Removing a car battery, especially from an electric vehicle like the Nissan Leaf, might seem daunting, particularly without specialized tools like an auto lift. This guide provides a step-by-step approach to safely lifting out a Nissan Leaf battery at home using common tools and a focus on safety. It’s crucial to understand the risks involved, as these batteries operate at high voltage and are extremely heavy. Working with a high-voltage battery pack is dangerous and can be lethal if safety precautions are not strictly followed. This guide is based on practical experience and aims to help you perform this task carefully and methodically.
Before we begin, it’s vital to emphasize safety. The Nissan Leaf battery pack contains 400 volts and weighs approximately 600 lbs. Mishandling can result in severe electric shock or serious injury from the weight. If you are not comfortable working with high voltage systems and heavy components, seek professional assistance.
Here are the tools used in this process, focusing on readily available items rather than specialized equipment:
- Electrically Insulating Gloves (Class 0 – 500 volt): Absolutely essential for handling high voltage components safely.
- Jacks (Three Recommended): Ideally, a high-lift jack and two standard jacks. The high-lift jack provides greater range, but standard jacks can be supplemented with wood blocks.
- Jack Stands (Four): Crucial for safely supporting the vehicle while you work underneath.
- Wood Blocks: To extend the reach of standard jacks and provide stable support.
- Wrenches and Sockets (10mm, 16mm, 18mm): Standard metric sizes for removing bolts.
- Socket Wrench and Impact Driver (Optional but Recommended): An impact driver speeds up bolt removal, especially for larger bolts.
- Pry Bar: For removing plastic rivets and underbody panels.
- Goggles: Eye protection is a must when working under a car and removing plastic components.
- Leather Gloves: For general hand protection and grip.
- Electrical Tape: For insulating exposed high voltage connectors.
- Rubber Mallet: For gently tapping tools or components if needed.
- Needle Nose Pliers: Helpful for manipulating small clips and connectors.
Safety Procedures Before Starting:
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Service Disconnect: The first crucial step is to disconnect the service disconnect, located under the rear passenger footwells. This panel needs to be accessed and the disconnect removed.
- Wear your 500-volt insulating gloves.
- Locate the service disconnect panel and remove the 10mm bolts securing the metal cover.
- Carefully lift the service disconnect slightly at the back, press the catch, and rotate it to a vertical position before pulling it out. This action splits the battery into two roughly 200-volt sections and breaks the high-voltage circuit.
- After removal, immediately wrap the socket of the service disconnect with electrical tape to prevent accidental reconnection. Store the disconnect in your pocket to ensure it remains removed while you are working.
- Replace the cover and bolts on the service disconnect panel.
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10-Minute Wait Period: Crucially, wait at least 10 minutes after disconnecting the service disconnect before proceeding. This allows capacitors in the inverter to discharge, further reducing the risk of electric shock.
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12-Volt Accessory Battery Disconnection: Disconnect the connections to the 12-volt accessory battery. This step is intended to prevent the battery contactors from accidentally engaging and re-energizing the high-voltage system. Even when working with the 12V system after disconnecting the main battery, wearing your 500-volt gloves adds an extra layer of precaution.
Nissan Leaf Battery Pack Information (2013 Model):
- Dimensions: Approximately 60.91 inches long, 46.77 inches wide, and 10.39 inches tall (at the highest point).
- Weight: Around 606 lbs, with the weight distribution skewed towards the rear.
- Voltage: Nominally 393 volts (48 modules in series, each at 8.2 volts).
- Current: Fused at 250 amps.
Step-by-Step Battery Removal Process:
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Vehicle Lifting and Securing:
- Use your jacks to lift the Nissan Leaf and place it securely on jack stands. You will need approximately 15 inches of clearance beneath the vehicle’s sides to accommodate the battery and dollies.
- Ensure the jack stands are level and stable before proceeding. Never rely solely on jacks to support the vehicle while working underneath.
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Underbody Shield Removal:
- Locate and remove the plastic aerodynamic underbody shield. It usually comes in three sections.
- The front section covers wiring connections at the front of the battery.
- Use a 10mm wrench or socket to remove bolts and a pry bar to carefully detach plastic snap rivets. Wear goggles during this step as plastic shards can fly forcefully.
- For easier removal of plastic rivets, try using a small flat-head screwdriver to pull out the center pin before prying out the entire rivet.
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Disconnecting High Voltage Cables:
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Motor HV Cable: Locate the large orange cable leading to the motor.
- Remove the 10mm bolt securing the metal bracket holding the cable.
- Wearing your 500-volt gloves, disconnect the battery harness clamp. This typically involves pulling out a lock tab, pressing a release, and sliding back the collar to disconnect the connector from the battery.
- Immediately cover the battery-side connector with insulated electrical tape.
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Cabin Heater Harness: Disconnect the cabin heater harness from the battery.
- This connector usually has a locking tab that needs to be pulled back. Needle-nose pliers can be helpful for this step while wearing gloves.
- Cover the battery-side connector with electrical tape.
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CAN Bus Connector: Disconnect the CAN bus connector by turning the ring counterclockwise. It will back out as you turn. While taping this slippery connector may be difficult, try to cover the wire plug to keep out dust.
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Battery Mounting Bolt Removal:
- There are a total of 12 bolts securing the battery.
- Side Bolts: Three 18mm bolts on each side rail of the battery (six total). Loosen these with an impact driver or wrench but do not remove them completely yet. These will be the last bolts removed to secure the battery during lowering.
- Front and Rear Bolts: Remove two 18mm bolts at the front and four 16mm bolts at the rear of the battery that attach it to support brackets. These need to be fully removed while you are under the car.
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Positioning Jacks and Dollies:
- Position at least three jacks to support the battery. Two smaller jacks at the front sides and a larger jack in the center rear is a recommended configuration.
- Place wheeled dollies under the battery, aligned to receive the battery as it is lowered. Furniture dollies or wheel dollies rated for sufficient weight can be used.
- Ensure each jack is applying slight upward pressure to the battery, but be extremely careful not to lift the vehicle off the jack stands.
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Final Bolt Removal and Lowering:
- From outside the vehicle and not from underneath, remove the remaining six side bolts using your impact wrench or wrench.
- Gradually and carefully lower each jack in small increments, alternating between jacks to ensure even lowering of the battery onto the wheel dollies.
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Battery Extraction:
- Once the battery is fully resting on the dollies, ensure you have enough clearance to roll it out from under the car. You may need around 15.5 inches of clearance. If needed, carefully jack up the car slightly higher to gain additional room.
- Attach a rope or chain to a secure point on the battery frame and carefully pull the battery out from under the side of the vehicle.
Conclusion:
Removing a Nissan Leaf battery at home without an auto lift is achievable with careful planning, the right tools, and a strong emphasis on safety. This DIY approach utilizes common tools like jacks and dollies, making it accessible for those without specialized automotive equipment. However, remember that working with high-voltage systems is inherently dangerous. Always prioritize safety, take your time, and if you are ever unsure about a step, consult a qualified professional. This guide provides a detailed process, but practical experience and caution are paramount for a successful and safe battery removal.
