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Delphis 113 Years of Innovation

Heritage Names and Products you Know!
Packard Electric Division Delco-Remy AC Spark Plug Harrison Radiator Frigidaire Delco Radio Inland Fisher-Guide Saginaw Steering Gear Fisher Body Rochester Products Delco-Moraine

2008 Hybrids
Automobile
Toyota Prius

Drive Train
FWD

Engine
1.5L 4 cyl

Transmission
Automatic

Hybrid
Full

Hybrid Definitions Assist: The Electric Motor Only Assists The Engine Mild: The Electric Motor Only Assists The Engine Full: The Vehicle Can Use Gas, Electric or Both For Power

Honda Civic
Honda Accord Honda Insight

FWD
FWD FWD

1.3L 4 cyl
3.0 L 6 cyl 1.0L 3 cyl

Automatic CVT
Automatic L5 Automatic CVT / 5Spd M

Assist
Assist Assist

Ford Escape
Mercury Mariner Mazda Tribute
Lexus 400 H Toyota Highlander

FWD 4 WD
4WD 4WD

2.3L 4 cyl
2.3L 4 cyl 2.3L 4 cyl

Automatic CVT/CVUSL
Automatic CVT/CVUSL Automatic CVT/CVUSL

Full
Full

Transmission Descriptions
Full

Continuously Variable User Selectable Lock-up (CVUSL) Computer Controlled Continuously Variable Lock-up (CCCVL)

FWD 4WD
2WD 4WD 2WD 4WD

3.3L V6
5.3L V8 5.3L V8

Automatic CVT
4Sp Automatic CCCVL 4Sp Automatic CCCVL

Full

Chevrolet Silverado GMC Sierra

Mild Mild

Back to the Future

Photo of Thomas Edison with 1914 Detroit Electric Model 47 From the Smithsonian (courtesy of the National Museum of Natural History)

Back to the Future

1921 Owen Magnetic Model 60 Used a gasoline engine to run a generator Which supplied electric power to motors mounted in both rear wheels

Development of the Hybrid

GM, Chrysler, Ford, Many of the European and Asia n Manufactures produced all Electric Vehicles.
Best use was in small vehicles used in the city Limited Range due to battery capacity Recharge took several hours

Other electric vehicles that were

42V Belt Alternator Starter System from Delphi

Delphi presented its Energen 42V Belt Alternator Starter System at Convergence 2002. The system replaces a conventional vehicle's existing starter and generator with a single high-power belt-driven motor/generator Providing an 8-10% fuel economy improvement in city traffic. The system provides dual-voltage 42V/14V architecture. In generating mode, the belt-driven electric machine, the electronics box, which contains a power inverter and machine controller, produces electrical power
42 volts and charges a 36-volt battery. A DC-DC converter is used to obtain 14 volts from 42

Engine Turnoff at Idle is Improves Vehicle Fuel Economy

A number of alternatives for implementation of the restarting function including:

The existing cranking motor

12V or 36V belt-starter, Crankshaft integrated-starter generator (ISG) More complex hybrid powertrain architectures. The 12V belt alternator- starter (BAS) offers fast, quiet starting at a lower system cost. There are two challenges are 1. Need to accelerate a large engine to idle speed quickly 2. Dynamic torque control during the start for smoothness.

42V C from Delphi

Energen 5 Designed for GM 5.3L V8

Starter Generator

Delphi Energen 5 SG (Starter Generator) RIC (Regulator Inverter Controller)

Control System Layout

The engine speed has to be limited by the PCM calibration to 5000 [rpm] to prevent over speed of the SG

The specified maximum speed allowed on the SG is 18000 [rpm].

