The Prius Generation 2 Hybrid (2000 – 2003)
We started reconditioning the Prius Generation 2 Battery in 2007. Since then we have developed many different techniques to increase the reliability of there rebuilt batteries. Unlike the Generation 1 the Generation 2 battery is still available new. Still installing the Power Jockey for $1800 is cheaper and more beneficial than paying $6000 for a replacement.
We now offer a full service of Hybrid vehicles. With our S2000 scanner from Japan we are able to fully service the Prius hybrids.
By doing so we have effectively preserved the value of the Prius Series 1 Hybrid. Owners of these vehicles that have had the benefit of our service will testify to this. Well maintained, these cars run as good as new, which belies their age, and will run for many more years to come.
The Toyota Prius Generation 2
Manufactured between 2001 and mid 2003 it has similar outer dimension to the series 1 but is roomier inside due to the smaller battery pack. The battery pack is changed to 38 prismatic modules. Both the gasoline engine and the electric motor are upgraded. The 1500 CC delivers 58 KW and the electric motor delivers 33 Kw. There is more power available, but best of all the battery pack is cheaper to replace at $6000.
Reconditioning a Prius Generation 2 Hybrid Battery
As the generation 2 battery pack is approaching it’s design life of 8 – 10 years we are starting to see battery failure in the Generation 2 Prius.
If a prismatic Nimh module fails the vehicle will be disabled. This actually protects the battery computer from damage.
Repairing the generation 2 battery pack involve locating replacing the faulty modules. Load testing all cell modules to determine capacity and cell integrity, Balancing all cells to ensure uniform strength and capacity. Reassembling and final in car testing. Cell balancing is the hardest to perform and require experience to execute well. The final in car test run is also very important as it is at this stage when we can determine if the petrol engine also needs to be repaired.
We have successfully repaired many battery packs. For those who wants to try repairing the battery pack themselves we have a video to show you how.
As the value of these vehicles reduce it makes more sense to repair and recondition rather than to replace the whole battery.
Your options
1) Replace with a new battery pack.
The Nimh prismatic module is used in Generation 2 as well as Generation 3 vehicles. Toyota service centers will recommend replacement. If you have money to burn and a spare $6000, OK, if not see below.
2) Let the Battery Clinic replace faulty Nimh modules.
We charge $600 plus $150 per module for locating and replacing modules only. If we find that the capacity of the whole battery is low and require reconditioning, we charge $1000 plus $150 per module replaced.
3) Do your own repair.
We have a video on this website explaining how to repair and replace the Nimh module.
How we recondition the Nimh Battery
a) We test to see if the battery computer is faulty. If it is still working perfectly you will have no error icons and messages after the battery is reconditioned. If not you will have an error message but the car will operate normally in every aspect, because cost of a new battery computer is about $3000.
b) We strip out the battery pack as seen in picture and discharge them individually. This is necessary to clear any memory effects that have developed over the years.
c) We then charge the cells individually over on our special programmable on a preset charging regime, maintaining constant current and monitoring the temperature. This is necessary to remove cells that are faulty from the pack, and to rebuild lost capacity.
d) We use desulphators in the charging process to assist in the restoring of lost capacity.
e) After charging we test each cell for voltage attained and internal resistance of each cell string.
f) We stress test each cell with 100 amps current. This will ensure that each string will survive the load required by the electric motor..
g) All faulty cells are replaced. We take the car or “battery” for a test run to balanced and equalise all cells and to ensure that the battery pack is performing normally.
h) We can now rebuilt tubes by spot welding good cells. This solves the problem of finding good tubes. With this we will be able to keep the series 1 prius running for a very long time to come.
Warranty
Each battery after reconditioning is tested in a car to ensure that it is operating correctly and that it will perform under stress. We offer 1 year free parts and labour warranty.
If the battery fails during the warranty period due to normal operating conditions, we will remedy the problem for no extra charge.
Getting the battery to us is at the owners cost. The cost of replacement modules about $150 each.
