remove the Li-ion battery heater relay unit. Refer to EVB-234, "LI-ION BATTERY HEATER RELAY UNIT
: Disassembly and Assembly".
10. Disconnect the Li-ion battery heater harness connector . And then remove the harness clips and move
them to a location where they do not inhibit with work.
JSCIA0781ZZ
: Harness clip
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
11.
EVB
JSCIA0716ZZ F
WARNING: G
To prevent electric shock, wear insulated protective gear and use insulated tools.
H
13. Follow the procedure below and remove the front module stack from the battery pack. I
a. Attach a carabiner at position as shown in the figure, and attach a sling belt to it.
J
L
JSCIA0722ZZ
WARNING:
M
To prevent electric shock, wear insulated protective gear.
b. Use the engine frame (A) and lift up the front module stack.
O
WARNING:
CAUTION:
Do not move the engine crane when the front module stack
is lifted up. JSCIA0718ZZ
CAUTION:
Place the removed battery pack upper case onto the battery pack for storage.
JSCIA0782ZZ
: Harness clip
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
INSTALLATION
Note the following items, and disassembly in the reverse order of disassembly.
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools.
• Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong ter-
minal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.
EVB
JSCIA0873ZZ
G
Correct position Wrong position
: Battery front
H
WARNING:
Install the Li-ion battery controller immediately before installing the battery pack upper case. Refer to
EVB-214, "LI-ION BATTERY CONTROLLER : Removal and Installation". I
EV Battery Tracking Identification Seal
When replacing the Li-ion battery with a new battery, perform the following operation.
1. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged J
together with the new part.
2. Cut the EV battery tracking identification tool into 2 pieces and apply them to the body of the replaced
(old) LI-ion battery and to the “Li-ion battery replacement history record”.
K
3. Enter the necessary information in the “Li-ion battery replacement history record”.
JSCIA0659ZZ
CAUTION:
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress.
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet
or similar item to prevent contact with other persons.
• Refer to EVB-6, "High Voltage Precautions".
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent-
ing electric shock, fire, and damage to parts.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK
1. Must be an indoor environment.
• The environment must utilize a shutter or other means to shut out the outside environment and prevent
rain, snow, dust, or other substances from entering.
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur
due to high temperature or humidity.
2. Metal powder, grease, and other foreign substances must not enter.
• The indoor environment must also prevent metal powder, grease, and other foreign substances from
entering due to maintenance performed on other vehicles and other sources during disassembly work.
• If there is a risk of the above substances entering, take appropriate countermeasures, such as use of a
vinyl curtain or an equivalent to shut out the outside environment.
3. The floor must be dry.
• The floor must not be wet as a result of factors such as vehicle entry during rain or snow.
4. Work space
• The work space must be approximately the size of one entire vehicle.
• Take appropriate countermeasures so that persons other than the operator do not enter the work space,
such as by placing signs indicating that disassembly work is in progress.
5. Standard fire fighting equipment
• Always place a standard fire fighting equipment in the disassembly work area.
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin-
guisher).
DISASSEMBLY
1. Follow the procedure below and remove the bus bar module from the front module stack.
EVB
JSCIA0720ZZ
DANGER: D
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools. E
F
• This work must not be performed by multiple operators because there is a risk of electric
shock if the operators contact one another.
G
b. Remove the voltage detection terminal mounting screws , then remove the bus bar module from the
front module stack.
H
J
JSCIA0721ZZ
DANGER:
K
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools.
L
M
• This work must not be performed by multiple operators because there is a risk of electric
shock if the operators contact one another.
c. Install a module terminal cover [SST: KV99111500 ( — )] onto all module terminals. N
JPCIA0123ZZ
WARNING:
2. Remove the end plate and disassemble the front module stack.
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
ASSEMBLY
1. When replacing the Li-ion battery with a new battery, perform the following operation.
a. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged
together with the new part.
b. Cut the EV battery tracking identification tool into 2 pieces and apply them to the body of the replaced
(old) LI-ion battery and to the “Li-ion battery replacement history record”.
c. Enter the necessary information in the “Li-ion battery replacement history record”.
2. Follow the procedure below to assemble the front module stack.
DANGER:
There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools.
a. Assemble the module so that the module terminals are arranged as shown in the figure.
JSCIA0681ZZ
WARNING:
Be careful of the directions of the + terminal and – terminal when assembling the module. If A
the polarity is incorrect, there is a risk of electric shock, fire, and component damage.
NOTE:
• To identify the module + terminal and − terminal, refer to the
figure. B
E
JSCIA0682ZZ
• Install the module while aligning the position of the module col-
lar .
