2011 Nissan LEAF Battery - Deep Dive

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 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: www.weber.edu/automotive
This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see 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 www.weber.edu/evtraining
DONATE TO OUR DEPARTMENT
Please consider a donation to the Department of Automotive Technology at Weber State University here: advancement.weber.edu/Automotive

[@bertcochran1770]

I almost feel guilty, getting this kind of education for free. From one of the best instructors I've ever seen.

[@jasonmosquera1751]

Absolutely! I went to his boot camp and he was amazing. Definitely one of the best instructors I’ve ever been around.

[@18890426]

@@jasonmosquera1751 how can I apply?

[@nhatauto159]

I agree. GOD bless him

[@TheDisgruntledMechanic]

Never thought I would be so interested to set through almost 2 hours watching someone take a battery apart but here I am! Thanks Professor!

[@WeberAuto]

LOL, Thank you very much!

[@NicholasLittlejohn]

2x : )

[@kakaduong2088]

Lllllllllll

[@Tron-Jockey]

Wow, not sure if anyone else noticed but reading ~3.8V across this 10 year old battery cell is not too shabby. If this represents the condition of the entire pack then it must have been well taken care of.

[@Cys62]

Same here.. its so complicated...

[@donlindell1994]

Thank You! As a developer of electric drive off-highway mining trucks, I really enjoyed the detailed explanation and your attention to detail. It's fascinating to see how other engineers solve similar problems. I liked the plastic bus-bar holder that aligns everything for attachment to the individual packs. What a great idea. Never would have thought of that were it not for your video. Thank you again for all the work and effort required for producing these videos. They are unique and unrivaled among the available teaching tools on the internet and speak highly of Weber State

[@watts-jake]

I love how organized everything is! I feel like I learn a lot better when things are clearly labeled and organized like how you have

[@WeberAuto]

Thank you

[@georgeheck1546]

@@WeberAuto thank you for your patience in explaining the electric automobiles. I’m 83 but learning is fascinating with your teaching. I am in Lao so I miss a lot of sleep while learning from you.

[@dansmith6909]

This channel is an absolute treasure. Thankyou to all involved.

[@LeonTroutskiunplugged]

First time seeing one of your videos. This was really impressive and thorough. Clear, and extremely well presented. As the owner of a 2012 leaf with severe battery degradation and only 40K miles, this really helps me make an informed decision about how or whether to try and keep this car on the road. Very well done. Your students are very fortunate.

[@brycelaw4950]

I dont know when i will ever need this information but i freakin love watching these videos! Glad your back up and firing on all... battery cells

[@WeberAuto]

Thank you!

[@obaidalmheiri194]

I

[@willydegeest8358]

This new tech is largely unknown and untested. Do you remember the first switched feed that where lighter than those with transformators, but broke down in large numbers, piling up to bulges? The huge batterie has also new chemistry and had already a huge fire that required a huge tub to be drawn. How many more electrical nuclear facilities will there be needed to supply all those crazy ecological drivers eager to outlaw the older diesel and gasoline motor cars? Please give us also a video on U-Tube about these. Willy Degeest, electrical engineer UCLv, 1966

[@JK360noscope]

Just bought a 2011 Nissan Leaf!

[@TT-dp8qh]

we will never have to open one of those in our life time.

[@jpridie]

I’ll probably never have the guts to take one of these apart but I find your videos very informative and watch them all. Thank you professor for posting these incredible videos. I have a 2015 Ford Fusion Hybrid, so because of you I have a good idea of what is under the hood.

[@JRo250]

I've seen dedicated engineering firms open those modules up and NONE have been this clean. That looks like a factory made cutaway. Congrats once again on an stellar video!

[@WeberAuto]

lol, that is awesome! Thank you!

[@timothylunde]

This guy is GREAT. I don't even know how I got here. These Lithium batteries are fascinating to me, in particular, for how much damage they can do if mishandled. We've lost pilots and cargo planes. The emphasis on safety cannot be glossed over. Well done, sir! Signed, New Fan

[@TheTomUtube]

What an amazing masterclass on so many levels! Leaf battery... Clarity... Teaching style... Motability... Demeanour... Etc. Etc. One of THE most useful additions to my collection of useful Leaf vids. Thank you, Sir!

