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How to fix a $4,000 hybrid battery problem with vinegar and baking soda

This is one of those 'Don't try this at home if you don't know what you're doing' DIY tales. Two weeks after imgur user "scoodidabop" bought a used Toyota Camry Hybrid with no warranty, he got the Christmas Tree dash display with warnings like "Check VSC System," "Check Hybrid System," and the Check Engine light. After some Internet sleuthing he figured it could be a faulty brake actuator, assuming the hybrid system warning was a false alarm. But it wasn't the actuator, it was the battery, a Toyota dealer telling him that his battery had "gone bad," and he'd need $4,457 to replace it. Then he had a brainstorm: it could be one of the cells that's gone bad, not the whole battery. Scoodidabop has some experience as an electrician, so he figured he could test it and replace any bad cells for about $45 apiece. He removed the battery unit from the trunk and over the course of two hours tested all 68 cells four times. He found nothing wrong. So he devised another type of test and checked every cell again. He couldn't find a problem with any of them. Turns out the problem wasn't in the cells, but with the dirty and corroded copper connectors at the ends of the high-voltage cables. He pulled the 34 connectors and their steel nuts, soaked them in vinegar, gave them a light steel wool scrub, soaked them in baking soda and water to counteract the vinegar, applied an anticorrosive and reinstalled them. That took an hour. When he replaced the battery, the warning lights had all gone out and the battery worked perfectly. Skill level: experience. Cost: less than $10. Perhaps it's time for hybrids to be able to test their own cells individually. Dealers, too.

Akio Toyoda pledges return to WRC in 2017 with a Yaris

There have been rumors of Toyota returning to the World Rally Championship since the end of 2013, and a Yaris prepped by Toyota Motorsport in Germany has been caught on The Continent several times last year in testing. Akio Toyoda visited Rally Finland while we were there with Hyundai to watch a race up close, and he said that the passion people still had for Toyota's past exploits encouraged him. He finally answered the question about when they planned to enter the series, announcing in Tokyo that they'd line up for the season in 2017. The Japanese company, a legend in rallying, got into the sport in 1979 and left in 1999 after winning seven titles in ten years through the nineties with Carlos Sainz and Juha Kankkunen. The 2017 return is likely due to the regulation changes that year to allow more power than the roughly 300-horsepower in today's challengers and the switch to a fuel-flow formula to let manufacturers use different kinds of engines. Toyota has been sitting in on the WRC rules meetings, and the final slate of changes will be announced at the end of this year. The Yaris that's been testing is powered by a 1.6-liter, four-cylinder that meets current regulations, but we can expect it to change somewhat before it's race-ready. TMG will test the car for the next two years, then it will go up against fellow manufacturers Volkswagen, Hyundai, and Citroen, as well as Fords run by M-Sport. There's video of the Yaris running solo through the Belgian countryside above, and a gallery of the coming car below.

Construction of Lexus' first US assembly line underway

The ES is Lexus' top-selling sedan, but the Japanese luxury marque has never manufactured it outside of Japan. In fact, Lexus has never made any cars in the United States, one of its largest markets worldwide. But that's about to change.
Yesterday, construction began in Georgetown, Kentucky, on the first Lexus assembly line in America, the first concrete (or steel) step in a $360-million expansion of Toyota's plant in the Bluegrass state that will create 750 new jobs. The expansion was announced last April by chief executive Akio Toyoda at the New York Auto Show.
Once the new assembly line gets online in the fall of next year, Toyota plans on building some 50,000 units of the ES each year. Lexus sold a record 72,581 examples of the ES in the United States last year - 30 percent more than the previous year - so Lexus will either have to import some more from overseas or leave some buyers disappointed.