REAR MODULE STACK: Disassembly and Assembly: Assembly

1. Enter the date of replacement on the EV battery traceability seal packaged with the new part.
2. Cut the EV battery traceability seal in two and affix each seal to the module and "Li-ion BATTERY REPLACEMENT RECORD".
3. Fill in the "Li-ion BATTERY REPLACEMENT RECORD".

1. Assemble rear module stack, and provisionally fasten it in place with the through bolt.
   WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.
   • Check that terminal of module is arranged as shown in the figure.
     Fig 1: Rear Module Stack Terminals Arrangement

     Courtesy of NISSAN MOTOR CO., U.S.A.
   • Check that mounting plate (1) is located at position shown in the figure.
   Fig 2: Identifying Mounting Plate Positions

   Courtesy of NISSAN MOTOR CO., U.S.A.
2. Use lashing belt (A) and apply pressure to rear module stack (1).
   WARNING: To prevent shock hazards, be sure to wear protective gear.
   Fig 3: Identifying Lashing Belt And Rear Module Stack

   Courtesy of NISSAN MOTOR CO., U.S.A.
3. Inspect the module installation condition, and correct it if it is incorrectly installed or a large distortion is found.
   Fig 4: Identifying Correct And Incorrect Module Installation Condition

   Courtesy of NISSAN MOTOR CO., U.S.A.
   WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.
4. Tighten to the specified torque the mounting nuts for the through bolt that is attached tentatively.
   • To tighten rear module stack, fix the tip of through bolt to tighten mounting nuts.
   WARNING:

   • To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.
   Fig 5: Tightening Rear Module Stack Mounting Nuts

   Courtesy of NISSAN MOTOR CO., U.S.A.

1. Temporarily install rear module stack member (1) to rear module stack.
   WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.
   Fig 6: Identifying Rear Module Stack Member

   Courtesy of NISSAN MOTOR CO., U.S.A.
2. Using the scale (A), inspect the module installation condition.
   WARNING: To prevent shock hazards, be sure to wear protective gear.
   • If the rear module stack is excessively distorted, loosen the through bolt of rear module stack and correct the condition.
   Fig 7: Inspecting Module Installation Condition

   Courtesy of NISSAN MOTOR CO., U.S.A.
3. Tighten to the specified torque the mounting nuts for the rear stack member.

Fig 9: Identifying Battery Temperature Sensor (Rear)

Courtesy of NISSAN MOTOR CO., U.S.A.

• Position module where sensor (1) will be installed so that it is aligned with concave part (A) of rear stack member.
• Position module where clip (2) will be installed so that it is aligned with concave part (B) of rear stack member.

Fig 10: Identifying Module Where Sensor, Module Where Clip And Concave Part

Courtesy of NISSAN MOTOR CO., U.S.A.

1. Install bus bars onto rear module stack.
   WARNING: To prevent shock hazards, be sure to wear protective gear.
2. Use an insulated torque driver (A) and tighten the voltage detection terminal mounting screws.

   DANGER: 

   • Touching high voltage components with using the appropriate protective equipment will cause electrocution. 
   • Work alone. Failure to do this may cause shock hazards. 
   Fig 11: Tightening Voltage Detection Terminal Mounting Screws

   Courtesy of NISSAN MOTOR CO., U.S.A.
3. Tighten module terminal mounting bolts in numerical order as shown in the figure.
   • When bolts 1 - 16 have been tightened, install left side bus bar cover.
   • When bolts 17 - 32 have been tightened, install right side bus bar cover.
   • When bolts 33 - 48 have been tightened, install center bus bar cover.
   Fig 12: Tightening Order Of Module Terminal Mounting Bolts

   Courtesy of NISSAN MOTOR CO., U.S.A.

   DANGER: 

   • Touching high voltage components with using the appropriate protective equipment will cause electrocution. 
   • Work alone. Failure to do this may cause shock hazards. 
4. Install bus bar cover (1).
   Fig 13: Identifying Bus Bar Cover Installation Position

   Courtesy of NISSAN MOTOR CO., U.S.A.
   WARNING: To prevent shock hazards, be sure to wear protective gear.
   CAUTION:

   • Be sure not to install with up/down sides facing in wrong directions.
   • After installation, verify that the joined part does not disconnect.

1. Use mobile floor crane (A) to lift up rear module stack (1).
   WARNING: To prevent shock hazards, be sure to wear protective gear.
   CAUTION: Do not move engine crane while rear module stack is hoisted up.
   Fig 15: Lifting Rear Module Stack Using Mobile Floor Crane

   Courtesy of NISSAN MOTOR CO., U.S.A.
2. Move work bench so that battery pack is underneath rear module stack.
3. Install rear module stack onto battery pack.
   WARNING: To prevent shock hazards, be sure to wear protective gear.
   CAUTION: Align position of locating pin.

Fig 17: Identifying High Voltage Harness Mounting Nuts

Courtesy of NISSAN MOTOR CO., U.S.A.

DANGER: 

Touching high voltage components with using the appropriate protective equipment will cause electrocution. 

1. Tighten mounting nuts and bolts in numerical order as shown in the figure.
   Fig 18: Tightening Order Of Battery Pack Upper Case Mounting Nuts And Bolts

   Courtesy of NISSAN MOTOR CO., U.S.A.
   WARNING: To prevent shock hazards, be sure to wear protective gear.
2. Install ground bolt (A).
   Fig 19: Identifying Ground Bolt

   Courtesy of NISSAN MOTOR CO., U.S.A.
   WARNING: To prevent shock hazards, be sure to wear protective gear.