The Nuts & Volts of Hybrid Repairs - BodyShop Business

The Nuts & Volts of Hybrid Repairs

An increasing number of hybrid vehicles entering collision repair facilities means that you need the proper training to ensure accurate repairs and keep yourself safe.

;t allow for a leak-checking dye. Understand the manufacturer-specific service procedure to avoid contamination of the system, which could be a costly mistake.

From 2004 to 2009, the Toyota Prius had a coolant storage reservoir mounted outside the left front lower frame rail. This is a double wall canister design-ed to store hot coolant to help the gas engine warm up under certain conditions. In that po-sition, it’s vulnerable to collision damage and is frequently replaced. There are specific procedures needed to properly bleed the system after replacement.

Many hybrids have two separate cooling systems. They may require two different bleeding procedures for proper operation of both.

As part of their drive systems, many of these vehicles have motor generators connected to the drive wheels capable of generating electricity during deceleration and braking.

Motion of the wheels creates an electric current which can be captured to recharge the batteries. That also means that an electric current is generated when the vehicle is pushed or rolled in the shop. To avoid a potential hazard, use wheel dollies to safely move the vehicle.

Dream On

As manufacturers approach that ideal all-electric vehicle that has been dreamed of for almost 180 years, some version of electric propulsion vehicles will be on the road. As their numbers increase, you can be assured of seeing more of these vehicles damaged and in your shop for repairs. Stay educated on the technology, and think safety first.

Jeff Poole is an I-CAR trainer who has been part of the collision repair industry since 1989. Prior to 1989, he gained valuable exposure to the industry through his father, now a retired vocational instructor from Silver Spring, Md. Poole joined the I-CAR team in 1995 and is currently working in the role of performance training coordinator, providing training and support to instructors throughout the United States. Inside the Ford Escape hybrid battery: 50 5-cell packs in series for a total of 250 1.2-volt cells. Each cell is about the size of a size “D” battery. Note that 165.9 volts is showing on the meter, which is for half the pack.High-voltage batteries typically contain a warn-ing that states, “You will be killed or hurt.” Notice the emphasis on the word “killed.”A lithium-ion battery module featured in some hybrid vehicles.

You May Also Like

New Welding Technology: Good or Bad?

Welding technology in the collision industry has advanced tremendously. But is the industry allowing techs to avoid the “why” in welding?

In the highly competitive automotive industry, change is inevitable. Manufacturers are challenged to meet new government standards in fuel economy as well as improve safety in their vehicle designs. Engineers consider many factors when developing materials to be used in the manufacture of their vehicles, including safety, fuel efficiency, manufacturability, durability, quality and environmental friendliness. 

Vehicle Scanning & Calibration Technology

Scan tools and calibration equipment have come a long way as far as ease of operation and ability to access the vehicle.

Welding on a Hybrid or Electric Vehicle

As more and more HEVs and EVs roll into your shop, there are considerations to take when welding.

Is Auto Glass Replacement Right For Your Auto Body Shop?

With ADAS features, required calibrations for auto glass and the variety of repairs currently being done in shops, glass seems an obvious fit to today’s business model.

Vehicle Calibrations and Mechanical Repairs

Whether you’re replacing a radiator or repairing collision damage, deviating from OEM requirements will make a shop a target for blame should something go wrong.

Other Posts

Preparing the Collision Industry for Electric Vehicles

Today’s electric vehicle/hybrid revolution combined with the lightning-speed proliferation of ADAS features has made training essential.

Automotive Painting: It’s Still a Good Trade

I can think of no other industry where a young man or woman can start in an entry-level position and excel to an extremely comfortable living — without ever going to formal schooling or training.

Vehicle Calibrations: Patience is a Virtue

You can train someone to use equipment, but experience comes with time — which can try your patience when you’re trying to get vehicles out the door.

Pre- and Post-Repair Scanning in Electric Vehicle Repairs

To achieve a complete, safe and quality repair, pre- and post-repair scanning must be part of your BEV and HEV collision repair process.