Department of Mechanical Engineering

DIPLOMA IN MECHANICAL ENGINEERING

(AUTOMOTIVE)
WORKSHOP REPORT
DJA40052– AUTOMOTIVE WORKSHOP PRACTICE 3

REPORT TITLE
2.3 TROUBLESHOOTING AND SERVICE OF HYBRID SYSTEM

CLASS DAD4B GROUP A3

Member of Group :
No. Name No. Matrix
1 MUHAMMAD SYAHRIL AZIM BIN SURIA 04DAD20F2053
2 MUHAMMAD AQIL FAHMI BIN FAUZI 04DAD20F2059
3 MUHAMMAD IKHWAN SYAFIQ BIN ABDUL WAHAB 04DAD20F2058

No. Name
1 EN MOHD AZRI BIN ABDUL GHANI
Date
Workshop In Due Date Report Received
Marks for Report

No Assessment Criteria 1 2 3 4 5 Score Weight Total

(100%)
1 Format & Aesthhetics 5 1
2 Aim/Purpose 5 1
3 Work Material/Equipment 5 2
4 Introduction 5 3
5 Work Method/Procedure 5 4
6 Work Result 5 1
7 Discussion 5 4
8 Conclusion/Recommendations 5 3
9 References/Appendices 5 1
TOTAL SCORE:

RUBRIC FOR REPORT

Unsatisfactory Fair Good Very good Excellent
Skill/ 1 2 3 4 5
Aspect
Format & Aesthetics Report format isconsistent Excellent
Work fails to follow Many departures Report format is generally
throughout including
 heading styles, fonts,
required report format required report format consistent
margins, white space and
etc
Aim/Purpose Purpose and
Purpose is vague and Purpose defined but Purpose and variables Purpose and variables
relevant variables
variables not defined variables are unclear somewhat defined clearly defined
not defined
List of Material was Did not list one or two Made complete list of Made complete list of
Work Material/ Equipment not missing or showed items used. Did Not materials used. Shoed materials used.
Equipment available only a few of the showdetails information aboutsize Explained why
materials used about itemsused units ofmeasurement materials were chosen
Introduction Little relation Effort made to relate Reasonable relation
No introduction Clear relation between
between result and result and between result and
made result and introduction
introduction introduction introduction
Description was
Setup included Setup was documented
general or did not
Setup was not Description was descriptive text and completely. Method
include diagrams.
described or generalfair. diagrams were was documented
Procedure was
Work Method/ document. Step by Information provided is provided if appropriate. completely and
missing multiple
Procedure step procedure was sufficient to replicate Experiment can be accurately making
steps. Information
missing or experiment. reproduced using the experiment easy to
provided is not
inadequate. steps provided. reproduce.
sufficient to replicate
experiment.
Work Result
Very Poor Fair Good Very good Excellent
Accurate statement
Accurate statement on
supporting
Discussion on results results that support
Discussion No or little Discussion is introduction.
which support introduction limitations of
discussion incomplete Limitation discussed &
introduction accuracy discussed
solution
recommended
Restated problem and
aim. Justified design and
Problem was restated.
Original problem was methods of work. Findings
Problem was stated. Statements and conclusion
not restated. Findings were discussed in detail.
No summarized and Conclusions were were based on the data
Conclusion/ were not summarized. Conclusion directly
conclusion was made simplistic. No clear collected. Showed a strong
Recommendations Conclusion were not address aim.
relationship between relationship between
relevant. Statements and
conclusion conclusion and aim
conclusion were
supported by data.

References/
0 References 1-2 references 3 references 4 references More 5 references
Appendices

TOTAL

STUDENT CODE OFETHIC

I, hereby confess that I have prepared this report on my own effort. I admit not to receive or give any help during the preparation
of this report and pledge that everything mentioned in the report is true

Student signature
Name : ……………………………………………………………………………………..
Student ID : ………………………………………………..
Date : ………………………………….

CONTENTS
NO THINGS M/S
1 INTRODUCTION 1

2 PURPOSE 1

3 COMPONENTS 2,3

4 WORKING METHOD/PROCEDURE 4,5,6,7,8

5 WORK RESULT 9

6 DISCUSSION 9

7 CONCLUSION 10

8 REFERENCE 10
 HYBRID CAR SYSTEM

Hybrid electric vehicles are powered by an internal combustion engine and one or more electric
motors, which uses energy stored in batteries. A hybrid electric vehicle cannot be plugged in to
charge the battery. Instead, the battery is charged through regenerative braking and by the internal
combustion engine.

PURPOSE

A hybrid car uses more than one means of energy, combining a petrol or diesel engine with an electric
motor, and the two systems work with each other to move the vehicle. This allows the car to burn less
gasoline, achieving better fuel efficiency than a traditional engine that solely uses fuel does.

