LEVC VN5 2020 User manual

VN5
De-pollution Manual
Date of publication: 09/2020

Table of contents
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1  Introduction 3
1.1  Introduction......................................................................................................................................... 3
1.2  Handling and Recycling Materials .................................................................................................... 4
2  Pre-Treatment - First Steps 5
2.1  High Voltage Warning......................................................................................................................... 5
2.2  Assess for Hazards ............................................................................................................................ 5
2.3  Identify Airbags .................................................................................................................................. 5
2.4  Isolate the 12 Volt and High Voltage Batteries................................................................................. 6
2.5  12 Volt Battery - Removal .................................................................................................................. 9
2.6  High Voltage Battery - Removal ........................................................................................................ 11
3  Pre-Treatment 17
3.1  Air-Conditioning Refrigerant - Removal........................................................................................... 17
3.2  Tyres - Removal.................................................................................................................................. 18
3.3  Gasoline Particulate Filter - Removal............................................................................................... 20
3.4  Brake Fluid - Removal........................................................................................................................ 22
3.5  Power Steering Fluid - Removal ....................................................................................................... 24
3.6  Fuel - Removal.................................................................................................................................... 27
3.7  Vehicle Coolant - Removal ................................................................................................................ 32
3.8  Windscreen Washer Fluid - Removal ............................................................................................... 35
3.9  Engine Oil - Removal ......................................................................................................................... 37
3.10  Oil Filter Removal............................................................................................................................. 38
3.11  Final Drive Oil - Removal ................................................................................................................. 40
3.12  Front Suspension Damper .............................................................................................................. 41
3.13  Rear Suspension Damper................................................................................................................ 45
4  Parts to remove before dismantling 49
4.1  Glazing ................................................................................................................................................ 49
4.2  Front Door Glass ................................................................................................................................ 49
4.3  Windscreen ......................................................................................................................................... 53
4.4  Door Mirror Glass............................................................................................................................... 55

Introduction 1
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Introduction
All LEVC vehicles comply with the latest European directive of End of Life Vehicles (ELVs)
(2000/53/EC).
When the vehicle is at the end of its life we must make sure that we complete the disposal,
recovery and recyclability with minimal effect on the environment.
LEVC vehicles use many components made from recycled material. LEVC's policy to increase
the use of these materials will make sure that the effect of our vehicles on the environment is
minimum and will continue to decrease.
To decrease our effect on the environment more, LEVC works together with a network of "take
back" and Authorized Treatment Facilities (ATFs).
This procedure will make sure that we keep and improve all of our re-use, recovery and
recycling data.
NOTE
Contact LEVC for the recommended Authorized Treatment Facilities (ATFs).
The ATF will take back at no cost, from the owner or keeper shown on the vehicle log book an
LEVC vehicle that qualifies.
A qualifying vehicle is legally defined as shown:
– The vehicle must be delivered to a manufacturer or importer approved free "take back"
facility.
– The vehicle must be complete, containing all of the essential components of the vehicle
including the high voltage battery, electric rear axle drive and final drive, engine, coachwork,
wheels and catalytic converter.
– The vehicle must not have any more waste inside, for example garden/household waste,
additional tyres etc.
All contracted ATF partner sites are in full compliance with the Department of the Environment,
Food and Rural Affairs (DEFRA) standards and are approved and licensed by the
Environmental Agency. Only modern approved recycling equipment is in use on contracted
sites.
The ATF will use a computer connection to the Driver and Vehicle Licensing Agency (DVLA)
and will de-register the vehicle. The owner or keeper of the vehicle ceases to be responsible for
it when ATF de-register it from the DVLA. The DVLA will issue a Certificate of Disposal (COD).

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Handling and Recycling Materials
Due to current legislation not all components on LEVC vehicles are deemed to be recyclable.
Some components must be recycled and stored in a specified way:
Batteries
– 12 volt batteries must be taken to an approved waste disposal company. The battery can
contain other valuable metals that can be re-used. Do not dump a battery as there is lead
inside which is toxic to the human body and sulphuric acid which is extremely corrosive.
– High voltage batteries must be stored in a secure area clearly marked High Voltage. The
secure area must be temperature controlled to make sure that combustion due to excessive
heat will not occur. The high voltage batteries must not be in direct contact with each other
and can only be stacked 2 high. When you have a high voltage battery from an LEVC
vehicle, you must contact LEVC so they can organise safe collection and recycling of the
component.
Oil filters
Oil filters can be recycled and in some cases re-used after draining. Oil filters contain some
harmful substances. Make sure that you check all local regulations before handling dirty oil.
Glazing
All of the glass on the vehicle can be recycled and re-used.
Electrical waste
Many electrical components contain recyclable materials, but they also contain chemicals that
can be harmful to the environment and the human body. Some parts can be burned, in
accordance with local regulations, for the reclamation of energy. Do not dump any hazardous
electrical waste.
Rubber
Rubber is not easy to recycle as it contains Chlorine and/or Fluorine. All of the vehicle tyres can
be ground down and re-used. It is also possible, in accordance with local regulations, to burn
rubber for the reclamation of energy. Rubber can only be burnt in an approved incineration
station.

