Toyota Prius Gen2 Hybrid Battery - The 101 and DIY Cell Module Replacement
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- čas přidán 17. 05. 2024
- [Replacement Modules]
Toyota Prius Hybrid Battery Cell Module Panasonic: amzn.to/3rTmjM1
[Replacement Hybrid Battery]
A1 Cardone 5H-4002 Hybrid Battery (Remanufactured Toyota Prius 04-09 Gen 2): amzn.to/2Y4SlZz
[Hybrid Battery Parts]
Hybrid Battery Bus Bars & Nuts set, compatible with Toyota Prius (2004-2015): amzn.to/3usvClz
[Recommended Tools]
Tenergy TB6-B Balance Charger Discharger 1S-6S Digital Battery Pack Charger for NiMH/NiCD/Li-PO/Li-Fe Packs: amzn.to/3gT1YjH
Small Slim Cordless Electric Ratchet Impact Wrench (Good!): amzn.to/3BrGnbi
[Misc Tools]
Metric Wrench Set 8mm - 22mm: amzn.to/2xQn3ot
Socket Set 123pc Metric and Imperial - Good Quality: amzn.to/2NhqhL9
Socket Set Metric/SAE 23pc - Good Quality: www.amazon.com/gp/product/B01...
U-Joint Set: 1/4", 3/8" and 1/2" Drive: amzn.to/3ambTvs
9pc Socket Extension Set: 1/4", 3/8" and 1/2" Drive: amzn.to/3pnvQGz
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[MORE INFO!]
The second generation Toyota Prius makes use of a 201.6-volt NiMH (nickel metal hydride battery) battery composed of 28 modules
where EACH of the 28 modules is comprised of SIX individual 1.2-volt, 6.5 Ah (6500mAh) Prismatic NiMH cells which are internally connected in series.
Each 7.2-volt module contains a charge controller and a relay.
It's basically a giant 201.6 Volt DC battery!
6.5 Ah (6500mAh) (Amp hour is the rating used to tell consumers how much amperage a battery can provide for exactly one hour)
28 modules/cells - 7.2V total officially OEM!
When measuring a module manually, it can measure anywhere between: 7.2V-7.8V volts (7.6V seems a good ballpark figure). It's usually on the higher side when freshly charged (or removed from a vehicle)
[Individual modules are compatibile with]
2004-2015 Toyota Prius
2007-2016 Toyota Camry
2007-2011 Nissan Altima
2011-2015 Lexus CT200 and some other Hybrid Models AND MORE
2008-2013 Yukon, Tahoe, Escalade
[Torque Specs]
28 x bus bar nuts (60 inch lbs)
2 x corner block bolts (90 inch lbs)
28 x bottom battery cell bolts (they hold the cells in on the underside of the battery) (60 inch lbs)
4 x compression block bolts (they are on the side holding the bars in place) (24 ft lbs)
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[VIDEOS MENTIONED IN THIS VIDEO]
How to Remove the Hybrid Battery on a Toyota Prius Gen2 (2004 05 06 07 08 09)
• How to Remove the Hybr...
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Instagram: / tutorialgenius
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Toyota Prius Gen2 Hybrid Battery - The 101 and DIY Cell Module Replacement
The car in the video is a Toyota Prius 2007 Gen II.
Gen II applicable years: 2004 2005 2006 2007 2008 2009
SUBSCRIBE FOR MORE!
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Chapters:
0:00 Aims of the Video
0:41 Disassembly 1
1:33 What is a Hybrid Battery?
2:46 Battery Capacity
3:29 The Brake Control Module (BCM)
4:40 A Note on State of Charge (SOC) and Shallow Cycling
5:26 Disassembly 2
7:58 Bus Bar Cleaning 1
9:05 Disassembly 3 + Module Replacement
14:28 Module Compatiblity
15:07 Bus Bar Cleaning 2
16:06 Torque Specs
17:04 What Can I do with my Old Modules?
17:38 Reconditioning Old Modules (Info)
18:15 Are my Old Battery Modules Good?
20:05 Load Testing Modules (Dirty DIY Guide)
24:10 Dr. Prius / Dr. Hybrid (OBDII Dongle + Phone Software)
#ToyotaPrius #HybridBattery #G951047020
Tags:
Prius Hybrid Battery Removal
Prius Gen2
How To Remove and Install Prius Hybrid Battery
Prius Hybrid Battery Replacement
I Bought the Most Hated Car on the Internet
How to remove Hybrid battery quickly and easily
How to Change a Battery in a Prius
Toyota Prius battery removal and repair
Toyota Drive Motor Battery Pack
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PART NUMBERS:
G9510-47020, CARDONE 5H4002, G951047020, CARDONE 5H4015PL, CARDONE 5M4002, G920047100, G920047120, G920047121, Cardone 5H-4002
Video Title: Toyota Prius Gen2 Hybrid Battery - The 101 and DIY Cell Module Replacement
Video File Created Date: Wednesday, 10 November, 2021 (Video may or may not have been captured on this date, it shows the date the video was last converted.)
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Video Tags:
toyota, prius, gen2, hybrid, battery, diy, cell, module, replacement, g9510-47020, g951047020, hybrid battery replacement, hybrid battery, battery pack, toyota prius battery, dead hybrid battery, battery cell, battery module, module replacement, hybrid battery modules, hybrid battery repair, hybrid battery reconditioning, hybrid battery charger, hybrid battery test, hybrid battery service, hybrid battery maintenance, hybrid battery cell replacement - Auta a dopravní prostředky
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Thanks for watching!
We need one for the "06" Highlander Hybrid.
I subscribed
Probably the best tutorial video I have ever watched dealing with such a complex topic. For myself, I'm not ready to tackle a project like this on my own Prius, but for those who are, this is a huge gift. Excellent camera work too, by the way. I salute you.
Thank you so much! 🔥🌝
You should be teaching in a Technical College!
The way you describe your subject is fantastic. Nothing left to chance, all's there in detail.
Thanks for the time to film and share this excellent video.
So nice of you! ☺ Glad you enjoyed the video!
You should have mentioned testing for leaky cells, my Prius had leaky cells, they held a load but they had micro fractures causing them to leak current which in return made my battery case live, any time you buy replacement cells you not only need to load test them but you also need to test to make sure they are not leaky as well, and the battery cells should also get cleaned off before putting your battery back together, dust can also cause the battery cells to bleed small amounts of currents
I could add many many more things, but youtube is platform that anybody can upload to, so you are welcome to do that yourself if you feel the need to
How do you check for micro fractures?
I had a random e-mail from Quora on hybrid battery questions which intrigued me to learn more. I do not have a Prius or hybrid myself but in my search for knowledge came across your video. I watched the entire video and your skills explaining are top notch and very much appreciated to quench my thirst for hybrid battery construction and repair. Great show & thank you!!
For a generalized tutorial channel you've done a great job with this Prius battery primer. Thanks very much.
Glad it was helpful!
WOW!! What a fantastic video! I have never seen a video with such detail and explanation.
This gentleman is indeed a tutorial genius!! He covered every question that I would have asked, and then some.
Thank you for your kind comments!! :)
@@TutorialGenius You are welcome and it's well deserved.
I learnt a lot about Prius Hybrid battery cells. I am trying to build a solar battery pack with some removed cells. Thanks a lot. How to charge cells was so interesting to me.
Heating the vinegar will speedup cleaning of the busbars, which takes ages otherwise. A concrete/paving cleaner, containing a bit of sulphuric acid, will clean them in about 30 seconds!
I bought some toilet bowl cleaner that's 10% hydrochloric acid, that would probably work too.
Great video! Is there a busbar attached to the black high voltage cutoff switch?
Good Job explaining in simple words! I enjoyed your video. Thanks for uploading this video.
If I have 4 amp charger, how many batteries I connect to charge together? Or Can I use 4 amp charger?
Wow. Amazing thank you i am facing battery issues on my prius. Those information are gold ! Very nice tuto.
You're welcome! I hope you subscribe soon! :)
Great detailed video! This helped me a lot during my battery cell replacement.
Glad it helped! :)
I'd recommend anyone doing the recondition of the modules (after you've replaced the bad ones) do the process with the modules still bolted into the 28 module braces. There is a tendency to expand during charging and discharging. You don't want to overdo it of course, but when the process is done in the braces, the modules are held in. If you recondition 'freed' modules, they are a beast to get back into the braces later. So, open the braces, replace the bad ones, close of the braces, begin the multi cycle charge/discharge to improve the remaining cells capacity. Note: NiMH gasses are highly caustic base chemicals. You don't want them coming out from over-charging. A tip I picked up somewhere was to find small rubber water balloons and place them on the safety valves of each module. That way, if gasses are released, they stay in the water balloons and also you might be able to observe that happening - a sign you're stressing the module with your charge rate. After you've got all the modules up to decent MaH capacity, you may need to open the rails to better match modules so that the 14 blocks they make up are comparable. I believe the matching is on internal resistance between the two modules in a block but done so that total blocks all have about the same resulting capacity. I didn't really know how to test internal resistance, so I didn't, but I did try to pair modules to make comparable total blocks.
I already talked about this in the video
You are a Godsent. This truly is the best video on youtube explaining this. I feel confident to do this myself. 🙏
Glad it was helpful! I hope you subscribe to my channel! :)
@@TutorialGenius I have a Toyota Voxy Hybrid ZWR80G..... I'm guessing it is the same process and maybe even the same battery. Any thoughts?
I put my bus bars in a sonic bath with vinegar, it will clean the bolts and bus bars better than most every other option.
I have a few hobby chargers/dischargers. I see you recommend 1-3amps for charging, what rate for discharge? I'm thinking about running some cycles on a pack I pulled out.
Is it good to change cells places since middle ones get high temperature
Is it possible to make a DIY hybrid battery using, for example, the TR 18650 cells, connecting a series of 28 modules that each contains 7 parallel banks with 2-cell series each? Shouldn't that give 7*.99Ah=6.9 Ah at 2x3.7*28=207V? These would be similar to the Prius hybrid battery parameters at less than half the cost.
I have a Prius gen 3 Iv got a RS 771-7730 1.0a 50/60Hz in put 100-240 VAC out put is max 257 V DC av 350mA I have used this to charge the complete pack my question is Is the out put ofmax 257 v dc at 350mA low enough not to damage the pack?
My 2013 on Dr prius shows temp 3 high temperature around 115 middle not hot so shall I put the end ones to middle
Great video and I’ve watched a few! You should be a teacher.
I think this is about the best video I've seen. A ton of info. I like the idea of pairing up modules to suit the capacity of the charger you might have. I have a load tester for the 6 and 12v batteries and I saw one by Commercial Electric that Home Depot says can be used on Nimh batteries. It might be able to dial in a certain voltage. I have to look at it and see if it's a continuous adjustment or if it has detents on the dial.
Someone suggested removing the small screws from underneath first and then going for all the screws and connectors on top. Sounds like an idea to me. I blew up the #4 module this morning and I can't lift the battery pack so I got the idea of putting a piece of plywood over the spare tire well and dragging the battery pack out onto it so I could work on it with a little more space. The weather is nice and I don't have a garage so maybe this will work.
I think it's better to skip the baking soda and just use the vinegar. Combining baking soda with vinegar neutralizes them. Sodium bicarbonate and acetic acid combine to make sodium acetate and water. Neither one is much of a cleaning agent. Vinegar, by itself, works pretty well. I think that's all that's needed.
(edit) Somebody was using salt or sea salt. ChatGPT says in produces hydrochloric acid to some degree.
Vinegar and salt combined makes hydrochloric acid.
@@sandywinnemueller3559 I was looking for the redox reaction. Didn't find it. Lotta stuff here I don't remember, or never learned in chemistry.
Is it a viable possibility to DIY make a module using 18650 cells (3.7V, .99Ah)? 2-cell series would deliver 7.4V, .99Ah, and 7 of those in parallel would deliver 7.4V and 6.9Ah, which is similar to the original Prius modules. Is that a possibility?
a video worth watching
So i have a 2012 sonata the cell are 26 27 when i yest it at the power relay its 242 volts ,on the dash the battery symbol doesn't show any percentage at all ,and the triangle symbol saying check carging system ,,any advice
Hello sir, i have prius zw30 2010 car, my battery 2 cells are weak, so i am gonna change those cells with 2018 cells, will it be ok ? Becouse i heard people saying 2010 HV battery and 2018 HV cells are different Ah range, can you please help me with your thoughts?
Excellent video brother, You just saved me $1000 dollars, Really appreciate you mate!
Smash that THANKS button on the video and sort me out then! 😆😆♥
Very good guide 👍👍👍
Glad you liked it :)
Excellent video, I like how you explain everything nice and steady. Thank you!!
You're welcome! :)
Thank you for grate detailed video. 😊
You're welcome! Thanks for watching! :)
Jazakallah Khair thank you, respect from Afghanistan
Glad it was useful :)
Superb!
Thank you! Cheers!
Excellent tutorial!
Glad you liked it!
How can I tell if the ecu is bad
Where find good cells they all used on eBay and how to charge them
Love the video! I was wondering if you have a good tutorial on how to read the Dr Prius app and OBD Link it works with?
In hindsight, it would have been a good one to make haha! But sadly the Prius has been ripped apart and the skeleton is sitting in my driveway. If I get another one, sure, it'll be the first video I make. I really liked this car
The battery is fixed and driving around. I'm wondering why the modules have to be balanced if the system balances them when you're driving. What's the back story on that.
lots of good info many thanks
Glad it was helpful!
Please.. What is the best charger to get to charge several cells or charge the fastest?.. Tenergy has several I heard that the 180 is the one to get however the cheaper one is one that people also get..
I'm not really familiar with brands of products! I'm more on the DIY side of things!
But I wouldn't look for the 'fastest' option. I believe I already mentioned this and the reasons why in the video already.
Does that Tenergy charger you recommend store memory when you’re cycling the batteries?
Or do I still use a timer and check what the voltage is at certain times during the cycle and then log it to the spreadsheet?
Keep noted
Notes
Thank you for your helpful video . I have a 2012 Toyota Camry hybrid now I opened my battery I want to know what’s voltage each cell minimum and maximum.? Thank you!
Glad it helped!!
After putting a new battery blade back in and putting it back together I get a p3004 from dr hybrid 😢
Just a a question if you take the battery out and do the cleaning and rotating the cells…. Can it be reinstalled right away or we have to wait for time thanks in advanced!! 🙏
Yes and yes!
@@TutorialGenius yes reinstalled right away … yes wait !? If yes how long is the wait thanks 🙏
FYI 60in lbs on the bus bar nuts is too much for my gen 2 2004 prius. Ended up stripping several posts and nuts.
I suspect the poper torque is closer to 48 in lbs. This is what worked for me.
Many of the nuts refused to tighten past 50 and started stripping. I've seen 60 in lbs circulating on other battery tutorials as well. Had to do some digging to find other people who encountered the same problem.
I was able to reassemble without replacing the modules i stripped because I heavily soldered the connections. Is running good now!
The torque specs I put in the video came straight from the service manual.
It's not uncommon to see aftermarket nuts and bolts on these
I suspected 60 inch pounds was too much for the battery bolts on a 2nd Gen, and sure enough, I ended up breaking one. I believe 48 inch pounds is correct.
I’ve done a couple more tear downs since then. 48 in lbs is correct
excellent video. thanks
Glad you liked it! :)
that was beautifully done.. clear and concise .. I am a 68 year old engineer and I have seldom seen better. Dr Prius says I have two duff clusters (4 cells) on my 135,000 mile old car . I wiill buy four conditioned cells from ebay and change them over
You're welcome, thank you for the kind comments! :) Good luck with the change over!
I know you can buy (for a crap load of money) but what’s to stop someone from replacing the old NIHM batteries with modern lifepo4 cells? Even with an oversized pack. A 200ish 100-200 AH pack. Plenty of room where the NIHM pack is, near as I can tell as long as the voltage is fine and the current the computer can’t tell a difference. Just a matter of wiring in a balance board etc.
no chance of fire with lifepo4.
You could add a few extra batteries in series so the lifepo4 cells never get near full. Lose some potential capacity but it makes them last longer.
Is there a list for compatibility between modules? I'm struggling getting the right ones for 2013 Lexus is300h
I put a list in the video description I believe!
Dr prius app shows. Temp 3 high 115 shall i move cells from there to other parts
hi, why are the temps high though?
1:15, see that green wire pair? Is that a temp sensor? There's a little black plastic pin holding to a metal tang. Mine has gone missing. What should I do about that? Right now there's nothing holding the wire. Thanks for any suggestions.
I mentioned what these are the video! Rewards are for people that don't skip around then ask the questions for things I already covered! 🤔
To recondition, do you completely (100% both ways) discharge and recharge
Yes, I would! :)
Just like when you buy a new phone. Let the battery go down to 0%, then give it a full charge.
@@TutorialGenius Thanks
i’ve got two of these batteries and I want to use them for my boat’s 36v trolling motor. I know I can rearrange the batteries cells sin five parallel and five in series . 7.2v x 5 = 36v. my question is, how much do you recommend I charge each cell voltage so i don’t hurt it? and what is safe discharge before need to recharge it? so i could get the most life out of the battery.
8.2 to 8.4 is full charge voltage and 6 voltage is the full discharge voltage dont get behind it
@@funhok8809 Thank you. where were you able to find his information?
@@vitaly19 i was just googling
แบตเตอรี่ กี่ a ในแต่ละโมดูล
When replacing a cell or 2....do they have a serial no or any new cell would fit any Where?
It's the same model :)
Do you discharge the cells before dismantling them otherwise they swell up when separated?
No, because you're not actively charging them
Isnt it required that the charger be for nickle metal hydras batterys?
On something like a hobby charger, you would match the charger and charging to the battery type, yes
is 8.2 a good voltage for the battery cell?
This is already answered in the video in so much detail. You should watch the video
My only question would be when you replace any module. Do all modules have to be charge at the same charge( voltage)before putting them back?
Not at all! :)
With regular servicing, will the whole battery ever need to be replaced?
I heard a Hybrid teacher, said, don’t matter if you make it work, still no good. I do very good mechanic, and I study electrician, refrigeration.
There is a hybrid shop near me, that said the same like that teacher, fix it, but it will be no good, or gives you a 60% of probabilities to be working good, also, it can work, but hard to erase coding from dash board.
So, they want for my Prius C 2013 $2800, to replace the battery. That’s from the shop, but the teacher it said, every year hybrid battery need care.
Many of this videos, don’t tell you everything you want to hear for all of this situations. :(
In my Prius car 2011 model ,,four cells are damaged,, I want to know it will work efficiently if I replaced the cells?
If they are damaged, then sure, replace them!
I think I lost the plastic pin for that temperature sensor on the top of the battery. Is that critical?
As long as it doesnt move around when you drive, its no big deal
Ni e job !
How to charge the hybrid battery w/o removing it from the car? How to create the Plug-in functionality of Prius Gen 2?
Sorry, you've lost me. what are you trying to do? the car charges it naturally
@@TutorialGenius I want to add a Plug-in functionality---an auxiliary/supplementary/alternative charging of the battery from a solar panel mounted on the root, or from the grid when desired. Apparently, both of the functionalities, Plug-in and roof mounted solar panel auxiliary charging, are available as options on the newest Prius.
does anybody know where to purchase new cell replacements, I searched hundreds of pages and can find nothing
Cell are inside the modules. Toyota doesn't sell modules. Sorry!
I hope you will subscribe to me soon!
Ebay
How'd you do finding new modules?
Hi. Wonder if anyone can help me, I charged my batteries the same way you have, and 3 of them exploded, I turned it off and the 4th was swelled so bad, I charged at 2amps, and after 2/3 hours they exploded. Any help please? Thankyou
Did you follow the advice in the video with regards to charging?
I mentioned two tips you should follow when charging these.
1. amps, which you did
2. They should be installed when charging, otherwise, the sides will swell
Witch side is cell #1?
On GEN 3. On GEN 2, Module #1 is farthest from the battery ECU (or just next to the compression plate you are going to crank tight).
I believe block one is always at the negative terminal end of the battery.
👍
😱🤯
I want to see if I can charge the whole battery pack together since it was good when I left 6 months ago.. that is not dead.. I have had six Priuses had four last year until one was stolen.. I have rebuilt the batteries two or three times.. I went to Europe 6 months ago and asked my buddy to drive them once a week but he lost the key..
So two of them were not driven for 5 months.. One of them the hybrid battery was very very low but finally the engine started.. of course I was jumping the 12 volt battery.. now to the point.. One of them did not start…instead of rebuilding the whole battery I want to put it in one of my other Priuses and jump the hybrid battery from one to the other or start the one Prius and switch the batteries while the engine is in neutral.. in other words I want to charge the whole hybrid battery at once.. I realized the danger to myself but not to any thing else.. I don't know how the charge controller works ..
I'm thinking to have clips on jumper cables on the two orange leads coming from the inverter to make the disconnection and connection to the dead battery easy..
Please.. What do you think?
It's certainly possible, but I'm sure there are a lot of safety measures you would need to take first. Perhaps you would need a schematic for the charge controller to double check. Maybe the pinouts might reveal something failing that.
I've left mine sitting for 1.5 years and it booted up ok (Pending a jump on the AUX battery). Do you live in a hot climate by any chance?
@@TutorialGenius Yes in California and it was sitting in the sun..
@@TutorialGenius so a couple days ago I jumped it by putting the battery in another Prius.. it brought all the modules up to 7.5v except for three.. it turned on the ignition and all the dash lights but I could not get it into gear and the engine would not start..
Canadian tire sells an automatic battery charger that reaches14.5 volts DC that can recondition the battery
Sounds great
Can you just test each cells and replace just the bad cells?
Modules... Yes, that's the idea
nimh batteries need permanent balancing for long life.
Rumors say that replacing bad cells will ruin the other good ones.
How true is that?
What rumors? Where did the rumors come from?
Wouldn't that be the Battery Control Module? 🤔
The BCM! :)
6.5ah is all? Or did you miss quote that? I would think it would be at least 65ah.
It's a very long video. Nobody is perfect. I probably did. I hope you will subscribe to me soon!
You didn’t show how do you test cells with the tools.
The video is called: 'Cell Module Replacement'. It already has 10000 things I didn't mention in the title.
I didn't mention the kitchen sink either, but nobody has called me out on that yet! :)
I hope you appreciate what you did see though :)
I'll pay for your membership if I can ask you a question or call you on the phone
Ask away!
never clean old coins!
THAT my friend was the SLOPPIEST marking of + and - on the sides of the battery - You got to put more effort than that bro!
But I tell you, I was sitting here earlier asking myself why the hell people won't use the regular laptop power supply adaptor to charge a block or even an adaptor - and then I see you do it. Great minds think alike - not saying that you have a great mind because of your handwriting quality ;)
Don't take everything you see literally. It's just an example. The battery in this video was parted out and sold, the marker was removed with rubbing alcohol after filming.
I'm glad you found the video useful.
@@TutorialGenius - came across your video again - you did a fine job - don't take my comments literally - some parts of it are jokes.
@@wizardmaster6639 Thanks I think
Come on man you have to be kidding He's the only one that had the read that plus and minus
6 "cells" in a "module".
You got it
Do not use these dirt cheap Chinese alligator leads...these can not handle any load
See my video on wire sizing :)
I jumped the hybrid battery in a different Prius and it charged but the car would not start when it was hooked up.. perhaps the voltage was low I don't know there were three cells that were very low but it did activate the system it just would not turn over the engine
Thanks for your kind comments! :)
Which battery are we talking about? The hybrid battery or the lead acid battery in the trunk/boot? It's definitely the hybrid batt?
@@TutorialGenius Yes I am talking about the hybrid battery.. The 12 volt battery I can always take out and charge.. but what I want to do is charge a good hybrid battery that has been discharged. I am thinking to charge it by starting the Prius and attaching jumper cables between the two hybrid batteries inside the prius. Of course that could be done before the engine is started. Or if that would not work I could start the car and disconnect the hybrid battery and attach the new hybrid battery to the leads coming from the inverter in order to charge the dead hybrid battery.
@@TutorialGenius I'm talking about the hybrid battery.. I was gone for 6 months and it went dead.. I want to charge it by using jumper cables with clips .. instead of trying to recharge all the cells individually.. both batteries are removed and can sit side by side in the operating Prius.. I would start to Prius and then jump from the orange inverter cables to the dead battery.. I know the danger about the high voltage.. I have had six Priuses and still have three now all Gen 2.. I've rebuilt hybrid batteries twice.