A normal start happens when the restart of the engine after IEO (Idle Engine Off) is done within 2 to 3 seconds. The SG on this application is only used for warm engine restarts from an IEO event. The DC starter is used for cold engine starts and in case of a detected fault on the RIC

Conventional Engine

with a Belt Alternator Starter System

Hybrid uses a conventional internal combustion engine and a generator with starter power the vehicle. Note: All intermediate voltage cables used on the hybrid are blue for easy identification

Always Use the Original Vehicle Manuel

When Working on vehicles correct information is necessary On a GM Hybrid 12V/36V Systems You Should Know Color Codes For Wiring Conduits:
Orange = 60 or More Volts Blue = 30V to 60V Red = Automotive Low Les than 30V

Hybrid Configuration
Parallel Hybrid: The primary energy source can drive a generator like the series system In addition it can also drive the vehicle parallel to the electric motor. The Honda Integrated Motor Assist (IMA) is an excellent example of a parallel hybrid drive system.

Series Hybrid: The primary power source is the internal combustion engine which drives a generator: Electric power is stored in batteries used to power an electric motor that drives the wheels Most true Series Hybrids in use today are medium-duty vehicles such as transit buses

Toyota Prius

Prius Dash View

Toyota Prius Hybrid Synergy Drive

Left side (black) is a 1.5 liter Internal Combustion Engine Drives the wheels and the electric generator. Right side (aluminum) High voltage unit part of the Toyota Hybrid Synergy Drive

Prius 1.5 liter, 1NZ-FXE engine

Cylinder Head Thermos

Toyota Thermos In Left Front Fender Ahead of Wheel Housing Keeps Coolant Warm to Circulate through the Head on Cold Start Up to Three Days Close to 200 F

Engine Control System Sensors

ECM VSV(for EVAP) Combination Meter VSV (for Canister Closed Valve w/ Trap Filter) Vapor Pressure Sensor

Mass Air Flow Meter

Charcoal Canister & VSV (for Purge Flow Switching Valve)

Throttle Body Water Valve DLC3 Coolant Heat Storage Tank & Water Pump Heated Air Fuel Ratio Sensor Accelerator Pedal Position Sensor

Heated Oxygen Sensor

Toyota Uses a Parallel Drive System

Parallel Hybrid: Both the battery and engine are connected to the transmission

Either the battery using the electric motor, or the engine and the transmission, can provide propulsion power.
Also propulsion can use a combination of both

Battery Module (98KB, MIME type)

Second generation Toyota Prius uses 28 of these modules to create a 200 volt DC battery pack Inverter is used to "step-up" the power to 500 Volts, converting the DC battery power to the AC required for the electric motors (The module s are only 10 inches long and can be serviced individually however labor cost will most likely force servicing as a unit) First generation Prius utilizes conventional round NiMH batteries inside a metal battery case to operate the 300 Volt hybrid electrical system While the battery voltage dropped from 300 Volts, to 200 Volts in the second generation Prius, the high-voltage inverter steps the power up to 500V A more powerful electric motor allows for approximately a 30% increase in overall power

HV Nickel-Metal Hydride Battery

Six 1.2V Nickel-Metal Hydride (Ni-MH) cells are connected in series to form one module. 28 modules are connected in series for the rated voltage 201.6V.

Battery Safety Sticker

On Battery module

Multi-Function Monitor

Energy Monitor

High Voltage Inverter

High Voltage Inverter

High voltage inverter unit with cover removed

Used in the NHW11 1st generation of the Prius 3 black coil like objects are capacitors

Engine and Drive System

Motor Gen.1 Motor Gen.2

Transaxle Damper

Silent Chain

Planetary Gear Set

Honda Motor and Rotor

Use Proper tool to:
Remove Rotor Install Rotor

Very Heavy Magnetic Field Could Injure Technician

Toyota Planetary Gear Transmission

Auxiliary AGM Battery

AGM
Absorbent Glass Mat (AGM) technology is the latest innovation in maintenance-free batteries (introduced on 2001 Corvette). The AGM battery is classified as a gas recombinant or recombination design. Recombination means that the hydrogen and oxygen gasses generated during charging are recombined to produce water. Consequently, gassing and its associated water loss are eliminated.

