Nissan Ariya: Disassembly and Assembly

Nissan Ariya (FE0) 2023-2025 Service & Repair Manual / Electric Power Train / Ev Battery System :: 66kwh Li-Ion Battery / Disassembly and Assembly

Li-Ion Battery Heater
Battery Pack Upper Case
Battery Pack Lower Case
Service Plug Bracket
Li-Ion Battery Controller
Busbar
Battery Junction Box and Battery Harness
Front Module Stack
Rear Module Stack

Battery Pack Upper Case

Exploded View

	Resin retainer	Resin retainer	Resin retainer
	Retainer	Resin retainer	Resin retainer
	Resin retainer	Retainer	Resin retainer
	Resin retainer	Resin retainer	Retainer
	Retainer	Service plug retainer	Battery pack upper case
	Seal	Battery pack lower case	Service plug
	: Comply with the assembly procedure when tightening. Refer to Removal & Installation.
	: Nissan Ariya Vehicle front
	: Always replace after every disassembly.
	: N·m (kg-m, in-lb)
,,,,,,,: Indicates that the part is connected at points with same symbol in actual Nissan Ariya vehicle.

Battery pack upper case	Heat shield sheet	Heat shield sheet
Heat shield sheet
: Nissan Ariya Vehicle front
: Always replace after every disassembly

Removal & Installation

DANGER:

Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and Nissan Ariya vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.

WARNING:

Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other container so that another person does not accidentally connect it while work is in progress.

Be sure to put on insulating protective gear before beginning work on the high voltage system.

Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the Nissan Ariya vehicle. When not working, cover high voltage components with an anti-static cover sheet or similar item to prevent contact with other persons. Refer to PRECAUTIONS FOR HIGH VOLTAGE : Precautions.

If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for preventing electric shock, fire, and damage to parts.

CAUTION:

There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the Nissan Ariya vehicle to READY status unless instructed to do so in the Service Manual.

ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK

Must be an indoor environment.

The environment must utilize a shutter or other means to shut out the outside environment and prevent rain, snow, dust, or other substances from entering.
The environment must not cause the intrusion of sweat during work, or cause condensation to occur due to high temperature or humidity.

Metal powder, grease, and other foreign substances must not enter.

The indoor environment must also prevent metal powder, grease, and other foreign substances from entering due to maintenance performed on other Nissan Ariya vehicles and other sources during disassembly work.
During disassembly without internal work, temporarily close the battery pack upper case or cover it with an insulating cover.

The floor must be dry.

The floor must not be wet as a result of factors such as Nissan Ariya vehicle entry during rain or snow.

Work space

The work space must be approximately the size of one entire Nissan Ariya vehicle.
Take appropriate countermeasures so that persons other than the operator do not enter the work space, such as by placing signs indicating that disassembly work is in progress.

Standard fire fighting equipment

Always place a standard fire fighting equipment in the disassembly work area.
Depending on type of fire (Nissan Ariya vehicle or battery) use standard fire fighting equipment (water or extinguisher).

REMOVAL

Remove tightening bolts of battery heater bracket from battery pack lower case.

WARNING:

To prevent electric shock, wear insulated protective gear.

Remove left and right retainers.

NOTE:

The figure shows the left side.

Remove bolts for each retainer in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Remove left and right resin retainers in the order of 3→2→1

: Nissan Ariya Vehicle

NOTE:

The figure shows the left side.

Remove bolts for each resin retainer in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Remove retainer .

: Nissan Ariya Vehicle

NOTE:

Remove bolts for each resin retainer in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Remove resin retainers in the order of 3→2→1.

: Nissan Ariya Vehicle

NOTE:

Remove bolts for each resin retainer in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Remove retainer .

: Nissan Ariya Vehicle

NOTE:

Remove bolts in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Remove service retainer .

: Nissan Ariya Vehicle

NOTE:

Remove bolts in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Remove bolt .

WARNING:

To prevent electric shock, wear insulated protective gear.

Hold both sides of the battery pack upper case to remove it.

NOTE:

The distance between the holding points is 1.2 m (3.93 ft) approx.

WARNING:

To prevent electric shock, wear insulated protective gear.

Remove seal from battery pack lower case.

WARNING:

To prevent electric shock, wear insulated protective gear.

INSTALLATION

Check that heat shield sheet is still stuck back of battery upper case.

When the sheet is peeled or battery pack upper case is replaced, stick new heat shield sheet according to the following procedure.