F
JSCIA0733ZZ
b. Install so that the end plate carabiner installation holes are in the positions shown in the figure. I
JSCIA0722ZZ L
NOTE:
There are 2 end plates, each with different carabiner installation hole positions. If they are installed
reversed, the carabiner installation hole is positioned on the inside and lifting up is not possible. M
c. Install the mounting bolts at opposite corners for each module, then insert φ7 mm (0.28 in) metal bars
(B) into the empty bolt holes and perform centering of the module collar position.
N
JSCIA0734ZZ
CAUTION:
If the collar position is incorrect, there is a risk of the bolts loosening because they are not sup-
ported by the collar between the modules.
d. Tighten the mounting bolt to the specified torque.
3. Follow the following procedure and install the bus bar module onto the front module stack.
a. Install the bus bar module , then use an insulated torque driver to tighten the voltage detection terminal
mounting screws .
JSCIA0721ZZ
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools.
• This work must not be performed by multiple operators because there is a risk of electric
shock if the operators contact one another.
b. Tighten the module terminal mounting bolts in numerical order as shown in the figure.
EVB
E
JPCIA0150ZZ
DANGER:
G
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools.
H
I
• This work must not be performed by multiple operators because there is a risk of electric
shock if the operators contact one another.
c. Install the bus bar cover.
J
REAR MODULE STACK
REAR MODULE STACK : Exploded View INFOID:0000000009298686
K
REMOVAL AND INSTALLATION
L
JSCIA0568GB
EVB
JSCIA0570GB
M
Battery temperature sensor harness Right end plate Harness bracket
(rear)
Harness bracket Front stack member Harness bracket N
Bus bar cover Bus bar module Through-bolt
Left end plate Module Rear stack member
O
: N·m (kg-m, in-lb)
JSCIA0704GB
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
WARNING:
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress.
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet
or similar item to prevent contact with other persons.
• Refer to EVB-6, "High Voltage Precautions".
Revision: October 2013
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EVB-254 2013 LEAF
LI-ION BATTERY
< UNIT DISASSEMBLY AND ASSEMBLY >
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent-
ing electric shock, fire, and damage to parts. A
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
B
so in the Service Manual.
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK
1. Must be an indoor environment. EVB
• The environment must utilize a shutter or other means to shut out the outside environment and prevent
rain, snow, dust, or other substances from entering.
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur
D
due to high temperature or humidity.
2. Metal powder, grease, and other foreign substances must not enter.
• The indoor environment must also prevent metal powder, grease, and other foreign substances from
entering due to maintenance performed on other vehicles and other sources during disassembly work. E
• If there is a risk of the above substances entering, take appropriate countermeasures, such as use of a
vinyl curtain or an equivalent to shut out the outside environment.
3. The floor must be dry. F
• The floor must not be wet as a result of factors such as vehicle entry during rain or snow.
4. Work space
• The work space must be approximately the size of one entire vehicle. G
• Take appropriate countermeasures so that persons other than the operator do not enter the work space,
such as by placing signs indicating that disassembly work is in progress.
5. Standard fire fighting equipment H
• Always place a standard fire fighting equipment in the disassembly work area.
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin-
guisher).
I
REMOVAL
1. Remove the battery pack upper case. EVB-204, "BATTERY PACK UPPER CASE : Removal and Installa-
tion". J
2. Remove Li-ion battery controller. Refer to EVB-214, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
3. Remove Li-ion battery heater RR1 and RR2. Refer to EVB-228, "LI-ION BATTERY HEATER : Disassem- K
bly and Assembly".
4. Disconnect the harness connector between the battery tem-
perature sensor harness (front) and the battery temperature L
sensor harness (rear).
WARNING:
M
To prevent electric shock, wear insulated protective
gear.
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JSCIA0647ZZ
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
6. Remove the harness clips of the voltage detection harness and the Li-ion battery heater harness
from the harness bracket, and move them to a location where they do not inhibit with work.
JSCIA0769ZZ
: Harness clip
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
7. Remove the mounting nuts and remove the high-voltage harness , from the rear module stack.
EVB
JSCIA0770ZZ F
: Harness clip
DANGER: G
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools. H
I
• Because there is a risk of electric shock, immediately protect the disconnected high-volt-
age terminals with insulating tape so that they are not exposed.
8. Remove the rear module stack mounting bolts . J
WARNING:
JPCIA0129ZZ
M
9. Follow the procedure below and remove the rear module stack from the battery pack.
a. Attach a carabiner to position (A) as shown in the figure and N
connect a lashing belt to it.
WARNING:
O
To prevent electric shock, wear insulated protective
gear.
P
JSCIA0251ZZ
CAUTION:
Do not move the engine crane when the rear module stack
is lifted up. JPCIA0130ZZ
c. Move the battery pack and place the workbench below the rear module stack.
WARNING:
CAUTION:
Place the removed battery pack upper case onto the battery pack for storage.
• Because there is a risk of electric shock, lay an anti-static rubber sheet on the workbench.