Jump Start Terminal at the Auxiliary Battery

Main Junction Block

Jumper Cable Tab

Jump starting a Prius is allowed if procedures are followed

Once started the charging system will return battery to normal state of charge 2004 and later Prius

Cable Routing
Auxiliary Battery

HD Battery

Aluminum Wiring Harness

Inverter Motor Generator 1 Motor Generator 2

Junction Box

Battery System Layout

Upper Case Cover

Service Plug Battery ECU System Main Relay (SMR)

Battery Module

Junction
Power Cable Voltage (-)
Power Cable Voltage (+)

+ 12V DC

Hybrid Vehicle Safety

Vehicle must be disabled
Toyota emblem is not chrome on the other side Turn off the hybrid system. Vehicles with smart key, disable it and make sure key fob is at least 15 feet away from the vehicle

Disconnect the negative (-) terminal of the 12V auxiliary battery.

2001 2003 Prius Auxiliary Battery

2004 & later Prius Auxiliary Battery

2004 to 2008 Smart key

Toyota emblem is chrome If inside the vehicle will start and get ready light Outside will not start and no ready light

Toyota Smart Key

Remove the Service Plug

Orange service plug

2001 2003 Prius

2004 and later Prius

You Must Wear insulated gloves (Be sure gloves are not damaged)
Remove Orange service plug and put it in your pocket Do not test or make repairs for Five minutes.

Toyota Prius Auxiliary Battery

Located in Trunk 12.6 V AGM Red Cables Should Be Disconnected to Work ON

Handling High Voltage Cables

Be Cautious of High-Voltage Components
High-voltage cables are orange Do Not Touch. If you are working near any high-voltage cables or components:
Use insulated tools Do not leave tools or parts (bolts, nuts, etc.) inside cabin. Do not wear rings, watches or metal objects

Need to Wear High Voltage Gloves

Cat III Rated Fluke 1587 DVOM & Insulation Tester

High Voltage Class 0, rated at 1000 volts with Leather Outer Shell

High Voltage Tools

Hybrid Vehicle Safety

CAUTION
Hybrid systems include high-voltage circuitry that carries up to 500V. Careless handling of the hybrid system can result in electrocution

When servicing the hybrid system, strictly follow the instructions given in the Repair Manual and Emergency Response Guide (ERG).

Lexus LS600hL

Honda Insight

Honda Civic Hybrid

Honda Engine

Honda First in the Market

The Honda Insight: Hondas hybrid electric vehicle debuted in late 1999 as an early 2001 model as a two seat vehicle In 2003, Honda introduced its second generation HEV, the five passenger Honda Civic Hybrid.

Honda Integrated Motor Assist (IMA)

Honda Models Use Parallel Configurations

The wheels are powered by both the internal combustion engine and an electric motor The two Honda Integrated Motor Assist (IMA) systems utilize smaller-than-normal gasoline engine and a thin, pancake-type electric motor/generator located between the engine and transmission
1.0-liter three-cylinder in the Insight 1.3-liter four-cylinder in the Civic When additional power is needed, when passing the integrated electric motor/generator kicks in and supplies added power. The motor/generator functions as a high-speed starter and for battery charging during regenerative braking.

Honda Configurations Not Like Ford and Toyota

Hondas hybrids cannot operate solely on battery power IMA fits the definition of a true integrated hybrid Designed to run super-efficiently on shared internal combustion and electric The less costly mild hybrids being developed by automakers typically use an integrated starter/generator that automatically shuts down an engine when a vehicle stops Then starts it up when its time to go again. Giving a slight improvement in fuel economy of maybe 10 percent A world apart from the 40, 50, and 60+ mpg fuel economy achieved by system like Hondas IMA.

Honda Engine
New Honda Hybrid System uses: Intelligent engine functions to achieve an approximate 20% increase in system output over the current system Giving the performance of a 1.8-litre engine while improving fuel economy Reducing the system size by 5% and attainting a greater level of emissions control The system offers significantly improved performance and fuel economy over the current system.