Place the battery pack upper case on a pre-cured area so that the outside of the battery pack upper case is not damaged Wipe the surface of the battery pack upper case where the heat shield sheet are stuck with a dry cloth to remove oil and dust. If the temperature of the work space is 15 ℃ (59 °F)or less, heat the surface of the battery pack upper case where heat shield sheet are stuck to 15 - 50 ℃ (59 - 112 °F)with a heat gun or equivalent.

CAUTION:

Work on carton box to prevent the warmed heat from escaping.

For the battery pack upper case, warm the surface where the heat shield sheet are stuck for at least 5 minutes so that the entire surface is at least 15 ℃ (59 °F).
Remove the release paper from the heat shield sheet, and then heat the side stuck to battery pack upper case for at least 1 minute so that its temperature is 15 ℃ (59 °F)or higher.

Stick the heat shield sheet

to the battery pack upper case as shown in the figure.

Position mark (Projection)

NOTE:

Stick the heat shield sheet that hides the inner position mark where two position marks are lined up.

Part does not have any problem even if it gets wrinkled when sticking the heat shield sheet.

After sticking the heat shield sheet, press the whole by hands.

Install seal to battery pack lower case.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

The flat side of seal faces battery pack lower case.

Install guide pin [SST: KV99119600 (J-53348)](A) to the center of battery pack lower case.

	: Nissan Ariya Vehicle rear side
	: Vehicle front side

WARNING:

To prevent electric shock, wear insulated protective gear.

Hold both sides of battery pack upper case and install it.

NOTE:

The distance between the holding points is 1.2 m (3.93 ft) approx.

WARNING:

To prevent electric shock, wear insulated protective gear.

Tighten bolts .

	: Nissan Ariya Vehicle
	: 11.1 N.m (1.1 ㎏-m, 8 ft-lb)

WARNING:

To prevent electric shock, wear insulated protective gear.

Install retainer.

	: Nissan Ariya Vehicle
	: 8.0 N.m (0.82 ㎏-m, 71 in-lb)

NOTE:

Tighten bolts in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Install service retainer .

	: Nissan Ariya Vehicle
	: 8.0 N.m (0.82 ㎏-m, 71 in-lb)

NOTE:

Tighten bolts in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Tighten bolt.

	: Nissan Ariya Vehicle
	: 8.0 N.m (0.82 ㎏-m, 71 in-lb)

WARNING:

To prevent electric shock, wear insulated protective gear.

Install resin retainers in the order of 1→2→3.

	: Nissan Ariya Vehicle
	: 8.0 N.m (0.82 ㎏-m, 71 in-lb)

NOTE:

Tighten bolts of each resin retainer in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Install retainer .

	: Nissan Ariya Vehicle
,	: 11.1 N.m (1.1 ㎏-m, 8 ft-lb)
	: 8.0 N.m (0.82 ㎏-m, 71 in-lb)

NOTE:

Tighten bolts in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Install left and right resin retainers in the order of 1→2→3.

	: Nissan Ariya Vehicle
	: 8.0 N.m (0.82 ㎏-m, 71 in-lb)

NOTE:

The figure shows the left side.

Tighten bolts for each resin retainer in the order of →→.

WARNING:

To prevent electric shock, wear insulated protective gear.

Install left and right retainers .

NOTE:

The figure shows the left side.

Tighten bolts for each retainer in the order of →→.

, : 11.1 N.m (1.1 ㎏-m, 8 ft-lb)

: 8.0 N.m (0.82 ㎏-m, 71 in-lb)

WARNING:

To prevent electric shock, wear insulated protective gear.

Install battery heater bracket to battery lower case. Refer to Exploded View.

WARNING:

To prevent electric shock, wear insulated protective gear.

Inspection

APPEARANCE CHECK

Check resin retainer for damage.

: Vehicle

CAUTION:

When resin retainer is damaged, remove battery upper case and check that no water is entering in the case.

AIR LEAK INSPECTION

Remove breather and install adapter (A) of air leak tester [SST: KV99112400 (J-53357)].

WARNING:

To prevent electric shock, wear insulated protective gear.

NOTE:

Tighten wing nut by turning 6 to 8 times.

Install gauge (A) of air leak tester [SST: KV99111400 (-)].

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

The gauge is a precision instrument. Be careful not to drop it when handling it.

Install service plug. Refer to HOW TO DISCONNECT HIGH VOLTAGE : Precautions.DANGER:

To prevent electric shock, wear insulated protective gear.

NOTE:

Because the service plug location is open, install the service plug for sealing the case.

Blocks high power connector and Nissan Ariya vehicle communications harness connector with vinyl tape or equivalent for preventing air leakage from connection area.

Use wide vinyl tape that is capable of covering all of the high power connector and Nissan Ariya vehicle communications harness connector with one strip.
Apply carefully so that no wrinkles in the tape occur.

