Project case study
Twisted Defender EV Charging Diagnostics
EV diagnostics / charging system repair
Specialist diagnostics and repair support for an EV-converted Land Rover Defender by Twisted. The vehicle arrived with a charging fault, and VASS traced the issue to the onboard charger, coordinated the repair process, reinstalled the system and returned the vehicle to full working order.
Discuss a related projectVehicle / platformLand Rover Defender EV conversion by Twisted
Project typeEV diagnostics / charging system repair
Client goal
The problem to solve
The client came to VASS with an EV-converted Land Rover Defender by Twisted that had developed a charging issue. The goal was to diagnose the fault properly, confirm the root cause, and return the vehicle to reliable working order without unnecessary guesswork or parts replacement.
The brief
What VASS was asked to do
VASS was asked to carry out a full diagnostic investigation into the Defender’s charging issue and identify why the vehicle was no longer charging correctly. The work required an understanding of EV charging systems, high-voltage safety, onboard charger behaviour and how the converted vehicle systems interacted.
Scope of work
Defined engineering work
- Charging system diagnostics
- Onboard charger fault investigation
- High-voltage safety checks
- Electrical system inspection
- Fault confirmation and reporting
- Coordination with the charger manufacturer
- Reinstallation of the repaired charger
- System recommissioning
- Final function testing
- Client handover support
Key systems
Systems involved
- Onboard AC charger
- High-voltage battery system
- Charging inlet and charging control system
- Low-voltage control wiring
- High-voltage interlock and safety-related circuits
- Vehicle charging communication
- EV conversion control system
- Diagnostic equipment and test procedures
Engineering challenge
What needed careful resolution
- The main challenge was diagnosing a fault on an existing EV conversion where the charging issue could have been caused by several different systems.
- A charging failure can come from the charge port, wiring, control logic, high-voltage interlocks, battery limits, communication faults or the onboard charger itself.
- Rather than assuming the fault, VASS carried out a structured diagnostic process to narrow the issue down. The onboard charger was identified as the root cause and sent back to the manufacturer, who confirmed the diagnosis.
Practical outcome
The result
The onboard charger was repaired, reinstalled and the system was successfully recommissioned. The Defender was returned to full working health, allowing the client to use and charge the vehicle again with confidence.
For similar clients
What this means for another project
This project shows that VASS can support owners and workshops with existing EV conversions, even when the original conversion was completed elsewhere. Many EV conversion issues are not solved by replacing parts at random; they require structured diagnostics, high-voltage knowledge and an understanding of how the full vehicle system works.