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What are some tips for diagnosing faults in hybrid and electric vehicles using vehicle diagnostic tools?

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Hybrid and electric vehicles (HEVs and EVs) are becoming more popular and common on the roads, but they also pose some unique challenges for diagnosis and repair. Unlike conventional vehicles, they rely on complex systems of batteries, motors, inverters, converters, and controllers to operate efficiently and safely. To diagnose faults in these systems, you need to use specialized vehicle diagnostic tools that can communicate with the vehicle's onboard computer and access the relevant data and codes. In this article, we will share some tips for diagnosing faults in hybrid and electric vehicles using vehicle diagnostic tools.

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Update vehicle software:

Ensuring the vehicle's software is current can resolve issues that mimic hardware problems. Regular updates can prevent headaches and keep everything running smoothly.
Understand EE architecture:

Knowing the electrical electronics setup in vehicles helps you troubleshoot effectively. Recognize how components like motors and controllers work and communicate for efficient diagnostics.

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Birkan Atlamaz, MSc

Chief E/E Officer | E/E, SW, HW | vCISO…
Avinash Kumar Singh

CEO - DIYguru / eMobility.academy /…

1 Know the basics

Before you start diagnosing any fault in a hybrid or electric vehicle, you need to have a solid understanding of the basic principles and components of these vehicles. You should know how the different types of hybrid and electric vehicles work, how they store and manage energy, how they control the powertrain and the regenerative braking, and how they protect the high-voltage system. You should also be familiar with the common symbols, labels, and warnings that indicate the presence and location of high-voltage components. Having this knowledge will help you avoid potential hazards and identify the source of the problem.

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Birkan Atlamaz, MSc

Chief E/E Officer | E/E, SW, HW | vCISO Vehicle Cybersecurity @ ANADOLU ISUZU | Innovative Startup Mentor | LinkedIn Top Voice in Automotive Electronics | Blogger
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One should know the basics of Electrical Electronics (EE) architecture. There are lots of electronics in EV and/or Hybrid vehicles, such as motor, inverter, converter, AC charging control unit, DC charging control unit, air compressor, steering motor etc. Without knowing how these components and systems operates with full functionality. One should also understand how these systems communicate with each other in terms of SW, J1939 or some internal comm, user defined. After all these is OK, diagnostics can very much help people to troubleshoot the issue.

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2 Choose the right tool

Not all vehicle diagnostic tools are compatible with hybrid and electric vehicles. Some tools may not be able to read the specific codes and data that these vehicles generate, or they may not support the communication protocols and standards that these vehicles use. Therefore, you need to choose a tool that is designed for hybrid and electric vehicles, or that has the appropriate software and hardware updates to handle them. You should also check the manufacturer's specifications and recommendations for the tool, and make sure that it is compatible with the vehicle's make, model, and year.

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Avinash Kumar Singh

CEO - DIYguru / eMobility.academy / Co-Founder - ev.care
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Check if the vehicle’s software is up to date. Software glitches can cause problems that may appear as hardware issues. Look for any TSBs or recalls issued for the vehicle model. These bulletins can provide information on common faults and recommended fixes.

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3 Follow the procedure

Once you have the right tool, you need to follow the proper procedure to connect it to the vehicle and access the diagnostic information. You should always refer to the vehicle's service manual or the tool's user guide for the specific steps and precautions to take. Generally, you need to locate the diagnostic port, which is usually under the dashboard or near the center console. You then need to plug the tool into the port and turn on the ignition or the accessory mode. The tool will then establish communication with the vehicle's computer and display the available options and menus. You can then select the functions and tests that you want to perform, such as reading codes, clearing codes, viewing live data, performing actuations, or running self-tests.

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4 Interpret the results

After you have performed the diagnostic functions and tests, you need to interpret the results and identify the cause of the fault. The tool will display the codes and data that correspond to the different systems and components of the vehicle, such as the battery, the motor, the inverter, the converter, the controller, or the sensors. You should compare the codes and data with the normal values and ranges, and look for any discrepancies or anomalies that indicate a malfunction or a failure. You should also consult the vehicle's service manual or the tool's user guide for the meaning and description of each code and data, and for the possible solutions and repairs.

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5 Verify the repair

After you have identified and fixed the fault, you need to verify that the repair was successful and that the vehicle is operating normally. You should use the tool to clear the codes and reset the system, and then perform another diagnostic scan to check that there are no remaining or new faults. You should also test drive the vehicle and monitor its performance and behavior, and look for any signs of trouble or warning lights. If everything is satisfactory, you can conclude the diagnosis and repair process and return the vehicle to the customer.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are some tips for diagnosing faults in hybrid and electric vehicles using vehicle diagnostic tools?

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1 Know the basics

2 Choose the right tool

3 Follow the procedure

4 Interpret the results

5 Verify the repair

6 Here’s what else to consider

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