Honda Engine
3-stage i-VTEC uses three hydraulic passages Providing three stages of valve control depending on the driving conditions Achieving a combination of responsive driving conditions and fuel economy by coupling and uncoupling five rocker arm assemblies During deceleration the cylinders are idle
Combustion in all four cylinders is shut off The cylinders sealed shut A 10% improvement in recovery of braking energy compared to the current Civic Aluminum die-cast pistons, which have less heat related expansion and less friction, ion-plated piston rings, and plateau honing of the cylinder walls for a smoother surface.

Engine, IMA and Transmission

Honda Transmission
Steel Belt Variable Cones

IMA (Integrated Motor Assist)

Motor Mode
IMA motor/generators starts the gasoline engine and brings it to 1000 RPM
As a back-up this job can be handled by the Hondas conventional 12-volt starter when: When the battery module state-of-charge is too low Operating in extremely cold or hot weather IMA system fails

Direct current from the battery module is converted to AC electric power by the motor drive module (MDM)
This electricity is supplied to the IMA motor/generator operating in motor mode for accelerating, climbing hills, and other high load conditions For maximum acceleration, both the IMA motor/generator and gasoline engine are used Under light acceleration, the motor/generator provides only partial assist in an amount determined by load and throttle position Once cruising, the Honda hybrid is propelled solely by the gasoline engine

IMA (Integrated Motor Assist)

IMA (Integrated Motor Assist)

Honda Series Hybrid: In the series type of hybrid the engine turns a generator and the generator can either charge the batteries or power an electric motor that drives the transmission. The engine never powers the vehicle directly.

Source:Toyota

IMA (Integrated motor Assist)

Honda Electric Motor Control

Hondas electric motor Employs coils designed with high-density windings High-performance magnets to attain output 1.5 times that of the current model while maintaining the same size The inverter used to control motor speed Independently developed and manufactured by HondaI Integrated with the motors ECU for more precise digital control
Contributing to even greater motor efficiency and fuel economy.

Battery output has been increased by around 30% over the current model
More compact, custom designed battery storage box offers increased cooling performance and vibration resistance for improved long-term reliability.

New Honda Hybrid System Modes of Operation

Vehicle stationary The engine is turned off and fuel consumption is zero. Startup and acceleration The engine operates in low-speed valve timing mode, with motor assist. Rapid acceleration The engine operates in high-speed valve timing mode, with motor assist. Low-speed cruising The valves of all four of the engines cylinders are closed and combustion halted. The motor alone powers the vehicle. Gentle acceleration and high-speed cruising The engine operating in low-speed valve timing mode powers the vehicle. Deceleration The valves of all four of the engines cylinders are closed and combustion halted. The motor recovers the maximum amount of energy released during deceleration and stores it in the battery.

Specifications for the New Honda Hybrid System

Power Source: Engine
Water-cooled in-line Number or cylinders 4-cylinders Displacement 1,339 Bore x stroke (mm) 73.0 x 80.0

Electric Electric motor type:

AC synchronous drive motor (Ultra-thin DC brush- less motor) Rated voltage (v) 158 Performance Engine Max. output 70[95]/6,000 (kW[PS]/rpm) Max. torque 123[12.5]/4,500 (Nm[kgm]/rpm) Electric Max. output 15[20]/2,000 motor (kW[PS]/rpm) Max.torque 103[10.5]/0~1,160 (Nm[kgm]/rpm) System Max. output 70+15[95+20] output (kW[PS]/rpm) Max.torque 167[17.0] (Nm[kgm]/rpm)

Orange Is A Safety Alert

All Orange Cables Are High Voltage and Dangerous Put In Service Mode and Wait For Capacitors to drain About 90 Seconds Use the Proper DMM Disconnect Auxiliary Battery Be Vehicles Are in Neutral Before Pushing In Shop

Toyota Fuse Box

UNDERHOOD FUSE BOX

Honda Battery

Silverado

Examples of Very Different Hybrids

Hybrid Features by Make/Model Make Model
Chevrolet Silverado 1500/GMC Sierra Hybrid
Ford Escape Hybrid Honda Civic Hybrid Honda Insight Toyota Prius Idle Stop X X X X X Regenerative Braking X X X X X X X X X X X Motor Assist Engine-Off Drive- EV Mode