WARNING:

To prevent electric shock, wear insulated protective gear.

Block breather with vinyl tape prevent air from leaking.

Apply carefully so that no wrinkles in the tape occur.

WARNING:

To prevent electric shock, wear insulated protective gear.

Perform battery case pressure test according to the following procedure.

WARNING:

To prevent electric shock, wear insulated protective gear.

Open cock

of air leak tester.

CAUTION:

Do not operate the pump before opening the cock of air leak tester. Doing so may damage the gauge. If the pump is operated before the cock is opened, first disconnect the air pump hose to release the pressure.

Operate the air pump slowly and apply the specified test pressure in the battery pack. If the gauge pressure does not rise, or if the gauge reading fluctuates, check for the location air leakage.

Specified test pressure

: 1.6 kPa (0.016 bar, 0.0163 kg/cm², 0.232 psi)

CAUTION:

Operate the air pump carefully when applying pressure. If pressure is applied suddenly to the gauge, the gauge may be damaged.

Do not apply pressure of 2.0 kPa (0.02 bar, 0.0204 kg/cm², 0.29 psi) or more to the battery case or air leak tester.

Close the cock and wait for 1 minute. Check that the air leak tester reading remains at or above the limit value.

Repair limit

: 1.4 kPa (0.014 bar, 0.0142 kg/cm², 0.203 psi)

If the pressure is below the limit value, check for the locations of air leakage.

NOTE:

Check for air leakage from the sound of air escaping when pressure is applied.

ELECTRIC EQUIPOTENTIAL TEST

After assembling Li-ion battery pack, remove the battery pack upper case ground bolt , then measure the resistance between the side of battery pack lower case and the seating surface of ground bolt (location of coating peeling) .

WARNING:

To prevent electric shock, wear insulated protective gear.

Specified value

: Less than 0.1 Ω

If the result deviates from the specified value, check the following and repair the malfunction parts.

Ground bolt connection condition
Corrosion on ground bolt mounting surface
Adhesion of paint, oil, dirt, or other substance on ground bolt mounting surface

After assembling Li-ion battery pack, remove the retainer ground bolt , then measure the resistance between the side of battery pack lower case and the seating surface of ground bolt (location of coating peeling) .

WARNING:

To prevent electric shock, wear insulated protective gear.

Specified value

: Less than 0.1 Ω

If the result deviates from the specified value, check the following and repair the malfunction parts.

Ground bolt connection condition
Corrosion on ground bolt mounting surface
Adhesion of paint, oil, dirt, or other substance on ground bolt mounting surface.

NOTE:

The figure shows retainer of left side.

Since retainers are symmetrical parts, do the same for the right retainer.

After assembling Li-ion battery pack, remove the rear retainer ground bolt , then measure the resistance between the side of battery pack lower case and the seating surface of ground bolt (location of coating peeling) .

: Nissan Ariya Vehicle

WARNING:

To prevent electric shock, wear insulated protective gear.

Specified value

: Less than 0.1 Ω

If the result deviates from the specified value, check the following and repair the malfunction parts.

Ground bolt connection condition
Corrosion on ground bolt mounting surface
Adhesion of paint, oil, dirt, or other substance on ground bolt mounting surface.

Service Plug Bracket

Exploded View

REMOVAL

Seal	Bracket	Service plug bracket
Seal	Busbar 8	Busbar 13
Breather
: Nissan Ariya Vehicle front
: Always replace after every disassembly.
: N·m (kg-m, in-lb)

DISASSEMBLY

Service plug bracket	Service plug switch	Engagement detection switch (service plug) harness
Busbar 11	Busbar 10	Busbar 12
Busbar 9
: Always replace after every disassembly.
: N·m (kg-m, in-lb)

Disassembly & Assembly

DANGER:

Because hybrid vehicles and electric vehicles contain a high voltage battery, there is a risk of electric shock, electric leakage, or similar accidents if the Nissan Ariya vehicle is handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.

WARNING:

Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other container so that another person does not accidentally connect it while work is in progress.

Be sure to put on insulating protective gear before beginning work on the high voltage system.

Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the Nissan Ariya vehicle. When not working, cover high voltage components with an anti-static cover sheet or similar item to prevent contact with other persons.

Refer to PRECAUTIONS FOR HIGH VOLTAGE : Precautions.

If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for preventing electric shock, fire, and damage to parts.

CAUTION:

ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK

Must be an indoor environment.

The environment must utilize a shutter or other means to shut out the outside environment and prevent rain, snow, dust, or other substances from entering.
The environment must not cause the intrusion of sweat during work, or cause condensation to occur due to high temperature or humidity.

