Nissan Leaf Battery Upgrade
Nissan Leaf range decreased
Nissan Leaf battery pack upgrade 24kWh to 40kWh
The following fault code(s) may be present
No specific fault codes were documented in this particular case.
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Parts Repaired or Replaced
- 40kWh unity battery pack
- Battery conversion kit
- Battery Control Module (BCM)
- Vehicle Charge Module (VCM)
Affected Vehicles
Nissan Leaf
- Nissan Leaf - All models with the original 24kWh battery pack
Common Failure Symptoms
- Noticeable drop in driving range: for example, a vehicle that once got ~80 miles may now only reach ~35 miles
- Battery health (SOH) reading significantly reduced (e.g., ~70 %)
- Charging system appears normal but range remains far below expectations
- Frequent need to recharge, or inability to meet daily driving requirements due to low battery performance
Nissan Leaf Diagnostic Report
In this job, the vehicle was a Nissan Leaf with a significantly reduced range and an SOH reading of ~70%. Once the diagnostics confirmed the battery pack’s reduced health and inadequate range capacity, we offered the customer the option of a battery upgrade from the original capacity to a higher-capacity pack. After selection, we began the upgrade process: re-engineering under-tray components, wiring the conversion kit and ensuring compatibility with the vehicle's electrical systems.
Nissan Leaf Repairs
The upgrade process involved:
- Removal of the original high-voltage battery pack in the Nissan Leaf
- Installation of a larger-capacity battery pack (for example moving from the original 24 kWh pack to a 40 kWh unit) including necessary wiring and under-tray modifications to accommodate the upgrade
- Fitting of a conversion kit and control module to ensure the new battery module integrated correctly with the vehicle’s EV system
- Full charging system check, software update of the Vehicle Charge Module (VCM) to support correct range read-out, and a road test to validate performance and safety
Resolution
Upon completion of the upgrade, the Nissan Leaf battery upgrade was successful: the SOH improved to ~94.6% and the vehicle achieved an estimated 165 miles range at full charge, which was a considerable improvement over the original degraded performance. The vehicle was returned to the customer with restored driving range, reliable performance and value for investment.
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