[@harrickvharrick3957]

without me being willing to look it up, at 4:00 am (for those among ya that never looked it up, that means 'Ante' = before, and 'Meridian' = point that's in the middle, mid-day here; so a time that's after midnight but before noon, or in-between those two points so to say. the other half of the day the times are expressed as 'pm', meaning 'post' (=after) 'meridian (mid-day).

[@LancePickup]

I really enjoy watching your videos. Your presentation style is very thorough, easy to understand, and actually entertaining. You are excellent at what you do!

[@WeberAuto]

Thank you!

[@richardwallinger1683]

as a 2011 Nissan Leaf owner I was fascinated by your excellent presentation .. My LEAF battery has lost two bars but still performs faultlessly with only 116 km / 72 miles range now from a 100% charge. I love this car and it,s futuristic looks . I am 75years old ex Donnington GT Championship 1980 winner in the 1 litre class. in one 12 lap race I lapped all but one of the 35 competitors . He was in sight and would have gone in one more lap.

[@WeberAuto]

Thank you, and thanks for your feedback

[@MrPatdeeee]

Awesome! But then this man is always unbelievable when it comes to keeping teaching enlightening. Thanks and keep the good work coming. It is truly awesome. So glad you were not hurt in that horrible accident.

[@WeberAuto]

Thank you very much

[@kevinwilliamson7294]

I do not own a Leaf or any electric vehicle for that matter. But I enjoy watching all your videos. Very informative, your explanations are clear and understandable. Thank you for your continued devotion to this channel.

[@WeberAuto]

Thank you!

[@habkhal]

What a blessing to have you, professor! Totally love your videos! love from Finland.

[@Importssuckass]

Thanks professor YOU'RE videos convinced me to give electric cars another try I used to have a 2013 Nissan Leaf SV it was a fun car but my winter range was 35-43 miles and summer was 60-85 battery degradation was pretty bad sold it after a year couldn't deal with it anymore plus no quick charge on it. 4 months ago I bought a 2017 Chevy BOLT and so far love it winter range is 160-190 miles and summer is 215- 270 ! Learned a lot from your videos and active battery thermal management is a very important thing plus this bolt has quick charge :)

[@WeberAuto]

Thank you very much!

[@stevencorrea6946]

Wow!

[@Pao19088]

I stumbled upon this video while doing research for a new car purchase. Looking at the length of the video, I thought it would be something nice to listen to while I clean up my apartment. BUT guess what, I found myself intermittently stopping cleaning to sit, watch and learn. I didn't expect that haha. Thank you for your hard work professor! I really appreciate it!

[@zafart7404]

Professor you are rocking... I cant even watch 5 minutes video without forwarding and here I'm .. I sat through whole 2 hours without a single forward. Great help to people like me.

[@benedikt5974]

Wow, that was a Deep Dive! Thank you very much! I am not a technician and it took me 2 days to get to the end of the video, and loved it! Compliments to your language as well - even as a non-native speaker of your language I was able to understand these complex (for me at least) topic. I am happy to now know a bit more about the battery I am sitting on every day. Thank you!

[@BrianD146]

My Dad was an airplane mechanic. He taught me how to use tools, mechanics, torquing and such. I'm so impressed with you doing all this, teaching us so much. Thank you Also impressed with how you buzz around in that scooter doing the work of two footed people.. Truly impressive. Thanks again.

[@tt-rs1457]

Actually along with Jason from Engeneering-Explain, one of my favourite KZbinr......glad that you are back.......

[@WeberAuto]

Thank you very much!

[@elcheapo5302]

I had no idea there was so much inside an EV battery. Thanks for another great vid, professor!

[@WeberAuto]

Thank you!

[@ashton9699]

Thank you Mr. Kelly for your excellent videos available for everyone to learn like they were at your program. I took automotive at the Southern Alberta Institute of Technology and can only imagine what it would have been like with professors that gave this clear and detailed level of education and presentation, never mind offering it on the web for free. Post secondaries everywhere need more professors like you, especially in automotive programs given the incoming influx of electric vehicles.