Metal powder, grease, and other foreign substances must not enter.

The indoor environment must also prevent metal powder, grease, and other foreign substances from entering due to maintenance performed on other Nissan Ariya vehicles and other sources during disassembly work.
During disassembly without internal work, temporarily close the battery pack upper case or cover it with an insulating cover.

The floor must be dry.

The floor must not be wet as a result of factors such as Nissan Ariya vehicle entry during rain or snow.

Work space

The work space must be approximately the size of one entire Nissan Ariya vehicle.
Take appropriate countermeasures so that persons other than the operator do not enter the work space, such as by placing signs indicating that disassembly work is in progress.

Standard fire fighting equipment

Always place a standard fire fighting equipment in the disassembly work area.
Depending on type of fire (Nissan Ariya vehicle or battery) use standard fire fighting equipment (water or extinguisher).

Disassembly

Remove busbar 8 and busbar 13 .

	: Nut
	: Bolt

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove interlock detecting switch (Service plug) harness connector .

WARNING:

To prevent electric shock, wear insulated protective gear.

Remove nuts of busbar 9 and busbar 12 .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove service plug bracket .

: Nuts

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove seal from service plug.

Remove busbar 9 and busbar 12 from service plug.

: Bolts

Remove bolts .

: Service plug

Remove service plug from service plug bracket .

Remove interlock detecting switch (Service plug) harness , busbar 10 and busbar 11 from service plug .

: Bolts

Assembly

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

Li-Ion Battery Controller

Exploded View

	Li-ion battery controller		Cell controller		Controller mounting plate
	: N·m (kg-m, in-lb)

Removal & Installation

DANGER:

WARNING:

Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other container so that another person does not accidentally connect it while work is in progress.

Be sure to put on insulating protective gear before beginning work on the high voltage system.

Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the Nissan Ariya vehicle. When not working, cover high voltage components with an anti-static cover sheet or similar item to prevent contact with other persons.

Refer to PRECAUTIONS FOR HIGH VOLTAGE : Precautions.

If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for preventing electric shock, fire, and damage to parts.

CAUTION:

ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK

Must be an indoor environment.

The environment must utilize a shutter or other means to shut out the outside environment and prevent rain, snow, dust, or other substances from entering.
The environment must not cause the intrusion of sweat during work, or cause condensation to occur due to high temperature or humidity.

Metal powder, grease, and other foreign substances must not enter.

The indoor environment must also prevent metal powder, grease, and other foreign substances from entering due to maintenance performed on other Nissan Ariya vehicles and other sources during disassembly work.
During disassembly without internal work, temporarily close the battery pack upper case or cover it with an insulating cover.

The floor must be dry.

The floor must not be wet as a result of factors such as Nissan Ariya vehicle entry during rain or snow.

Work space

The work space must be approximately the size of one entire Nissan Ariya vehicle.
Take appropriate countermeasures so that persons other than the operator do not enter the work space, such as by placing signs indicating that disassembly work is in progress.

Standard fire fighting equipment

Always place a standard fire fighting equipment in the disassembly work area.
Depending on type of fire (Nissan Ariya vehicle or battery) use standard fire fighting equipment (water or extinguisher).

LI-ION BATTERY CONTROLLER

Disassembly

CAUTION:

When replace Li-ion battery controller, perform necessary work according to the procedure of "SERVICE WHEN REPLACING LI-ION BATTERY PARTS". Refer to Work Item List.

Remove battery pack upper case. Refer to Removal & Installation.

Remove busbar 8 and busbar 13 .

	: Nuts
	: Bolts

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove harness connectors from Li-ion battery controller.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connectors with insulating tape.

Remove Li-ion battery controller .

: Nuts

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Assembly

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

CELL CONTROLLER

DISASSEMBLY

Remove harness connector from cell controller .

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connectors with insulating tape.

Remove cell controller by pressing part of controller mounting plate.

: Direction of removal

WARNING:

To prevent electric shock, wear insulated protective gear.

NOTE:

Do not press strong because part of cell controller mounting plate is soft.

Assembly

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
There two types of cell controller harnesses for high voltage and low voltage. When inserting high voltage harness connector to low voltage system, it may cause fire or damage parts. Carefully avoid mistake when inserting connectors.

CAUTION:

If cell controller moves erratically, lift part of cell controller mounting plate and then fixed properly.

CONTROLLER MOUNTING PLATE

DISASSEMBLY

Remove service plug bracket. Refer to Disassembly & Assembly.

Remove harness connector and ground nut .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Remove high voltage harnesses.

