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Fur and dirt causing major battery problems

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by rondodog, Oct 6, 2008.

  1. rondodog

    rondodog Junior Member

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    The problem!
    [​IMG]

    While I was drive north on I-5 in the middle of Nowhere, California (about 60 miles west of Bakersfield), I got the "Christmas Tree" of lights on my dashboard. My Prius (2006) shuddered slightly and the cruise control disconnected. After a few frantic calls to friends (thanks Gordon and Tori!) we decided that I could continue to drive (not that I had any real alternative), but all the lights on the dash still made me nervous (especially the triangle "!").

    When I got to San Jose I took my car to Stevens Creek Toyota where I was lucky enough to get a 25-year veteran Toyota mechanic (who is apparently a passed master on Prius cars). I gave him the bullet-point symptoms: mileage down by 4+mpg, cruise control disconnects after about twenty minutes, engine stays on. I had asked my local (L.A.) Toyota mechanic several times about low MPG and that my engine hardly ever turned off at red lights and never when the headlights were on, but they never found anything.

    This guy at Stevens Creek Toyota was *good*! He discovered the problem: the cooling fan for the batteries was clogged solid with fur (I have two border collies) and dirt (I love driving with the windows open). The cell phone pic shows what they found: the battery compartment was so full of fur and dust that my car was the talk of the shop! The batteries were over-heating because of the layer of gunk and the clogged fan (in this model, it's the fan/intake to the side of the rear passenger seat). Am I the only Prius driver that likes open windows and four-legged passengers? Most of my Prius friends have such tidy cars!

    Here's a cell phone pic the mechanic took of the clogged squirrel fan:[​IMG]
    After everything was cleaned out, I wanted to prevent this from happening again. Gordon suggested heater vent filter: these are used on the floor vents in houses to prevent dust from being blown out when the heater goes on. Since this is also a low air-flow situation, I hoped it would work to prevent dirt and fur from entering the compartment, yet still draw air in.

    We made a paper pattern and cut out the vent filter. Removing the fan cover was easy (one bolt) and the filter was easily placed inside the cover (save the little square of filter material-- you'll see where it goes when you put the filter in).
    [​IMG]
    Hopefully this will be helpful for the two other Prius drivers who have four-legged passengers and enjoy open windows! Be sure to check your battery compartment! This was a $700 fix!
    [​IMG]
    Outcome? Not sure yet...I will check the compartment in a month or two and see what it looks like. But I checked when the fan turned on and there was air flow into the compartment and my mileage increased by 4-6 MPG and my engine now shuts down at all stops. Car and I are much happier now!

    Edit: here are the install photos:
    Removing the filter cover: you need to pull the bottom seat cushion out a bit to get to the single bolt holding the battery fan cover down. The bolt is probably metric, but a 1/2" crescent worked. The black hole in the center is the vent leading to the battery compartment. Last photo is fan cover replaced with filter inside.
    [​IMG]
    Installing the filter: After you cut out the filter material (see above), you just slide it into the area behind the fan opening. I didn't use any adhesive-- the pressure of the closed fan cover holds it in place.
    [​IMG]
    After one month, the filter was this dirty, so I guess it's working!

    Full size pics in this Flickr set:
    Prius Fan Problem - a set on Flickr
     
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  2. Boo

    Boo Boola Boola Member

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    Thanks rondodog for the tips and pics.

    So maybe it was only the fur and dirt that brought you bad mileage, and not the hills as you had posted on another thread?
     
  3. Flying White Dutchman

    Flying White Dutchman Senior Member

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    700 dollars? just to clean out your fan?

    and bring on the install pics please
     
  4. Celtic Blue

    Celtic Blue New Member

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    If we had an MFD temperature indication for the batteries something like this would be a lot easier to diagnose...if we know the battery is getting hot then finding the cause becomes a lot simpler.


    rondodog,

    Thanks for sharing the info and your solution.

    What exactly did the dealer do to justify $700? That's at least 10 hours of labor even at stealership rates.
     
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  5. rondodog

    rondodog Junior Member

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    Boo: Oh, this was in addition to the hills: I lose about 4mpg going fast up the hill (Newhall Pass between Los Angeles and Valencia) and fast going down the hill (it's a major trucking route, so drifting downhill is...harrowing). A week of no-hill and only street and freeway driving pops my mpg up by 4-5mph easily.

    Dutchman: I'll get those on my Flickr asap (and add them to the post if possible). Here's about how the $700 breaks down: $150 just to do a general check on the car; $120 just for initial inspection; the rest is for all the tests and, once the problem was discovered, to clean it out: $150 to perform tests on the batteries; $200-300 to open up the battery compartment and check; 150 to clean compartment and fans. Heaven forbid if the fan had burnt out!

