Hybrid Electric Vehicles – Diagnosis and Repair

Training

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Duration: 8 hours

Face to face Diagnostics & Test Equipment Hybrid Electric Vehicle Training Series

Course Overview

Course number: SV11242-11B1 / Hands-On Training!

Now that you understand the major components and have performed maintenance services on hybrid vehicles, it’s time to prepare for the diagnosis and replacement of failed components. Hybrids vehicles have been on the road since the late 90s and most of these vehicles are out of the manufacturer’s warranty period. Being prepared to diagnose and replace major components is important.

This course is designed to educate technicians, and shop owners on proper diagnosis, testing procedures and replacement of components related to hybrid vehicles. Important safety procedures and the disabling of high voltage systems making them safe to test and repair will also be covered.

This course will guide you through the maze of electronic and mechanical systems you are likely to encounter when diagnosing, and repairing hybrid vehicles.

PLEASE NOTE: The customer must provide a facility to bring a vehicle into. A lift is preferred. There also must be at least one of the following hybrid vehicles available for this class: Toyota Prius, Ford Hybrid Escape / Mercury Hybrid Mariner or Ford Hybrid Fusion / Mercury Hybrid Milan.

Audience

All automotive aftermarket technicians
Skill level

Advanced
Prerequisites

Hybrid Electric Vehicles – Service and Maintenance (SV11240-11B1) completed

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This course includes:

Hands-On Training
Diagnosis and testing procedures
Replacement of hybrid vehicle components
Safety procedures

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Fuel Module Replacement Tech Tips

1. Always clean the tank FIRST

Most tanks contain debris that can get into the new fuel module and permanently damage it, as well as the evaporation emissions vent (EVAP), fuel filters, rails, and injectors.

2. Use the updated wiring plug

Some replacement fuel modules included an updated wiring harness plug. This corrects a design flaw in the OE plug. Failure to install the new plug can cause the fuel module to overheat. Use a crimping tool, not pliers when splicing in the new connector. Pinched harness wires can result in faulty fuel level readings.

3. Follow OE install procedures

Do not use excessive force or bend the float arm when installing.
Perform a fuel pressure test to ensure a successful installation.

4. Change the screen and the filter

Where applicable, install a new screen on the module and change out the in-line fuel filter(s).

5. For GDI vehicles

Inspect the pump plunger follower and all accessories for wear/proper installation.
Always replace the high-pressure feed line.
GDI pump bolts are torque to yield/single use

10 Steps to Properly Clean the Tank

Clean dirt and debris from around the fuel module.
Detach remaining fuel lines and then remove fuel module.
Pump out any remaining fuel into an approved container.
Soak up residual fuel with shop towels, dry tank with compressed air.
Add low-suds detergent and water to the tank; swirl to coat internal surfaces.
Wipe down the tank interior with clean shop towels, then dump out remaining solution.
Rinse tank with fresh water, then pour out the water and remaining debris.
Rinse again with fresh water, the pour the water out.
Dry the interior with clean shop towels, and then with compressed air.
Allow tank to air dry for at least 30 minutes to ensure all water has been removed.