Differentiate hybrids based on the features:

Mild-Incorporate Idle Stop and Regenerative Braking

Strong-Incorporate Idle Stop, Regenerative Braking, Motor Assist, and Engine-Off Drive-EV Mode

Saturn Vue hybrid

Saturn Vue Hybrid Engine

Saturn Vue hybrid

System Operation
The Saturn VUE Hybrid Used to Cover GM Vehicle Lines:
Gasoline-electric hybrid vehicle Introduced in the summer of 2006 Uses a 36 volt electrical and a traditional 12 volt battery and sophisticated technology to achieve its fuel savings.

The vehicle is equipped with a 2.4 liter, 4-cylinder

engine and a traditional 12 volt starter motor, which is used only for initial starts of the vehicle.

Starter Generator with three phase AC cable assembly

System Operation
The PEB integrates the inverter and DC to DC converter into one unit The PEB also includes the transmission electric pump controller as well as auxiliary input and output drivers The inverter portion of the power electronics box (PEB) will control the motoring or electrical generating function of the SG Other drivers include controls which provide power to the electric transmission oil pump

BAS Hybrid Battery Assembly

The BAS (Belt Alternator System) battery assembly has several components which are serviceable and can be replaced as necessary
However, the actual batteries, when replaced need to be replaced together Control module looks at each of the modules state of charge and condition If one of the three modules does not meet the set criteria with relation to each other (exceeds 0.6 volts) this is called Imbalance, the battery control module will not allow the battery to function

BAS 42V Beneath the Rear Compartment

GM Hybrid Vehicles

Pictured is Delphi's Hybrid Inverter

Delphi research and development of hybrid powertrain Help manufacturers like Ford fit the most efficient powertrain for their hybrids.

GM Hybrid Vehicles

GM Daimler Chrysler BMW Group Global Hybrid Cooperation. The hybrid with two driving modes optimizes power and torque for the given driving conditions
The first mode provides fuel-saving capability in low-speed and stop-and-go driving, with a combination of full electric propulsion and engine power. The second mode is used primarily at highway speeds to optimize fuel economy, while providing full engine power when conditions demand it, such as trailer towing or climbing steep grades. .

Two 60 kW Motors and a 300-Volt Battery Pack

Porsche Cayenne Hybrid S

Cayenne Hybrid S
V-8 power with four-cylinder fuel efficiency accomplished by using:
Parallel hybrid system Audi 3.0-liter V-6 Supercharged, gasoline-direct-injection Three-phase synchronous electric motor Nickel-metal-hydride battery pack Up to 385 hp and 545 lb-ft of torque Zero to 60 mph acceleration of 6.8 seconds Fuel economy is listed at 26 mpg on the European driving cycle

Cayenne Hybrid S
Using a totally new eight-speed automatic transmission Top vehicle speed is achieved in 6th The two higher gears boost fuel economy by lowering engine RPM Eighth gear, allows the vehicle to coast without the combustion engine at speeds up to 86 mph Travel in all-electric mode is less than two miles The electric motor is located between the engine and transmission The acts as an alternator to capture lost energy while the vehicle is driven

Cayenne Hybrid S
The hybrid controller can switch between:
Electric, combustion operation or any combination of the two in 30 milliseconds The controller accomplishes this while monitoring 20,000 data parameters The new design adds an electrical drive pump to assist the conventional transmission oil pump allowing the transmission to shifts gears smoothly in electric mode

Cayenne Hybrid S
The Cayenne hybrid will generate 20% less carbon dioxide emissions than a standard engine, qualifying it as a ULEV II The 154-lb battery, for example, is in the spare tire well The hybrid Cayenne is due to roll into showrooms by early 2010

Ford Escape Hybrid

Safety Concerns
Escape Hybrid or Mariner Hybrid emergency response procedures are similar to those for a traditional gasoline powered vehicle with the exception of the high voltage electrical system. The Escape Hybrid or Mariner Hybrid vehicle uses a conventional gasoline engine in addition to an electric motor to power the vehicle. The energy used to power the vehicle comes from gasoline (used by the internal combustion engine) and electricity (used by the electric motor). The energy used to power the vehicle is stored:

Gasoline is stored in a traditional fuel tank Electricity is stored in the high voltage battery

PACK

Safety Concerns
The combination of a gasoline engine and electric motor provides for improved performance (V6 performance with a 4 cylinder engine and electric motor), reduced emissions and most importantly improved fuel economy. The system is self contained (a generator recharges the battery during braking and cruising) so you never have to plug a hybrid in to recharge the batteries.

