NTB14059A
Service Bulletin Details
Public Details for: NTB14059A
Service information if the high voltage (hv) battery pack needs to be replaced for any reason: 2013 - 2015 leaf * the hv battery pack listed in the parts information table is a direct replacement and does not require any additiona
- 2015 - 2014 - 2013 - 2012 - 2011 -
Models from 2015
2015 NISSAN LEAF |
Models from 2014
2014 NISSAN LEAF |
Models from 2013
2013 NISSAN LEAF |
Models from 2012
2012 NISSAN LEAF |
Models from 2011
2011 NISSAN LEAF |
Classification: Reference: EL14-031a Date: NTB14-059a September 15, 2015 2011-2015 LEAF; REPLACEMENT HIGH VOLTAGE BATTERY PACK This bulletin has been amended to update the Applied Vehicles and Parts Information and to add information to register the Li-ion Battery Controller (LBC). Please discard the previous version. APPLIED VEHICLES: 2011 – 2015 LEAF® (ZE0) SERVICE INFORMATION If the High Voltage (HV) Battery pack needs to be replaced for any reason: 2013 – 2015 LEAF The HV Battery Pack listed in the Parts Information table is a direct replacement and does not require any additional parts. NOTE: o Refer to the applicable Electronic Service Manual (ESM) section EVB EV Battery System for the procedure to replace the HV Battery Pack. o Refer to Service Information Overview on page 2 for additional services required when replacing the HV Battery Pack. 2011 – 2012 LEAF The HV Battery Pack listed in the Parts Information table can be retrofitted with the list of additional parts and the Service Procedure starting on page 2. IMPORTANT: DO NOT “READ & WRITE” any Li-ion Battery Controller (LBC) data to the new HV Battery Pack assembly. Writing the old HV Battery Pack LBC data to the new HV Battery Pack assembly will cause the vehicle to read only 8 bars of capacity and will require the LBC to be replaced. Nissan Bulletins are intended for use by qualified technicians, not 'do-it-yourselfers'. Qualified technicians are properly trained individuals who have the equipment, tools, safety instruction, and know-how to do a job properly and safely. NOTE: If you believe that a described condition may apply to a particular vehicle, DO NOT assume that it does. See your Nissan dealer to determine if this applies to your vehicle. 1/20 Service Information Overview If a HV Battery Pack is being replaced. Is LEAF a 2013 – 2015 model year? Yes 2011 – 2012 LEAF? No Refer to ESM for procedure to replace HV Battery Pack Use HV Battery Pack retrofit procedure in this bulletin. For all model years perform: Registering the New HV Battery Pack Assembly For all model years perform: EV/HEV BATTERY GRADUAL CAP LOSS DATA CLEAR For all model years perform: Register the HV Battery Installation Date SERVICE PROCEDURE 2013 – 2015 LEAF Refer to the ESM for HV Battery Pack replacement. And then proceed to page 7 and perform the following procedures in order: a. Registering the New HV Battery Pack Assembly b. Clearing EV/HEV BATTERY GRADUAL CAP LOSS DATA CLEAR c. Register the HV Battery Installation Date 2011 – 2012 LEAF Follow the complete procedure for Retrofitting HV Battery Pack starting on page 3. 2/20 NTB14-059a Retrofitting HV Battery Pack These procedures are to be performed ONLY by a Master Technician with current LEAF certification. Follow all Warning, Caution, and Danger instructions in the ESM. DANGER: Touching high voltage components without using the appropriate protective equipment will cause electrocution. Electric vehicles contain a high voltage battery. There is the risk of electric shock, electric leakage, or similar accidents if the high voltage components and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing this procedure. WARNING: Be sure to remove the service plug in order to disconnect the high voltage circuits before performing 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 gloves, shoes, a 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 insulating sheet except when using them. Erect the safety barriers around the vehicle to prevent un-authorized personnel from entering high voltage work area. CAUTION: Never turn the vehicle ignition to the READY status with the service plug removed unless otherwise instructed in the ESM. A malfunction may occur if this is not observed. 1. Write down the radio settings. Presets AM FM 1 FM 2 SAT 1 SAT 2 SAT 3 Bass 1 2 Treble 3 Balance 3/20 4 Fade 5 6 Speed Sen. Vol. NTB14-059a 2. If equipped, Write down the customer preferred setting for the Automatic Air Conditioning System. If needed, refer to System Settings in the HAC section of the ESM. 3. Check to see if the timer for “charging” or “climate control” is ON. If ON, turn OFF and make sure to turn back ON after the HV battery pack is replaced. For charging timer on vehicles with navigation – write down which days are OFF, Timer 1 or Timer 2. 