[@swirlixxx1322]

L

[@swirlixxx1322]

Ll

[@swirlixxx1322]

L

[@swirlixxx1322]

Lll

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L

[@cameron20020]

Thanks for another quality video! Love seeing how these things are put together.

[@WeberAuto]

Thank you!

[@jt8251]

Fascinating content. Appreciate you putting all the effort into producing these videos.

[@CmnTomas]

Now I found the best one to learn about eletric cars 👏🏻👏🏻👏🏻👏🏻

[@Right_Wing_V]

Just sold my 2011 Nissan leaf because the battery brand new would have cost me 5,325 new so glad I got more info

[@WeberAuto]

Sorry to hear that, best wishes

[@TheMailrouter]

The Bob Ross of EV tech. Love watching

[@WeberAuto]

Thank you very much

[@stevencorrea6946]

Mercy Bob Ross what happened to your fro

[@raymondj8768]

you are such a good teacher every move you make is slow n mithodical and well exsplaind this channel is a gold mine of knolage thank you very much sir !!!!!

[@Sanjayadon]

Hands down the best educational video on a LEAF battery pack! Thanks a lot for your hard work!

[@juerbert1]

Thank you, Professor, for explaining every step carefully and in detail !!

[@--Zook--]

Being a old car guy, you explain all this electric car stuff in a way that interests me. More like a hot rodder exploring new technology. I truly appreciate your videos for how you show the in depth workings of electric cars for us old guys to understand. Keep it up!

[@WeberAuto]

Thank you very much!

[@iamher6422]

I took auto shop in high school back in the 80’s and good Lord, what boredom! Learned absolutely nothing! If only we had classes like this. Professor Kelly is a gem. Hope his students feel fortunate. 🤦🏼‍♀️🤷🏼‍♀️

[@vitulbansal1719]

Thanks Proff., you are providing premium content.

[@WeberAuto]

Thank you!

[@moisesdosramos7529]

Our favorite Professor is back! Battery is full! Thanks for share, Professor.

[@WeberAuto]

Thank you!

[@briangsandoval]

I enjoy ur videos. I love all the details being explained. Can’t wait to be there in March for the hybrid boot camp. So excited. Thank u for all of ur educational videos.

[@WeberAuto]

Thank you! See you in March

[@bergssprangare]

Your knowledge and ability to explain is at Intergalactic level..Tank you Professor..Spread the light

[@gayanmapatuna8918]

Thank you very much for this, Professor and team!

[@pomonabill220]

You amaze me! Having the "handicap" and working with it to produce excellent information! I salute you! Amazing! Thank you.

[@ronaldmail00]

A Legendary video Professor. I learned so much, thank you for all your hard work.

[@oariv]

Truth be told professor, your content is simply priceless; hands down. Bless you!

[@dansmith6909]

This channel is one of my very favourite things to watch

[@Brendon_M]

Great informative tear down. Thank you for posting all these videos

[@WeberAuto]

Thank you!

[@Maltanx]

Thank you again for another great and interesting lesson, Professor Kelly!

[@WeberAuto]

Thank you!

[@Martinsp16]

Glad you’re back. Awesome video as always thank you.

[@WeberAuto]

Thank you!

[@linseyyoung1772]

Very interesting - I'm sure this will come in useful for a conversion I have planned. I've watched about 20 minutes, so far - will watch the rest later. Thanks for doing this.

[@WeberAuto]

Thank you!

[@AndrewKNI]

A fascinating video. So interesting to see how complicated a battery pack is, though you made it look simple. Thank you Professor Kelly. Merry Christmas.

[@simonmills2375]

Absolutely fantastic presentation and tutorial. Very impressive and I learnt heaps. Thank you

[@parhammohseni3522]

I really enjoyed watching your videos. I got much information watching them. Thanks a lot.

[@carlcadogan4510]

A real battery assembly video! So appreciate this video. Thank you!

[@spotter113]

Very interesting, i could not stop watching. I didn't know it was that complicated. Thanks for this well made video.

[@andreatresoldi8444]

Well done John Kelly! I follow you from Italy and I have appreciated this video as usual.