Safety Concerns
The information will allow you to respond to Escape Hybrid or Mariner Hybrid vehicles as safely as you do with conventional vehicles.
The Escape Hybrid or Mariner Hybrid has been designed with many features for your protection. These features should help provide you with safe access to the vehicle under various conditions. However whenever you approach a high voltage vehicle in a Fire, Rescue or Recovery situation, you must always follow one cardinal rule.

ALWAYS ASSUME THE VEHICLE IS POWERED UP

HYBRID VEHICLE IDENTIFICATION

ESCAPE HYBRID OR MARINER HYBRID VEHICLE IDENTIFICATION A unique Hybrid label is located on the lift gate, the front driver's door, and the front passenger's door. This can be used to identify an Escape Hybrid or Mariner Hybrid vehicle.

HYBRID VEHICLE IDENTIFICATION

HYBRID VEHICLE IDENTIFICATION

The 5th, 6th, and 7th alphanumeric characters of the Vehicle Identification Number (VIN) identify hybrid vehicles. Hybrid Escapes have a U95 or U96 in the 5th, 6th, and 7th position of the VIN. Hybrid Mariners will have U98 in the same positions. SAMPLE

1FMYU96H35KA00141 4WD Hybrid Escape

Ford Escape Hybrid

Ford Escape Hybrid

Ford Escape Hybrid Component Location

NOTE: All High Voltage wires and harnesses are wrapped in orange-colored insulation.

Warning Decal

Battery and Inertia Switch Location

Escapes Battery
Batteries consist of 250 individual cells (similar in shape to a size D flashlight battery). Each individual battery cell is contained in a stainless steel case. Each individual cell is 1.3 volts. The cells are welded and wrapped together in groups of 5 to form a module. There are 50 modules in the battery pack. The total voltage of the battery pack is 300 volts DC The batteries are Ni-MH (Nickel-Metal Hydride). The battery pack contains sealed batteries similar to the batteries used in radio control toys, laptop computers and cell phones. The battery case is designed to be water resistant. The battery cells contain a base electrolyte (consisting of potassium hydroxide as the dominant active ingredient) that is absorbed in a special paper. The electrolyte will not leak from the battery under most conditions; however if the battery is crushed, it is possible for a small amount (drops) of electrolyte to leak.

Two cautions should be observed when working with a damaged battery

1. Exposure to electrolyte could cause skin/eye irritation and or burns. If exposed, rinse with large amounts of water until the soapy feel is gone. Safety items such as face mask, insulated rubber gloves and boots, and a protective raincoat or apron are required when handling a damaged battery 2. If the battery is exposed to intense heat, it is possible that hydrogen could be released from the battery. Appropriate cautions should be taken to make sure the area is properly ventilated such as opening/removing the lift gate or rear glass.

Note: The High Voltage Service Disconnect Switch should be moved to the service/shipping position if possible

APPROACHING A DAMAGED HIGH VOLTAGE VEHICLE

1. FOLLOW EXISTING TRAINING AND INCIDENT COMMANDER DIRECTION This information as it pertains to the Escape Hybrid or Mariner Hybrid. The same rules apply when approaching any potential high voltage situation. Always follow your high voltage safety training. Some pre-cautions to be taken in any high voltage situation include:

Remove all jewelry, watches, necklaces, earrings, etc. Metal objects are conductors of electricity.
Wear the necessary protective clothing (high voltage rubber gloves, face shield, insulated boots, protective raincoat or apron) Bring the following equipment: o Class ABC powder type fire extinguisher o A non-conductive object about 5 feet long (1.5 meters) used to safely push someone away from the vehicle if they accidentally come in contact with high voltage.

