Hybrid Diagnostics!           Safety First! 

Hybrids are designed to minimize the need to directly measure live high-voltage circuits. However, there will be times when the experienced hybrid vehicle technician will need to do just that. Although articles such as this can only supplement OEM service information, there are some general precautions that a professional technician should take when approaching a high-voltage circuit.

Jack Rosebro is the founder of Perfect Sky, a company that develops and delivers technical training for hybrid, electric, and other innovative vehicle technologies in North America, Europe, and Asia.

Click here to read the article!

The Triangle of Doom 
The diagnostic journey of a 2001 Prius with 98k
Courtesy of Jerry Truglia and Wells Mfg Counterpoint

Click here to read the article!

Toyota Emergency Response & Hybrid Information
Courtesy of Toyota Corporation

Click here to visit their site!

Hybrid Vehicles & Manfuacturers

Toyota has developed a new-generation Toyota hybrid system called THS II, which achieves high levels of compatibility between environmental performance and power by increasing the motor output by 1.5 times, greatly boosting the power supply voltage and achieving significant advances in the control system, aiming for synergy between motor power and engine power. Bottom line: higher power and higher fuel economy.

For more information please visit: http://www.toyota.co.jp/en/tech/environment/ths2/index.html

When to Wear Protective Gloves
Courtesy of Craig Van Batenburg

Before disconnecting hybrid system or orange cables you should do the following:
1. Remove ignition key / disable smart key (Toyota Prius).
2. Use rubber gloves rated to 1000v minimum.
3. Depending on your vehicle:
    A) Honda Turn HV safety switch to off *
    B) Toyota/Lexus Remove HV service plug (orange)*
    C) Ford/Mercury Remove Service Switch (orange) and install in Shipping Position.*
4. Disconnect 12 volt battery (optional but recommended)
5. Test any source for high voltage. Use a CATIII DVOM rated for 1000v Min.*
6. Proceed if voltage is 12.6 volts or less.
* Wear rubber gloves when performing these tasks!

Rubber gloves rated to 1000v minimum will protect you from the the high voltage found on hybrid vehicles.  However, you must also protect the gloves from damage.  That is why this HV Glove Kit also includes a set of leather protectors and a storage bag.

Adventures of a Hybrid Mechanic
Courtesy of www.hybridcars.com

What's the best way to understand hybrid technology? You can read the marketing literature put out by the carmakers-or discuss theories with hybrid engineers. Or you can get the straight dope from the mechanics who see, touch, and smell actual hybrids after the vehicles have been on the road. Intrepid hybrid technicians experience the everyday adventure of maintaining and fixing hybrids-and most of the time, they live to tell the tale.

There's no better adventure guide than Paul Cortes of Art's Automotive in Berkeley, California.

Honda Insight Oil Leak
The repair of a messy oil leak on a Honda Insight becomes a kaleidoscopic journey through the mechanics of the retired king of hybrid fuel economy. Along the way, we learn about the similarities and differences between the Insight, other hybrids, and conventional vehicles.  Includes lots of photos.

Toyota Prius RFID Unit
Replacing the ECU for a Toyota Prius RFID immobilizer is harder than it looks.

How Stray Voltage Affects Multimeter Measurements...
and What You Can Do About It
Courtesy of Fluke Corporation

Click here to read this article!

Comparing CAT III Approved Multimeters
Courtesy of Fluke Corporation

Article: What makes a Hybrid a Hybrid?
Identifies 5 technology steps that separate battery electric vehicles from conventional vehicles:
1) Idle-Off capability
2) Regenerative Braking capacity
3) Power Assist and Engine downsizing (a "mild" hybrid)
4) Electric-only drive ("full" hybrid)
5) Extended Battery-Electric Range (a "plug-in" hybrid)

Article: Hybrid Drivetrain 
Describes three drivetrains common in hybrid vehicles:
1) series drivetrain; 2) parallel drivetrain; 3) series/parallel drivetrain
Also includes a nifty Flash animation showing each drivetrain in OFF, SLOW, ACCELERATION, CRUISE and BRAKING.

Locations of HV Batteries and Service Switch/Plugs