EV Annual Inspection

Comprehensive annual safety and maintenance inspection of all major EV systems including high voltage battery, charging system, braking, cooling, and drivetrain components to ensure safe operation.

Warnings

Tools required

Parts

• Cabin air filter × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Power off vehicle completely and remove key fob from vicinity
3. Allow vehicle to sit for at least 5 minutes to allow capacitors to discharge
4. Disconnect 12V auxiliary battery negative terminal
5. Lift vehicle safely and support on jack stands
6. Verify all tires are cool to touch for accurate pressure readings

Procedure

1. 1

   Perform initial diagnostic scan
   Connect OBD-II scanner with EV capability to the diagnostic port. Retrieve and document all stored fault codes, pending codes, and freeze frame data. Check for any high voltage system warnings, battery management system alerts, or motor controller faults. Record battery state of health (SOH) and state of charge (SOC) readings.
2. 2

   Inspect high voltage battery pack
   Visually inspect the underside battery pack enclosure for any signs of physical damage, corrosion, or fluid leaks. Check for any signs of impact damage to the protective skid plates. Inspect all visible HV cable connections for security, damage, or corrosion. Verify battery cooling inlet and outlet are not obstructed. Do not remove any HV covers or disconnect any orange cables.
3. 3

   Check charging system components
   Inspect the charge port door for proper operation and weatherstripping condition. Check charge port contacts for signs of arcing, burning, or corrosion. Verify charge port locking mechanism operates correctly. Inspect onboard charger cooling passages if visible for debris or damage. Test charge port communication by connecting a charging cable and verifying proper handshake (do not initiate full charge).
4. 4

   Inspect electric drive motors and inverters
   Visually inspect front and rear drive motor housings for any signs of leaks, physical damage, or loose mounting hardware. Check motor cooling lines and connections for leaks or damage. Inspect inverter housings for damage or overheating signs. Verify all electrical connections to motors and inverters are secure with no signs of corrosion or heat damage.
5. 5

   Inspect thermal management system
   Check coolant reservoir level for EV Battery/Motor Coolant system and verify level is within MIN/MAX marks. Inspect all visible coolant hoses for cracks, leaks, or deterioration. Check coolant condition visually for contamination or discoloration. Inspect radiator and cooling fans for damage or debris. Verify coolant pump operation by checking for proper coolant circulation when vehicle is powered on (listen for pump operation).
6. 6

   Inspect brake system
   Check brake fluid level in reservoir and verify DOT 4 fluid is within proper range. Test brake fluid moisture content using test strips (should be below 3% water content). Inspect brake lines, hoses, and fittings for leaks, corrosion, or damage. Check brake pad thickness at all four corners (minimum 3mm remaining). Verify regenerative braking system operation by checking for smooth deceleration when lifting accelerator pedal. Inspect brake calipers for proper operation and signs of sticking.
7. 7

   Inspect drivetrain and differential systems
   Check front and rear differential fill plugs for leaks or seepage. Inspect CV axles and boots for tears, leaks, or damage. Check driveshafts for damage or excessive play. Verify differential mounting hardware is secure. Inspect transmission/reduction gear housing for leaks or damage. Check for any unusual wear patterns on drivetrain components.
8. 8

   Inspect suspension and steering components
   Check all suspension components for damage, excessive wear, or leaks. Inspect control arm bushings for deterioration or separation. Check ball joints and tie rod ends for excessive play. Verify shock absorbers show no signs of leaking. Inspect steering rack and electric power steering motor for leaks or damage. Check wheel bearings for play by attempting to rock wheels with hands at 12 and 6 o'clock positions.
9. 9

   Inspect tires and TPMS system
   Measure and record tire tread depth at multiple points on each tire (minimum 4/32 inch). Set tire pressure to specification on door jamb label (typically 42-45 PSI for EDV 500). Inspect tires for uneven wear, cuts, bulges, or embedded objects. Verify TPMS sensors are functioning by checking that all tire pressures display correctly on dash. Check for proper tire rotation patterns based on wear.
10. 10

    Inspect 12V auxiliary battery system
    Reconnect 12V battery and test voltage (should read 12.4-12.8V at rest). Perform load test on 12V battery if tester available. Check battery terminals for corrosion and ensure connections are tight. Inspect 12V battery cables for damage or corrosion. Verify DC-DC converter operation by checking 12V system voltage with vehicle powered on (should read 13.5-14.5V).
11. 11

    Inspect cabin and exterior components
    Replace cabin air filter with new OEM specification filter. Check windshield washer fluid level and top off to full. Inspect wiper blades for wear or damage. Test all exterior lights including headlights, taillights, brake lights, turn signals, and charging port light. Verify horn operates correctly. Check all door seals and weatherstripping for damage or deterioration.
12. 12

    Perform functional systems test
    Power on vehicle and verify all dashboard warning lights illuminate during self-test then extinguish. Test operation of HVAC system in heating and cooling modes. Verify infotainment system boots properly and responds to inputs. Test all power windows, door locks, and mirrors. Check backup camera and parking sensor operation. Verify keyless entry and proximity unlock functions work correctly.
13. 13

    Perform test drive evaluation
    Test drive vehicle on varied road conditions. Verify smooth acceleration and regenerative braking operation. Listen for any unusual noises from drivetrain, suspension, or brakes. Test conventional friction brakes for proper operation and pedal feel. Verify steering operates smoothly with no binding or unusual noises. Check that vehicle tracks straight with no pulling. Verify all drive modes function correctly (Sport, Conserve, All-Purpose, etc.).
14. 14

    Review and document inspection results
    Document all inspection findings including any wear items that need attention, fluid conditions, tire measurements, and diagnostic codes. Clear any non-critical fault codes that were addressed during inspection. Generate inspection report with recommendations for any needed repairs or services. Update vehicle maintenance records with inspection date and findings. Reset service reminder if equipped.

Reassembly

1. Ensure all access panels and covers are properly secured
2. Verify 12V battery is connected with terminals clean and tight
3. Lower vehicle from lift or jack stands safely
4. Verify tire pressures are set to specification
5. Ensure no tools or equipment are left in or under vehicle

Verification

• Confirm no warning lights are illuminated on dashboard after powering on vehicle
• Verify all documented fault codes have been addressed or documented for customer
• Test drive vehicle to confirm normal operation of all systems
• Verify charging system operates correctly by initiating a charge session
• Confirm all fluids are at proper levels and no leaks are present
• Verify tire pressures match specification and TPMS shows no warnings

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