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.
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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.

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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
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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

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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

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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.
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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.

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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

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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