Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

Hi,

Because SOH% in our Fluence is at 69% (And because of personal interest) I decided to take a route of replacing cells with ones from GEN2 Leaf 24kw battery. I already bought Leaf battery pack with 98% SOH out of 2015 Leaf. Should Leaf cells be same physical size and swapping cells be quite straightforward?

Tero

If you can send a photo of the cells I can tell you...

Now I have these:

https://photos.app.goo.gl/cjFwPCoWvr8deDEf6

https://photos.app.goo.gl/Ftu54j4eY7c4V8Qr9

https://photos.app.goo.gl/Cc7y3NTux4K5dGYH8

Should these fit?

Hi, they look very similar to the original Fluence cells but they are not identical.

I would expect the same issues that I had with the Leaf 30kWh cells:

- Different usage of the cooling mats
- Modification of the horizontal support bars
- Modification of the end-plates.

So, in the end, they will fit, but it's not a seamless replacement.

Cheers
Andreas

Hi,

I will follow steps from guide you made, before I start my project. Btw how much range you have now with 30kw battery?

Tero

Hi Tero,

as I wrote in the modification thread I drove in summer 189km on a fully charged pack. That was 26kWh out of a 30kWh pack (SOH 102%). These values sound reasonable as the cells are only charged to 4.1V/cell in the Fluence.
For a healthy 24kWh pack you could expect getting about 20kWh.

Cheers
Andreas

Some project photos:

https://photos.app.goo.gl/1UM7gewXcrAPsg8q9

It is done. And car still works Thank you very much Andi for great guide. Swap was similar to that you did. Only one minor difference was that cells with studs had bracket spot welded to other side so those had to be "flipped to get corret +-+-+- order for stacks. How soon should I expect SOH% to increase?

Tero

Amazing pictures buddy.

I think you need to reset the range by holding down one of the buttons on the wiper stalk until it resets.

Congratulations - well done

ow soon should I expect SOH% to increase?

It will increase each time you charge. I did a full charge after I swapped and then dive the car until I was in turtle mode. Then I recharged.
But even without that you should see an increase every time you charge.

Cheers
Andreas