	: Harness connector
	: Ground nut
	: Clamp

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Remove controller mounting plate .

: Nut

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

If necessary, remove Li-ion battery controller, cell controller and harnesses.

ASSEMBLY

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

Battery Junction Box and Battery Harness

Exploded View

BATTERY JUNCTION BOX

	Nut cap	Busbar 1	Busbar 20
	Battery junction box	Battery pack pressure sensor	Bracket
	High-voltage harness connector	High-voltage harness connector	Battery pack water temperature sensor
	: N·m (kg-m, in-lb)
,: Indicates that the part is connected at points with same symbol in actual Nissan Ariya vehicle.

BATTERY HARNESS

	Bracket	Clip	Nissan Ariya Vehicle communication harness
	Vehicle communication harness (battery PTC)	Busbar terminal block	Cell voltage detection harness
	: N·m (kg-m, in-lb)
	: N·m (kg-m, ft-lb)
,: Indicates that the part is connected at points with same symbol in actual Nissan Ariya vehicle.

Disassembly & Assembly

DANGER:

WARNING:

Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other container so that another person does not accidentally connect it while work is in progress.

Be sure to put on insulating protective gear before beginning work on the high voltage system.

Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the Nissan Ariya vehicle. When not working, cover high voltage components with an anti-static cover sheet or similar item to prevent contact with other persons.

Refer to PRECAUTIONS FOR HIGH VOLTAGE : Precautions.

If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for preventing electric shock, fire, and damage to parts.

CAUTION:

ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK

Must be an indoor environment.

The environment must utilize a shutter or other means to shut out the outside environment and prevent rain, snow, dust, or other substances from entering.
The environment must not cause the intrusion of sweat during work, or cause condensation to occur due to high temperature or humidity.

Metal powder, grease, and other foreign substances must not enter.

The indoor environment must also prevent metal powder, grease, and other foreign substances from entering due to maintenance performed on other Nissan Ariya vehicles and other sources during disassembly work.
During disassembly without internal work, temporarily close the battery pack upper case or cover it with an insulating cover.

The floor must be dry.

The floor must not be wet as a result of factors such as Nissan Ariya vehicle entry during rain or snow.

Work space

The work space must be approximately the size of one entire Nissan Ariya vehicle.
Take appropriate countermeasures so that persons other than the operator do not enter the work space, such as by placing signs indicating that disassembly work is in progress.

Standard fire fighting equipment

Always place a standard fire fighting equipment in the disassembly work area.
Depending on type of fire (Nissan Ariya vehicle or battery) use standard fire fighting equipment (water or extinguisher).

VEHICLE COMMUNICATION HARNESS

DISASSEMBLY

Remove service plug bracket assembly. Refer to Disassembly & Assembly.

Remove controller mounting plate. Refer to Removal & Installation.

Remove busbar. Refer to Disassembly & Assembly.

Remove battery junction box.

Remove harness connector from module.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

NOTE:

Remove from each module.

Harness connector lock is located on the bottom.

Remove bolts and then remove brackets.

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove bolts .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Open busbar terminal table and then remove nut .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove connectors , and .

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Remove Nissan Ariya vehicle communication harness from battery pack lower case.

WARNING:

To prevent electric shock, wear insulated protective gear.

If necessary, Remove bracket from Nissan Ariya vehicle communication harness.

ASSEMBLY

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

HIGH-VOLTAGE HARNESS CONNECTOR

DISASSEMBLY

Remove interlock detecting harness connector .

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Open cap and then remove bolt .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove bolts and then remove high-voltage harness connector .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove another high-voltage harness connector in the same way.

NOTE:

Busbar 20 has two claws on a cap.

Assembly.

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

BUABAR 1 AND BUSBAR 20

DISASSEMBLY

Remove high-voltage harness connector.

Remove nut cap

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove bolt and then remove busbar 1 .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove busbar 20 in the same way.

Assembly.

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

BATTERY JUNCTION BOX

DISASSEMBLY

Remove high-voltage harness connector.

Remove busbar 1 and busbar 20.

Remove busbar 2 and busbar 19. Refer to Disassembly & Assembly.

Remove clip and then push Nissan Ariya vehicle communication harness connector in the battery pack lower case.

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Remove bolts .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove harness connector of battery pack pressure sensor and harness connector of battery pack water temperature sensor.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Remove harness connector of battery pack pressure sensor.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Remove connector harness of Nissan Ariya vehicle communication harness.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Remove nuts of battery junction box

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Lift battery junction box and release claws on upper cover of battery junction box.

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove harness clips from battery junction box.

