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This technical report details the end-of-life fuel efficiency and battery testing on two model year 2001 Honda Insight hybrid electric vehicles (HEVs), two model year 2003 Honda Civic HEVs, and two model year 2002 Toyota Prius HEVs. The end-of-life testing was conducted after each vehicle has been operated for approximately 160,000 miles. This testing was conducted by the U.S. Department of Energy’s (DOE) Advanced Vehicle Testing Activity (AVTA). The AVTA is part of DOE’s FreedomCAR and Vehicle Technologies Program. SAE J1634 fuel efficiency testing was performed on the six HEVs with the air conditioning (AC) on and off. The AC on and off test results are compared to new vehicle AC on and off fuel efficiencies for each HEV model. The six HEVs were all end-of-life tested using new-vehicle coast down coefficients. In addition, one of each HEV model was also subjected to fuel efficiency testing using coast down coefficients obtained when the vehicles completed 160,000 miles of fleet testing. Traction battery pack capacity and power tests were also performed on all six HEVs during the end-of-life testing in accordance with the FreedomCAR Battery Test Manual For Power-Assist Hybrid Electric Vehicles procedures. When using the new-vehicle coast down coefficients (Phase I testing), 11 of 12 HEV tests (each HEV was tested once with the AC on and once with the AC off) had increases in fuel efficiencies compared to the new vehicle test results. The end-of-life fuel efficiency tests using the end-of-life coast down coefficients (Phase II testing) show decreases in fuel economies in five of six tests (three with the AC on and three with it off). All six HEVs experienced decreases in battery capacities, with the two Insights having the highest remaining capacities and the two Priuses having the lowest remaining capacities. The AVTA’s end-of-life testing activities discussed in this report were conducted by the Idaho National Laboratory; the AVTA testing partner Electric Transportation Applications, and by Exponent Failure Analysis Associates

Hybrid Electric Vehicle End-Of-Life Testing On Honda Insights, Gen I Civics And Toyota Gen I Priuses