Body and Frame: Testing and Inspection

REPAIR WORK FLOW

Repair Judgment Flow


WARNING:
- Because 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 vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- To prevent the removed service plug from being connected by mistake during the procedure, always carry it in your pocket or put it in the tool box.
- Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses 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 vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.
- Refer to ["High Voltage Precautions"].

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 vehicle to READY status unless instructed to do so in the Service Manual.

OVERALL SEQUENCE







DETAILED FLOW


1. CHECK LIGHTING OF MASTER WARNING LAMP

Check that the master warning lamp is ON.
Revision: 2011 September2012 LEAF
Is master warning lamp ON?
YES- GO TO 2.
NO- GO TO 3.

2. DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS, ACCORDING TO THE SERVICE MANU-

AL
Connect CONSULT to check malfunction information.
Is there malfunction information in high voltage parts?
YES- GO TO 5.
NO- GO TO 3.

3. CHECK HIGH VOLTAGE PARTS FOR DAMAGE

Visually check high voltage parts for damage.

WARNING:
When performing high voltage-related work, always wear insulating protective gear.
Is there a malfunction in high voltage parts?
YES- GO TO 5.
NO- GO TO 4.

4. CHECK AREA ADJACENT TO DAMAGE FOR THE PRESENCE OF HIGH VOLTAGE PARTS

Check high voltage parts requiring additional removal work.
Is additional removal work required for high voltage parts?
YES- GO TO 5.
NO- Start body repair and painting.

5. PRECONDITIONING


WARNING:
Disconnect high voltage. .
Check voltage in high voltage circuit. (Check that condenser are discharged.)
1.Lift up the vehicle and remove the battery under covers. .
2.Disconnect high voltage connector from front side of Li-ion battery. .
3.Measure voltage between high voltage harness connector terminals.
DANGER:


Touching high voltage components without using the appropriate protective equipment will cause electrocution.
Standard: 5 V or less






CAUTION:
For voltage measurements, use a tester which can measure to 500V or higher.
- GO TO 6.

6. REMOVE HIGH VOLTAGE PARTS AS AN ADDITIONAL WORK, ACCORDING TO THE SERVICE MANU-

AL
Remove high voltage parts as an additional work, according to the Service Manual.

WARNING:
When performing high voltage-related work, always wear insulating protective gear.
- Start body repair and painting.
Revision: 2011 September2012 LEAF