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.
Link to blank excel sheet for test results: https://drive.google.com/open?id=1T-ldtt90Y9oMNl01dcKttKFFmUYMpakS
***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.
 DIY')){kind=link}
Dear Igor, Id like to consult with you prior to the balancing exercise. what shall be the minimum discharge voltage. In your video i saw 6v – 9v cycles, however as per Prolong (R) they suggest discharge termination voltages to be extremely low, for an individual module (6 cells/module) . 1st discharge : 4.8v, 2nd discharge 3V, 3rd discharge 0.6V. Similarly for charging, they suggest, 8.58V to be the peak voltage during balance charging phase for an individual module.
Perfect guide.Thank you
Amazing work Igor! could you please share the blank excel sheet?
Excellent guide Igor ! Thank you !
can we get a link on the power supply
Thank you very much for this tutorial! You are amazing!!!