REAR MODULE STACK: Disassembly and Assembly: Disassembly

WARNING: This page is about a different car, the 2011 Nissan Leaf. However, it is still accessible from the selected car via links, so may be relevant.

Clean any contamination and dust from the battery pack.
Remove service plug retainer (1).
WARNING: To prevent shock hazards, be sure to wear protective gear.

Fig 1: Identifying Service Plug Retainer
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove mounting bolts (A), (B) and mounting nuts (C), then remove battery pack upper case.

Fig 2: Identifying Battery Pack Upper Case Mounting Bolts And Nuts
Courtesy of NISSAN MOTOR CO., U.S.A.

WARNING: To prevent shock hazards, be sure to wear protective gear.
Remove vehicle communication harness connector (A) on rear module stack.
WARNING:
- To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.
- To prevent shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.
Fig 3: Identifying Vehicle Communication Harness Connector On Rear Module Stack
Courtesy of NISSAN MOTOR CO., U.S.A.
Disconnect Li-ion battery controller harness connector (A).
WARNING:
- To prevent shock hazards, be sure to wear protective gear.
- To prevent shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.
Fig 4: Identifying Li-ion Battery Controller Harness Connector
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove Li-ion battery controller mounting bolts (A).
WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.

Fig 5: Identifying Li-ion Battery Controller Mounting Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Disconnect harness connector and remove Li-ion battery controller.
WARNING:
- To prevent shock hazards, be sure to wear protective gear.
- To prevent shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.
Disconnect battery temperature sensor harness connector (A) from bracket.
WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.

Fig 6: Identifying Battery Temperature Sensor Harness Connector
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove harness clip (A) from harness bracket and move vehicle communication harness (1) to the position without the hindrance for work.
WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.

Fig 7: Identifying Vehicle Communication Harness And Harness Clip
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove mounting nuts (A) and remove high voltage harness from rear module stack.

Fig 8: 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.

WARNING: To prevent shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.
Remove rear module stack (1) mounting bolts (A).
WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.

Fig 9: Identifying Rear Module Stack Mounting Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Follow the procedure below and remove rear module stack from battery pack.
1. Attach a carabiner to the position (A) in the figure and connect a lashing belt to it.
  WARNING: To prevent shock hazards, be sure to wear protective gear.
  
  Fig 10: Identifying Carabiner Position
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Use mobile floor crane (A) to lift up rear module stack (1).
  WARNING: To prevent shock hazards, be sure to wear protective gear.
  
  Fig 11: Lifting Rear Module Stack Using Mobile Floor Crane
  Courtesy of NISSAN MOTOR CO., U.S.A.
  
  CAUTION: Do not move engine crane while rear module stack is hoisted up.
3. Move the battery pack and place work bench underneath rear module stack.
  WARNING: To prevent shock hazards, be sure to wear protective gear.
  
  CAUTION: Place removed battery pack upper case onto battery pack for storage.
4. Place rear module stack onto work bench.
  WARNING:
  - To prevent shock hazards, be sure to wear protective gear.
  - Be sure to place an insulating rubber sheet on the work bench.
Remove harness bracket (1) from rear module stack.
WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.

Fig 12: Identifying Harness Bracket On Rear Module Stack
Courtesy of NISSAN MOTOR CO., U.S.A.
Follow the procedure below and remove bus bars from rear module stack.
1. Remove central bus bar cover and remove module terminal mounting bolts (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.
  Fig 13: Identifying Module Terminal Mounting Bolts (Central Bus Bar Cover)
  Courtesy of NISSAN MOTOR CO., U.S.A.
  
  CAUTION: Remove all bus bar covers at the same time, and do not remove module terminal mounting bolts.
2. Remove right-side bus bar cover and remove module terminal mounting bolts (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.
  Fig 14: Identifying Module Terminal Mounting Bolts (Right-Side Bus Bar Cover)
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Remove left-side bus bar cover and remove module terminal mounting bolts (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.
  Fig 15: Identifying Module Terminal Mounting Bolts (Left-Side Bus Bar Cover)
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Remove voltage detection terminal mounting screws (A), and then remove bus bar from rear module stack.
  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 16: Identifying Voltage Detection Terminal Mounting Screws
  Courtesy of NISSAN MOTOR CO., U.S.A.
5. Attach module terminal covers [SST: KV99111500] (A) to all module terminals.
  WARNING: To prevent shock hazards, be sure to wear protective gear.
  
  Fig 17: Identifying Terminal Covers (KV99111500)
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove battery temperature sensor (1) from rear module stack.
WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.

Fig 18: Identifying Battery Temperature Sensor On Rear Module Stack
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove front stack member (1).
WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.

Fig 19: Identifying Front Stack Member
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove rear stack member (1).
WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.

Fig 20: Identifying Rear Stack Member
Courtesy of NISSAN MOTOR CO., U.S.A.
Use lashing belt (A) to fix rear module stack (1) in place.
WARNING: To prevent shock hazards, be sure to wear protective gear.

Fig 21: Identifying Rear Module Stack And Lashing Belt
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove through bolt nut (A) and disassemble rear module stack (1).
WARNING: To prevent shock hazards, be sure to put on insulated protective gear and use insulated tools.

Fig 22: Identifying Rear Module Stack And Through Bolt Nut
Courtesy of NISSAN MOTOR CO., U.S.A.

NOTE: When through bolt is removed, the spacer between the modules will fall out and it will be difficult to return it to its original position. Therefore pull the through bolt out only to the position necessary for the module that will be removed.