2010-2016 Nissan Leaf (ZE0) Service & Repair Manual

BODY SHOP ADMINISTRATION MANUAL FOR CERTIFIED EV DEALER Global Aftersales Planning Dept. Nissan Motor Co., Ltd. Global Aftersales Planning Dept. Nissan Motor Co., Ltd. Draft as of Aug. 1９ th ,2010 Update as of Sep. 21 ｓｔ ,2010 Final Version as of Oct.15 th ,2010 Revised Version as of Nov.1２ nd ,2010

Ｆｏｒｅｗｏｒｄ This manual describes the body and paint repair processes that dealers should follow as they are related to the Nissan Leaf Electric Vehicle. This vehicle is equipped with a high-voltage Li-ion Battery pack. Improper repair procedures may result in serious consequences such as electrocution. Please read this manual before beginning any body or paint repair procedures on the LEAF Electric Vehicle. Follow the instructions to ensure a safe repair. IMPORTANT INFORMATION FOR SAFETY DESCRIPTION You will see various symbols in this manual. They are used in the following ways: This is used to indicate the presence of a hazard that will cause death. To avoid or reduce the risk, the procedures must be followed precisely. This is used to indicate the presence of a hazard that could cause death or serious personal injury. To avoid or reduce the risk, the procedures must be followed precisely. This is used to indicate the presence of a hazard that could cause minor or moderate personal injury or damage to your vehicle. To avoid or reduce the risk, the procedures must be followed carefully. Please note that there may be differences between the information provided in this manual and the actual vehicle you are working on due to specification changes. All information,specifications and illustrations in this manual are those in effect at the time of printing. NISSAN reserves the right to change specifications or design at any time without notice.

Table of Contents １．Summary of Body Repair Work Flow ２．High-Voltage Parts Requiring Removal ３．Business Consignment to Outsourced Body Shops ４．Work Flow from Certified EV Dealer to Body Shop 4-１ Customer Reception and Vehicle Processing 4-2 Identifying Related Parts 4-3 Removal of Related Parts 4-4 Arranging for Transport 4-5 Preparation of Repair Estimate 4-6 Approval to Start Repairs from Insurance Company (Customer) 4-7 Feedback to Estimate 4-8 Ordering Parts 4-9 Repair of Damaged Vehicles 4-10 Arranging for Vehicle Transport 4-11 Finalize Repair Cost 4-12 Installation of Related Parts and Final Inspection 4-13 Invoice to Customer 4-14 Vehicle Delivery to Customer ５．Process Procedure Details for Body Repair and Painting ６．Precautions for Body Repair and Painting ７. In the Event of an Accident 7-1 Protection for Electric Shock 7-2 In the Event of Li-ion Battery Pack Damage

１． Summary of Body Repair Work Flow ※3．High-voltage parts except for Li-ion battery pack ・Traction Motor Inverter ・ＤＣ/ＤＣ J/B ・Traction Motor ・Electric Compressor ・ＰＴＣ Elements Heater ・On Board Charger・Service plug ・Charge port ・Front Side Li-ion Battery High Voltage Harness Connector Customer Certified EV Dealer’s workshop Is it the minor damage ※1 ? Removal of both Li-ion battery pack and high- voltage parts ※2 Yes No Return of the vehicle for installation of both Li-ion battery pack and high-voltage parts The EV vehicle, should only be delivered to a body shop after removing Li-ion battery pack, high-voltage parts and any related parts that may be an obstacle to the body repair and painting process. Body shop (Body Repair and ainting) : EV Dealer’s workshop : Body shop Body shop (Body Repair and Painting) ※2 ※1. The minor damage ・There is only a scratch or unevenness on an outer panel(fender,door,etc) or bumper ※2. The temperature of paint booth (Refer to 6.Precautions for Body Repair and Painting for details.) ・If the paint booth temperature is more than 140°F(60℃), have the Li-ion Battery removed from the vehicle by the certified EV dealer and then deliver the vehicle to body shop.

High-voltage parts requiring removal when replacing welded panel components-1 (Front body) Layout of high-voltage parts NO Major welding operation items High-votage parts requiring removal 1 Radiator Core Support Li-ion Battery,Service plug,Charge port, Front Side Li-ion Battery High Voltage Harness Connector 2 Hood ledge partial replacement 3 4 5 Hood ledge complete replacement Li-ion Battery,Service plug, Charge port, Front Side Li-ion Battery High Voltage Harness Connector,PTC Elements Heater, Traction Motor, Electric Compressor, Traction Motor Inverter, DC/DC J/B Front side member partial replacement Li-ion Battery,Service plug,Charge port, Front Side Li-ion Battery High Voltage Harness Connector Front side member complete replacement Li-ion Battery,Service plug, Charge port, Front Side Li-ion Battery High Voltage Harness Connector,PTC Elements Heater, Traction Motor, Electric Compressor, Traction Motor Inverter, DC/DC J/B Refer to the following table. For further details, refer to BRM section of Electronic Service Manual (ESM). ２．Ｈｉｇｈ-Vｏｌｔａｇｅ Pａｒｔｓ Requiring Removal 3 5 4 2 2 １ 2 On Board Charger Service plug Traction Motor Inverter Li-ion Battery PTC Elements Heater Charge port Electric Compressor Traction Motor DC/DC J/B ※ ※This component include a DC/DC converter and high voltage junction box(J/B).