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Assembly

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

Install upper cover to battery junction box .

Install battery junction box to battery pack lower case.

BATTERY PACK PRESSURE SENSOR

DISASSEMBLY

Remove harness connector of battery pack pressure sensor.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Remove bolt and then remove battery pack pressure sensor .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove left battery pack pressure sensor in the same way.

ASSEMBLY

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

BATTERY PACK WATER TEMPERATURE SENSOR

DISASSEMBLY

Disconnect harness connector of battery pack water temperature sensor and battery pack pressure sensor.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

Remove nut and then remove battery pack pressure sensor .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

NOTE:

The figure shows the state that battery pack pressure sensor is removed.

ASSEMBLY

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

Front Module Stack

Exploded View

	Bracket	Bracket	Bracket
	Module No.12(MD12)	Module No.11(MD11)	Module No.10(MD10)
	Module No.9(MD9)	Bracket	Module No.4(MD4)
	Module No.3(MD3)	Module No.2(MD2)	Module No.1(MD1)
	: Comply with the assembly procedure when installing. Refer to Disassembly & Assembly.
	: N·m (kg-m, ft-lb)
,,: Indicates that the part is connected at points with same symbol in actual Nissan Ariya vehicle.

Disassembly & Assembly

DANGER:

WARNING:

CAUTION:

ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK

Must be an indoor environment.

The environment must utilize a shutter or other means to shut out the outside environment and prevent rain, snow, dust, or other substances from entering.
The environment must not cause the intrusion of sweat during work, or cause condensation to occur due to high temperature or humidity.

Metal powder, grease, and other foreign substances must not enter.

The indoor environment must also prevent metal powder, grease, and other foreign substances from entering due to maintenance performed on other Nissan Ariya vehicles and other sources during disassembly work.
During disassembly without internal work, temporarily close the battery pack upper case or cover it with an insulating cover.

The floor must be dry.

The floor must not be wet as a result of factors such as Nissan Ariya vehicle entry during rain or snow.

Work space

The work space must be approximately the size of one entire Nissan Ariya vehicle.
Take appropriate countermeasures so that persons other than the operator do not enter the work space, such as by placing signs indicating that disassembly work is in progress.

Standard fire fighting equipment

Always place a standard fire fighting equipment in the disassembly work area.
Depending on type of fire (Nissan Ariya vehicle or battery) use standard fire fighting equipment (water or extinguisher).

DISASSEMBLY

Remove service plug bracket assembly. [module No. 4 (MD4) and module No. 9 (MD9) only] Refer to Disassembly & Assembly.

Remove controller mounting plate. [module No. 4 (MD4) and module No. 9 (MD9) only] Refer to Removal & Installation.

Remove busbar. Refer to Disassembly & Assembly.

Remove harness connector from module.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

NOTE:

Lock of harness connector is located lower side.

Remove bolt and then remove bracket .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

NOTE:

The bracket is located beside the module.

Remove bracket bolts that contact to the module to be removed.

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove bolt and then remove bracket .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

NOTE:

The figure shows left bracket.

When removing module 12 (MD12) from module 9 (MD9), remove right bracket.

Remove bolt . [module No.1 (MD1) or module No.12 (MD12) only]

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

NOTE:

The figure shows module No.1 (MD1).

Remove bolt . [module No.4 (MD4) or module No.9 (MD9) only]

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

NOTE:

The figure shows module No.4 (MD4).

Hang carabiners (service part: 299A3 5MP0A) in the lifting holes and install belt slinger.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Install carabiners in the lifting holes on the opposite side part of the terminal.

NOTE:

Carabiners (service part: 299A3 5MP0A) are packed with new module.

Install temporarily module mounting bolt to terminal side by screwing several rotations.

WARNING:

To prevent electric shock, wear insulated protective gear.

NOTE:

To prevent movement when removing the module.

Leave a gap between the bolt head and the module.

Lifting load is applied to the module using the mobile floor crane (A).

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

If too much load is applied, the shock when it comes off is large. so carefully apply the load.

Battery pack is not lifted up by the load.

NOTE:

lifting load must be within 100kgf approximately.

The figure shows module No. 10 (MD10).

Drive resin scraper (service parts: 299A3 5MP0A) (A) in gap filler with a resin hammer and pry left and right to peel the adhesion of gap filler.

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Do not use metal bar, etc., it may cause electric shock, damage to floor surface due to battery pack, damage to module, and liquid leakage.

CAUTION:

Insert one with the thinner tip of resin scraper (service part: 299A3 5MP0A) (C) between the module end plate and the cross member of battery pack lower case.