APPROACHING A DAMAGED HIGH VOLTAGE VEHICLE

2. APPROACHING A DAMAGED VEHICLE Disable the high voltage electrical system using as many of the following steps possible: Secure the vehicle - Put the shift lever into Park. Remove the ignition key. Block the wheels if necessary. Removing the ignition key or turning it to the off position will disconnect the high voltage system. Disconnect the negative cable from the 12-volt battery this will also disconnect the high voltage. If possible, place the High Voltage Service Disconnect Switch (see section on Hybrid components for location) into the service position. To place it in the service position, turn counter clockwise and then lift out. Reinsert the Disconnect Switch with the arrow aligned to the service or shipping position.

High Voltage Service Disconnect Switch

Place in-service or shipping position

WARNING Removing the High Voltage Service Disconnect Switch disconnects high voltage from the vehicle. The individual cells inside the battery pack will still be charged. Do not cut into the high voltage battery case or penetrate the batteries in any way.

APPROACHING A DAMAGED HIGH VOLTAGE VEHICLE

SPECIAL NOTES If the vehicle is on fire, use Class ABC powder type extinguisher to contain and smother the flames. Or, if water is used, large amounts are required (e.g., from a fire hydrant). If the vehicle has any exposed cables, make sure you are wearing insulated gloves and other protective clothing. Do not touch any broken or damaged orange cables. Treat severed lines as if they contain high voltage.

If the vehicle is submerged in water, do not touch any high voltage components or cables while extricating the occupant. Do not remove the vehicle until you are sure the high voltage battery is completely discharged. A submerged high voltage battery may produce a fizzing or bubbling reaction. The high voltage battery will be discharged when the fizzing or bubbling has completely stopped

3. IF THE HIGH VOLTAGE BATTERY CASE HAS BEEN RUPTURED Just like any other battery: hose the area down with large amounts of water.

Moving the Vehicle

4. MOVING DAMAGED VEHICLES WRECKER DRIVERS Turn the vehicle ignition key to the accessory position to release the locking steering wheel. If possible, remove the High Voltage Service Disconnect Switch by turning it counter-clockwise and lifting out. Reinstall in the service/shipping position.

Follow guidelines in the Wrecker Tow Manual.

Front Tow: Wheel Lift with Dolly for 4WD and no Dolly for FWD Rear Tow: Wheel lift with Dolly for all (FWD or 4WD) Flat bed: Front and Rear

5. SPECIAL NOTE TO SALVAGE YARDS

If a vehicle with a high voltage battery is to be scrapped, the high voltage battery must be disposed of properly.

Cooling System in Hybrid Electric Vehicles

Fuel economy and environmentally friendly vehicles have expedited HEV development in recent years. HEVs are the helping meet these needs In addition to the IC (Internal Combustion) engine in a conventional vehicle, an HEV has several electrical subsystems, such as:
Electric motor Electric motor inverter Voltage converter Traction battery

All needing thermal management.

Streamlining Under Hood Air

HEV Cooling System Needs An Additional Cooling System

There are different coolant temperature and fluid flow rates. The engine cooling system is already slammed into a narrow space under the hood now we must add:
Heat exchanger Electric pump and plumbing Due to a large electrical capacity

Mechanical pump's used in the conventional cooling are replaced with electrical components responding to vehicle cooling demands.

Next Generation Radiator

Delphi is working on the next generation of radiators, which will be ultra compact. The designs will further reduce weight and materials used while enhancing performance.

Hybrid Cooling System

Delphi is leveraging its system knowledge to address the specific needs for hybrid engines:
Including increased cooling requirements for the new electrical loop Additional heat exchangers in the existing system space while also providing additional cooling power Delphi's air-to-oil cooler technology will help achieve lower transmission oil temperature requirements.
DELPHI Cooling Module