AUTO 242 - Hybrid/EV Power Electronics and Supporting Systems

Credits: 3
Instructional Contact Hours: 3

Practices the diagnostic procedures and repair of hybrid/EV vehicle power electronic control, HVAC, and braking systems. Practices ASE Education Foundation Tasks related to High Voltage/Electric Vehicle systems.

Prerequisite(s): ASEP 100 or AUTO 100, ASEP 101 or AUTO 101, ASEP 102 or AUTO 102, and ASEP 106 or AUTO 106 and AUTO 236 with a grade of “C” or ASE (Automotive Service Excellence) A1, A2, and A6 Certification as verified by instructor or program coordinator.
Corequisite(s): None
Lecture Hours: 15 Lab Hours: 30
Meets MTA Requirement: None
Pass/NoCredit: No

Outcomes and Objectives

Diagnose and complete advanced ASE Education Foundation tasks as listed below:
1. Safety Related tasks
  1. Perform high voltage disconnect procedure; reconnect/enable high voltage system.
  2. Select, test, and use proper safety gloves.
  3. Select, qualify, and use proper electrical testing equipment and leads.
2. Power Electronics
  1. Retrieve and diagnose DTCs; determine needed repairs.
  2. Diagnose problems caused by damaged or failed harnesses, connectors, and terminals.
  3. Identify procedures necessary to establish the proper vehicle operational power mode during service (OFF, ACCESSORY, POWER ON, READY TO DRIVE).
  4. Diagnose the cause of a hybrid system warning displayed on the instrument panel and/or a driveability complaint.
  5. Diagnose impact sensor problems; determine needed repair.
  6. Demonstrate knowledge of high-voltage thermal management systems.
  7. Diagnose AC/DC inverter overheating; determine needed repair.
  8. Diagnose AC/DC inverter failure; determine needed repair.
  9. Replace AC/DC inverter cooling pump.
  10. Remove and install AC/DC inverter.
  11. Diagnose failures in the data communications bus network; determine needed repair.
  12. Locate and test the voltage level of capacitors.
  13. Diagnose, locate and safely disable/enable safety interlocks.
  14. Diagnose failed DC/DC converter; determine needed repair.
  15. Remove and install DC/DC converter.
  16. Test high voltage cable integrity and loss of isolation.
  17. Perform 12-volt battery testing.
  18. Diagnose system main relay (SMR)/contactor malfunctions; determine needed repairs.
3. Hybrid Supporting Systems
  1. Diagnose problems caused by damaged or failed harnesses, connectors, and terminals.
  2. Retrieve and diagnose DTCs; determine needed repairs.
  3. Inspect, test, and diagnose EVAP emission system components; determine needed repairs.
  4. Observe and interpret driver indicators, power flow display and energy monitor; determine necessary action.
  5. Test and diagnose high voltage air conditioning compressor malfunctions; diagnose system problems; determine needed repairs.
  6. Remove and install high voltage air conditioning compressor; identify and select proper system oil.
  7. Demonstrate knowledge of safe handling procedures associated with high-voltage A/C compressors and wiring
  8. Diagnose cabin heating system performance problems; determine needed repairs.
  9. Diagnose and repair electric/electronic steering systems.
  10. Diagnose brake system performance problems; differentiate between braking problems caused by hydraulic system and regenerative system malfunctions; determine needed repairs.
  11. Deactivate brake system self-test prior to service.
  12. Service liquid cooling system(s).