Common Problems

Most EVs, years 3–5

Symptom:

Car won't wake, random warnings, phone key stops working.

Cause:

Small 12 V battery ages; DC-DC keeps it topped up but can't revive a failing cell.

Fix:

Replace 12 V battery (often AGM or lithium specific).

All EVs, salted-road regions

Symptom:

Grinding, pulling to one side, hot wheel.

Cause:

Regen means friction brakes are rarely used and corrode.

Fix:

Clean, lubricate or replace calipers and discs.

Many models

Symptom:

Port won't open or cable won't release.

Cause:

Ice, debris or actuator failure.

Fix:

Use manual release (see handbook); replace actuator.

High-torque/heavy EVs

Symptom:

Inner-edge wear, noise.

Cause:

Weight, torque and alignment drift.

Fix:

Rotate tyres, check alignment, use EV-rated tyres.

Heat-pump equipped EVs

Symptom:

No cabin heat, range drop in winter.

Cause:

Valve, sensor or refrigerant leak.

Fix:

Diagnose with scan tool; refrigerant service.

Various

Symptom:

AC charging fails, DC still works.

Cause:

OBC internal fault or supply surge.

Fix:

Replace or repair OBC module.

Liquid-cooled packs

Symptom:

Low coolant warning, isolation fault.

Cause:

Hose clamp or pump seal leak.

Fix:

Pressure test and repair; check HV isolation.

Heavy EVs

Symptom:

Clunks over bumps.

Cause:

Worn bushings/links due to vehicle mass.

Fix:

Replace worn links or bushings.