The original 24 kWh lithium-ion battery from the 2011 Nissan LEAF was quite an achievement at the time, but a few years later it turned out to be one of the most controversial designs - that is because of the lack of an active cooling system.

In one of the recent videos on WeberAuto channel, Professor John D. Kelly from the Weber State University (WSU), not only presents the entire battery (cells, modules and pack), but literally assembled it from the ground up.

The lack of a cooling system affected the longevity of the cells, closed in module cans and then again in the battery case. The only thermal management system was optional heaters, inside the pack.

2011 Nissan LEAF battery info:

  • 24 kWh battery produced by AESC in Japan (Nissan and NEC joint venture)
  • 48 modules
  • 192 cells (4 cells per module)

Video Description via WeberAuto on YouTube:

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 for your hybrid and EV battery needs.

Introduction at 0:07
Thank you for providing battery at 0:37
Battery Modules at 1:48
MUST SEE: See inside a battery module at 2:36
MUST SEE: Comparison of Li-Ion pouch sizes at 9:15
Module voltage measurements at 13:40
See the three battery stacks of the LEAF battery at 15:55
See the series circuit order of the 48 modules at 16:30
MUST SEE: The module spacers to allow thermal conduction and convection with the battery tray (Passive Cooling) at 21:30
Module physical alignment requirements at 24:26
Bolt torque dilemma at 26:30
See the module polarity stacking requirements at 28:50
See the module stack bus bars at 29:25
See the module voltage sensing wiring at 30:19
Installation and torque of the bus bars at 30:50
Battery stack voltage measurements at 37:06
See the installation and weight of the three battery module stacks into the empty battery tray at 46:30
Installing and torquing the battery module stack bolts at 55:18
See the battery heater system brackets at 56:55
Battery heater (Electrolyte freeze prevention) operation at 1:00:40
MUST SEE: Battery heater disassembly at 1:02:00
See the installation of the battery heater wiring harness at 1:05:46
Structural Support Beam installation at 1:09:50
Harness bracket and junction block bracket installation at 1:11:10
Installation of the 4 battery temperature sensors at 1:12:15
Battery heater controller installation at 1:13:45
MUST SEE: Battery junction block demonstration and installation at 1:15:18
Low voltage harness and cell voltage monitoring harness installation at 1:18:45
Front electrical connector installation at 1:20:56
High voltage connections and Personal Protective Equipment (PPE) at 1:24:10
Module cell voltage sensing line connections at 1:28:18
Installation of high current, high voltage internal cables at 1:28:56
Service disconnect lever connector installation at 1:30:28
Service disconnect lever (with its 225A 450V Fuse) information at 1:31:45
Service disconnect lever connector interlock circuit connection at 1:34:42
Installation of high current, high voltage internal bus bars at 1:36:20
Lithium Ion Battery Computer (LBC) installation and precautions at 1:39:10
Digital Multimeter qualification precautions at 1:41:00
MUST SEE: Demonstration of service disconnector lever and contractor function at 1:44:10
MUST SEE: Battery housing air leak check port and procedure at 1:48:00
Video summary at 1:50:50

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

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 shown and operation will be similar to many other electric vehicles.

We offer both online training and hands-on training classes on Hybrid and Electric Vehicles to the general public. Visit for more information.

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 joining the Weber Automotive program, visit:

This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see

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