INSTALLATION
1. When replacing the Li-ion battery with a new battery, perform the following operation.
a. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged
together with the new part.
b. Cut the EV battery tracking identification tool into 2 pieces and apply them to the body of the replaced
(old) LI-ion battery and to the “Li-ion battery replacement history record”.
c. Enter the necessary information in the “Li-ion battery replacement history record”.
2. Follow the following procedure and install the rear module stack onto the battery pack.
a. Use the engine frame (A) and lift up the rear module stack .
WARNING:
CAUTION:
Do not move the engine crane when the rear module stack
is lifted up. JPCIA0130ZZ
b. Move the workbench and place the battery pack below the rear module stack.
c. Mount the rear module stack onto the battery pack.
WARNING:
CAUTION:
Be sure to align the locating pin position.
B
3. Tighten the rear module stack mounting bolts .
WARNING:
EVB
To prevent electric shock, wear insulated protective
gear and use insulated tools.
D
E
JPCIA0129ZZ
4. Tighten the mounting nuts , and then install the high-voltage harness , onto the rear module stack. F
JSCIA0770ZZ
L
: Harness clip
DANGER:
M
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools.
N
• Because there is a risk of electric shock, immediately protect the disconnected high-volt- O
age terminals with insulating tape so that they are not exposed.
5. Install the voltage detection harness and the Li-ion battery heater harness .
P
JSCIA0769ZZ
: Harness clip
WARNING:
JSCIA0647ZZ
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
NOTE:
Install the battery temperature sensor onto module No. MD12.
JSCIA0658ZZ
D
8. Install the Li-ion battery heater RR1 and RR2. Refer to EVB-228, "LI-ION BATTERY HEATER : Disassem-
bly and Assembly".
9. Install the Li-ion battery controller. EVB-214, "LI-ION BATTERY CONTROLLER : Removal and Installa- E
tion".
10. Install the battery pack upper case. EVB-204, "BATTERY PACK UPPER CASE : Removal and Installa-
tion".
F
CAUTION:
• Be sure to reinstall the high voltage harness clips in their original positions. If a clip is damaged,
replace it with a new clip before installing.
• Check the following items after installing battery pack: Refer to EVB-269, "Inspection". G
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST
H
REAR MODULE STACK : Disassembly and Assembly INFOID:0000000009298688
DANGER: I
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and J
maintenance.
WARNING:
• Be sure to remove the service plug for shutting off high voltage circuits before performing inspec- K
tion or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress.
L
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet
or similar item to prevent contact with other persons. M
• Refer to EVB-6, "High Voltage Precautions".
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent-
ing electric shock, fire, and damage to parts. N
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual. O
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK
1. Must be an indoor environment. P
• The environment must utilize a shutter or other means to shut out the outside environment and prevent
rain, snow, dust, or other substances from entering.
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur
due to high temperature or humidity.
2. Metal powder, grease, and other foreign substances must not enter.
• The indoor environment must also prevent metal powder, grease, and other foreign substances from
entering due to maintenance performed on other vehicles and other sources during disassembly work.
JSCIA0635ZZ
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
2. Follow the following procedure and remove the bus bar from the rear module stack.
a. Remove the center bus bar cover, then remove the module ter-
minal mounting bolts .
DANGER:
JSCIA0154ZZ
• This work must not be performed by multiple opera-
tors because there is a risk of electric shock if the operators contact one another.
CAUTION:
Do not remove all bus bar covers and all module terminal mounting bolts at the same time.
JSCIA0148ZZ
• This work must not be performed by multiple opera- D
tors because there is a risk of electric shock if the operators contact one another.
c. Remove the right-side bus bar cover, then remove the module
E
terminal mounting bolts .
DANGER:
JSCIA0155ZZ
• This work must not be performed by multiple opera- H
tors because there is a risk of electric shock if the operators contact one another.
JSCIA0191ZZ L
• This work must not be performed by multiple opera-
tors because there is a risk of electric shock if the operators contact one another.
NOTE:
• Because “module B” interferes with the bracket and cover, cut JSCIA0192ZZ
P
the module terminal cover at the position shown in the figure.
JSCIA0729ZZ
JPCIA0126ZZ
JSCIA0723ZZ
JSCIA0240ZZ
EVB
JPCIA0131ZZ
D
ASSEMBLY
1. When replacing the Li-ion battery with a new battery, perform the following operation.
E
a. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged
together with the new part.
b. Cut the EV battery tracking identification tool into 2 pieces and apply them to the body of the replaced
(old) LI-ion battery and to the “Li-ion battery replacement history record”. F
c. Enter the necessary information in the “Li-ion battery replacement history record”.
2. Follow the procedure below to assemble the rear module.
G
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
H
a. Assemble the rear module so that the module terminals are arranged as shown in the figure. I
JSCIA0683ZZ L
WARNING:
Be careful of the directions of the + terminal and − terminal when assembling the module. If
M
the polarity is incorrect, there is a risk of electric shock, fire, and component damage.