Pre-Treatment - First Steps 2
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High Voltage Warning
All LEVC vehicles are high voltage electrical vehicles. Be aware that high voltage components
and cables are located throughout the vehicle.
WARNING
Do the Pre-Treatment - First steps in the sequence shown. If you do not, there
is a risk of injury or death.
Assess for Hazards
Assess the vehicle for health and safety hazards such as sharp objects, glass, contamination or
damage.
If the vehicle has been in a collision, airbags may have been deployed or structural components
may be compromised.
Identify Airbags
WARNING
The explosive materials used inside airbags are toxic and hazardous to health.
These materials are safe to handle when they are sealed inside the generator
in manufacture. If the generator is split open extreme care is needed. See
Health and Safety guidelines HSG184.
Understand the locations of the airbags and whether they have been deployed, damaged or if
the area around them is damaged.

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The location of the airbags is shown below.
Isolate the 12 Volt and High Voltage Batteries
Before starting this task:
WARNING
This procedure must only be done by approved personnel.
WARNING
You must do this procedure in the exact sequence shown. Failure to do so
could result in serious personal injury.
WARNING
Make sure that you obey all local legislation when you work with high voltages
and high voltage systems.
WARNING
Approved personal protective equipment includes: safety glasses or visor,
rubber gloves meeting Class 0 or better and non-flammable, non-melting
clothing, must be worn when instructed to do so.
WARNING
Always wear the applicable protective safety equipment when you work with
batteries. Batteries contain poisonous and corrosive acid that can cause body
injuries.

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CAUTION
Set the ignition to OFF with the rotary switch - start/stop before you start this
procedure.
1. Access the 12V battery. It is located in the right side of the load space above the wheel arch.
Release the seven fasteners and release the cover - battery 12V. Disconnect the electrical
connector from the power outlet - 12V and remove the cover - battery 12V.
2. Disconnect the sensor - battery monitor and the cable - ground - battery 12V from the
battery - 12V and move to one side.
3. WARNING
Stay a safe distance from the vehicle for a minimum of 5 minutes before
you continue to do work on the vehicle.

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4. Access the switch - safety - high voltage battery. It is located in the centre console and
accessed underneath the coin tray.
5. WARNING
You must use eye protection and rubber gloves of Class 0 or better for this
step.
WARNING
Lock the switch - safety - high voltage battery in a safe position a minimum
of 5 meters from the vehicle.
Release the tab and pull the lever fully to the maximum up position to release the switch -
safety - high voltage battery.

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6. Remove the switch - safety - high voltage battery from the battery - high voltage.
7. Install the blank plug - high voltage battery on the battery - high voltage.
12 Volt Battery - Removal
Before starting this task:
DANGER
You must isolate the battery - 12V and the battery - high voltage before you continue
with this procedure. If you do not isolate the battery - 12V and the battery - high
voltage, it can cause injury, or damage to the vehicle.

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WARNING
Always wear the applicable protective safety equipment when you work with
batteries. Batteries contain poisonous and corrosive acid that can cause body
injuries.
1. Release the pipe - vent from the battery - 12V. Open the access cover. Loosen the fastener
for the battery - 12V positive terminal.
2. WARNING
This item is heavy. To decrease the risk of injury always lift heavy
components correctly, or use the applicable equipment to move and attach
heavy components.
Remove the four fasteners. Remove the lower bracket. Lift the fuse box - 12V battery and
remove the battery - 12V.

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High Voltage Battery - Removal
Before starting this task:
DANGER
You must isolate the battery - 12V and the battery - high voltage before you continue
with this procedure. If you do not isolate the battery - 12V and the battery - high
voltage, it can cause injury, or damage to the vehicle.
WARNING
This procedure must only be done by approved personnel.
WARNING
You must isolate the battery - 12V and the battery - high voltage before you
continue with this procedure. If you do not isolate the battery - 12V and the
battery - high voltage, it can cause injury, or damage to the vehicle.
WARNING
This is a high voltage component. Do not disassemble the component. If there
is damage to the component, or it is defective, you must replace the full
assembly.
1. Drain the coolant - high voltage battery system.
Disconnect the hose - coolant from the right side of the battery - high voltage and collect the
coolant.
Repeat this for the hose - coolant on the left side of the battery - high voltage.

