Lesson 1Battery Pack Arrangement and Positions: Underfloor, Rear Cargo, Engine Bay—Service Access, Heat Management, and Crash Safety ChecksThis part looks at where hybrid and PHEV battery packs are fitted in the vehicle, how their position affects repairs, cooling, noise levels, and crash protection, and what mechanics should inspect before taking out or putting back a pack safely.
Underfloor pack designs and body fittingRear cargo pack position and space choicesEngine bay packs and heat danger risksService entry points, lifting and removal routesCrash safety areas and damage preventionLesson 2Heat Management for High-Voltage Batteries: Liquid vs Air Cooling, Coolant Paths, Sensors, and Effects on Electric Range and Battery LifeThis part compares air and liquid cooling methods for HV batteries, looks at coolant paths, pumps, valves, and sensors, and shows how keeping temperature right impacts power use, available energy, travel distance, and battery lasting power over time.
Air-cooled pack setups and air flow routesLiquid-cooled plates, covers, and coolersCoolant pumps, valves, and heat changersTemperature, flow, and pressure sensorsCold weather pre-heating and warmersHeat limits, power reduction, and wear effectsLesson 3Standard Pack Voltages: Usual Ranges for Mild Hybrids, Full Hybrids, Plug-In Hybrids, and BEVs and How Pack Setup Affects VoltageThis part reviews common pack voltage levels for mild, full, and plug-in hybrids, plus BEVs, and explains how number of cells in series, module setup, and switch devices set the standard voltage and safety limits for technicians to follow.
Voltage ranges for mild hybrid setupsFull hybrid and PHEV voltage levelsBEV pack voltages and division methodsSeries cell numbers and module pilingContactors, precharge, and HV bus planningVoltage class, safety gear, and service boundariesLesson 4High-Voltage Cables, Connectors, Service Plugs, and Safety Locks: Colour Coding, Insulation, Shielding, and Common Damage TypesThis part details high-voltage cables, connectors, and safety locks, including orange colour coding, insulation types, shielding against interference, lockout features, and how to spot, test, and record common damage or failures safely in the workshop.
Orange HV cable rules and marksInsulation kinds, gap and space limitsShielding, earthing, and interference controlService plugs, cut-offs, and lockout stepsSafety lock chains, continuity tests, and errorsUsual wear, rust, and spark damageLesson 5High-Voltage Extra Systems: DC-DC Converters, Onboard Charger, EVSE Inlet, and Power Electronics Basics (Inverter, Motor)This part introduces high-voltage extra parts, like DC-DC converters, onboard chargers, charge inlets, inverters, and motor drives, and explains power flow routes between the battery, 12V system, and drive parts for reliable operation.
DC-DC converter jobs and setupsOnboard charger stages and power factorsEVSE inlet kinds and talk basicsInverter work and pulse control fundamentalsMotor types in hybrids and PHEVsEarthing, separation, and leak testsLesson 6Battery Types Used in Modern Hybrids/PHEVs (Li-ion, NMC, LFP, NiMH) and How Type Affects Performance, Wear, and SafetyThis part surveys main battery types in hybrids and PHEVs, including Li-ion kinds like NMC and LFP, plus NiMH, and explains how each type influences energy storage, power output, cycle durability, cost, and safety features important for service.
Main Li-ion cell parts and reactionsNMC type features for hybrids and PHEVsLFP type features and safety benefitsNiMH type and old hybrid systemsType effects on energy and power storageType-based safety and damage responseLesson 7Battery Module and Cell Structure: Series/Parallel Setups, Module Monitoring, and Role of the Battery Management System (BMS)This part explains how cells are grouped into modules and packs with series and parallel links, how current and voltage increase, and how the BMS watches modules, balances cells, and guards the pack from harmful conditions during use.
Series lines and pack voltage increaseParallel groups and current strengthModule building, bars, and fusesSensing wires and module watch chipsCell balancing methods: simple and advancedBMS guard limits and error responsesLesson 8Battery Status Measures: State of Charge (SoC), State of Health (SoH), State of Power (SoP), and Their Usual Measurement Ways and Check LimitsThis part defines state of charge, state of health, and state of power, describes common calculation methods and sensor data, and shows how makers set check limits that start warnings, power cuts, or service needs for safe operation.
State of charge ideas and calculationState of health signs and capacity lossState of power and changing limitsVoltage, current, and temperature dataFilter methods and model watchersCheck limits and error code plans
