Electric/Hybrid Vehicle Routine Maintenance Activities — The Institute of the Motor Industry End-Point Assessment Motor Vehicle & Transport Revision

    This element covers essential, non-high-voltage routine maintenance activities on electric and hybrid vehicles, including safe system identification, hazar

    Topic Synopsis

    This element covers essential, non-high-voltage routine maintenance activities on electric and hybrid vehicles, including safe system identification, hazard awareness, risk management, and correct preparation procedures. Learners must demonstrate the ability to safely carry out tasks such as fluid checks, brake inspections, and cabin filter replacements without exposing themselves or others to high-voltage dangers.

    Key Concepts & Core Principles

    Exam Tips & Revision Strategies

    Common Misconceptions & Mistakes to Avoid

    Examiner Marking Points

    Electric/Hybrid Vehicle Routine Maintenance Activities

    THE INSTITUTE OF THE MOTOR INDUSTRY
    vocational

    This element covers essential, non-high-voltage routine maintenance activities on electric and hybrid vehicles, including safe system identification, hazard awareness, risk management, and correct preparation procedures. Learners must demonstrate the ability to safely carry out tasks such as fluid checks, brake inspections, and cabin filter replacements without exposing themselves or others to high-voltage dangers.

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    Learning Outcomes
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    Assessment Guidance
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    Key Skills
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    Key Terms
    5
    Assessment Criteria

    Assessment criteria

    IMI Level 3 Technical Specialist in Electric/Hybrid Vehicle System Repair and Replacement (Award)

    Topic Overview

    The IMI Level 3 Technical Specialist in Electric/Hybrid Vehicle System Repair and Replacement (Award) is a specialised qualification designed for experienced motor vehicle technicians who want to advance their expertise in high-voltage (HV) vehicle technology. This award focuses on the safe diagnosis, repair, and replacement of electric and hybrid vehicle systems, including battery packs, electric drive motors, inverters, and HV cabling. It builds on the mandatory IMI Level 3 Award in Electric/Hybrid Vehicle System Repair and Replacement, which covers the principles of HV safety and system isolation. This specialist award takes you deeper into the practical and theoretical aspects of HV system repair, preparing you for a career as a senior technician or specialist in the rapidly growing EV market.

    In the UK, the shift towards electric vehicles (EVs) is accelerating, with the government banning the sale of new petrol and diesel cars by 2035. This means there is a growing demand for technicians who can safely and competently repair and replace HV components. This qualification covers critical areas such as HV battery diagnostics, thermal management systems, regenerative braking, and the use of diagnostic equipment for HV systems. You will learn how to interpret manufacturer-specific data, perform high-voltage insulation tests, and safely handle damaged or degraded HV batteries. Mastery of these skills is essential for ensuring vehicle safety and performance, and for meeting the legal requirements of the Electricity at Work Regulations 1989 and the Health and Safety at Work Act 1974.

    This award is not just about technical know-how; it also emphasises the importance of following manufacturer procedures and using the correct personal protective equipment (PPE) and insulated tools. You will develop a systematic approach to fault-finding, using wiring diagrams and diagnostic software to identify issues in complex HV systems. By the end of the course, you will be able to carry out repairs that are both safe and compliant with industry standards. This qualification is recognised by the Institute of the Motor Industry (IMI) and is a key step towards achieving IMI TechSafe accreditation, which is increasingly required by employers and insurers for technicians working on HV vehicles.

    Key Concepts

    Core ideas you must understand for this topic

    • →High-Voltage (HV) Safety Procedures: Understanding the correct isolation and de-energisation processes, including the use of voltage testers, lock-off/tag-out systems, and the importance of waiting for capacitor discharge (typically 5-10 minutes) before working on HV systems.
    • →HV Battery Pack Construction and Repair: Knowledge of battery cell types (e.g., lithium-ion, nickel-metal hydride), module arrangement, battery management systems (BMS), and procedures for safely removing, repairing, and replacing battery modules or cells, including balancing and capacity testing.
    • →Electric Drive Motor and Inverter Diagnostics: Ability to diagnose faults in AC induction motors or permanent magnet synchronous motors, and inverters (DC-AC converters), including checking for insulation breakdown, winding resistance, and sensor signals (e.g., resolver, Hall effect).
    • →Thermal Management Systems: Understanding of liquid cooling and heating systems for batteries and power electronics, including coolant types, pump operation, and the use of thermal imaging to identify hot spots or cooling system blockages.
    • →Regenerative Braking and HV Energy Flow: Analysis of how regenerative braking recovers kinetic energy, the role of the DC-DC converter in stepping down HV to 12V, and the interaction between the HV battery, inverter, and electric motor during acceleration and deceleration.

