Edd China Reveals the Shocking Truth About EV Battery Repair

Should you pull the plug on your EV and its pricey battery just because of a fault? Absolutely not! Fixing it might seem electrifyingly complicated, but don’t worry—you won’t be shocked to learn that with the right steps, it’s entirely doable. In this video, I shed some light on how to safely replace a faulty battery component. A while back, I charged over to Bosch to get the current insights on what you can and can’t do, along with the specialised training and tools needed to tackle the high-powered parts of today’s EVs.

Edd China’s Workshop Diaries Episode 68 - Bosch Level 4, Cheap Battery Pack Fix

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#bosch #thefutureisBosch #EddChina #WheelerDealers #WorkshopDiaries #Presenter #Mechanic #Motor #MotorSpecialist #Inventor #leaf #Garage #Nissan #Tesla

Chapters

00:00 - intro
00:34 - Fixing a welded contactor fault on Nissan Leaf
00:54 - Connect wirelessly to the Nissan Leaf battery pack
03:25 - Connect car to the oscilloscope
05:44 - Bosch Level 4 training course
06:14 - Making a High Voltage EV safe to work on
07:24 - Subscribe!
07:55 - Store High Voltage disconnector in a safe place
08:47 - Final stage of decommissioning the high voltage system
09:20 - Removing a Nissan Leaf Battery Pack
12:28 - Cutting open the EV battery pack
13:19 - Opening up an EV battery pack
14:45 - Remove and test a Nissan Leaf contactor
15:16 - Installing a new contactor to a Nissan Leaf and resealing the battery pack
16:04 - Installing a fixed battery to an Electric Car
17:24 - Testing a replacement contactor on a Nissan Leaf
18:52 - Final results and final cost to fix

[michaelgoode]

Edd sees a car which needs repairing and sets about it. He doesn't bother himself about the fuel that it uses, the age of the vehicle, the complexity of the repair. No, Edd sees this as an opportunity to learn new skills and repair a perfectly good vehicle.

Thanks Edd. Great work.

[Jansson]

I’m so glad that you make youtube videos! The reason i watched Wheeler dealers was you Edd 🙂👍🏻

[JoFreddieRevDr]

Would have been interesting to see dismantle the contactor pack so we could see the actual the fault.
Update: see Edd's video "1 Surprising Thing I Found Inside a Welded EV Contactor:"

[rkan]

2:20 - The steel braid is just not for EMI shielding but also to detect and prevent high voltage from ever going to the car body, even if the fuses or contactors would fail. The braid is the last defence basically shorting the possibly cut cable within the high voltage system.

[mbak]

I have been working on and repairing high voltage valve gear as a hobby for years. Everything is common sense. I like the one hand behind your back because I have done that for years probing circuits up to 2Kv DC. This work can be done indoors by anyone who has brought the correct gear. This example is not difficult. Going on a level 4 course would be worthwhile as it shows the correct attitude. I suspect a lot of the training is aimed at the garage situation but no amount of 'experience' means that something new, useful and potentially life saving could not be learnt by training.

[paulcrankshaw]

I was certainly on the edge of my seat seeing Edd stripping back the shielding and going near the HV cables with a metal pointy thing with the MSD still inserted 😮

[Sickiey]

from ED I learnt how to change my own oil, brakes 15+ years go , I'll probably never get an EV, but love the way the man like to solve problems

[volt]

As a reasonably competent ICE diyer this scares me to death. Brilliant Ed such a talent

[Poxtheengineer]

1. don't eat yellow snow
2. don't touch orange cables
training done!

[SpiritintheSky.]

I've just come across this channel and immediately subscribed to it. What greater compliment could I pay Mr China?

[paulstubbs]

Fascinating stuff. Nice to see Ed back.

[CitEnthusiast]

Outstanding. Love that you are showing that literally everything can be fixed if you: have the proper certified training, have the proper testing gear, and have a lovely flat panel lift. Well done, hopefully garages will see this an learn to not rip off customers, and not waste perfectly good batteries and cars. Just as we learned new things when the internet came around, or when the ICE car was first introduced, it's time to learn about EVs. Good on you and others in the repair business who refuse to stick their heads in the sand.

[Mladjasmilic]

6:40
Though safety disconnect flows the full current that drives the car. So in order to measure the current, you could have a modified disconnect with a loop of wire for measuring. And not mangle the main power cable.

[PoweredbyRobots]

Left hand behind your back, nice to watch. I work on old valve amps, sure that's saved my life more than once.

[kdlxl]

I love this content. It's really fascinating seeing all the tools, training, and safety procedures for this type of work. All I've heard before is "we can't do that in-house". The complexity of the repair doesn't seem too bad compared to ICE repair, a piston swap for example.

[andyb]

Not watched one of your videos for ages but this was really quite impressive! Loved the Humour also.

[jeremiahrex]

This is awesome content Edd! The work isn't complex but it's new so it seems very daunting. Videos like this, and a whole lot of elapsed time, will build comfort. It's amazing how simple the battery packs are inside, way less complex than an engine.

My EV is still under warranty but this is work I'll be doing myself one day. Hopefully they make these parts a bit more accessible through subsequent designs. I'm starting to see some intrepid individuals offering fixes especially for Leafs. Between the contactors and the single cell failures, they often get some off super cheap. These folks are buying them for a few thousand off, fixing them for $500 and selling them back for a few thousand profit.

[WagnerGimenes]

Well Edd, as a Brazilian, I would like to commend you and your production team on the selection of background music used throughout this episode 😂😂😂😂👏👏👏👏😂😂😂😂 Also, the comedic value of your production will certainly guarantee the next 1 million subscribers to flock in numbers to this channel. I again give it a 12 out of 10 stars 👏👏👏👏

[idlewise]

@15:16 good to see you are using your training! One-handed whenever possible.

[pjday]

If ever there was a video that should have started with "Do Not Try This At Home" this is it.