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EV and Hybrid Battery Replacement

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Battery Inspection

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Physical damage to the Toyota prismatic battery modules

Cracks

These modules are prone to cracks if mishandled, dropped, or due to manufacturing defects. herefore, inspect them for these obvious defects.
Toyota hybrid battery module showing signs of electrolyte leakage

Electrolyte Leaks

The battery can often leak due to mishandling or manufacturing defects, leaving a prominent white mark or visible liquid bubbles on the casing.
Heat sink of the Toyota prismatic battery module

Cleanliness of the heat sink

The walls of the battery serves a dual purpose: dissipating heat generated within the cell and maintaining the battery’s structural integrity. It is crucial that the aluminum wall is clean and free of obstructions during assembly to ensure optimal performance
Broken ground screw on the Toyota battery module

Broken Ground Screws

The battery ground screw is used to attach the battery to the frame. Sometimes, due to cross-threading or over-torquing, it can break. If this happens, the broken screw must be removed to properly ground the battery module and ensure overall safety.
Battery Inspection - Threaded Terminals integrity | iHybrid | Lower Mainland

Threaded Terminals integrity

If the nut is improperly installed, it can damage the threads, necessitating the use of a tap and die set to rethread it
Comparing damaged locks to intact ones for the Toyota prismatic hybrid battery

Interlocking Mechanism

Improper packing of the battery can damage it. The protruding part of the interlock may push against the battery wall and potentially puncture it.
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Identify Battery Module Parts

Hybrid Battery Specification - Discharge Rate | Lower Mainland

Terminals

To connect the battery in a pack

Battery Module Parts: Temperature Well | iHybrid | Lower Mainland

Temperature Well

Used to measure the temperature of the module in a test setting or when assembled in a pack

Battery Module Parts: Safety Valve | iHybrid | Lower Mainland

Safety Valve

This will release the electrolyte gases in case the pressure inside the cells exceeds the limits

Battery Module Parts: Heat Sink | iHybrid | Lower Mainland

Heat Sink

Alluminium casing on the either side of the module is meant to dissipate battery heat

Battery Module Parts: Ground | iHybrid | Lower Mainland

Ground

This is located in the bottom and is used to secure the module to the frame and additionally serve as the ground

Battery Module Parts: Interlocking Mechanism | iHybrid | Lower Mainland

Interlocking Mechanism

interlocking mechanics is provided to lock the battery modules for efficinet ventilation and structureal integrity

Ground nut of the Toyota prismatic battery module
Toyota prismatic battery terminals, safety valve and temperature well features
Hybrid battery module mechanical interlocks
Battery Module Parts: Heat Sink | iHybrid | Lower Mainland
Hybrid System | iHybrid

The Toyota Prius relies on a durable hybrid battery to enhance fuel efficiency and performance. Its battery packs store and deliver energy to support the electric motor. Over time, maintenance or replacement may be needed to keep your Prius running smoothly, ensuring long-term reliability and efficiency.

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