How to modify upgrade Repair Nissan Leaf Charging Cable....

Source : http://www.evsrilanka.com/viewtopic.php

One day morning my brother came and show me his New Nissan leaf cannot charge No lights when plug in to power

IMG_5108[1].jpg (364.51 KiB) Viewed 205 times

I just observe and spot diagnosed this should be a problem of power supply (step down transformer) then I opened it and found primary winding (AC side open circuit) I decide to replace the Power transformer.

I just try to open the Charging controller all the nails are covered by long plastic knobs you need to remove those 6 knobs to access the nails

IMG_5107[1].jpg (342.02 KiB) Viewed 205 times

you can make small drill hole and put the needle nose flier and pull it then you can see the nail.

To remove nail you need Allen key set then remove all six nails and remove the cover make sure you place the silicon beading which used to prevent water entering into the controller do not damage twist during re assembling

This is how it looks like

IMG_4524[1].jpg (488.79 KiB) Viewed 205 times

Identify the parts remove two nails on transformer block using plus screw driver

I found transformer primary side is open and give infinite resistance my diagnosis is correct so I proceed the repair replacing the step down transformer. 

[flash=]I came to know some people charge nearly 20,000/= Rs for this repair or Upgrade to 240V as both use the same procedure I decided to write this article prevent this racket do not pay more than 2000/= if have no skills to do this job contact me I will help you. [/flash]

Disconnect the two connectors Yellow and Red and check with ohm meter for connectivity if faulty AC side Red wires give infinite resistance so it is time to replace the transformer you can not find the same model but we can find same or better specifications 

Panasonic use 200V primary and 19v secondary we can find locally 240V 9v X 9V that is half wave 18V that is enough for the work you need to choose at least 500ma transformer you can find this very easily in open market. see the picture bellow.
secondary side center wire is not used in this project cut short and insulate 

Cut both connectors close to old black transformer and solder to new transformer red wires to Primary side and yellow wires to secondary side. if you have heat shrinkable tube insert it to the four ends of the wires before soldering and push away from your soldering area to prevent shrink those during solder. 

IMG_4528[1].jpg (343.2 KiB) Viewed 205 times

you may find it difficult to fix due to plastics you may remove disturbing plastic notches to accommodate new transformer screw the two nails and fix the transformer connect the connectors to correct place.

assemble it and power up enjoy you have saved over 100000/ rupees with less than 1000/= rupees any comments or suggestions are welcome