How do garages work on repairs with hybrid and electric vehicles?

The European Parliament has recently approved the emissions target for EU vehicles for 2030. This way, all new cars registered starting that year will have to meet accumulated  CO₂ emission data 37,5% lower than the total emission number registered for that same brand in 2021, while the reduction target for vans will be 31%. This agreement also includes an intermediate emission reduction target of 15% for 2025.

Likewise, the European Council and the European Parliament have agreed on creating a procedure to encourage sales of low emission vehicles, such as electric and plug-in hybrid cars.

This way, a new push is given to these types of vehicles that will become more present fleet-wide in Europe. According to a report by analysis company Standard & Poor's Global, 25% of cars sold in Europe in 2025 will be electric or plug-in hybrids. In China, 20% of the cars sold in this same year will be electric or plug-in hybrids, while in the US it will reach 10%.

This growth of electric and hybrid vehicles will have (it already has) an special impact on garages’ work. Why? Plug-in hybrids and electric cars come with a technology with its own characteristics that require specific training for garage professionals, not only for technicians specialized in mechanics, but also for collision repair specialists. 

Therefore, mechanics will need basic safety training and an understanding of how components work in this type of vehicle. In addition, training is needed regarding how to unplug and work with the high voltage parts present in these vehicles. It is also important to know other details like where some of the components of these vehicles are located (inverter, high voltage battery, service disconnection system, AC and all the wiring).       

Each vehicle will have its own repairing procedure and it is necessary to know how it works to perform tasks safely. In the same way, car makers offer garage professionals the safety protocols of each specific vehicle with all the necessary information required to perform safe repairs.   

In addition to counting on some basic safety and personal protection measures, garage technicians need specific equipment and tools to work with electric components (category III multimeter with 1000 volt capacity, non-metallic work benches, equipment to move the car in the garage without pushing it…).

Removing batteries, which are often located inside an armored casing, integrated to be protected from vibrations and impacts, for example, requires time and specialized attention. On hybrids, switching off the gasoline or diesel engine does not necessarily dislodge the electric battery, which could pose a danger to non-trained technicians.

In the painting stage, electric vehicles also pose challenges, because many of them cannot be cured in a spray booth at temperatures higher than 120º Fahrenheit (48,8º C), the reason for this being the electric battery.

25% of cars sold in Europe in 2025 will be electric or plug-in hybrids. In China, 20% of the cars sold in this same year will be electric or plug-in hybrids, while in the US it will reach 10%.                                             Standard & Poor's Global

In a typical garage procedure, the high voltage system, for safety reasons, must be disconnected when working with electric vehicles. This turns off the battery refrigeration system, so the battery is susceptible to overheating and damage.

Since electric vehicles cannot be cured with a normal baking cycle in the painting cabin, technicians often use an extended low-bake cycle. Though effective, it doubles the baking time, which significantly slows the overall garage performance. Garages can also use an air-dry or low bake clear coat, in which case, if not using a quality product, could compromise its shine and durability.

The best solution to cure electric vehicles without causing damage or reducing the garage performance is through short wave infrared electric curing technology. This technology directly penetrates into the substrate surface, be it metal, plastic or other material, to heat it and cure the coating from the inside out.

The PPG logo is a registered trademark and We protect and beautify the world is a trademark of PPG Industries Ohio, Inc. ⓒ 2019 PPG Industries, Inc. All rights reserved.

Third-party trademarks referenced in this article are property of their respective owners.