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2. Remove the exhaust downpipe and the heat shield exhaust - front.
3. Disconnect the three electrical connectors from the front of the battery - high voltage.
4. Disconnect the two electrical connectors from the rear of the battery - high voltage.
For a vehicle with a secondary charger - high voltage - on board only: Disconnect the
electrical connector from the rear of the battery - high voltage.
For a vehicle with CHAdeMO only: Disconnect the electrical connector from the rear of the
battery - high voltage.

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5. For a vehicle with CHAdeMO only: Release the eight fasteners that attach the CHAdeMO
cables - high voltage to the battery - high voltage. Tie the cables - high voltage to the side.

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6. Disconnect the electrical connector from the junction box - combined charging system. Move
the wiring harness away from the battery - high voltage.
7. Release the hose - coolant from the fastener. Remove the two fasteners and remove the
bracket from the battery - high voltage.

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8. Remove the eight fasteners from the centre of the battery - high voltage.
9. WARNING
This item is heavy. To decrease the risk of injury always lift heavy
components correctly, or use the applicable equipment to move and attach
heavy components.
Use an applicable hydraulic lift platformwith a safe working load more than 350 kg to
hold the battery - high voltage in the installed position.

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10.Remove the 27 fasteners from the battery - high voltage.
11. Make sure that all of the hoses - coolant, cables - high voltage and the wiring harness do not
touch the battery - high voltage.
Use the hydraulic lift platform to lower the battery - high voltage away from the vehicle. Or
raise the lift to move the vehicle away from the battery - high voltage.

Pre-Treatment 3
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Air-Conditioning Refrigerant - Removal
Read through the safety regulations before you do work on the air conditioning system.
WARNING
• Wear protective glasses and sealed gloves. There is a risk of burn and freeze
injuries.
• If refrigerant touches your skin, put that area of your body in a bath of cold
water to prevent a burn injury.
• If you get coolant in your eyes, flush them fully with water for a minimum of
10 minutes. This prevents eye injury.
• Do not release refrigerant into the atmosphere. If this is done accidentally,
open doors or windows and let air flow free before you do work again.
Refrigerant gas is dangerous to your health.
• Stay away from refrigerant gas that can come from hot HVAC parts. It is
dangerous to your health and can cause damage to your lungs.
• Start to work immediately when you drain the A/C system. There can be an
A/C oil fume leak if you do not start the work in a small period of time.
• Do not smoke and do not go near open flames when you do work with
refrigerants.
• Do not keep refrigerant containers adjacent to heat. The pressure can
increase and cause an explosion.
WARNING
Servicing must only be done by approved personnel for both the vehicle and
the pressure and test equipment.
Refrigerant is dangerous. Refrigerant is pressurized, it boils at room
temperature and is flammable.
All operations must be done in an area with good air flow away from open
flames and high temperature sources.
Open the hood assembly.
WARNING
Do not disconnect one or more connections in the air conditioning system
with refrigerant in the system.

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Remove the two caps from the air conditioning charge ports.
Connect an approved refrigerant collect and recharge machine to the ports. Examine the
machine manufacturer's instructions for the correct operation of the machine.
Attach the blue hose to the low-pressure valve connection.
Attach the red hose to the high-pressure valve connection.
The valves are Schrader-type, you must make the connection in two steps: Connect the
quick-coupling to the connection. Turn the handle clockwise to make the valves open and make
the refrigerant flow through the connection.
Follow the equipment instructions and fully drain the system.
Tyres - Removal
NOTE
All four of the tyres on the vehicle can be recycled. Some LEVC vehicles are
supplied with a spare wheel. The tyre on the spare wheel can also be recycled.
Remove and discard the hub caps and the outer rings from all the wheels.

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Loosen the five fasteners on all four wheels, by 180 degrees. Lift the vehicle to the correct
height to work.
Remove the five fasteners from all the wheels. Remove the wheel and tyre assemblies.

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Remove and recycle the wheel balance weights.
Use an approved tyre machine to remove the tyre and valve from all the wheel rims. Recycle
the rubber components.
Gasoline Particulate Filter - Removal
1. Remove the sensor - GPF pressure.