    Here's quoting what the invoice said:
    Customer states that check engine light came, cruise control turned off while driving. Customer also reports mpg is a less than normal. Inspect and advise.
    Inspected and found fault codes P3000 battery control.
    POA82 Battery pack fan 1 malfunction. C2315 H.V. systemC2318 low voltage trans., B1200, B1207, B1271 gateway (battery low), POA82 battery fan, freeze frame set @86 mph with outside 98 degrees temp.
    Performed active test for battery fan, removed battery pack and found excessive dog hair in the fan blades. Also found a thick layer in channels of H.V. battery fan blades. Tech then cleaned fans, fan blades, reassembled and rechecked.

    Labor: $720
    Parts: -0-


    I have since had one of my Prius-owning friends show me how to get to the battery compartment myself to check in the future (it just never occurred to me about the dog hair-- but since the same thing happens with the computer, I should have had a clue.). FYI: Take out the spare, undo the four bolts you find under spare and remove the plate to get to the batteries.
     
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  6. Celtic Blue

    Celtic Blue New Member

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    It seems outrageous to me that they would soak you for so many hours if they were getting codes from the battery pack, particularly the one for fan malfunction. The first $150 and $120 seem like triple charging since they are the same thing (double charge) and they also charged for the battery test and cleanout, amounting to a triple charge. This is pure profit for them.

    How many hours did the guy actually work on the car?
     
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  7. paprius4030

    paprius4030 My first Prius

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    WOW talk about expensive, but at least it seems you found a good Prius Tech, but did you try to negioate a better price?
     
  8. rondodog

    rondodog Junior Member

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    Shawn: yeah, I was pretty shocked, too. The mechanic was great-- the charging policies of this dealership were not-so-great. The local Prius owners all recommend Sunnyvale Toyota head-and-shoulders over Stevens Creek (probably for this very reason), but wasn't logistically available for me at that time. I was told that if the battery fan had failed, it could be up to $700 more (but I could be mis-remembering...it was a big enough number that I was stunned).

    The hours worked on the car? Not sure-- they didn't put that on the invoice (just what I wrote above). I don't know when they started working on the car (we dropped it off at 9am), but they were working on it until at least 4pm.

    Paprius4030: Yeah-- I'm grateful for the tech checking everything out: he's apparently a direct consultant to Toyota regarding Prius cars. They did warn me how much it would cost to get to the battery compartment, and I gave them the go-ahead. Negotiate? I'm such a beaten horse when it comes to dealer service that it never occurred to me (I've tried in the past and they just look at their papers and repeat the same figure-- ie, I've never known them to negotiate).
     
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  9. hyo silver

    hyo silver Awaaaaay

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    A filter on the battery vent looks like a good idea, though it shouldn't impede the airflow much. Short of shaving the dogs, I'd recommend checking the air cabin filter at least once a week. I'm pretty sure I don't want to see pictures, but you might check if it's time for a new bag in the vacuum. ;)
     
  10. Patrick Wong

    Patrick Wong DIY Enthusiast

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    My guess is that the labor rate is $120/hour so you were charged for six hours of time. Considering that the tech had to open up the battery case and deal with all that dirt and fur in the fan, it doesn't seem so bad.

    The good news is that your problem (which was pretty unique) was accurately diagnosed and repaired. Good idea to install the filter, hope that you are planning to check it frequently.
     
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  11. galaxee

    galaxee mostly benevolent

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    just for clarification, flat rate doesn't equate the the actual amount of time spent on the car. $70/hour labor rates are a thing of the distant past even on the east coast.

    props to the tech for figuring it out, might be worth sticking with him in the future too if it's feasible for you. repeat business is always appreciated, and i assure you he will remember you :)
     
  12. tochatihu

    tochatihu Senior Member

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    Perhaps this situation is unique, but as Rondodog has posted the DIY photos, we can hope that there will be some filter inspections done on the various pet-hauling Prius of PC. It would be a good thing.

    Shawn: I agree completely, and furthermore that every Prius would be better if we knew when the max HV battery temp. reched 45 oC
     
  13. dogfriend

    dogfriend Human - Animal Hybrid

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    I'm thinking with 2 Border Collies, you are going to want to check that filter once in the spring and once in the fall just after the seasonal shedding times.
     
  14. Celtic Blue

    Celtic Blue New Member

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    I've never been charged anywhere close to that on an hourly basis. At that rate they better be whizzin' gold and crapping diamonds as they are charging out at $240,000/yr per tech (never mind the markup on parts & "shop supplies.")

