Nissan LEAF 62 kWh “EV Service” Mystery — Battery Isolation Fault EXPOSED & Fixed! ⚡🔧

Описание: A Nissan LEAF ZE1 (2017+, 62 kWh) came in with the dreaded EV Service Warning / restart inhibited after power off. Range was fine, but the high-voltage isolation test failed. We proved the leak was inside the battery pack, dropped the pack, split banks, isolated the faulty 33 V module, replaced it, verified cell balance (7–15 mV), and road-tested. Final isolation test passed ✅

What we cover:

ZE1 62 kWh pack architecture (12 modules, ~33 V each, ~350 V total)

Correct isolation testing at the service plug & HV connectors

Finding a leak to chassis and narrowing it to a single module

Replacing one 33 V block, re-sealing, reassembly & BMS checks

Transparent costs (pack £1200+VAT, labour £1500+VAT → £2700+VAT total)

Final charge, drive test, autonomy & health

We’re OGS Mechanics — Hybrid & EV (London). Real diagnostics, safe HV work, component-level fixes.

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OGS Mechanics
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Rear of 28 Long Lane
London N3 2QG

📞 07918 061897

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🕒 Timestamps:
0:00 Intro — LEAF ZE1 62 kWh, EV Service Warning (restart inhibited)
1:05 Live scan: no drive errors, range OK — but hidden HV issue
2:20 Battery health & balance check (SoH ~95%, Δcells ~14 mV)
3:10 Isolation test at service plug — fault confirmed
4:20 Underbody HV connectors isolated — fault is internal to battery
5:40 Pack removal (why ZE1 is “easier”)
7:00 Opening the 62 kWh pack (sealant, cover, layout)
8:20 Splitting banks & busbars to locate the leaking module
10:05 The culprit: end module with leak under compression
11:10 Replacement 33 V block — voltage matching & balance checks
12:30 Reassembly: torque, busbars, BMS harness, isolation re-test
13:40 Reading BMS data — cell delta 7–15 mV (good)
14:30 Reseal, install, ready mode & road test
16:00 Final isolation test passed, no warnings
16:40 Costs & recap — why not to replace a whole pack by default

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