High-voltage parts requiring removal when replacing welded panel components-2 (Side body, Under body) NO Major welding operation items High-voltage parts requiring removal 6 7 Outer Center pillar partial replacement 8 9 10 11 12 Outer Front Pillar partial replacement Outer Sill partial replacement Rear Fender partial replacement Rear panel replacement Rear Side Member Extension replacement Rear Floor Rear replacement Li-ion Battery,Service plug,On Board Charger,Front Side Li-ion Battery High Voltage Harness Connector Li-ion Battery, Service plug, Front Side Li-ion Battery High Voltage Harness Connector Refer to the following table. For further details, refer to BRM section of Electronic Service Manual (ESM). ２．Ｈｉｇｈ-Vｏｌｔａｇｅ Parts Requiring Removal 9 11 11 10 12 8 7 6

In the case of a certified EV dealer that does not perform body & paint work in-house, business consignment to an outsourced body shop is necessary. Customers must be informed that some repair work will be performed by someone other than the dealership. Please keep the following points in mind when servicing customers so as to prevent any confusion. Points to keep in mind when consigning business to an outsourced body shop ３．Business Consignment to Outsourced Body Shops 1 Reception Even if the repair is consigned, customer reception and processing should be handled at the certified EV dealer. In some cases , customers may drive the vehicle to the outsourced body shop if it is more convenient for the customer. 2 Transport between the certified EV dealer and an outsourced body shop Because related components (including high-voltage parts) ※ are removed by a certified EV dealer, a transportation fee is added to the customer’s account. (Refer to 3-4 and 3-10 for details.) 3 Completion inspection After being repaired at an outsourced body shop, vehicles will be returned to the certified EV dealer where the high-voltage parts are to be reinstalled and a final quality inspection using CONSULT-Ⅲplus. Certified EV dealers that do not own an in-house Body & Paint shop, it will be necessary to negotiate and sign a business consignment agreement with an outsourced body shop. ※: Related parts are parts located in surrounding area of vehicle damage and include high-voltage parts that may cause an obstacle for body repair and painting.

When the business consignment contract is finalized, the certified EV dealer shall make an offer to the outsourced body shop. The contents of the business consignment contract should be prepared referencing the following items. • Consigning party and consigned party • Consignment fee • Term of contract • Delivery and receipt of vehicles • Dealing with accident during the term of consignment • Re-repair • Confidentiality、etc A certified EV dealer that does not own an in-house body shop. Outsourced body shop Customer Scope of business Carrying in/out vehicle B&P entry Request for body repair and painting Removal and installation of related parts ※ and final inspection ※: Related parts are parts located in surrounding area of vehicle damage and include high-voltage parts that may cause an obstacle for body repair and painting. ３．Business Consignment to Outsourced Body Shops

(4) Arranging for transport（EV dealer～Body shop) ４．Work Flow from a Certified EV Dealer to Body Shop The following are the assignments and workflow from receipt of a vehicle that has been in an accident to vehicle delivery to the customer after repair completion. Detailed work processes are described from the next page forward. Body Shop (1) Customer reception and vehicle processing (8) Ordering parts Certified EV dealer Estimator (7) Estimate feedback Service advisor(SA) or Sales person (5) Preparation of estimate sheet (6）Approval to start repair from insurance company (customer) (10) Arranging for transport (Body shop～EV dealer) (9) Vehicle repair (11) Finalize repair cost (13) Invoice to customer (14) Vehicle delivery to customer (12) Installation of related parts* and final inspection (3) Removal of related parts* *: Related parts are parts located in surrounding area of vehicle damage and include high- voltage parts that may cause an obstacle for body repair and painting. (2) Identifying related parts*

４-１Customer Reception and Vehicle Processing Certified EV dealer When a customer requests repairs to be done to a car that has been in an accident, the Service Advisor (SA) or a sales person will process the request. If the vehicle is insured, check if the insurance company has been informed. When the vehicle arrives, perform a walk-around check in the presence of the customer. Certified EV dealer will consign the repair to the body shop. Note: Some customers may want to repair just small scratches on the bumper,etc.In such a case, where to consign the repair work may be determined by the Certified EV dealer in consultation with the customer. Inform the customer that repairs by the body shop entail a transportation fee. < Regarding the transport fee> To ensure the safety of body shop personnel, EV Li-ion Battery and High-Voltage parts located near the damaged portion of the vehicle shall be removed and installed by a certified EV dealer. Certified EV dealers have the facilities, equipment and exclusively trained technicians to safely service your vehicle. Failure to have a certified EV technician remove or install EV Li-ion Battery and High-Voltage parts could result in serious personal injury or death. Transportation fees are necessary to move the vehicle between the certified EV dealer and body shop. These fees are invoiced to the insurance company or the customer. Certified EV dealer Body shop

2010-2016 Nissan Leaf (ZE0) Service & Repair Manual

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