Ni‑MH Hybrid Battery Pack for Toyota Highlander 1st Gen (2006–2009)

Product Overview

The Ni-MH Hybrid Battery is a high-reliability traction battery exclusively engineered for the 1st Generation Toyota Highlander Hybrid (2006–2009) (XU40 series). As a core component of Toyota’s early Hybrid Synergy Drive (HSD) system for mid-size SUVs, it features premium prismatic nickel-metal hydride cells, a robust modular design, and efficient air-cooled thermal management. Fully OEM-compatible in dimensions, electrical parameters, and connector layout, this battery delivers stable high-power electric assist, efficient regenerative braking, and consistent fuel economy—perfectly restoring the Highlander Hybrid’s original hybrid performance for aging vehicles or replacement needs. It is built to withstand the demands of SUV driving, ensuring long-term durability and seamless integration with the vehicle’s hybrid control unit.

2. Key Features

100% 1st Gen Highlander Compatibility: Tailored for Toyota Highlander Hybrid 2006–2009 (XU40 series), fully matching OEM specifications for plug-and-play installation.

Premium Prismatic Ni-MH Cells: High-grade nickel-metal hydride cells with low self-discharge (≤3% per month) and stable charge/discharge performance, built for SUV load demands.

HSD-Optimized Performance: Calibrated for Toyota’s early Hybrid Synergy Drive system, supporting strong electric assist for heavy loads, regenerative braking, and low-speed EV mode.

Efficient Air-Cooled System: Forced air cooling with integrated temperature sensors, maintaining optimal battery temperature (-20°C to 55°C) for consistent performance in all driving conditions.

Robust Modular Design: 28 series-connected 7.2V modules forming a 201.6V system, ensuring balanced voltage, long cycle life, and resistance to vibration (ideal for SUVs).

OEM-Level Safety: Built-in overcharge, over-discharge, over-current, short-circuit, and over-temperature protection, compliant with Toyota’s automotive safety standards.

Long Cycle Life: ≥2,500 shallow charge-discharge cycles (≥80% capacity retention), adapting to the Highlander’s hybrid working mode for SUV daily use.

Plug-and-Play Installation: Direct replacement with no modifications required, matching original mounting points, wiring harnesses, and BMS compatibility.

Low Maintenance: Sealed, maintenance-free design with no need for electrolyte refilling or water top-ups, suitable for long-term SUV ownership.

SUV-Tailored Durability: Reinforced housing and vibration-resistant construction, built to handle the Highlander’s weight and off-road-capable chassis.

3. Specifications

Battery Type: Nickel-Metal Hydride (Ni-MH) Hybrid Traction Battery

Fitment: Toyota Highlander Hybrid 1st Gen (2006, 2007, 2008, 2009) | XU40 Series | FWD & AWD

Nominal Voltage: 201.6V (28 modules × 7.2V, series connection)

Cell Configuration: 168 prismatic Ni-MH cells (1.2V each)

Nominal Capacity: 6.5Ah (6500mAh)

Total Energy: ~1.31 kWh

Cooling System: Forced air cooling (active thermal management)

Peak Discharge Rate: 30C (195A, 10-second pulse)

Continuous Discharge: 12C (78A, 60-second pulse)

Operating Voltage Range: 180V – 220V

Cycle Life: ≥2,500 cycles (80% DOD, capacity retention ≥80%)

Self-Discharge Rate: ≤3% per month (at 25°C)

Operating Temperature: -20°C to 55°C (optimal: 15–35°C)

Protection Functions: Overcharge, over-discharge, over-current, short-circuit, over-temperature

Dimensions (L×W×H): ~700mm × 320mm × 110mm (OEM-matched)

Approximate Weight: ~40 kg

Connector Type: OEM-compatible high-voltage connectors

Warranty: 3 years / 100,000 km (capacity decay ≤20% within warranty)

Compliance: ISO 9001, IEC 61951-2, Toyota OEM quality standards