Never pry except module end plate to prevent module from damaging, deforming and leaking liquid.

Never remove 2 modules or more to prevent battery pack from weight unbalance except replacement work of battery pack lower case.

NOTE:

Modules are in close contact with gap filler applied to battery pack lower case.

It can be peeled off from gap filler by sliding module sideways.

Since adhesive strength of gap filler is weakened, the part that was peeled off once is not re-bonded.

Remove module that was temporarily installed to terminal side.

WARNING:

To prevent electric shock, wear insulated protective gear.

NOTE:

When module is lifted up, load the module on battery pack lower case by lowering mobile floor crane .

Hang carabiners (service part: 299A3 5MP0A) in the lifting holes and install belt slinger.

WARNING:

To prevent electric shock, wear insulated protective gear.

NOTE:

Carabiners (service part: 299A3 5MP0A) are packed with new module.

Remove module from battery lower case by lifting up 4 points of module with mobile floor crane.

WARNING:

To prevent electric shock, wear insulated protective gear.

Peel off gap filler from battery pack lower case.

WARNING:

To prevent electric shock, wear insulated protective gear.

NOTE:

Gap filler can be peeled off with hands.

If it is not peeled off with hands, use resin scraper without damaging battery lower case.

ASSEMBLY

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

Check battery pack lower case inside for foreign material or peeled gap filler

Set gabari sheet to battery pack lower case as shown in the figure and then write lines on battery pack lower case with oil-based pen.

CAUTION:

Use a pen that does not have a thickness like paint.

Place gabari sheet in close contact with module mounting bracket and center it..

NOTE:

Size of gabari sheet is shown in the figure.

Cut the static mixer at the position shown in the figure.

After taking out cartridge from packing box, check the followings;

No evidence of liquid leakage in the packing box.
No liquid leakage from bottom of cartridge .

CAUTION:

If leakage is found, gap filler is separated. Prepare a replacement [Battery Gap Filler Kit (Service Part: B9522 5MP0A)] without using it.

Check carefully for leakage because liquid is colorless.

Set static mixer to cartridge.

Set cartridge to the gap filler gun [SST: BP2000400Z (J-53350)].

Attach guideline label to cartridge as shown in the figure.

CAUTION:

Since guideline labels are depending on specification of battery and attached positions, select and attach specified one.

Guideline label

:C-108ml

Apply gap filler in accordance with lines written on the battery pack lower case.

CAUTION:

Apply one row using one scale on cartridge. (If there is surplus, add it to a place with less amount.)

If gap filler is applied thicker than the width of the lines, the amount will be short, so be careful.

When applying gap filler, if the coating bead contains colorless liquid , stop to use it because gap filler is separated and prepare a replacement [Battery Gap Filler Kit (service part: B9522 5MP0A)].

The process from the start of gap filler application to the completion of module installation (including tightening bolt ) must be within 1 hour.

NOTE:

One cartridge can be applied for just one module.

Install locate pin [SST: KV99119700 (J-53349)] to battery pack lower case.

Install module in the reverse order of removal.

NOTE:

When installing module mounting bolts, remove locate pin [SST: KV99119700 (J-53349)].

Rear Module Stack

Exploded View

	Bracket	Bracket	Module No.7(MD7)
	Module No.8(MD8)	Module No.5(MD5)	Module No.6(MD6)
	Bracket	Bracket	Bracket
	Bracket	Bracket	Retainer
	: Comply with the assembly procedure when installing. Refer to Disassembly & Assembly.
	: N·m (kg-m, in-lb)
	: N·m (kg-m, ft-lb)
: Indicates that the part is connected at points with same symbol in actual Nissan Ariya vehicle.

Disassembly & Assembly

DANGER:

WARNING:

CAUTION:

ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK

Must be an indoor environment.

The environment must utilize a shutter or other means to shut out the outside environment and prevent rain, snow, dust, or other substances from entering.
The environment must not cause the intrusion of sweat during work, or cause condensation to occur due to high temperature or humidity.

Metal powder, grease, and other foreign substances must not enter.

The indoor environment must also prevent metal powder, grease, and other foreign substances from entering due to maintenance performed on other Nissan Ariya vehicles and other sources during disassembly work.
During disassembly without internal work, temporarily close the battery pack upper case or cover it with an insulating cover.

The floor must be dry.

The floor must not be wet as a result of factors such as Nissan Ariya vehicle entry during rain or snow.

Work space

The work space must be approximately the size of one entire Nissan Ariya vehicle.
Take appropriate countermeasures so that persons other than the operator do not enter the work space, such as by placing signs indicating that disassembly work is in progress.

