Hybrid Battery Repair Ultimate Guide (Toyota Prius 2nd Gen 2004-2009) DIY
Igor Kadulenkov Igor Kadulenkov
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 Published On Oct 29, 2018

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: https://hobbyking.com/en_us/quad-4x6s...

Link to blank excel sheet for test results: https://drive.google.com/open?id=1T-l...

Accucel-6 charger on the video: https://amzn.to/3eJvnJT
Replacement battery modules: https://amzn.to/2XZDFqb

Recommended tools:
1. Screw driver set: https://amzn.to/2XAk3sH
2. Sockets and wrenches set: https://amzn.to/36xLnMn
3. Multimeter: https://amzn.to/3dae9F5
4. Pliers: https://amzn.to/2U4rY0q
5. Wire cutters: https://amzn.to/3eLd9aS
6. Floor fan: https://amzn.to/3cwOmG6

Parts:
1. Alligator clamps: https://amzn.to/3eHL7x4
2. 16 gauge cables: https://amzn.to/2Mqyuuk
3. Banana plugs: https://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.

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