4. Remove the HV Battery Pack. Use the procedures from the ESM for the following steps unless otherwise directed. NOTE: Refer to the applicable ESM section EVB EV Battery System for the procedure to replace the HV Battery Pack. Figure 1 shows the new and old HV Battery Packs side by side. NOTE: For 2013-2015 vehicles the new HV Battery Pack is a direct replacement and does not require this retrofitting procedure. Original HV battery pack for 2011-2012 LEAF Mounting flange has changed New HV battery pack Figure 1 4/20 NTB14-059a Preparing the Rear Support Brackets 5. Enlarge support bracket bolt holes: a. Place the support brackets in a vise one at a time. Enlarge only these bolt holes Figure 2 b. With a ½” drill bit, enlarge the bolt holes indicated in Figure 2 ½” drill bit. c. Cover the newly exposed metal with a zinc rich paint to prevent corrosion. After the paint has dried and before assembling the brackets to the new HV battery, Bitumen wax will also be applied to these areas. NOTE: See page 18 for paint and Bitumen wax. Figure 3 5/20 NTB14-059a 6. Install the new HV Battery Pack: a. Attach the HV Battery Pack to the vehicle. IMPORTANT: Do not make any electrical connections at this time. NOTE: Refer to the applicable ESM section EVB EV Battery System for the procedure to replace the HV Battery Pack. b. Install only the front HV Battery Pack ground straps. Figure 4 and Figure 5 show the front HV Battery Pack ground straps (two total). Discard the rear HV Battery Pack ground straps. Ground straps Figure 4 Figure 5 c. Apply Bitumen wax to the brackets at the areas that were enlarged in step 5. d. Install the two new brackets to the HV Battery Pack with the four new bolts from the Parts Information table and to the vehicle with the two pre-existing bolts and tighten. 72 N•m (7.3 kg-m, 53 ft-lb) Parking brake cable bracket. Figure 6 7. Remove the right side parking brake cable bracket (Figure 6) from the cable and discard. This bracket will be replaced with the standoff in the Parts Information table. 6/20 NTB14-059a 8. Install the new brake cable standoff from the Parts Information table. Brake cable standoff Figure 7 9. Reassemble the remaining components in the reverse order. NOTE: Refer to the applicable ESM section EVB EV Battery System for the procedure to replace the HV Battery Pack. 10. Install new undercovers A and B from the Parts Information table. Registering the New HV Battery Pack Assembly: NOTE: An unregistered HV Battery Pack will set P3102 (Invalid Battery). IMPORTANT: DO NOT “READ & WRITE” any Li-ion Battery Controller (LBC) data to the new HV Battery Pack assembly. Writing the old HV Battery Pack LBC data to the new HV Battery Pack assembly will cause the vehicle to read only 8 bars of capacity and will require the LBC to be replaced. 1. Install the HV Battery Pack registration card into the CONSULT PC. 7/20 NTB14-059a 2. Attach the CONSULT PC to the vehicle. Connect the plus VI to the vehicle. Connect the AC adapter to the CONSULT PC. 3. Turn ON the CONSULT PC and then open C-III plus. 4. Depress the vehicle’s power (“ignition”) switch twice without depressing the brake pedal. The meter and gauges will illuminate. CAUTION: Do Not set the vehicle in “READY to drive” mode. NOTE: Make sure all accessories are turned OFF. 5. After the plus VI is recognized, select Diagnosis (All Systems). NOTE: Make sure all applications other than C-III plus are closed. Plus VI is recognized Step 5 Figure 8 8/20 NTB14-059a 6. Select LEAF and appropriate model year or Automatic Selection(VIN). If Automatic Selection (VIN) is selected, wait for the Reading VIN screen to complete (picture not shown). 7. Select Select. This works, too Step 6 Step 7 Figure 9 8. Verify the VIN in VIN or Chassis # matches that of the vehicle. If the correct VIN is displayed, select Confirm. Verify here If OK, select Confirm Figure 10 9/20 NTB14-059a 9. Select Confirm. Step 9 Figure 11 10. Select EV/HEV. Wait for system call to complete. Step 10 Figure 12 10/20 NTB14-059a 11. Select the “right arrow” (Figure 13). NOTE: This arrow will only be available if the HV Battery registration card is installed in the CONSULT PC. The card must be installed before opening C-III plus. If the card is installed, but the arrow in Figure 13 is not available, reboot the CONSULT PC. Step 11 Figure 13 12. Select LOAD BATT ID. Step 12 Figure 14 11/20 NTB14-059a 13. Select Next. Step 13 Figure 15 14. Select Start. Step 14 Figure 16 12/20 NTB14-059a 15. When the status displays “Complete”, select End. Step 15 Figure 17 16. Return to EV/HEV Self-Diagnosis screen and then erase DTC P3102. Proceed to “Clearing EV/HEV BATTERY GRADUAL CAP LOSS DATA CLEAR” on the next page. 13/20 NTB14-059a Clearing EV/HEV BATTERY GRADUAL CAP LOSS DATA CLEAR 17. Select EV/HEV Work support. 18. Select BATTERY GRADUAL CAP LOSS DATA CLEAR. 19. Select Start. Step 17 Step 18 Step 19 Figure 18 20. Select Start again. 