I Bought the Most Hated Car on the Internet (and made $1000)

Summary

This detailed DIY guide walks through the process of replacing a faulty hybrid battery in a Toyota Prius using a rebuild kit. From safely removing the old battery cells and swapping out corroded bus bars to installing the new battery cells in the correct order, every step is covered. The video also includes tips for better cooling through sensor placement and reassembling the car’s interior. By following the instructions, viewers can save money on repairs and even make a profit by reselling the car with its new, high-quality battery.

Takeaways

• 😀 Proper battery orientation is crucial during installation, with positive and negative terminals clearly marked for each cell.
• 😀 When replacing hybrid battery cells, it's important to keep the new cells in order as labeled for optimal performance and longevity.
• 😀 Battery packs should be handled carefully to avoid damage, such as cracking, and should fit together securely to ensure cooling efficiency.
• 😀 Tightening compression block bolts to the correct torque is essential to secure the battery in place properly and prevent damage.
• 😀 Temperature sensors should be repositioned towards the middle of the battery pack to improve cooling efficiency and battery performance.
• 😀 The battery case should be carefully reassembled, ensuring all bolts are tightened to the correct specifications to prevent issues.
• 😀 New bus bars are included in the rebuild kit, and swapping out old, corroded ones is crucial for proper electrical connection between battery cells.
• 😀 All nuts, bolts, and connectors should be torqued to the manufacturer’s specifications to ensure the hybrid battery system functions properly.
• 😀 After installing the hybrid battery, a successful start-up and the charging of the battery by the engine indicates correct installation.
• 😀 Reassembling the car interior requires following the disassembly steps in reverse, ensuring all clips and bolts are securely fastened to avoid loose parts.

Q & A

Why is it important to install the new battery cells in the correct order?

The battery cells need to be installed in order because they are balanced using a computer algorithm to ensure long battery life and optimal performance. Keeping them in the correct order maintains this balance.

What precautions should be taken when handling the new battery cells?

It is important not to drop or bang the battery cells as they can crack or get damaged. Also, ensure that the battery cells are aligned properly, as they fit together like LEGO pieces, and must be flush and even for proper function.

Why is the positioning of temperature sensors important in a hybrid battery replacement?

Positioning the temperature sensors toward the middle of the battery is crucial because it allows the fan to trigger earlier, keeping the battery cooler, which improves its lifespan and performance.

What is the purpose of the compression block in the hybrid battery?

The compression block is used to hold the battery cells in place securely, ensuring they remain aligned and prevent any movement that could lead to damage or inefficiency.

Why is it necessary to replace corroded bus bars during the hybrid battery replacement?

Bus bars connect the battery cells in series, and corrosion can impair their ability to transfer electrical current. Replacing them ensures a clean and efficient connection, maintaining optimal performance.

What torque specifications are critical during the hybrid battery reinstallation process?

Several torque specifications are crucial: Compression block bolts should be torqued to 24 ft-lbs, bus bar nuts to 60 in-lbs, and various battery case bolts and components like the air duct and side trim pieces should be torqued to specific values, such as 71 in-lbs or 14 ft-lbs, to ensure everything is properly secured without over-tightening.

How can you ensure the battery is properly reconnected to the car after installation?

Once the battery is installed, you should reconnect all the necessary electric harnesses and high voltage wires, ensuring each clicks into place. Additionally, you must lock the safety plug and reconnect the 12-volt battery for the system to function.

What safety measures should be taken when working with high voltage wires in a hybrid battery replacement?

When working with high voltage wires, it is essential to wear proper protective equipment, handle wires carefully to avoid short circuits, and ensure they are securely tightened to prevent any electrical hazards.

Why is it important to torque bus bar nuts to the correct specification?

Properly torquing the bus bar nuts to 60 in-lbs ensures a secure and reliable electrical connection between the battery cells. If not tightened correctly, the connection could be unstable, affecting battery performance and potentially causing failure.

What are the key benefits of replacing the hybrid battery yourself rather than outsourcing the job?

By replacing the hybrid battery yourself, you can save money on labor costs, gain hands-on knowledge of your vehicle, and potentially make a profit if you choose to resell the car after repair. Additionally, it allows for the installation of high-quality, cost-effective rebuild kits.