Swapping HV Battery Electronics

Welcome to Prius Chat .

The main thing you’ll be doing is assembling the modules and using the new hardware that came with the battery. The toughest part is packing it so you get the core charge back.

Good luck and keep us posted .

 

Sounds like an opportunity for you to contribute to the community and share how it is done.

Basically it is removing the connecting screws, nuts and connectors, black hoses, white rectangular plastic clip, etc.

Then swap them onto the new core.

Be sure to use the 6 new nuts. Noting that the contactor nuts are different than the battery post nuts. Use the new foam baffles. One has a larger opening than the other. That one goes on the wireframe side of the pack.

Double check that you didn't accidentally knock the temp sensor on the end of the pack when handling it. Ot should be clipped tight to the underside of the module.

Be sure to properly tighten the HV battery connections with an inch-pound torque wrench. DO NOT GUESS ON TIGHTNESS. Do it right. You saved on the pack cost, so you can certainly rent or buy the proper tool. Undertoqued can lead to arcing and a fire. Overtorquing can lead to broken parts.

 

Its unfortunate given the thousands of posts about the hybrid battery rebuild there's not a special and specific HYBRID BATTERY FORUM.
Frustrating as all hybrid battery posts are spread out among the different G2 forums. Lots of really good info but its just a mess.

Best bet is to use the blue search forums button up top and search the G2 forum for:

HYBRID BATTERY

You will find gold you just have to dig a little. Settle in for some reading and printing.

 

Torque Specifications for Hybrid Control System :

https://share.qclt.com/%E4%B8%B0%E7%94%B0%E6%99%AE%E7%91%9E%E6%96%AF%E5%8E%9F%E5%8E%82%E8%8B%B1%E6%96%87%E6%89%8B%E5%86%8CPDF%E6%A0%BC%E5%BC%8F/Prius%20Service%20Manuals%202004/%E4%BF%AE%E7%90%86%E6%89%8B%E5%86%8C/04pruisr/03/21av4/torque40.pdf