Nissan Leaf. Manual - part 1239

PDM(POWER DELIVERY MODULE)

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< REMOVAL AND INSTALLATION >

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• Do not use a metal scraper as it may produce metal particles.

CAUTION:

• Work with the protective cover installed.

• Do not use an air blow.

• Do not use part cleaner.

• Do not use gasket remover.

• Be careful that the removed liquid gasket does not enter into the circuit board.

3. Moisten shop paper with ethanol, and degrease the liquid gasket application surface.

WARNING:

Be sure to put on insulating protective gear before beginning work on the high voltage sys-

tem.

CAUTION:

• Do not use part cleaner.

• Do not use gasket remover.

4. Apply liquid gasket   (Three Bond 1217H or an equivalent) to

the position shown in the figure, checking that there are no gaps. 

WARNING:

Be sure to put on insulating protective gear before

beginning work on the high voltage system.

5. Remove the protective cover.

WARNING:

Be sure to put on insulating protective gear before beginning work on the high voltage sys-

tem.

CAUTION:

Remove the protective cover slowly in order to prevent any dust or other substances on the pro-

tective cover from entering the inside.

6. Lower the PDM (Power Delivery Module) cover vertically to install it.

WARNING:

: PDM (Power Delivery Module) cover side

: PDM (Power Delivery Module) side

: Vehicle front

: Start and end point of liquid gasket application

C

: 

φ3.4 - 5.1 mm (0.314 - 0.201 in )

D

: 1.3 mm ( 0.051 in )

E

: 10 - 15 mm ( 0.39 - 0.59 in )

F

: 23.5 mm ( 0.925 in )

G

: 38 - 43 mm ( 1.50 - 1.69 in )

JPCIA0315ZZ

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< REMOVAL AND INSTALLATION >

PDM(POWER DELIVERY MODULE)

Be sure to put on insulating protective gear before beginning work on the high voltage sys-

tem.

CAUTION:

When lowering the PDM (Power Delivery Module) cover, be careful not to contact the circuit board

section.

7. Tighten the mounting bolts in the order from 1 to 16 as shown in

the figure.

WARNING:

Be sure to put on insulating protective gear before

beginning work on the high voltage system.

NOTE:

In the figure, 9 and 16 indicate the second tightening of 1 and 2.

8. Follow the procedure below and install the air leak tester attachment [SST: KV99112400].

WARNING:

Be sure to put on insulating protective gear before beginning work on the high voltage sys-

tem.

NOTE:

The air leak test is a check performed after PDM (Power Delivery Module) installation. However because

it is difficult to install the attachment when the PDM is installed in the vehicle, install only the attachment

before installing the PDM (Power Delivery Module) into the vehicle.

• Disconnect the breather.

• Adjust the length (A) of the attachment part to match the pre-

scribed value.

CAUTION:

Be sure to check because this is the reference for screw-

ing in the attachment.

• Insert the attachment (A) at the location where the breather is

disconnected.

NOTE:

Check that it is inserted securely all the way.

• Rotate the wing screw 5 times in the tightening direction

(clockwise).

NOTE:

Although the screw can be rotated more than 5 in the tighten-

ing direction, it is not necessary to further tighten it when the

air leak test is performed.

: Vehicle front

JPCIA0309ZZ

Standard : 20 mm ( 0.79 in )

JPCIA0316ZZ

JPCIA0317ZZ

PDM(POWER DELIVERY MODULE)

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< REMOVAL AND INSTALLATION >

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Inspection

INFOID:0000000010121295

INSPECTION AFTER INSTALLATION

Air Leak Inspection

CAUTION:

• Install the attachment before installing the PDM (Power Delivery Module).

• To prevent leakage of air, check that each harness is securely installed.
1. Install the air leak checker [SST: KV9911400 (J-50378)] onto the

attachment.

WARNING:

In order to prevent electric shock, be sure to wear

insulated protective gear.

CAUTION:

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

it when handling it.

2. Follow the procedure below and perform the pressure inspection.

WARNING:

To prevent electric shock, wear insulated protective gear.

a. Open the cock   on the pressure inspection gauge.

CAUTION:

Do not operate the pump before opening the stopcock on

the pressure inspection gauge. Doing so may damage the

gauge. If the pump is operated before the stopcock is

opened, first disconnect the air pump hose to release the

pressure.

b. Operate the air pump slowly and apply the specified inspection pressure inside the PDM (Power Delivery

Module). If the gauge pressure does not rise, or if the gauge reading fluctuates, check for the location of

air leakage.

CAUTION:

JPCIA0329ZZ

JSCIA0638ZZ

Prescribed inspection pressure

: 20.0 kPa (0.2039 kg/cm

2

, 2.90 psi)

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< REMOVAL AND INSTALLATION >

PDM(POWER DELIVERY MODULE)

• Operate the air pump carefully when applying pressure. If pressure is applied suddenly to the

gauge, the gauge may be damaged.

c.

Close the cock and wait for 30 minutes.

d. Check that the pressure inspection gauge reading remains at or above the limit value.

e. 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.

3. If it is confirmed that airtightness is maintained, remove the pressure inspection gauge and remove the

attachment from the PDM (Power Delivery Module).

WARNING:

Be sure to put on insulating protective gear before beginning work on the high voltage sys-

tem.

4. Install the breather.

Electric Equipotential Test

• Check the resistance between the PDM (Power Delivery Module) (aluminum part) and the body (ground

bolt).

• Check the resistance between the PDM (Power Delivery Module) (aluminum part) and other high-voltage

part (housing or conducting part).

WARNING:

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

If result deviates from standard values, check that no paint, oil, dirt, or other substance is adhering to bolts or

conductive mounting parts. If any such substance is adhering, clean the surrounding area and remove the

substance.

Repair limit

: 19.8 kPa (0.2019 kg/cm

2

, 2.87 psi)

Standard

: Less than 0.1

Ω