Watch as an entire 2011 Nissan LEAF battery is assembled starting with an empty battery case and ending with a fully functional battery. This is one of the most controversial electric vehicle battery designs due to the lack of an active cooling system. See the parts that affect the battery cooling ability

Thank you to GreenTec Auto Hybrid Batteries for providing the battery for this video. Visit https://greentecauto.com/weberauto for your hybrid and EV battery needs.

TIMELINE:
0:00 Introduction
0:37 Thank you for providing battery
1:48 Battery Modules
2:36 MUST SEE: See inside a battery module
9:15 MUST SEE: Comparison of Li-Ion pouch sizes
13:40 Module voltage measurements
15:55 See the three battery stacks of the LEAF battery
16:30 See the series circuit order of the 48 modules
21:30 MUST SEE: The module spacers to allow thermal conduction and convection with the battery tray (Passive Cooling)
24:26 Module physical alignment requirements
26:30 Bolt torque dilemma
28:50 See the module polarity stacking requirements
29:25 See the module stack bus bars
30:19 See the module voltage sensing wiring
30:50 Installation and torque of the bus bars
37:06 Battery stack voltage measurements
46:30 See the installation and weight of the three battery module stacks into the empty battery tray
55:18 Installing and torquing the battery module stack bolts
56:55 See the battery heater system brackets
1:00:40 Battery heater (Electrolyte freeze prevention) operation
1:02:00 MUST SEE: Battery heater disassembly
1:05:46 See the installation of the battery heater wiring harness 6
1:09:50 Structural Support Beam installation
1:11:10 Harness bracket and junction block bracket installation
1:12:15 Installation of the 4 battery temperature sensors
1:13:45 Battery heater controller installation
1:15:18 MUST SEE: Battery junction block demonstration and installation
1:18:45 Low voltage harness and cell voltage monitoring harness installation
1:20:56 Front electrical connector installation
1:24:10 High voltage connections and Personal Protective Equipment (PPE)
1:28:18 Module cell voltage sensing line connections
1:28:56 Installation of high current, high voltage internal cables
1:30:28 Service disconnect lever connector installation
1:31:45 Service disconnect lever (with its 225A 450V Fuse) information
1:34:42 Service disconnect lever connector interlock circuit connection
1:36:20 Installation of high current, high voltage internal bus bars
1:39:10 Lithium-Ion Battery Computer (LBC) installation and precautions
1:41:00 Digital Multimeter qualification precautions
1:44:10 MUST SEE: Demonstration of service disconnector lever and contractor function
1:48:00 MUST SEE: Battery housing air leak check port and procedure
1:50:50 Video summary

CORRECTION:
When removing the service disconnect lever, the battery is divided into two 180 Volt sections. The service disconnect lever separates the rear module stack from the front side stacks.

ABOUT US:
Weber State University (WSU) - Department of Automotive Technology - Ardell Brown Technology Wing - Transmission Lab. This episode covers the reassembly of the 24kWh 360.0 volt 60 Ah battery from a 2011 Nissan LEAF EV. The components and their operation are similar to many other electric vehicles.

WSU is a leader in Hybrid and Electric Vehicle education. This topic is taught as part of our 4-year bachelor's degree program. For information on joining the Weber Automotive program, visit: http://www.weber.edu/automotive

This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see http://www.weber.edu/automotive/J_Kel...

ADDITIONAL TRAINING FOR YOU
Join us for hybrid and electric vehicle training with two online courses and in a 5-day on-campus boot camp with Professor John D. Kelly. See http://www.weber.edu/evtraining

DONATE TO OUR DEPARTMENT
Please consider a donation to the Department of Automotive Technology at Weber State University here: http://advancement.weber.edu/Automotive