EV Annual Inspection

Comprehensive annual safety and performance inspection of electric vehicle high-voltage systems, cooling systems, brakes, tires, and battery condition to ensure safe operation and optimal range.

Warnings

Tools required

Parts

• Cabin air filter × 1 — Use OEM specification
• 12V battery (if needed) × 1 — Group 48 AGM battery

Fluids

• ACDelco DEX-COOL (Orange) — 0.5 qt
• ACDelco DOT 4 Brake Fluid — 0.25 qt
• Windshield Washer Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and remove key fob from interior
3. Allow vehicle to sit for at least 10 minutes to allow high-voltage system to discharge
4. Open hood and inspect for any obvious damage, fluid leaks, or loose components
5. Connect OBD-II scan tool and retrieve any stored diagnostic trouble codes

Procedure

1. 1

   Inspect 12V battery and connections
   Visually inspect the 12V auxiliary battery located in the engine compartment. Check for corrosion, damage, or leaks. Test battery voltage (should be 12.4-12.8V with vehicle off). Load test battery if voltage is low. Inspect battery terminals for tightness and corrosion. Clean terminals if necessary and verify torque specification.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Inspect high-voltage system components
   Perform visual inspection of high-voltage battery pack (located under floor), power inverter module, and onboard charger. Look for any orange high-voltage cable damage, exposed conductors, coolant leaks around battery pack, or physical damage to enclosures. Check for diagnostic codes related to high-voltage system. Do not remove any covers or disconnect any orange cables.
   ⚠️Maintain distance from orange high-voltage cables. Do not touch or manipulate any high-voltage connectors during visual inspection.
3. 3

   Inspect EV cooling system
   Check coolant level in reservoir (should be between MIN and MAX marks when cold). Inspect coolant color and condition - should be orange/red. Test coolant freeze protection and pH if equipment available. Visually inspect all coolant hoses, particularly those running to battery pack and power electronics, for leaks, cracks, or deterioration. Check for coolant stains or residue.
   ⚠Only check coolant level when system is completely cold. Hot coolant is under pressure and can cause severe burns.
4. 4

   Inspect charge port and charging system
   Open charge port door and inspect charge port for damage, corrosion, or foreign debris. Check all pins for straightness and cleanliness. Verify charge port latch operates smoothly. Connect scan tool and verify onboard charger operation through diagnostic monitoring. Check for any charging system fault codes. Inspect charging cable (if vehicle-supplied EVSE is available) for damage.
   ℹ️Do not use any cleaners or lubricants inside charge port. Use only dry compressed air if cleaning is needed.
5. 5

   Check brake system and fluid
   Check brake fluid level in master cylinder reservoir (should be at MAX mark). Inspect fluid color (should be clear to light amber). If dark or contaminated, schedule brake fluid service. Check brake fluid age - should be replaced every 3 years regardless of appearance. Test brake pedal feel for firmness. Scan for any brake system or regenerative braking fault codes.
   ⚠Use only DOT 4 brake fluid. Do not mix fluid types. Brake fluid is hygroscopic and absorbs moisture over time, reducing effectiveness.
6. 6

   Inspect brake components
   Raise vehicle on lift or jack stands. Remove all four wheels. Inspect brake pads for remaining thickness (minimum 3mm). Check rotors for scoring, cracking, or excessive wear. Measure rotor thickness if concern exists. Inspect brake calipers for leaks, damage, or seized guide pins. Due to regenerative braking, pad wear may be minimal - verify pads are not seized or corroded from lack of use.
   ℹ️EV brake pads often last significantly longer than ICE vehicles due to regenerative braking, but can develop corrosion from infrequent use.
7. 7

   Inspect tires and suspension
   Check tire pressure in all four tires including spare (refer to door placard for specification, typically 38-41 PSI). Measure tread depth at multiple points on each tire (minimum legal 2/32 inch, replace at 4/32 inch). Inspect for uneven wear patterns indicating alignment issues. Check for cuts, bulges, or embedded objects. Visually inspect suspension components, CV boots, and steering linkage for damage or leaks.
   ℹ️EVs are heavier than comparable ICE vehicles and may experience accelerated tire wear. Rotate tires every 7,500 miles.
8. 8

   Inspect drivetrain and motor
   Visually inspect electric drive motor and single-speed transmission for leaks or damage. Check transmission fluid level through fill plug if accessible (transmission is sealed but has check/fill provision). Inspect motor mounts for deterioration. Check CV axles and boots for tears, grease leaks, or damage. Scan for any drive motor or transmission fault codes.
   ⚠Single-speed transmission uses Dexron VI ATF. Fluid should be red and clear. Dark or burnt-smelling fluid indicates internal issues.
9. 9

   Test vehicle systems and diagnostics
   Using OBD-II scan tool with EV capability, check battery state of health (SOH), state of charge (SOC), and individual cell voltages. Verify all cells are balanced within 0.05V. Check for any abnormal temperature readings in battery modules. Review charge/discharge history if available. Verify all vehicle control modules communicate properly. Check for any pending or stored fault codes in all systems.
   ℹ️Battery SOH below 85% may indicate degradation. Cell voltage imbalance greater than 0.1V requires further diagnosis.
10. 10

    Inspect cabin and safety systems
    Check operation of all exterior lights including headlights, taillights, brake lights, turn signals, and charge port light. Test horn operation. Verify windshield wipers and washers function properly, top off washer fluid if needed. Check cabin air filter condition and replace if dirty or restricted. Test HVAC system operation in heat and cool modes. Verify all seatbelts operate and retract properly.
11. 11

    Inspect underbody and high-voltage battery shield
    With vehicle raised, inspect entire underbody for damage, particularly to battery pack protective shield. Check for impact damage, missing fasteners, or compromised seals. Inspect all underbody covers and aero shields for security. Look for any signs of road debris damage or corrosion. Verify all protective covers are properly secured.
    ⚠Battery pack shield damage can allow water intrusion or expose high-voltage components. Any damage to battery shield requires immediate repair.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

    Module Mounting Bolts8 Nm (6 lb-ft)
12. 12

    Perform final system verification
    Reinstall all wheels and torque lug nuts to specification. Lower vehicle. Start vehicle and verify all warning lights extinguish. Check instrument cluster for any warning messages. Verify estimated range display is consistent with state of charge. Test drive vehicle briefly to verify normal operation, regenerative braking function, and absence of unusual noises or vibrations. Clear any diagnostic trouble codes that were resolved during inspection.

Reassembly

1. Ensure all wheels are torqued to manufacturer specification (typically 140 Nm/103 lb-ft)
2. Verify all inspected components are properly secured and no tools or parts are left in engine compartment
3. Reset maintenance reminder if equipped
4. Document all findings, fluid conditions, and any recommended service items

Verification

• No diagnostic trouble codes present in any vehicle system
• All fluid levels within specified ranges and fluids in good condition
• 12V battery voltage between 12.4-12.8V with vehicle off
• High-voltage battery SOH above 85% with balanced cell voltages
• Brake pad thickness above 3mm on all corners
• Tire tread depth above 4/32 inch with even wear
• All lights, wipers, and safety systems functioning properly
• No fluid leaks, damage, or unusual noises during test drive
• Vehicle displays normal estimated range for current state of charge

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