NOTE:
• To identify the module + terminal and − terminal, refer to the
figure. N
JSCIA0682ZZ
JSCIA0240ZZ
c. Inspect the module installation condition, and correct it if it is skewed or a large distortion is found.
JSCIA0313ZZ
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
d. Install the 2 through-bolts at opposite corners of the module, then insert φ7 mm (0.28 in) metal bars (A)
into the bolt holes and tighten the mounting nuts to the prescribed torque.
JSCIA0717ZZ
CAUTION:
If the collar position is incorrect, there is a risk of the bolts loosening because they are not sup-
ported by the collar between the modules.
e. Install the remaining 2 through-bolts, and tighten the mounting nuts to the prescribed torque.
EVB
JSCIA0347ZZ
D
3. Install the rear stack member .
WARNING:
E
To prevent electric shock, wear insulated protective
gear and use insulated tools.
F
G
JSCIA0723ZZ
JPCIA0126ZZ
K
5. Remove the module terminal cover [SST: KV99111500 ( — )]
(A).
WARNING: L
N
6. Follow the procedure below and install the bus bar module onto
the rear module stack. JSCIA0192ZZ
a. Install the bus bar module onto the rear module stack.
O
WARNING:
JPCIA0135ZZ
• This work must not be performed by multiple opera-
tors because there is a risk of electric shock if the operators contact one another.
c. Tighten the module terminal mounting bolts in numerical order as shown in the figure.
• When tightening of 1 – 16 is completed, install the left-side bus bar cover.
• When tightening of 17 – 32 is completed, install the right-side bus bar cover.
• When tightening of 33 – 48 is completed, install the center bus bar cover.
JPCIA0136ZZ
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools.
• This work must not be performed by multiple operators because there is a risk of electric
shock if the operators contact one another.
d. Install the bus bar cover .
JPCIA0137ZZ
WARNING:
CAUTION:
• Be careful not to install with the top and bottom facing in the wrong directions.
• After installation, check that the mating is not skewed.
EVB
JSCIA0635ZZ
WARNING: D
To prevent electric shock, wear insulated protective gear and use insulated tools.
E
CAUTION: F
• Be sure to reinstall the high voltage harness clips in their original positions. If a clip is damaged,
replace it with a new clip before installing.
• Check the following items after installing battery pack: Refer to EVB-269, "Inspection". G
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST
Inspection INFOID:0000000009298689
H
L
JSCIA0645ZZ
2. Install the gauge (A) of the air leak tester [SST: KV99111400
( — )]. M
WARNING:
O
CAUTION:
The gauge is a precision instrument. Be careful not to drop JSCIA0646ZZ
it when handling it. P
There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear.
NOTE:
Because the service plug location is open, install the service plug for sealing the case.
4. Use vinyl tape or similar means (A) for preventing air leakage
from the PTC harness connector.
• Use wide vinyl tape that is capable of covering all of the PTC
harness connector with one strip.
• Apply carefully so that no wrinkles in the tape occur.
WARNING:
JSCIA0686ZZ
5. Use vinyl tape or similar means (A) to prevent air leakage from
the breather.
• Use wide vinyl tape that is capable of covering all of the
breather with one strip.
• Apply carefully so that no wrinkles in the tape occur.
WARNING:
JPCIA0128ZZ
JSCIA0638ZZ
b. Operate the air pump slowly and apply the specified inspection pressure inside the battery pack. If the
gauge pressure does not rise, or if the gauge reading fluctuates, check for the location of air leakage.
Specified inspection pressure : 1.6 kPa (0.016 bar, 0.0163 kg/cm2, 0.232 psi)
CAUTION:
• Operate the air pump carefully when applying pressure. If pressure is applied suddenly to the
gauge, the gauge may be damaged.
• Do not apply pressure of 2.0 kPa (0.0204 kg/cm2) or more to the battery case or air leak tester.
Repair limit : 1.4 kPa (0.014 bar, 0.0142 kg/cm2, 0.203 psi)
B
e. If the pressure is below the limit value, check for the locations of air leakage.
NOTE:
Check for air leakage from the sound of air escaping when pressure is applied.
EVB
ELECTRIC EQUIPOTENTIAL TEST
After assembling the Li-ion battery pack, remove the battery pack upper case ground bolt , then measure
the resistance between the high-voltage harness connector flange ground bolts and the ground bolt seat D
(location of coating peeling) .
JSCIA0747ZZ
WARNING: J
To prevent electric shock, wear insulated protective gear.
Items Specification
Type Li-ion battery
Structure 48 modules (192 cells)
Rated voltage (V) Approx. 360
Battery capacity (kWh) Approx. 24
Weight [kg (lb)] Approx. 275 (606)
JSCIA0644ZZ