    Cleaning up a little dirt and fur? What's such a big deal about that? Now if it was full of wet manure, I could see where it might not be a job for the squeamish. But either way it is a straightforward low skilled clean up task of the $6/hour variety, not 20 times that.

    If someone asks you whether you want to clean out the dirt and fur or have them do it, at what price would you say, "you do it?" I figure it at maybe half an hour at $40/hour, or $20 total. Any more than that and I'll do it myself, thanks. When I go to a dealer I'm paying for expertise, lifts, and some tools I don't have, not to keep my hands clean. I won't be grateful to someone for charging me several hundred dollars to pick some dog hair out of a squirrel cage blower (any more than if it was full of leaves & insects or rodent infestation.) I've replaced, cleaned, reworked, swapped bearings, motors, etc. on similar blowers before on personal cars and HVAC, it is no big deal. It's pretty low tech at that point.

    I'm all for giving folks an honest profit, but not being charged outrageous sums for trivial aspects of the work. Seems there is a growing disconnect between real value and perceived value.
     
  15. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Hi Shawn,

    The cost-of-living in Silicon Valley is quite high; a starter single-family home located near Stevens Creek Toyota in San Jose is priced in the high six-digits. (I know the area well as I lived in Sunnyvale for 21 years prior to moving to OC.)

    Further, the untrained tech (say the junior guy who is assigned to engine oil changes, and who according to other posters can't even do a Prius oil change without adding one quart too many) would not know how to retrieve the DTC, interpret them, and disassemble/clean the correct assemblies without screwing something up.
     
  16. Genoz World

    Genoz World ZEN-style living

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    this is a very interesting thread. ronodog, thanks for the information on this.

    never fails to amaze me what i can learn here.
     
  17. galaxee

    galaxee mostly benevolent

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    well, let's clarify how flat rate works. this is not a flat per-hour-worked system. each job (remove/replace, drain/fill, diagnose/test, etc for parts x, y, and z) carries a certain number of hours as a standard time. it's much like piecework.

    say job A carries a rate of 0.5 hours. no matter how long it takes the tech to do the job, whether it's 10 minutes or 2 hours, he gets paid 0.5 hours at his rate of pay per hour. so you see sometimes the tech comes out ahead a little bit, that's considered a good paying job. the ones where you barely break even or get behind, those screw the guy over.

    this means you can put in 60 hours at work in a week (standard for dealerships) and get paid for anywhere between 20 and 100 hours.

    local rates are $90/hour here.

    you're paying for the expertise as well as the tools, supplies, and facilities that you may not have at home. the guy is specially trained in diagnosing the source of the problem and correcting it. if correcting that involves removing some clogged fur, that's that, he does it. ever remove a bloody former-mouse from a heating duct? they're not trained to do that either but it sure happens in the course of business.
     
  18. Celtic Blue

    Celtic Blue New Member

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    I grew up on a farm, so there isn't much that makes me squeamish...other than $700+ bills to clean out a blower fan.

    Lived in Silicon Valley for a year, but that was long ago...the place is way too overpriced now to even consider living there.

    As it is, the OP was still at least triple charged for this. Cleaning a blower fan shouldn't be more than 0.5 hours. Most of the rest was multiple billing of the same troubleshooting along with whatever the charge was for the actual assembly/ disassembly.



    When you see the battery pack fan malfunction that screams, "CHECK THE FAN FIRST!" If I'm paying for expertise I expect the expert to be smart enough to go after the low hanging fruit first, rather than soaking me for a bunch of dead ends. Dead ends are on the dealer's dime, NOT MINE!
     
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  19. galaxee

    galaxee mostly benevolent

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    the tech did check the fan first: he ran an active test once he had the codes. then he started dismantling the battery cooling system (though i doubt removal of battery itself was necessary, unless just to be thorough) and found all the dog hair. and cleaned it out. where's the dead end? the guy did a fine job.

    the OP wasn't paying for dead ends. he was paying an entry fee to walk into the dealership with a problem, plus the cost of the job. fwiw, the act of plugging in the scantool bills 0.5 hours alone.
     
  20. Celtic Blue

    Celtic Blue New Member

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    Apparently the "entry fee" was about $600 dollars of that.

    Plugging in the scantool is part of that up front cost of walking in. That's the problem with stealerships: triple charging you for everything at a labor rate that is several times normal.

    I'll be glad when there is some familiarity with handling hybrids so that it will be unnecessary to rely on the stealerships.