[@WeberAuto]

Thank you very much

[@dev4u85]

I'm sure that not only the students of technical education but also the technical professionals would have enjoyed this video, in spite of big in length. but the way you are challenging the physical ability, I salute you. I wish if I would be there and reduce your efforts by one-tenth. Prof. I wish you all the best.

[@oisiaa]

Thanks! I'll be watching this in full...right now!

[@WeberAuto]

Thank you very much

[@JoseJimeniz]

I love how you don't skimp on any information. An example here was the winding order of the modules. Nobody would have blinked if you just said the have a specific order, and left it at that. But this is a deep-dive; we don't gloss over anything. So here's the diagram of the module numbering, and here are the stickers that give each module's number. For those of us who are simply here to further our understanding about things in the cosmos - the entertainment of learning something, and will never use any of it in practice, it's nice to *really* see how everything goes together. Even down to fastening the screws and nuts on the bus-bar. Thank you for all the detailed work that you do; it really is appreciated.

[@JoshuaPritt]

Another GREAT EV video! Thanks so much for all the effort.

[@stephensun9111]

best introduction of battery video i've ever seen , thanks!

[@cwilsonpa]

Another wonderful enlightening and interesting video presentation by Professor Kelly. Especially interesting for EV owners. I have a 2017 BOLT EV , but I always wanted to see the construction of the LEAF battery to compare it to the BOLT EV battery. Thank you for a great job.

[@yosyp5905]

You're back! I know what to see in the end of this day, now ;)

[@WeberAuto]

Thank you!

[@Demy26]

Thanks professor

[@WeberAuto]

Thank you!

[@rogerm4578]

Excellent video John! This will for sure get me started if I ever have to replace cells on my Leaf.

[@martink7945]

The video was amazing and the amount of information is immeasurable. Thank you very much!

[@gianfavero]

This guy is just lucky all the things he opens up are already pre-labeled.

[@WeberAuto]

LOL, True!

[@centralev2371]

For real, I can't wait for AR goggles so everything will be labeled anyways. (Won't forget anyone's name at a party either.)

[@LionheartTM]

@@centralev2371 AR will be a game changer for these kinds of applications.

[@KTPurdy]

LoL

[@yoyutube100]

Excellent attention to detail in the nomenclature and explanations. Thanks professor.

[@javee-th5no]

I did my own hybrid truck(09 Escalade) battery reconditioning nd now I'm planning on doin my 2011 Nissan leaf.. just tryna school up as much as I can, grear video, thanks 2ur professionalism!

[@carlosg.reggiardo902]

You are a great mechanic, and a great teacher

[@bsaiatechnology7824]

Wow this was a long video but I enjoy every second of it thank you

[@davidbolt4707]

A truly excellent tutorial. Thank you Dr Kelly

[@CodfishCatfish]

Awesome stuff. So many videos are condescending and assuming and this video is fresh air in comparison. A video thats back to basics and gradually educates from the ground up. Very knowledgable and instructional just like being back at school. I understand EV technology in theory but never had a practical. If I ever got into battery servicing I would build a cable testing jig and eliminate problem cables rapidly but that’s another story. Thank you, it was a rapid learning curve and well presented.

[@yantaoyou2976]

It's really great video for learning the battery inside structure!

[@michael931]

Thank you for taking the time to show us. I have a '16 E-golf. Maybe some similarities. Passive cooling also on that one.

[@WeberAuto]

Thank you, i did not know that

[@AzeazAboud]

Thank you very much for this long video appreciate It I enjoyed watching the high voltage battery a parts

[@mikeycbd]

Hey Professor, thank you for the video. My 2020 Leaf arrives this week so it will be interesting to see how the car performs in the Victoria Climate in Australia, temperatures can reach high 30s (Degrees C) frequently. We do also get temps below 0C. I was very pleased to hear you telling us to keep the battery plugged in during cold winters. Best wishes. Mikey

[@ChannaGun]

Thank you very much for this, Professor and team! I'm a Nissan LEAF owner from Sri Lanka, where, when paired with rooftop solar, the LEAF is arguably the most practical vehicle to own, if not for the effect our otherwise great tropical heat has on it's battery's State of Health. I'm hoping your video will help me to understand and evaluate options, if and when my battery's SoH makes some kind of repair or replacement necessary.