21. When the Current status displays “Completed”, select End and then Home. Step 20 Step 21 Figure 19 Proceed to “Registering the HV Battery Installation Date” on the next page. 14/20 NTB14-059a Registering the HV Battery Installation Date 22. Select Maintenance. Step 22 Figure 20 23. Select EV Battery usage report. Step 23 Figure 21 15/20 NTB14-059a 24. Select Next. Step 24 Figure 22 25. Input the correct “Battery registration date”. 26. Select Register. NOTE: If a print-out of the battery health maintenance report is needed: The prior calendar year must first be entered before the report is printed. After the report is printed, the current calendar year must be re-entered. Step 25 XXXXXX XXXXXX XXXXXX XXXXXX Step 26 Figure 23 16/20 NTB14-059a 27. When “Registration is completed successfully” is displayed select OK. 28. Select Next. Step 27 Step 28 Figure 24 29. Select Home and close the CONSULT PC. 17/20 NTB14-059a Reset Customer Settings 1. Reset the clock in the combination meter. 2. Reset the radio settings. 3. If equipped, check/reset the clock in the navigation system. 4. If equipped, reset the customer preferred settings for the Automatic Air Conditioning System. If needed, refer to System Settings in the HAC section of the ESM. 5. If equipped, turn the Charge and A/C timers back ON if they were turned OFF. 6. Inform the customer: If equipped, some memory settings in the navigation system may need to be reset. 7. Reinitialize and check the Anti-Pinch Function for all Auto-UP power windows: Reinitialize: a. Turn the ignition ON. b. Operate the power window switch to fully open the window (glass all the way down). c. Hold the window switch UP until the glass stops at the fully closed position, and then continue holding the switch UP for 2 seconds or more. d. Check that AUTO-UP function operates normally. Check Anti-Pinch Function a. Fully open the door window (glass all the way down). b. Hold a piece of wood near the fully closed position. c. Close the door window glass using the AUTO-UP switch. Allow the window glass to hit the wood. d. Check the following conditions: Check that the glass lowers for approximately 150 mm (5.9 in), without pinching the wood, and stops. Check that the glass does not rise when operating the power window main switch, while the widow is lowering after hitting the wood. CAUTION: Do not check anti-pinch function with hands or other body parts because they may be pinched. 18/20 NTB14-059a PARTS INFORMATION DESCRIPTION MODEL 2013 - 2014 LEAF HIGH VOLTAGE BATTERY PACK 2015 LEAF HIGH VOLTAGE BATTERY PACK HIGH VOLTAGE BATTERY PACK 2011 Without Cold Weather Package HIGH VOLTAGE BATTERY PACK 2011 With Cold Weather Package 2012 All 2011 - 2012 LEAF PART# QUANTITY 295B0-3NF2A 295B0-9RB9A 1 1 295B0-3NF9E (replaces 295B03NA7A) 1 295B0-3NF9D* (replaces 295B03NA8B) (Only) * BRKT ASSY - BAT MTG 740D0-3NF1A 2 (support brackets) BOLT - FLG, HEX 01125-N0111 4 BRAKE CABLE STANDOFF 24220-7S020 1 SWITCH - DISCONNECT, 297C1-3NF0A 1 SERVICE (SDSW, Figure B) COVER - BAT, A 748N2-3NF0A 1 (undercover) COVER - BAT, B 748N3-3NF0A 1 (undercover) Cold Weather Package vehicles can be identified by having heated steering wheel, heated front and rear seats, heated outside mirrors and rear HVAC duct. New style Original style Figure A Figure B IMPORTANT: The original style SDSW (Figure A) cannot be used with any of the battery pack assemblies listed above. Figure B shows the New style SDSW that is to be used. The two styles are not interchangeable. 19/20 NTB14-059a PARTS INFORMATION (continued) 999MP-9G001P (1) (shop supply) Local Source (2) (shop supply) Bitumen Wax Zinc-Rich Primer as needed as needed (1) Order this item through the Nissan Maintenance Advantage program: Phone: 877-NISNMA1 (877-647-6621). Website order via link on dealer portal www.NNAnet.com and click on the “Maintenance Advantage” link. (2) Use one of the following Zinc Rich Primers or an equivalent: 3M™ Zinc Spray 16-501 For help finding a local source for 3M™ products or obtaining an MSDS, contact 3M™ Automotive Aftermarket Division at 1-877-MMM-CARS. CRC® Zinc-It® 18412 For help finding a local source for CRC® products or obtaining an MSDS, contact CRC® Customer Service Representative at 1- 800-272-8963. NOTE: Do NOT submit a claim for the Bitumen Wax or the Zinc Rich Primer as these are considered shop supplies. CLAIMS INFORMATION Submit a Primary Failed Part (PP) line claim using the following claims coding: DESCRIPTION PFP OP CODE SYM DIA FRT R&I OR RPL LI-ION BATTERY JQ01AA (2) REGISTER HV BATTERY JX38AA 0.2 (1) HG 32 CHECK LI-ION BATTERY CAPACITY ** JQ98AA 0.3 (1) Reference the Parts Information Table and use the applicable High Voltage Battery Part Number as the Primary Failed Part. (2) Reference the current Nissan Warranty Flat Rate Manual and use the indicated flat rate time. ** Only use this operation code if the failure is due to capacity loss. 20/20 NTB14-059a