Hybrid battery cooling fan running constantly, lots of warning lights!

Kathy,

I would hook up a Prius aware scanner and see if you get a P0A80 code along with P03XXX codes. If you don't see that with a good Prius aware scanner then I would check the voltage of the 12 volt. It wont hurt to check the 12 volt. Chances are it is weak especially if the battery is original. But I suspect the 12 volt might be only part of the problem.

You have the symptoms of a possible traction battery failure but without the codes it is a wild guess at this time.

Also make certain that you see turbulence in the inverter coolant reservoir under the hood when in "Ready Mode".

Note: Not all scanners are Prius Aware. Just because the scanner you are using does not show a code mean that there are no codes present. A trip to the dealer may be in order for a "diagnostic only" service. In other words, ask for the codes to be pulled but not have any other work done. Also ask the dealer to furnish you with all the codes they found. You can expect to pay a one hour service charge for the diagnostic which varies from dealer to dealer.

If you have access to a laptop that has the mini vci set up on it, that will be equivalent to what the dealer uses. The dealer uses what is known as "Techstream" software. It is rather expensive, that is one of the reasons why the mini vci is so popular here on Prius Chat. You can find the mini vci on Ebay and Amazon. It runs on a 32 bit Windows based system (XP or Win7) I believe you can run it on a Mac if you are running bootcamp, but I am not a Mac expert.

Below is a link that will lead you to a google search for the mini vci.

Google

Best of luck to you and I hope this information helps you.

Ron (dorunron)

 

To check for turbulence you simply put the Prius in "Ready Mode"

Then raise the hood and look at the side of the inverter coolant reservoir. The backside (closest to the windshield) of the reservoir fluid level will look higher than the front side. Note that you are looking at the side of the bottle or in other words looking at the reservoir from the side of the car. If the Prius is not in ready mode, the level of the fluid should be even from front to back. But in "Ready Mode" the fluid tends to look higher in the back versus the front of the bottle. Below is a picture of the inverter coolant reservoir that I am referring to.

 

It would not be a bad idea for you to run the test to check the 12 volt with the MFD. Link in my signature below (Test the 12 volt battery).

Post back all three values. Also best to run the test after the Prius has set overnight BEFORE you drive it.

 

press brake and push power button for 'ready mode'.

 

+1, especially if Kathy doesn't know what "Ready Mode" is or understand the term used here on Prius Chat.

 

The battery fan is a fairly consistent clue. At 200,000 miles in an often hot climate, you are doing very well if the traction battery is just now ready for repair. And you are hopefully close to one of the Dorman Battery installers, such as Taylor Automotive:
Dorman Hybrid Drive Batteries - Installers

 

To be honest, that event may have somewhat hastened your traction battery's demise.

I had a similar event the first summer that I owned my 2005 Prius (s/h in 2009). You've got to hand it to the dealers and their detailing - the car was immaculate inside and out when we picked it up. You would have sworn it was owned by the proverbial little old lady who only drove it to church on Sundays. That was until I had to open up the back to clean the fan and ducting - then all of a sudden it looked like the previous owner had been breeding ferrets in the back seat or something!

Anyway, in my case I might have been lucky in that I think I caught it fairly early. No warning lights or loss of power, but a few minor driving anomalies and the fan running a lot more alerted me to it.

 

You are close enough that you might want to check out "autobeyours" in Scottsburg, Indiana. Steve is standup guy, and pretty much a guru of Gen 2 Prii. The page linked below says he has rebuilt HV packs for $1095 installed, which seems like a decent price. A number of folks on this list have bought rebuilt salvage Prius from Steve over the years (myself included) and I can't say enough good things about both his skill and support.

Plug In Hybrid Electric Vehicle PHEV

Good luck!

Rob

 

replacing cells isn't as easy as it sounds, or else the dealer would be doing it. it's a slow complicated proceedure of charging and testing. it's great for knowledgable diy'ers because it's all time and labor and few parts and chargers. but to send it out, you have to pay for all that. you might be better off looking around for a decent total replacement or trading the car in. all the best!

 

You might find someone who is willing to do individual cells, but the challenge is it takes time. The whole pack has to be torn down and each cell characterized to assess its health. Then you need a supply of "good" cells so substitute in for the weak ones. Preferably having a variety of cells to chose from to pick those best matched to the cells being left in. I'm guessing most commercial outfits are going to prefer to rebuild the packs on their own time (basically the same procedure as above) and have a few ready to just swap out for customers who need one at a flat rate rather than having you down for a week or two while your pack is rebuilt. Its always worth asking though!

Rob

 

Taylor Automotive has a really good reputation. I suggest giving them a call and discussing options of pack Vs module replacement.

 

Note that it is possible to travel at highway speeds without much battery use. On level terrain, at constant speed, the engine does all the work. The energy display shows no arrows going to or from the battery under that circumstance. So you can go long distances without a problem if you are careful.

I agree that a rebuilt pack is your best option. Cell replacement is for DIY types.

 

I gave Sanford Automotive a call since I suspect traction battery problems is not too far into my future. Dave Taylor sold his garage to the MacGills, and now works down the street in the hybrid battery rebuilding shop of Dorman.

As for the Dorman remanufactured batteries, Mr. MacGill was kind enough to answer my question by email of which modules are used in the rebuiling:

Since I personally only want lightly used and pretty new G3 modules in a remanufactured battery, I will avoid the Dorman option. If I cannot find a rebuilt battery to my liking I'll simply buy a new Toyota one and look for a less expensive installation than the dealership.

 

Hi SageBrush. At the moment you're only showing the 2012 V wagon in your profile. I assume that you've still got your old gen2 and that's what you're referring to here. Is that correct?

Anyway, I'm just wondering if you're getting any early warning symptoms of battery failure, or if the prediction is just based on age and mileage.