How to: install Nexcell lithium battery

Installation guide on YouTube

Prius Gen2: https://youtu.be/em4-vP52GR8

Prius Gen3: https://youtu.be/N660fkvbXb8

Prius C: https://youtu.be/w47GMVKtwKw

 

Things to know before we begin:

  1. Do not mix Lithium battery with NiMH battery.
  2. Identify and locate a special blade that has terminals on both sides. This is the battery blade for connecting to the orange service plug.
  3. 'CAUTION' Do not short circuit the positive and negative terminals. DISCLAIMER: Damaged cell or cells due to short circuit or install/user error is not covered by warranty.
  4. Clean the green corrosion (if any) from the factory copper connectors.
  5. Clean the cooling fan blades at this time during your install process.

 

Tools you will need to start the battery swap:

  1. 8mm, 10mm, 12mm, 14mm socket wrench (a good power tool will save you time, but be careful with over torque with power tool)
  2. Pry tool to remove black plastic plug
  3. Voltmeter

 

Installation Guide:

  1. Remove all trunk panels and black plastic tray.
  2. Unplug the 12v battery and orange service plug FIRST. This is to protect your safety as well as reset error code(s) and reset SOC (state of charge) to 60%.
  3. Take out/remove the back seat, take out/remove the interior panel trims and remove all metal shields/covering to the battery pack.
  4. Disconnect the 3 white connectors to the battery ECU and disconnect the orange battery power cable.
  5. Take out the entire battery container and place it on a steady table. (Warning: The Factory battery is heavy at this point, around 80 lbs).
  6. Remove copper bus bar on both sides by taking out all 8mm bolts.
  7. Remove all bolts from the bottom of the blades that hold them in place.
  8. Carefully remove all the stock blades and store them in a safe place.
  9. Brand new lithium blades should be ready to install right out of box; however, it is recommended to do a quick check with volt meter to make sure all blades have the same voltage (tolerance 0.05 delta volt)
  10. Install the lithium blades into the container and install m8 bolts at the bottom to secure all blades.
  11. Note: You do not need one side of the copper bus bar as they are now internally connected.
  12. Note: You do not need all the rubber vent tubes as lithium does not vent toxic fumes.
  13. Install the remaining bus bar to the lithium blades. Bolts should be torque to 3 ft-lb (do not exceed 5 ft-lb as it could create internal damage)
  14. Put battery container back into the car.
  15. Connect the orange power cable as well as the 3 white ECU connectors.
  16. Plug the orange service plug back in and make sure you not only turn the handle 90 degrees, but also push and click the handle in place. Next, connect the 12v battery (Warning: car alarm may sound, prepare to disarm).
  17. Before installing all bolts and panels back into the vehicle, test start the car to insure there are no error codes.
  18. Turn off the car and install all bolts and panels back in place in the reversed order as removed.
  19. Drive the car gracefully for the first 100 miles to break in the new battery.
  20. Congratulations! Now enjoy improved fuel economy, better acceleration and increased EV range!

 

-If you have any questions, please be sure to send us an email or reach out to us on Facebook.