Components of a Hybrid Electric Car

 Components Description
BATTERY In an electric drive vehicle, the low-voltage
auxiliary battery provides electricity to start the car
before the traction battery is engaged; it also
powers vehicle accessories.

DC/DC converter: This device converts higher-voltage DC power

from the traction battery pack to the lower-voltage
DC power needed to run vehicle accessories and
recharge the auxiliary battery.

Electric generator: Generates electricity from the rotating wheels while

braking, transferring that energy back to the traction
battery pack. Some vehicles use motor generators
that perform both the drive and regeneration
functions.

Electric traction motor: Using power from the traction battery pack, this
motor drives the vehicle's wheels. Some vehicles
use motor generators that perform both the drive
and regeneration functions.

Exhaust system: The exhaust system channels the exhaust gases

from the engine out through the tailpipe. A three-
way catalyst is designed to reduce engine-out
emissions within the exhaust system.
Fuel filler: A nozzle from a fuel dispenser attaches to the
receptacle on the vehicle to fill the tank.

Fuel tank (gasoline): This tank stores gasoline on board the vehicle until
it's needed by the engine.

Internal combustion engine (spark-ignited): In this configuration, fuel is injected into either the
intake manifold or the combustion chamber, where
it is combined with air, and the air/fuel mixture is
ignited by the spark from a spark plug.

Power electronics controller: This unit manages the flow of electrical energy
delivered by the traction battery, controlling the
speed of the electric traction motor and the torque it
produces.

Thermal system (cooling): This system maintains a proper operating

temperature range of the engine, electric motor,
power electronics, and other components.

Stores electricity for use by the electric traction

motor.

Traction battery pack:

 The transmission transfers mechanical power from
the engine and/or electric traction motor to drive the
wheels.

Transmission:

3
WORKING METHODS

EQUIPMENT & MATERIALS

PICTURE DESCRIPTION
Safety Tools - safety clothing in the workshop

Tools Box – essential equipment during workshop

work
 Spanar – serves as a component decomposer

Hybrid Battery - Drains electrical current on

vehicle components to power the vehicle

Standard operation procedure for servicing hybrid

PICTURE INFORMATION
1. Before starting work make sure to wear
special gloves that are rubber type so that
you do not get electrocuted
1. Release the key from the power-on switch,
for systems using the smart key, place the
smart key in the OFF position.

2. Take the car keys and park away from the

car so that it does not happen to start the
engine by accidentally pressing the key
button

3. Remove the -ve terminal from the additional

12V battery. Wear insulated golve.

4. Remove the service plug and close the

service plug using plastic or sap and place it
in a safe place
5. Use special tools to open the oil filter ( oil
filter )

6. Change the old discarded engine oil and

replace the new one , hibrib engine oil it
uses petronas syntium 7000

7. Clean or replace the air filter (water filter)

8. Wear gloves
9. Check the battery voltage by using a
multimeter and measure it in the right place.
Avoid connecting HV ( HV contact ) from
contact with any other components
 6

Procedure of battery installation and removal for hybrid system car

Before servicing the HV system:

1. Turn the power switch OFF, and remove the key from the interior detection area for the entry and
start system.
• When the vehicle is in READY mode, the engine may not be running – but it can start at any time,
without warning
• Secure the smart key at least 10 feet away from the vehicle to provide additional safety
2. Disconnect the cable from the auxiliary battery negative terminal.
3. Check the insulated gloves.
• Before use, check the insulated gloves for cracks, tears and other types of damage by performing
the following procedure:

1 Place the glove on its side

2 Roll the opening up 2 or 3 times, trapping as much air as possible
within the glove
3 Fold the opening in half to close it
4 Confirm that there are no air leaks by listening for escaping air or
holding the gloves against your cheek to feel for escaping air

STEP 4

4. Wearing insulated gloves, remove the service plug grip.

• Keep the removed service plug in your pocket (or other secure location) to prevent other technicians
from accidentally reconnecting it while you are working on the high-voltage components
Refer to the Repair Manual for the vehicle you’re servicing for the specific location of and procedure for
removing the Service Plug.

Even with the service plug removed, the HV battery still has highvoltage components inside. Note that using
non-insulated tools can cause a short circuit between high-voltage components resulting in an electrical arc
and burns. Always follow the safety precautions described in the Repair Manual when working around the HV
battery.

5. Wait for 10 minutes or more to discharge the high-voltage capacitor inside the inverter assembly.

• The capacitor stores and releases high-voltage electricity supplied by the HV battery and the motor
generators

• The capacitor must be allowed to fully discharge before servicing the HV system
 STEP 6
6. Check the voltage at the designated inspection points in the inverter (0V check).

• Before using the voltmeter to measure voltage at the inverter terminals, test the voltmeter by measuring the
voltage of the auxiliary battery

• Be sure the meter is set to measure the appropriate voltage range as specified in the Repair Manual

Refer to the Repair Manual for the specific test points for voltage measurements for the vehicle you’re
servicing.

