Module-level specs, fault codes, and repair guides for Toyota Prius, Camry Hybrid, RAV4 HV, Tesla LFP, and Honda Insight hybrid battery systems. All data cross-referenced with OEM service manuals.
OEM HV battery pack specs by vehicle model. Scroll horizontally on mobile.
| Vehicle Model | Battery Type | Voltage | Capacity (Ah) | Modules/Cells | Cooling | Weight | Warranty | Replacement Cost |
|---|---|---|---|---|---|---|---|---|
| Toyota Prius (Gen 2, 2004–2009) | NiMH | 201.6 V | 6.5 Ah | 28 / 168 cells | Forced air | ~110 lbs | 8yr / 100k mi | $1,300–$3,500 |
| Toyota Prius (Gen 3, 2010–2015) | NiMH | 201.6 V | 6.5 Ah | 28 / 168 cells | Forced air | ~105 lbs | 8yr / 100k mi | $1,500–$3,800 |
| Toyota Prius (Gen 4, 2016–2022) | NiMH / Li-ion | 207.2 V | 6.5 Ah | 28 modules | Forced air | ~95 lbs | 8yr / 100k mi | $2,000–$4,500 |
| Toyota Camry Hybrid (2007–2011) | NiMH | 244.8 V | 6.5 Ah | 34 modules | Forced air | ~130 lbs | 8yr / 100k mi | $1,800–$4,000 |
| Toyota RAV4 HV (2016–2018) | NiMH | 244.8 V | 6.5 Ah | 34 modules | Forced air | ~135 lbs | 8yr / 100k mi | $2,000–$4,500 |
| Honda Insight (Gen 2, 2009–2014) | NiMH | 100.8 V | 5.75 Ah | 14 / 84 cells | Natural/forced | ~80 lbs | 8yr / 80k mi | $1,200–$2,800 |
| Ford Fusion Hybrid (2010–2012) | NiMH | 275 V | 5.5 Ah | ~36 modules | Forced air | ~140 lbs | 8yr / 100k mi | $2,000–$4,200 |
| Tesla Model 3 (LFP, 2021+) | LiFePO4 (LFP) | 350–400 V | ~150 Ah | 4 modules (CATL) | Liquid-cooled | ~1,000 lbs | 8yr / 100k mi | $5,000–$15,000 |
| Lexus RX 450h (2010–2015) | NiMH | 288 V | 6.5 Ah | 40 modules | Dual fan forced | ~150 lbs | 8yr / 100k mi | $2,500–$5,000 |
The diagnostic trouble codes our readers search for most often.
Weak cell failure detected. Most serious hybrid battery code — replacement is needed.
Battery efficiency and capacity have dropped significantly. Often precedes P0A80.
General HV battery control system fault. Communication error between BMS and ECU.
Voltage sensor circuit fault. Module voltage monitoring is compromised.
HV battery temperature sensor circuit malfunction. Without temp data, BMS can't properly cool.
Inverter/converter system fault. DC-to-AC conversion failure — limp mode or no start.
What actually happens when a hybrid battery wears out, and what you can do about it.
Individual modules develop slightly different internal resistance. The BMS tries to balance them but can only do so much. You'll notice a small MPG drop — 2–4 mpg.
One or more specific modules can't hold charge like the rest. The battery gauge fluctuates rapidly. Codes like P3011–P3024 appear. MPG drops 5–10 mpg.
Overall pack capacity has dropped below the BMS threshold. The car still runs but the electric motor is less available.
Cell failure is confirmed. The vehicle may enter fail-safe mode with limited power. Don't delay — driving with P0A80 can damage the inverter.
Best value. New matched cells, tested BMS, 2–3 year warranty. Installed by specialty hybrid shops.
Factory new, perfect fit, longest warranty (8yr). Premium pricing — often more than the car is worth on older models.
Replace only the bad modules. Cheaper short-term but the rest of the pack continues aging.
High risk. You don't know the pack's history or health. May fail in months. Not recommended.
Common questions about hybrid battery maintenance and replacement.
In moderate climates, 150,000–200,000 miles (10–14 years) is typical for the original NiMH pack. In very hot climates, 100,000–130,000 miles is more common due to heat accelerating cell degradation. The 8-year / 100k-mile factory warranty covers early failures.
Technically yes — the vehicle enters fail-safe mode and runs primarily on gas. But it's risky: the inverter must work harder to compensate for weak cells, and a complete pack failure can leave you stranded. If the 'Check Hybrid System' light is on with P0A80, get it diagnosed within a week or two.
Replacing only weak modules costs less upfront but is usually a false economy. Hybrid battery cells age together — if one or two have failed, the rest are close behind. A remanufactured pack with all-new matched cells and a 2–3 year warranty is almost always better value.
Dr. Prius is a mobile app that reads Toyota hybrid battery data through a Bluetooth OBD-II adapter. It shows individual module voltages and can estimate pack health. It's reasonably accurate for identifying which modules are weak, but don't treat its 'battery life remaining' percentage as gospel.
The HV battery cooling fan intake is usually in the rear parcel shelf or side panel. Locate the intake grille, gently vacuum dust from the surface, then use low-pressure compressed air to blow out dust from the fan housing. Do this every 10,000–15,000 miles. A clogged fan causes the battery to run hot and shortens life significantly.
Start with the most common fault code and work through diagnostics step by step.