[@WeberAuto]

Thank you and best wishes!

[@ShR33k]

I had a Nissan Leaf (30kwh version), and although I'm never going to dive into the battery pack like this - I do find it fascinating. Great video!!! Very informative :)

[@Horsecockbadger]

This my freinds is what you call a master automotive technician !

[@rafaelcaamano3008]

Thank you very much Professor!!! From the Dominican Republic, where vehicles have a very high cost due to the burden of taxes, I greatly appreciate your teachings,

[@nickmayo2974]

Whatever you're earning from KZbin ad revenue, it isn't enough! I love the information you provide for all of us. It's cool to see what kind of repairs I'll be doing in the future as ICEs are phased out.

[@WeberAuto]

Thank you very much

[@lucgauthier3201]

You have all my respect sir to do this high quality teaching on KZbin. I will sleep tonight with a lot more knowledge because of you. God bless you Sir

[@t.h.o.r.]

Thankyou so much for these vids. Im a creator too and I recognise the challenges you face and the depth you go to with the content tabs all through the vids. Im restoing a 1974 LWB Lan Rover and Im toying with Leaf power!

[@xeroinfinity]

another great video professor! Its interesting how battery modules differ from one car manufacturer to another. And I cant wait for the day they can make these batteries lighter, hold more voltage, for longer periods of run time.

[@aymanwaleed5228]

Thank you very much Professor I am not a technician But I learned a lot from you I wish you good health

[@nokhuthulamuzemba7313]

I honestly respect this Gentleman. Love from Zimbabwe

[@ricardofelippe834]

Well done professor John. Fantastic video and tips. Very helpful. Congratulations

[@stairstoeternity]

Thank you so much.You've done an enormous job.Very,VERY few people will put so much effort to create a KZbin video.It was informative,it was interesting,it was the way subjects should be thought.

[@WeberAuto]

You are most welcome

[@tadrian33]

I am not a technician, however, the info you provide is detailed and easy to understand. I especially enjoyed your video when you explained how the high voltage system workes and is isolated even if it is compromised.

[@iorlovich]

Awesome video- thank you. Gives way more info than even reading service manuals gave me. My 2018 had a bad cell module at 8k btw. Detected as HV leakage to ground. Took a long time to replace and now those cells are 60-70mV above the rest even though tech specifically told me he balanced them prior to assembly. Seems a bit out of spec!

[@WeberAuto]

Thank you very much. New cells will normally be slightly higher after balancing and driving. As long as the difference does not exceed the specification, it will me okay.

[@IsmaelAnso]

You are doing some ground breaking work here, these videos are much appreciated, it would be great if you can get your hands on Hyundai Ioniq EV batteries, thanks!

[@WeberAuto]

Thank you

[@muchogustocaffelambrate5783]

Dall'Italia.. Complimenti formidabile video.. Sei davvero una grande persona.. È stato difficile ma molto piacevole guardare tutto il video in lingua inglese ma ne valeva la pena.. Grazie mille

[@recallbarack]

Thank you so much for all the effort you put into this video. Indispensable information.

[@sergeyspirin4539]

Hi Professor John Kelly! Thank you!

[@WeberAuto]

Hello! Thank you!

[@williamhurst7766]

Very interesting. I have a Leaf and always wondered how the battery was configured. As a retired techie, I really liked the video.

[@hypersomrizz]

Welcome back DR. #respect

[@WeberAuto]

Thank you!

[@randalbloomquist7812]

Nice job explaining this battery!

[@AlexandreBueno1968]

Excellent and comprehensive video! Thanks for sharing

[@kens97sto171]

Really fascinating video, glad to see that you're back. Seems really short-sighted of them to not do some kind of active cooling. there's plenty of room around the perimeter that they could have done cooling blocks or internal radiators and run a coolant loop to the outside of the battery case.

[@WeberAuto]

Thank you and thanks for your feedback

[@TheMarcball]

Thank you sir, very well done and instructive. Regards from France !

[@rodmoffatt686]

Thank you for such a detailed video.

[@StarJoon]

Thank you for sharing your knowledge with us. It will be used to make our world cleaner and healthier. 😀

[@WeberAuto]

Thank you very much!