DIY Refurbish / Repair Hybrid Battery 2nd Gen Toyota Prius - EV-Peak smart charger POA80 P0A80

Introduction

This tutorial guides you through the process of refurbishing and repairing a hybrid battery for a 2nd Generation Toyota Prius, specifically the 2006 model with a common battery issue indicated by a red triangle warning light. By following these steps, you can save money and extend the life of your vehicle’s battery.

Step 1: Gather Necessary Tools and Equipment

Before starting the refurbishment process, make sure you have the following tools and equipment:

• EV-Peak smart charger (model POA80)
• Safety gloves and goggles
• A multimeter
• Screwdrivers (Phillips and flathead)
• Wrench set
• Battery refurbishing kit (if needed)
• Container for battery cells
• Fire extinguisher (for safety)

Step 2: Prepare the Workspace

Ensure your workspace is safe and organized:

• Find a well-ventilated area.
• Clear the workspace to have enough room for disassembly and assembly.
• Keep tools and equipment within easy reach.

Step 3: Remove the Hybrid Battery from the Vehicle

To access the battery pack, follow these steps:

1. Disconnect the negative terminal of the 12V battery to avoid electrical issues.
2. Remove the battery cover by unscrewing the bolts securing it in place.
3. Carefully disconnect the battery connectors and sensor wires attached to the hybrid battery.
4. Lift the hybrid battery pack out of its compartment; this may require assistance due to its weight.

Step 4: Disassemble the Battery Pack

Once the battery is out, proceed with disassembly:

1. Unscrew the battery pack casing and carefully separate the halves.
2. Take note of the arrangement of battery cells for reassembly later.
3. Remove the battery cells and inspect them for any signs of damage or corrosion.

Step 5: Test Battery Cells

Check the health of each battery cell:

1. Use a multimeter to measure the voltage of each cell.
2. Identify any weak or defective cells that need replacement.
3. Discard any cells that do not meet the voltage requirements.

Step 6: Refurbish or Replace Battery Cells

Depending on the condition of the cells:

• If refurbishing:
  • Use the EV-Peak smart charger with the following settings:
    • NIMH = 6.3V
    • CYCLE = Discharge/Charge = 3x
    • WAIT TIME = 5 Min.
    • TEMP CUTOFF = 176F
    • SAFETY TIMER = 720 Min
    • CAPACITY CUTOFF = 7500mAh
    • DISCHARGE = 1.0A
    • CHARGE = 3.0A
• If replacing:
  • Install new battery cells that match the specifications of your original cells.

Step 7: Reassemble the Battery Pack

Once all cells are refurbished or replaced:

1. Reinsert the battery cells into the battery casing in the original arrangement.
2. Secure the casing by re-screwing the bolts.
3. Reconnect all connectors and sensor wires securely.

Step 8: Reinstall the Hybrid Battery

To complete the process:

1. Carefully lift the battery pack back into its compartment in the vehicle.
2. Reconnect the battery connectors and sensor wires.
3. Reattach the battery cover and secure it with screws.
4. Reconnect the negative terminal of the 12V battery.

Conclusion

You have successfully refurbished and repaired the hybrid battery of your Toyota Prius. Regular maintenance of your battery can help prolong its life and ensure your vehicle runs smoothly. If you encounter any issues, consider consulting a professional mechanic. Remember to regularly check your battery health and follow safety precautions during battery work.