maintenance will be achieved only if the power electronics, sensing, and computer control systems
in these vehicles (which may be more extensive than in conventional vehicles) are relatively
maintenance-free--not a foregone conclusion. Finally, many of the batteries that are candidates for
EVs are not sealed and maintenance-free.Maintenance costs for ICEVs typically are low for scheduled maintenance, on average about
$100/year for the first 10 years^71 ; unscheduled^72 costs may be closer to $400/year for that time
period.^73 These costs maybe changing with technological change, however. Engines and emission
control systems are becoming more complex, incorporating monitoring and control of more
parameters (e.g., valve timing) and adding components such as additional catalytic converters for
controlling cold-start emissions. New engines now being introduced into the market, however, do
not require tuneups for 100,000 miles and generally have fewer parts than the engines they
replace; in addition, automakers are succeeding in improving quality control to the point that they
can offer extended warranties for up to 100,000 miles at real costs (to them) of only a few
hundred dollars.
Because hybrid vehicles (HEVs) combine elements of ICE and electric drivetrains, clear
differences in maintenance costs between ICEVs and HEVs are more difficult to predict. Series
hybrids, which have no multispeed transmission, are less complex than parallel hybrids and may
retain some maintenance advantages over ICEVs. This potential advantage will depend on
whether the smaller engines in series hybrids, with limited speed ranges and gentler load changes
within these ranges, will require substantially less maintenance than conventional ICES; which
seems likely. On the other hand, parallel hybrids may enjoy no clear advantages, or may have
higher maintenance requirements, because they retain an engine and transmission and add a
complete electric drivetrain.
Fuel cell vehicles (FCEVs) are basically EVs with the fuel cell stack and hydrogen storage
system or methanol reformer (with methanol fuel system) substituting for the larger EV battery,
or hybrids with the fuel cell/fuel system providing the base power and a battery, flywheel, or other
storage device providing peaking power and cold start capability. Fuel cells have fewer moving
parts and a less severe operating environment than ICES, and some analysts have concluded that
fuel cells will require little maintenance. One analyst, for example, estimates that fuel cell stacks
will cost less than $40/yr to maintain.^74 It appears premature, however, to draw such conclusions.
The fuel cells considered here have a fairly complex “balance of plant,” and a methanol reformer,
with required gas cleanup to avoid poisoning the fuel cell’s catalysts, will be similarly complex.
Problems such as oxidation of the graphite cathode and deterioration of membranes must be
solved. Further, vehicle designers may make tradeoffs--for example, choosing lower quality
membranes to reduce first cost--that might add to fuel cell maintenance requirements.
(^71) Maintenance costs will be higher if owners follow the dealers recommended maintenance schedules, which typically call for much more
maintenance than recommen 72 ded by owner's manual.
73 Costscannot be scheduled even if they are regular, e.g., brake repairs.
74 M. Delucchi, University of California at Davis, Hydrogen Fuel Cell Vehicles, UCD-ITS-RR-92-14, September 1992, table B-3.
Ibid. Delucchi estimates that the annual levelized maintenance costs of mid-size FCEVs will be $390, compared to $430 for EVs and $520 for
ICEVs.