7. Insulate the disconnected high-voltage connectors with insulated vinyl tape.

Prepare for Storage

• Hybrid vehicles with smaller batteries can be lifted out with the help of a co-worker. Larger Hybrid
batteries inside the vehicle may need the use of an engine hoist to pull the battery out of the engine
compartment.

• Move the battery to the designated HV battery storage area immediately after removal from the vehicle.
See Moving a Hybrid or BEV manually on the ground or with a forklift p 65 in Guidelines.

• Never leave a vehicle with a partially removed HV battery inside the building overnight. Complete the
removal process before leaving the vehicle unattended for any extended length of time.

WORK RESULT

When we want to do some work with the hybrid car we make sure our equipment and clothes are complete
with the necessary safety features, hybrid cars are not the same as other cars, if we ignore the safety features
and continue to do some work it can endanger the lives of people fix the hybrid car. We make sure to wear
special gloves and special tools to change car batteries, change black oil and more. When we want to change
the battery we need to wear gloves and a special wrench because the voltage of this hybrid battery is very
high and it is dangerous if we use gloves and a normal wrench. The process of changing engine oil and
others can use normal gloves and spanners but for safety we use special gloves and spanners. After finishing
the repair we made sure that the oil cap and the screw that we opened earlier were properly locked before
handing this car over to the owner.

DISCUSSION

Vehicles that use on board reachargable energy and fuel-based power supplies to power vehicles. These
vehicles consume less fuel and produce less pollution. Hybrid vehicles use the kinetic energy generated
when braking to recharge the battery by using a braking regenerative system. Some hybrid vehicles use
combustion engines to produce electricity that serves to rotate the generator to either charge the battery or
directly power the electric motor used to drive the vehicle. This condition is used during low speeds.

9
ADVANTAGES OF HYBRID SYSTEM
Hybrid cars are becoming more popular and more common. Basically, a hybrid car is one that uses two or more
engines, i.e., an electric motor and a conventional engine (either petrol or diesel). The electric engine powers the car at
lower speeds, and the gas engine powers it at higher speeds. A hybrid car like the Toyota Prius or Honda Civic Hybrid
not only conserves fuel but also produces less CO2 emissions. 

Though hybrid vehicles are now growing in popularity still few people are actually using them, mainly due to a lack
of knowledge of how hybrid vehicles work and whether they’re as good as other gasoline-powered vehicles.

When the vehicle comes to a stop, it automatically shuts off the engine and restarts it when the accelerator
is pressed down. This automation is much simpler with an electric motor.

The additional power provided by the electric motor can potentially allow for a smaller engine. The battery
not only powers auxiliary loads,  but it also reduces engine idling when it stops.  These features altogether
result in better fuel economy without hampering performance.

While most people associate hybrid vehicles with the kinds that use electricity as their primary alternate
fuel, there are more options available now. There are cars that use hybrid technologies with propane
and natural gas as well.

CONCLUSION

The conclusion that can be made, a hybrid car is a type of vehicle that has two sources of energy to move. In
addition, oil saving for long-distance driving and when congested on the road is not only a priority for
drivers in Malaysia, but also the whole world. The criterion for the selection of oil-saving vehicles is the
reason why manufacturers consistently produce compact models. On the other hand, the production of large
volumes of cars is also the cause of the increase in air pollution in the city. Just look at the environmental
report of the last Movement Control Order (MCO) season, there has been a significant decrease in the
pollution index in cities throughout Malaysia. In an effort to address the pollution problem, automotive
manufacturers are taking the initiative to develop more environmentally friendly electric vehicle
technologies. However, the technology still has various shortcomings in terms of the capabilities of the car
battery. So to begin with, the manufacturer combines an internal combustion engine system and an electric
motor for which a vehicle with two systems is called a hybrid. Based on history, hybrid systems are widely
used vehicles such as electric bicycles, electric motorcycles, diesel-electric buses and others. All such
vehicles combine the internal combustion system and the ability of the battery to move.

REFERENCE

 https://afdc.energy.gov/vehicles/how-do-hybrid-electric-cars-work#:~:text=Hybrid%20electric
%20vehicles%20are%20powered,by%20the%20internal%20combustion%20engine.
 "History of Hybrid Vehicles". HybridCars.com. 2006-03-27. Diarkibkan daripada yang asal pada
2009-02-08. Dicapai pada 2010-03-21.
 ^ Matt Lake (2001-11-08). "How it works; A Tale of 2 Engines: How Hybrid Cars Tame Emissions".
The New York Times. Dicapai pada 2010-03-22.
 ^ Elizabeth Lowery (2007-07-01). "Energy diversity as a business imperative". The Futurist. Dicapai
pada 2010-03-21.
10