What EV to buy? - Robaizkine - Car Electronics Store

Are All EVs Good? Are Hybrids Really That Bad?

This is a topic we’ve been contemplating for some time due to frequent inquiries. It’s incredibly complex and requires extensive experience and information, both inside and outside our laboratory. This article, which we will periodically update based on new data, will focus solely on “real-life” experiences and events, free from sponsorships or media influence.

Over the past five years, both as a user and as a technician who repairs EVs, we’ve identified which vehicles to avoid and which ones are reliable. We’ll cover when issues typically arise, the costs of repairs and parts, and overall sustainability.

Battery Systems in EVs

The battery system is the most critical and often the most expensive component of any EV. While most batteries are repairable, they do degrade over time and usage. When degradation exceeds 50%, the battery is considered technically unserviceable and requires replacement. Often, individual cells within a battery cannot be substituted, necessitating the purchase of a new or used battery system.

Based on our experience and data from 15-20 different global locations, battery failures are low on the list of concerns over a decade of EV use. Common issues are more likely with:

Electric Motors
OBC Chargers
DCDC/Inverters
Batteries

Some EVs don’t experience any failures or require service over ten years, leading to significant cost savings compared to fossil fuel vehicles.

Comparing EVs to Fossil Fuel Vehicles

Even with potential repairs, EVs are cheaper to maintain than fossil fuel vehicles. Fossil fuel cars cost an average of €0.13 per kilometer in fuel alone, not including maintenance and repairs, which add at least €0.08 per kilometer. Over 200,000 km, this amounts to over €40,000. Thus, even a faulty EV is more economical than a fully functional fossil fuel vehicle.

Battery Repairs and Life Cycle

Battery systems operate in cycles. The first cycle lasts 5-8 years before any issues arise, during which modules or cells are replaced. After this, maintenance every 2-3 years extends the battery’s life cost-effectively. However, restoring a battery to its original 8-year, 200,000 km capacity is not feasible. Repairs typically extend battery life by 2-3 years or 100,000 km, depending on the model.

Hybrid Vehicles: A Critical Look

Hybrid batteries often deplete their charge cycles faster due to constant overuse. At around 100,000 km, they typically require replacement. The notion of “battery regeneration” is a myth; once cells are exhausted, replacement is the only option. Hybrid batteries can be the most expensive, sometimes even pricier than EV batteries.

Recommendations for Used EVs

Tesla Models (S, 3, X, Y): Despite negative media coverage, Tesla produces some of the best powertrains. The Model S and X use Pansonic cylindrical cells, while Models 3 and Y use a mix of cylindrical and prismatic cells. Tesla’s battery systems have proven reliable, though Model S and X require sealing to prevent water ingress.

Maintenance and Repairs:

Motors: Last approximately 500,000 km; repairs cost about €1,800.
Battery System: Minor issues at 200,000-300,000 km; repairs range from €800-€4,500.
OBC Chargers: Fail at 300,000-500,000 km; repairs cost around €1,200.

Other Notable EVs

Hyundai Ioniq 28kWh: Known for its reliability, with no significant recorded issues. Costs range from €10,000 to €16,000.

VW eGolf: Surprisingly reliable despite initial skepticism. Major repairs typically cost:

Motors: €1,400 for repairs.
Battery System: Minor issues at 150,000-250,000 km; repairs range from €800-€2,500.

VW eUp/Skoda Citigo e iV: Reliable city cars, though winter range drops significantly due to lack of thermal management.Repair costs are similar to the eGolf.

Fiat 500e

Introduction: The Fiat 500e stands as a pioneer in the electric vehicle revolution, periodically offering a glimpse into a laboratory we can confidently categorize as the most reliable veteran in its class. Remarkably, even after 12 years, its motors have not failed, and we have not encountered a single case with such an issue. We have received a mere 2-3 inquiries regarding battery degradation. There was one instance where a battery system was faulty, not due to a defective cell, but due to a malfunctioning Battery Management System (BMS), which we successfully resolved for the client. The most frequent issue we encountered, about 5-6 times, involved the On-Board Charger (OBC), which is extremely expensive when new (over €8000) and almost impossible to find used. The battery system contains custom PRISMATIC NMC cells, with no available aftermarket replacements. Replacement costs range from €4000-6000.

Common Issues:

Expected motor failure: Unknown.
Preventive maintenance: Change differential oil every 100,000 km.
Major battery degradation: Occurs at 150,000-200,000 km.
Occasional air compressor failure: 2 inquiries.
OBC failure: Every 50,000-100,000 km, repair cost €1200, new €8000.

Purchase Recommendations: When buying this vehicle, take it for a test drive to assess its range. Test both Type1 home and city charging to ensure the OBC is functioning correctly. Note that Chademo charging may still work if the OBC is faulty.

Realistic Range: Approximately 80-100 km.

Fiat 500e (USA)

Introduction: This small, city-friendly electric vehicle, developed by Chrysler and BOSCH under the FCA group, is a timeless masterpiece and one of the highest quality EV systems. Featuring a reliable permanent magnet electric motor (BOSCH SMG 180), the Fiat 500e has not reported any motor issues. The BOSCH-designed battery system, with active thermal management and antifreeze cooling, contains PRISMATIC NMC cells of non-standard dimensions with no aftermarket replacements. We handled 4 vehicles with discharged batteries due to long container transport from the USA, all of which we successfully repaired. Another rare issue involved the OBC charger, which is no longer produced and very difficult to find used. The vehicle only has a Type1 port for charging, with no fast charging options like Chademo or CCS.

Common Issues:

Expected motor failure: Unknown.
Preventive maintenance: Change differential oil every 100,000 km.
Major battery system failure: Occurs at 200,000-300,000 km.
Minor BMS failure: Occurs at 50,000-100,000 km, repair cost €1400.
OBC failure: Every 50,000-100,000 km, repair cost €1200, new €7000 (no longer available).

Purchase Recommendations: Test drive to check the range and test Type1 home and city charging to ensure the OBC is functional. Use diagnostics to check the State of Health (SOH) of the battery; if below 60%, the battery is in poor condition.

Realistic Range: Approximately 130-160 km.

Kia Soul

Introduction: Despite its unconventional appearance, the Kia Soul is a standout vehicle from its era, offering abundant features and a very comfortable ride. Known for its heated steering wheel, ventilated seats, and excellent infotainment system with CarPlay, the Soul impresses on many fronts. The most frequent issues have involved battery systems, with 5-6 vehicles needing repairs and around 10 clients declining repairs due to poor SK Innovative POUCH cells that degrade quickly. Replacement cells of the same dimensions and parameters are not available, making repairs dependent on used batteries. In one severe case from Serbia, even after replacing 30% of the battery system, the issue persisted, indicating the need for a complete battery replacement. Diagnostics can check the battery’s SOH; below 60% suggests minor repairs are needed, while below 40% indicates significant damage and the need for extensive cell replacement or a new battery system. We are planning to build a larger battery with next-generation cells from another EV. The vehicle is recommended if the price is right and the battery is in good condition or can be repaired. Prices range from €6000-16000 depending on battery condition. The vehicle has a Type1 single-phase connection and CHADEMO DC connection.

Common Issues:

Expected motor failure (buzzing): At 150,000 km, new motor €9500, repair €1400.
Preventive maintenance: Change differential oil every 100,000 km.
Minor battery system failure: At 40,000-80,000 km, 2-20 cells faulty, costing €1500-3500.
Major battery system failure: At 80,000-150,000 km, 20-50 cells degrade significantly, costing €3500-5500.
OBC failure: Every 50,000-100,000 km, repair cost €800, new €4000, used €1000.

Purchase Recommendations: Ensure the vehicle is in good condition and test the range during a test drive. Test Type1 home and city charging to confirm the OBC is operational.

Realistic Range: Approximately 130-160 km, or 50-90 km if faulty.

Mercedes B-Class W246 Electric Drive

Introduction: Mercedes’ only notable venture into the EV market, the B-Class Electric Drive, was a collaborative project with Tesla during Daimler’s partial ownership. This vehicle uses many components from the Tesla Model S 85, including the notorious Large Drive Unit (LDU) motor, which can suffer from coolant leakage and motor damage. Preventive repair to upgrade and protect the motor is essential. We have handled 3 faulty units, with issues including a defective PTC heater for the battery system and minor battery system problems. The battery system, using 18650 cylindrical cells similar to those in the Tesla Model S, is highly repairable. Prices range from €8000-15000 depending on mileage and features. Compared to other vehicles like the eGolf or Zoe, this is likely the best choice if the motor has been upgraded; otherwise, factor in a lower price for the vehicle.

Common Issues:

Expected motor failure (coolant leakage): At 40,000 km, new motor €9500, repair €3500.
Preventive maintenance: Change differential oil every 200,000 km.
Minor battery system failure: At 150,000-200,000 km, 2-20 cells faulty or wiring issues.
Major battery system failure: At 200,000 km, battery degradation.

Purchase Recommendations: Check for coolant leakage by inspecting the rotor sensor. If antifreeze is present, the motor needs repair. A temporary fix involves creating a drain to prevent motor damage if the seal fails.

Realistic Range: Approximately 130-160 km.

Renault Fluence

Introduction: Renault’s Fluence was a pioneering EV built on a fossil-fuel chassis, designed for quick battery swaps at “Better Place” stations tested in Israel. We personally drove a Fluence from Zagreb. Prices are low, but ensure the battery SOH is above 60%; if it drops to 50%, the BMS triggers a permanent error, causing the vehicle to operate in reserve mode to protect the battery. The POUCH cells, similar to those in Nissan Leaf batteries, are notoriously unreliable despite thermal management. New batteries are unavailable, and used ones are scarce. Building a new battery with modern cells would cost around €6000-8000 for about 18 kWh net capacity. The motors are very reliable, with brush replacements costing €40-80 in Slovenia at an authorized Renault service center. We have handled 10-15 cases of worn-out batteries and 2 with faulty motors. Other sporadic issues were usually due to the 12V battery. Prices range from €2000-6000.

Common Issues:

Expected motor failure or insulation problems: At 50,000-150,000 km, OEM service €100, repair €800.
Preventive maintenance: Change differential oil every 100,000 km.
Major battery system failure: At 100,000 km, battery degradation (SOH below 50%).

Preventive Measures: Change the 12V battery before winter. This vehicle is recommended only if the price is low and it can replace a fossil-fuel car for short trips, quickly amortizing the cost. It lacks a fast charger, having only an old single-phase Type1. Not suitable for long trips due to battery overheating.

Realistic Range: Approximately 80-120 km.

Dacia Spring

Introduction: The Dacia Spring is the cheapest new EV you can buy, especially with incentives making it the most affordable EV in Europe. A small city car, it has not generated any significant repair inquiries, except for complaints about noise or clicks in the electric drive during regenerative braking. The battery system is produced by Donfeng Sunwoda, featuring 27 kWh usable capacity with NMC PRISMATIC cells.

Common Issues:

Expected motor failure: Unknown.
Expected battery system failure: Unknown.
New battery cost: Around €12,000.

Realistic Range: Approximately 150 km.

Smart 451ED

Introduction: Mercedes created the impressive B-Class Electric Drive, but surprisingly, their first-generation Smart 451ED is even more noteworthy. The 451ED features batteries made in Germany with POUCH cells designed and produced by Li-Tec, an EU manufacturer. Li-Tec’s innovative cells use an advanced ceramic separator, eliminating defects common in SK batteries. The EV system is the most reliable we have tested, with many cars showing only 10-15% degradation after more than 10 years. We never encountered motor or OBC issues, and battery repairs were needed only for worn-out 12V batteries. The only maintenance involved differential oil changes. We have encountered around 20 vehicles with discharged batteries due to shipping or non-use for extended periods. These cars require careful charging, ideally with a small charger, to regain functionality. Prices range from €5000-9000 depending on battery condition and vehicle features.

Common Issues:

Expected motor failure: Unknown.
Preventive maintenance: Change differential oil every 100,000 km.
Major battery system failure: Degradation at 200,000-300,000 km.
Minor BMS failure: Rare.
OBC failure: Every 50,000-100,000 km, repair cost €1200, new €7000 (no longer available).

Realistic Range: Approximately 90-120 km.

Tesla Model S

Introduction: Tesla’s Model S, a groundbreaking EV, has various configurations and long-term ownership insights. Key areas of concern include the battery system and drive units. Prices range from €20,000-50,000 depending on the model, battery capacity, and condition.

Common Issues:

Expected motor failure (drive unit issues): At 100,000 km, repair cost €3,500.
Preventive maintenance: Regular software updates.
Major battery system failure: At 200,000-300,000 km, battery degradation.
Minor battery system failure: Wiring or cell issues.
OBC failure: Occasional, repair cost €1,200.

Purchase Recommendations: Test drive to check range and inspect charging system functionality. Diagnostics to check SOH is recommended.

Realistic Range: Varies by model, approximately 300-500 km.

What About Hybrid Vehicles, are they any good?

Overview: We have repeatedly debunked the notion of hybrids as sustainable with real-world examples. Despite updates to our findings, our stance remains firm: we do NOT recommend any hybrid vehicles. Opt for either a fully electric or a traditional gasoline engine.

Case Study: Battery Replacement Issues A stark example is a hybrid vehicle requiring a battery change at 90,000 km, only to need another complete replacement at 150,000 km. For more details, visit this link.

Sustainable Hybrid Systems: Range Extenders The only viable hybrid systems are Range Extenders (REX), where the primary drive is electric, supplemented by a small generator. BMW’s i3 and i8 models exemplify this concept, featuring batteries robust enough to handle stress without significant wear.

Cost and Maintenance Concerns:

Hybrid batteries are often more expensive than those in pure EVs, ranging from €10,000 to €32,000 (e.g., Range Rover).
Most hybrids have their batteries replaced once under warranty (before 100,000 km), then again at 200,000 km when out of warranty.
Misguided attempts to import these hybrids as a cheaper alternative often lead to high costs due to battery replacements that exceed the vehicle’s value.

Misconceptions and Realities:

Many believe lithium-ion batteries can be “regenerated” cheaply, but this is false. Battery cells often degrade beyond second-life applications.
Statements like “the battery costs more than the car” originate from hybrid vehicles (and Nissan Leaf) due to mainstream misinformation about EV battery problems.

Sustainable Battery Capacity: A sustainable hybrid system should have at least a 40-50 kWh battery. Otherwise, relying on the electric drive alone raises the question of why an internal combustion engine (ICE) is necessary at all.

Notable Exceptions and Issues:

Toyota Prius: Early models are somewhat sustainable due to their affordable NiMH batteries, costing about €1900 for a replacement at authorized services. However, design flaws cause premature battery degradation, with significant issues arising around 100,000 km.
Battery maintenance often reveals poor system design, leading to early overheating and damage.
Although Toyota’s battery systems are designed to last, real-world use shows frequent need for cell replacements.

Mild Hybrids: Mild hybrids are expensive to maintain and often problematic, with the notable exception of Suzuki, which has proven reliable.

Conclusion: While hybrid vehicles present an attractive middle ground between fossil fuels and full electrification, they often fall short in terms of long-term sustainability and cost efficiency. Fully electric or gasoline-powered vehicles remain the more reliable and economical choices for consumers.