Standard fire fighting equipment

Always place a standard fire fighting equipment in the disassembly work area.
Depending on type of fire (Nissan Ariya vehicle or battery) use standard fire fighting equipment (water or extinguisher).

DISASSEMBLY

Remove service plug bracket ASSY. Refer to Disassembly & Assembly.

Remove controller mounting plate. Refer to Removal & Installation.

Remove busbar. Refer to Disassembly & Assembly.

Remove harness connector from module.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Because there is the danger of electric shock, immediately insulate removed connector with insulating tape.

NOTE:

Lock of harness connector is located lower side.

Remove bracket bolts that contact to the module to be removed.

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

Remove bolt and then remove bracket .

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

NOTE:

The figure shows left bracket.

When removing module 7 (MD7) or module 8 (MD8), remove right bracket.

Remove bolt . [module No.6 (MD6) or module No.8 (MD8) only]

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

NOTE:

The figure shows module No.6 (MD6).

Tighten bolts temporarily.

WARNING:

To prevent electric shock, wear insulated protective gear and use insulated tools.

NOTE:

The figure shows module No.5 (MD5).

Tighten bolts to prevent gap filler from peeling from modules uninstalled.

Hang carabiners (service part: 299A3 5MP0A) in the lifting holes and install belt slinger.

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

Install carabiners in the lifting holes on the opposite side (B) part of the terminal.

NOTE:

Carabiners (service part: 299A3 5MP0A) are packed with new module.

Install temporarily module mounting bolt to terminal side by screwing several rotations.

WARNING:

To prevent electric shock, wear insulated protective gear.

NOTE:

To prevent movement when removing the module.

Leave a gap between the bolt head and the module.

Lifting load is applied to the module using the mobile floor crane (engine crane) (A).

WARNING:

To prevent electric shock, wear insulated protective gear.

CAUTION:

If too much load is applied, the shock when it comes off is large. so carefully apply the load.

Battery pack is not lifted up by the load.

NOTE:

lifting load must be within 100 kgf approximately.

The figure shows module No. 10 (MD10).

Pry resin scraper (service parts: 299A3 5MP0A) left and right to peel the adhesion of gap filler.

WARNING:

CAUTION:

Insert one with the thicker tip of resin scraper (service part: 299A3 5MP0A) (B) between the module end plate .

Never pry except module end plate to prevent module from damaging, deforming and leaking liquid.

Never remove 2 modules or more to prevent battery pack from weight unbalance except replacement work of battery pack lower case.

NOTE:

Remove module that was temporarily installed to terminal side.

NOTE:

When module is lifted up, load the module on battery pack lower case by lowering mobile floor crane

Hang carabiners (service part: 299A3 5MP0A) in the lifting holes and install belt slinger.

WARNING:

To prevent electric shock, wear insulated protective gear.

NOTE:

Carabiners (service part: 299A3 5MP0A) are packed with new module.

Remove module from battery lower case by lifting up 4 points of module with mobile floor crane.

WARNING:

To prevent electric shock, wear insulated protective gear.

Peel off gap filler from battery pack lower case.

WARNING:

To prevent electric shock, wear insulated protective gear.

NOTE:

Gap filler can be peeled off with hands.

If it is not peeled off with hands, use resin scraper without damaging battery lower case.

ASSEMBLY

Note the following items, and assemble in the reverse order of disassembly.

DANGER:

There is the danger of electric shock caused by contact with the terminals. Be sure to wear insulated protective gear and use insulated tools.
Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong terminal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

Check battery pack lower case inside for foreign material or peeled gap filler

Set gabari sheet to battery pack lower case as shown in the figure and then write lines on battery pack lower case with oil-based pen.

CAUTION:

Use a pen that does not have a thickness like paint.

Place gabari sheet in close contact with module mounting bracket and center it..

NOTE:

Size of gabari sheet is shown in the figure.

Cut the static mixer at the position shown in the figure.

After taking out cartridge from packing box, check the followings;

No evidence of liquid leakage in the packing box.
No liquid leakage from bottom of cartridge .

CAUTION:

If leakage is found, gap filler is separated. Prepare a replacement [Battery Gap Filler Kit (Service Part: B9522 5MP0A)] without using it.

Check carefully for leakage because liquid is colorless.

Set static mixer to cartridge.

Set cartridge to the gap filler gun [SST: BP2000400Z (J-53350)].

Attach guideline label to cartridge as shown in the figure.

CAUTION:

Since guideline labels are depending on specification of battery and attached positions, select and attach specified one.

Guideline label

: A-78 ml

Apply gap filler in accordance with lines written on the battery pack lower case.

CAUTION: