Hybrid Battery Repair Ultimate Guide (Toyota Prius 2nd Gen 2004-2009) DIY
Vložit
- čas přidán 7. 06. 2024
- This is a comprehensive guide on how to repair your 2nd Gen (2004-2009) Prius HV Battery. I will show how to take battery out, determine which blocks are weak, replace modules, restore the rest of the pack, clean copper plates, reinstall the battery.
Quick Links:
1:52 Battery Removal
12:15 Initial Voltage Measurement
14:20 Internal Resistance Test
15:48 Measure/Restore Capacity
23:11 Replacing Bad Modules
30:36 Cleaning Copper Plates
31:59 Leveling the Voltages
36:36 Battery Installation
Power supply on the video is HP DPS-600PB B 575W. It can be found on ebay for 35$ or so.
Turnigy charger on the video has been discontinued. I would try an updated version: hobbyking.com/en_us/quad-4x6s...
Link to blank excel sheet for test results: drive.google.com/open?id=1T-l...
Accucel-6 charger on the video: amzn.to/3eJvnJT
Replacement battery modules: amzn.to/2XZDFqb
Recommended tools:
1. Screw driver set: amzn.to/2XAk3sH
2. Sockets and wrenches set: amzn.to/36xLnMn
3. Multimeter: amzn.to/3dae9F5
4. Pliers: amzn.to/2U4rY0q
5. Wire cutters: amzn.to/3eLd9aS
6. Floor fan: amzn.to/3cwOmG6
Parts:
1. Alligator clamps: amzn.to/3eHL7x4
2. 16 gauge cables: amzn.to/2Mqyuuk
3. Banana plugs: amzn.to/2BsZRSd
**CAUTION** You must only work on the battery with the safety plug out. Otherwise you are in danger of electrical shock/death.
You must wear electrical safety gloves when connecting and disconnecting the terminals. - Věda a technologie
This battery reconditioning program exceeded my presumptions. It worked on any drill battery, several AA and AAA batteries batery.repair and any camera battery. The steps are simple and the act itself is exciting to do. No matter what type of battery you`ve got, it is sure to function again!
Great idea with the excel spreadsheet and multicharger, seriously best tutorial on CZcams for fixing hybrid batteries.
You are the man, Igor! Not only doing this repair in the wind and cold of winter with snow on the ground, and on your street (!) but also filming your repair under these conditions, wow, kudos to to you and thanks for the informative video!
Igor, as many others have said, WELL DONE SIR! It’s a very detailed video with a lot of relevant editing. Obviously you have put a lot of effort into both the video and battery reconditioning process. Thank you so much, it’s very helpful.
This is probably the best video on reconditioning of battery modules that I have found to date online. Some other people have some decent ones, but you explained it pretty well and it's my reference video I go back and watch again and again to understand everything going on with the batteries I am trying to recondition and change out.
From a aerospace engineer, thanks so much for an excellent teaching and most of all the spreadsheet.
Nice job aerospace engineer
I followed this step by step and my Prius is now running as new. This is a great piece of work. Well done and thanks for making it available.
How long did you let the modules rest to read the "V after test" referred to on the spread sheet? Ty
Most excellent comprehensive and well documented video for Hybrid battery on CZcams! Thanks Igor. I did reconditioning in the past but your methodology was superior! Great Job!
Igor, this is an EXCELLENT step-by-step video!! Thank you for taking the time to walk through every part so thoroughly, very much appreciate by me and no doubt many others seeking reliable help for doing this job. Keep up the great work my friend! =)
Thank you Dan! Really appreciate your feedback 🙂 I am glad I was able to help
I congratulate you for your dedication and hard work. You cannot get this kind of service from anywhere no matter how much you are willing to pay.
Good job...
but you can buy brand new battery :)
@@rivan0 ~$400 vs $2500-3000
New Dr Prius gen 2 lithium conversion 1600
One of the most extensive video on the subject, you are covering the module balancing which is rare. Thanks
Great video man! I'm about to do the same to our 2008 Camry Hybrid. I have done tutorials like this in forums and it's not an easy thing to do. I really appreciate the detail and time you spent!
Thank you so much for the detailed step by step process. It was a great help in reconditioning my own battery🙏🏻
Thanks for taking the time to film this while doing it... in the snow and wind.
Brilliant video as I’m having problems with my hybrid and wanted to know the work involved in reconditioning the battery. You sir have the patience of a saint very meticulous and methodical which you need on a very time consuming job. Impressive to say the least 😊
I totally enjoyed this video. Very learning experience. I learned enough to know I don’t want to work on it. I was a project manager for the DD on the F16, F110 engine in Turkey. I’m retired now. However, some of the same principles apply to the electronics on the engine and the engine test stand.
My God! I'm freezing just watching this video, and I'm in sunny Florida! LOL So much RESPECT to you for doing this in 28-degree weather with possibly a wind chill factor! Great job!
Dear Igor, I wanted to thank you for your video which along with the Prius Chat threads enabled me to do a good job re-balancing all the modules in our 2006 Prius. I only had to replace one cell! She's running great now with no Triangle of Death nor any codes whatsoever. I did forget to push down the handle on the orange service plug which resulted in the car not going into drive, reverse or even the motor starting. So I wanted to emphasize this step for others considering this process. BTW, I wanted to mention that I used the Hi-Tec X4 AC Pro AC/DC 4 Port Multicharger which performed flawlessly and didn't require any external power supplies to keep up with the load.
Thanks for feedback, Bill! I am glad you fixed your battery. It's funny, but it happened to me too, even though it's not on the video, I forgot to reinstall safety plug and it would not start. I even got upset that I would have had to disassemble it again, but then I realized my mistake and fixed it quickly :) Thanks for the tip about the charger. The one I recommended is not available anymore
Bill Byrd can you rebalance this hybrid battery until draining all the cell till the lowest cell? To even out the modules? I’m just trying to learn how to rebalance.
how many hours did it take you to refurbish your battery?
@@AJTarnas I was working on it for about a week during the day. I'm still on the same battery 3 years later.
That was a lot of work, thanks for putting this together and sharing it and congratulations for restoring your battery
this is the best video for charging the cells on your own! Great work!
Best hybrid batteries repair tutorial.
Thank you and we are waiting for more batteries repairing tutorials!
Great vid! And doing it in the winter and in the street makes it double awesome!
Good work man. This is done right and better than other test and swap videos I've seen.
Hello Igor, thank you so much for the effort you put forward into making this video. My wife's car needs this service and so I will be trying it myself soon. You've helped me a lot. Cheers!
Hello Michael, thanks for your feedback and good luck with the project!
@@IgorKadulenkov How long did you let the modules rest to read the "V after test" referred to on the spread sheet? Ty
Hope ur channel grows its the best one i found so far
Thank you so much for doing this, Igor! This is definitely the most thorough guide out there. I have used everything you provided to fix my Prius battery. I will be reinstalling it tomorrow. Wish me luck 🤞
Good luck!
@@IgorKadulenkov 7 months and 30,000 miles since I followed your guide, and my Prius battery pack is still running strong! I replaced 6 modules in total. Can you drop me your CashApp? I would love to thank you for helping me prolong my Prius battery. 200k miles and counting!
Best tutorial on CZcams for fixing hybrid batteries. Thank you. One comment: With the Ideal grease on the contact, your torque may be too high as the grease will make a slippery surface.
That's a good point, thanks. I guess you could decrease the torque in this case
Actually, it is just the opposite. The lubricant allows the proper torque. Lawson Products studied this and came out with a lubricant for lug nuts on HD trucks so that the proper torque is achieved.
Best prius video on CZcams - Well done!
Hello, for hybrid or nimh batteries to work for many years, they require passive and permanent balancing due to their low cell tension, they will not be the same. This is solved by connecting a shunt zener diode with its current limiting resistor. It balances all the cells at the same voltage. It is not perfect and a small percentage of capacity is lost, but it is better than a dead battery after 3 years. This method is highly effective, reliable and easy to integrate, achieving triple the useful life of a battery.
do you have a video or link to instructions?
Can you please provide details of how to do it? Thanks
Hi, any details about that it's kind of a good idea?
hello everyone on the internet there is a lot of information on shunt balancing methods.
Thanks Igor for the great video. It allowed me to get my prius 05 back on the road. Your video was very good.
Great Video. Thank you for sharing your experience. I very much wanted to see you start your Prius at the end with full bars :)
This was fantastic! Now I know what my options are once my 2008 needs battery work.
very amazing method. completely scientific methodology to replace battery.
Dear Igor, Thanks for sharing a very helpful and descriptive video
Thanks for posting this. You've helped alot of us to save money and learn
Thank you .. this is a very good example of what is required.
Scary watching you wave uninsulated screwdriver around. Apart from that this was the best start to finish video out there, thanks for posting so we may all learn more about EV'S.
Thanks Igor. I like the interior in your Prius.
Excellent guide Igor ! Thank you !
Thank you!
Very well done, congratulations for a well balanced informative video.
I just got a quote for a new battery pack at my local Toyota dealership for $1,600 (June, 2022) marked down from the original price of $2000 ...so now watching this video.
That is good news. I have seen some hybrid repair shops in England got some new battery packs from Toyota in 2022 and are selling them for about $1600.
Great video. Thank you. I see you working in the snow and I remember before I had a shop to work indoors. Burrrrr.
Thank you! Yeah, it was freezing, street parking, I had to go home back and forth a few times to warm up my hands and feet while I was getting the battery out. Gladly it's not on the video (yeah, some people include all sorts of nonsense) :)) The 12V battery had died on me also.
Thank you for your time and effort and sharing it.
Perfect guide.Thank you
Thank you, for smart individuals like yourself much peace ☮️
Thank you very much for this tutorial! You are amazing!!!
Very patient man. Well done. Very good work
Excellent video.Congratulations.
Igor, Thank You so much for Best video in Internet!!!! It helps to save a lot of time and money!!!!
Thanks for helping us Igor!
Igor, thanks for this awesome tutorial. I have very similar setup in my Pug 508 Hybrid and will try this for myself. It's 200V 5.5Ah battery pack like yours I asume. Have you ever consider adding more cells to the battery? Or even adding extra battery in parallel for extra capacity?
I did a full battery reconditioning according to this guide! It is a great guide! Thanks a lot.
I had to replace 4 cells and after cycling and reconditioning, the battery works way better than before :)
But be aware of the fact, that it takes a lot of time (I spent about 1,5 week to do all the steps). Of course it is not hard work and not that difficult but
My experience: I used a 4x Turnigy Charger and a 2x Skyrc T200 charger. The Skyrc T200 worked better than the Turnigy.
Thanks anyway for this really great tutorial! It saved me about 2400€!!!!!
Thanks a lot for your feedback! Stories like yours keep me going. DIY is easier than many of us tend to think. I am glad you fixed your battery!
Did you need an external power source for the skyrc t200? If so, what did you use?
Thank you so much for the video.. It is great. Thank you to you and others my nephew could by a cheap Prius with a bad battery than then he fixed and now it is helping him to take his children to train with the Costarican national Tae Kwon Do selection. He needed a newer fuel efficient car. His children train everyday and he needs to drive almost 2 hours in each direction and gasoline is expensive over there..
Thank you for the feedback, I am so glad my video helped your nephew and his children 😊
Waw...you're amazing..very detailed video... Good job bro...you're so good.
Perfect Video. I drive since 2016 a 2006 Lexus GS450H. Since 2016 i have 4 hybrid errors. 2 times i use the voltages testing. But since 2019 i use your capacity testing. The first test was 2019. Now the car is in 2021 down. And the modules lost from 2019 to 2021 over 450 mA/h. But run 2 years without error. Thanks to your video !!!!!
At the moment i thing that NIHM batterys lost capacity when they get older. So please don`t by a hybrid car that is older then, let me say.. 12 years.
I bay 1 Prius and one Auris battery to find good modules to bring my GS back on road.
Did you see in your analysis also a curve in the capacity when you repair your car? I found that the first and the last modules in the battery most are better then the modules in the middle of the battery.
But realy Thanks for your video. It bring me back on track do drive this good car. It is like a couch.. perfect for 48 old people ;-)
Hi Igor, nice work!!! I got a question, once you finish the cycles of every cell, how do you arrange them back? I mean some cells are going to be a little bit better than others, i.e. 5800 mAh, 5300 mAh, 6000 mAh... do you sort them ramdomly?
Thank you for the great video!!!
Brilliant video with correct information.
Would like to know reasons for battery battery failures in hybrid cars..
And how to overcome this.
Great video Igor! I will have to say that I have two major questions though. What is that HP hot-swappable power supply used for, and what is the charging voltage for the cells and where are you setting this? Other than that, everything was quite clear. Thanks for your fantastic work on this!
Thanks for the video. Very comprehensive.
What volt meter apps were you using on your smart Phone? Thanks
THANK YOU SO MUCH THIS VIDEO IS GOING TO SAVE ME THOUSANDS OF DOLLARS!!!!!!!!!!!!!
Glad to hear that, you're welcome!
Great video. At what level of capacity degradation would you replace an individual battery brick?
Nice video , very informative.
Greatest tutorial! Thanks!
Hi, thank you for this great video best one on youtube, a question other than you have the car up and running what is you MPG now after the fix and what it was before?
Thank you, Francisco! The MPG had definitely improved, but it all depends on how you drive it. Before and after the battery failure I was able to get 55mpg if I wanted to. But it’s easier now, I can definitely tell that it takes longer to discharge the battery after the fix. I can drive further in the straight line
Wel done and very nice, thanks a lot for sharing it.
This video helped alot keep it up bro
Thank you, Very Thorough. Helped my Friend with an 2005 Gen 2. Worked like a charm. He is quite happy :-). PSA: make sure you guys with Smart Keys push in the switch under the steering wheel or it will not Start.
A button or a switch?
@@markpennella Sorry, button
I like your special dish washing protection gloves!
Yes , dual purpose!
Thank you so much for the video very useful, I just have one question, with the power supply, can you advise if there is any specific output plugs that I can use with DPS-600PB?
Great video. I will be attempting to try this soon. Can we use any charger discharger or does it have to be specific kind? Thanks for the great tutorial video
BEST VIDEO ON CZcams SOO FAR.what app are you using ???
Thank you! I use Adobe Premiere
Like most others...great video, great help. Thanks
Finished changing two cells today...and my 2005 with 277k runs like new-:))
bro did it in the winter. outside.. props...
Thank you very much @Igor Kadulenkov for the Video, I am now in the process to prepare one I got from scrap, then I can change the one in my car much quickly. Until now ( I process 12 modules) and I got values between 5454 and 6586 mAh of discharging, moslly over 6000 mAh, with that good values do you consider that is also necessary do a internal resistant test? I observ in the video that the #15 even that gots over 5400, you discard because was the worst in internal resistant test, by other hand you discard also #18 because has volts very low respect the others, In my case the #1 was even under 6 volts, after 3 cycling it gots 5891 mAh, In resumen is not mAh good values enough to consider that he module is in a good state? In the pass I mount a module that the internal resistance was very bad but after re-cycling It gots good values for mAh and until now is working fine in the car, Is not the re.cycling a way to recover modules , that are not so bad , Is true that other modules with bad internal resistance, never got good values in recycling .
Amazing video
This is an AWESOME Video. I noticed the hobby king charger unit has a discharge feature. Why did you not leverage the discharge feature of the unit?
paman igor kereeenn, minta tolong lebih sering juga update mengenai perbaikan kendala prius. terima kasih
Gr8 video, how long in real time did it take U? What app U using with scan tool, cheers
It’’s an awesome job and very informative video manual Igor. Thank you for sharing. Congratulations for concluding with success.
Wow what a pain in the as removal. Then a special charger and complex testing. Toyota you make quality but common.
you are brilliant! great video. Best to also clean out the fan battery and filter components at the same time to ensure no debris gets to the newly reconditioned battery. Very impressive..
Igor, Thanks for the great video! Did you say you got your replacement batteries from Prius Chat? On Ebay how do you tell if the batteries are good when only voltage (not ma discharge) is shown in listing?
Thanks!
Hello. I've got a few modules from eBay and the rest from Eric from PriusChat. Here is his profile: priuschat.com/members/ericbecky.1015/ He's known in the comunity and he sells good quality modules. Not sure how to really tell what you buying on eBay. The only way to know for sure is to do capacity test after you received it. I would try to buy from sellers with a lot of good reviews left for modules.
Igor, this is an awesome video. Thanks. I heard you using Torque App. Which brand of OBD ii scanner you used or using. I am going to order one for my Prius based on your recommendations. A scanner that can read each Modules voltage like on your phone display. Thanks.
Hello, thanks. I would not order an expensive scanner. Just google for "elm327 bluetooth adapter", they run for 10$ and can be used with android phones. Then in the Torque app you can install a profile for Prius and it will be showing all the data
Thank you so much for making this video. Very informative video. Please can you teach me about repairing of hybrid systems?
Simply Fantastic!
Nice work- Thank you!
Nice tutorial, I appreciated. I have 2007 Camry Hybrid and I follow a few tutorials and took apart my battery and cleaned the copper plates and measure voltages on the cells all came good at 8.05V lowest was 7.96V so I put it back. Did not know you have to load test them to make sure they are all good. Now I have to take off again, lol. Is there a particular seller that sells good quality sells you can recommend?
Thank you for this. Which OBD2 Scanner are you using to get the voltages of the cells?
Any OBDII bluetooth reader would work with torque app for Android. You will need to download Prius profile for Torque app , then you will get all these additional parameters.
Thank you for this very informative video. It's fantastic.
I have One question. Since little more than 2 years has passed since you did this operation. How is the status for your hybrid battery today?
I have a prius Gen 3. When using "DR PRIUS APP" it says that my status is 47% at the moment. This is after i have evened out the modules.
In Juli 2020 i measured 65%. So i was little bit surprised getting that low rate after doing this even-out-operation.
I did not balance the modules. i'll guess that i just can't skip this procedure.
In your section where you give the links to the equipment used I would discard the trunigy 4x6 for some other charger. They did away the capacity results after doing the discharge/charge cycle. I thought I was doing something wrong and finally reached out. Turns out they updated the firmware on this unit and it no longer gives you the capacity report on each charge/discharge session at the end. Total crap imho, as I will now be returning the unit as we bought it for this vital function that is no longer available due to their firmware update. I mean you can watch it in live action and try to catch it when it switches cycles, but some sessions last up to eight hours and I don’t really feel like sitting there staring at this unit. Any suggestions on what other charger can perform this would be appropriated.
Igor, you’ve done the world a great service with this video. Thank you! But now that you’ve educated us on how to recondition our batteries; that it isn’t just a matter of one quick test on the cells before replacing one or two of them-and with the recommended Turnigy Charger now backordered for a month or so, I find myself in the middle of a lengthy process I wasn’t prepared for. So here’s my question:
With the 1-cell charger I now have, my project looks to not be complete for a good month or more; when the Turnigy Charger would finally be available.
So, would you recommend I just replace the worst of my cells right now, reinstall the battery, and then start the project anew when the Turnigy Charger comes in next month, or recondition just one cell a day for the next twenty-eight? And, are there any procedural changes to take, given the long timeline?
Again, great video; great research you share! Thank you! I look forward to your reply.
Hello Jim, thanks for your feedback! For your question: i think it should be fine to just throw in a replacement module, if you already know which module had failed. This is a short term solution, performed by many questionable battery repair companies and it usually works just fine for a year or so until another module fails. If you do this, you need to level the voltage in replacement module to the rest of the pack. If you planning this as a temporary solution for a month or two, this sounds like a lot of work - removing and reinstalling the battery twice. Maybe it's better to get 3-4 more chargers from what is available? hobbyking.com/en_us/batteries-chargers/chargers.html?wrh=2%2C3&stock=1
I think some people were using IMAX B6 50W which is 25$ each. There is a bit of discussion about IMAX B6 on PriusChat forums. TURNIGY REAKTOR is really good, but it starts at 50$. You can also get Turnigy double chargers for 100$. You could also sell them on eBay later, once you've done with reconditioning.
Igor Kadulenkov
Thank you, Igor. At your suggestion, I look to get enough chargers to recondition seven cells at a time, and then probably resell the chargers. Easier to resell, though, if a power supply is included, so that may limit me to buying chargers with included power supplies. Crazy that power supplies aren’t more commonly included, or at least offered as a simple add-on. But, thanks again, Igor! I love the resell idea.
Great video, thank you!
@igor Kadulenkov Thank you very much for this detail video. Very informative for newbies like my self.
Can you please explain how one can tell if the charging or discharging is complete for a cycle. I am using the imax B6AC v2 and just following your settings. it just keeps changing from discharge to charge or charge to discharge. But how can I tell if cycle 1,2 or 3 is completed. I have my setting on discharge/charge 3 cycle. After over 6 hours, I press on stop and I only see the reading CH1 5866mAH, DISC 1- 4366 mAH, CH2 6975 mAH, DISC 2- 4645 mAH, CH3 0000 mAH, DISC 3 - 417 mAH Working on a prius hv battery
Good Job Igor! Thanks
Great video. It’s been over a year since you’ve done this. Has the Prius battery held up since then?
I’ve heard that only replacing a few battery cells doesn't get you many miles.But you seem like you’ve done everything properly.
That's if you don't do the testing and conditioning steps he did
Уп
How long does it take to recondition (go through cycles)? Thank you
if anyone's curious, the electrolyte leak from NiMH can be neutralised with a baking soda solution (this applies to leaking primary alkaline and ¨dry¨ cells too).
It´s better to apply this before attempting to scrape off corrosion as it will make cleanup a breeze
An ultrasonic cleaner makes cleaning small parts really easy
Great job!
When you discharge and charge cycles, is that like when sellers online refer to as "reconditioning? the cells?