    Learning Objectives

    What you need to know and understand

    • 1. Know about electric/hybrid vehicle system components and operation 2. Understand the hazards surrounding electric/hybrid vehicles3. Know how to reduce the risks to yourself and others when working on electric/hybrid vehicles 4. Know how to safely prepare the vehicle when carrying out routine maintenance on electric/hybrid vehicles (NOT high voltage components or systems) 5. Be able to work safely on an electric/hybrid vehicle (NOT high voltage components or systems)

    Assessment Criteria

    Key criteria assessors look for in your portfolio

    • Award credit for producing a detailed job card or risk assessment that correctly identifies the vehicle's high-voltage components and their locations.
    • Award credit for clearly demonstrating the isolation and lockout/tagout procedures for the low-voltage system before commencing any maintenance task.
    • Award credit for consistent and correct use of appropriate personal protective equipment (PPE) such as insulating gloves (if required) and safety eyewear throughout the activity.
    • Award credit for verifying the absence of high-voltage potential using a dedicated voltage detection tool where specified by the manufacturer’s instructions.
    • Award credit for completing all routine service items without any infringement of safety zones or accidental contact with high-voltage cabling or connectors.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Always follow a manufacturer-specific service procedure and reference it in your evidence; assessors look for adherence to official technical data.
    • 💡When describing risk reduction, structure your answer around the hierarchy of control: elimination, substitution, engineering controls, administrative controls, and PPE.
    • 💡In practical assessments, narrate your actions clearly to explain why you are performing each safety check, demonstrating underpinning knowledge.
    • 💡For written assignments, include real-world examples of routine maintenance tasks (e.g., tire rotation, coolant top-up) and detail the specific precautions taken for each.
    • 💡Tip 1: Always reference the manufacturer's service information in your answers. Examiners look for evidence that you can follow specific procedures, not just generic steps. For example, when describing HV battery removal, mention the need to consult the manufacturer's manual for the exact location of service plugs and the correct sequence of disconnection.
    • 💡Tip 2: Use correct technical terminology and units. For instance, refer to 'high-voltage (HV) interlock loop' rather than 'safety circuit', and specify voltages (e.g., 400V DC) and resistances (e.g., >1 MΩ for insulation resistance). This demonstrates your specialist knowledge and attention to detail.
    • 💡Tip 3: Show your understanding of the 'why' behind safety procedures. For example, explain that the orange HV cabling is designed to be easily identifiable and that the interlock loop ensures the HV contactors open if a connector is accidentally disconnected. This depth of understanding scores higher marks than simply listing steps.

    Common Mistakes

    Common errors to avoid in your coursework

    • Assuming all orange cables are instantly lethal even after system shutdown, leading to unnecessary fear or avoidance of basic tasks.
    • Failing to disconnect the 12V auxiliary battery before performing any non-HV work, which can still cause electrical shorts or unintended system activation.
    • Neglecting to place warning signs and barriers around the work area to alert others that a high-voltage vehicle is present.
    • Using unapproved cleaning products on electric motor housings or regenerative braking components, potentially damaging insulation or sensors.
    • Misconception: 'Once the HV system is isolated, it is completely safe to touch any component.' Correction: Even after isolation, capacitors in the inverter and DC-DC converter can retain a lethal charge for several minutes. Always use a suitable voltage tester to confirm zero voltage before touching any HV component, and follow the manufacturer's specified discharge time.
    • Misconception: 'A damaged HV battery can be repaired by simply replacing individual cells.' Correction: Many manufacturers prohibit cell-level repair due to safety risks and warranty issues. Instead, the entire battery pack or module must be replaced. Always consult the manufacturer's service information; some allow module replacement but require specialised training and equipment.
    • Misconception: 'Regenerative braking is the same as engine braking in a conventional car.' Correction: Regenerative braking converts kinetic energy into electrical energy to recharge the battery, while engine braking uses friction and pumping losses. Regenerative braking can be adjusted via the vehicle's control system and may not provide the same feel as engine braking, especially at low speeds.

    Frequently Asked Questions

    Common questions students ask about this topic

    Before You Start

    Prior knowledge that will help with this topic

    • •Before starting this specialist award, you should have completed the IMI Level 3 Award in Electric/Hybrid Vehicle System Repair and Replacement (or equivalent). This covers the fundamental principles of HV safety, system isolation, and basic HV component identification.
    • •A solid understanding of conventional vehicle electrical and electronic systems (e.g., from IMI Level 2 or 3 in Light Vehicle Maintenance and Repair) is essential, as HV systems integrate with 12V systems via DC-DC converters and control modules.
    • •You should be familiar with using diagnostic equipment such as multimeters, oscilloscopes, and scan tools, as well as interpreting wiring diagrams and technical data from manufacturer sources.

    Key Terminology

    Essential terms to know

    • 1. Know about electric/hybrid vehicle system components and operation 2. Understand the hazards surrounding electric/hybrid vehicles3. Know how to reduce the risks to yourself and others when working on electric/hybrid vehicles 4. Know how to safely prepare the vehicle when carrying out routine maintenance on electric/hybrid vehicles (NOT high voltage components or systems) 5. Be able to work safely on an electric/hybrid vehicle (NOT high voltage components or systems)

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