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Hybrid battery fan issues

Discussion in 'Gen 2 Prius Main Forum' started by PriusHead05, May 17, 2022.

  1. PriusHead05

    PriusHead05 Member

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    I've got a 2009 Prius that we have owned since early this year. Just in the past couple of weeks, We have noticed the SOC drop from about 3/4 full down to one bar (based on the MFD). We've also noticed that the battery seems to not hold a charge very well while driving around. Sitting at a stop light for a couple of minutes, the HV battery's charge will drain and will take a good 5-10 mins (3 miles) to charge back up above two bars. I decided to run the Dr. Prius tests on it. It told me that there is poor balance in blocks #9 and #12. I did the test a few of times so I could see if anything else was wrong. After about the third time testing, Dr. Prius started to give a warning saying that the battery was running warm. I checked the temp, 115°F. - 118°F. Ok, I was doing some hard acceleration and deceleration for the test. So I gave it a break and drove it normally for 5-10 mins. The temperature started to climb up to 122.9°F. by the time I got home. So I cleaned the HV Battery fan. It wasn't too dirty, for being cleaned for the first time. Put everything back together and took it for a test drive. Battery SOC dropped from 6-7 bars down to one bar on the MFD, just from backing out of the drive way for 5 seconds. Got Dr. Prius up and running. Noticed at a stop light, that the A/C was on high and drained the HV Battery, but when I took off, even though Dr. Prius showed that is was charging the battery, the SOC on Dr. Prius dropped from 45% down to 35% and in the red zone. Temperature by this time had gone up into the red zone and over 123°F. The SOC stayed below 45% for about 3 miles. I am now aware that the battery seems to be running hot and the fan won't go on high unless you override it in Dr. Prius. The big question is why and what could be causing this? The car has 163k mi. on it. The previous owner said that the hybrid battery was replaced. (Don't know when it was replaced or whether it was a new or reconditioned one.) Everything else is great about the car (other than the JBL CD Changer thats doesn't work, but that's minor in comparison to the HV Battery). The other thing is that I believe water has made it's way in from where the hatch hinges mount to the body. Above the HV Fan is rusty along with the metal bracket on the HV Fan. This connection to the right of the fan is also corroded on the same two wires on both sides of the connector. Not sure if this has anything to do with the problem. I'm sorry for the long post, but hopefully everything makes sense.
     
  2. PriusHead05

    PriusHead05 Member

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    Here is the connector I was talking about. In the pictures, you can also see the rust I'm talking about that's above the HV Fan and this connector.
     

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  3. bisco

    bisco cookie crumbler

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    that corrosion is very common. i'm surprised you don't have a warning on the dash
     
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  4. PriusHead05

    PriusHead05 Member

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    I did check the 12 volt battery this morning at it is at 11.8/11.9 volts with the car on but not in "ready" mode.
     
  5. bisco

    bisco cookie crumbler

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    check it at the jump point with the car off
     
  6. PriusHead05

    PriusHead05 Member

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    Ok. I checked with the MFD maintenance screen, Dr. Prius, and Torque Pro, but not with a multimeter yet. I will do it though.
     
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  7. jerrymildred

    jerrymildred Senior Member

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    A low 12V won't make the hybrid battery run hot or make the SOC bounce up & down like that. At those temperatures, I'd think you'd be hearing the battery fan running very loudly. At normal temperatures it's very unlikely that you'd hear it unless you have very good hearing and there is no background noise at all.

    Checking the 12V with a multimeter at the jump point and then comparing that to the voltage on the battery terminals will give good info on that battery but won't enlighten you on the hybrid battery anomaly. Check the delta SOC on Dr. Prius. I suspect it's pretty high which is what's reducing the hybrid battery capacity.

    The symptoms you've described pretty much scream that the battery is a reconditioned one. They don't often last very long. SOC up and down would lead me to go after the battery itself but high temps with quiet fan would send me to the fan.
     
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  8. PriusHead05

    PriusHead05 Member

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    I have tested about 5 or 6 different Prius and the Delta SOC always says 0 which never makes sense to me. The 2009's resistance is up there around 26-27 ohms. The fan works perfectly fine manually in Dr. Prius. After watching it a little more, it seems to not go above 2 (out of the 6 speeds). I decided to compare it to my 2012 (yes I know it's a different generation) but the battery temps were up there. My fan was on three and seemed to be cooling efficiently. My 2012's battery doesn't jump around like the 2009's does. I figured it's a reconditioned battery based on the way it's been acting. So pretty much now just sit back and wait for the triangle of death to come on, correct?
     
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  9. jerrymildred

    jerrymildred Senior Member

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    That's one option. Your location shows you in Florida, but that's too imprecise for anyone to suggest a hybrid shop that might help you pin down a diagnosis and give you options. Florida is over 800 miles end to end. There's one in Tampa that I like so much that I started working there part time after retiring. We've also bought our last six cars there.
     
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  10. PriusHead05

    PriusHead05 Member

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    The only hybrid shop I know of is Tampa Hybrids in Tampa. I have met Todd before and he is very knowledgeable. Not sure if that is who you are referring to, but was wondering if you could recommend something around the Ocala area. Tampa is about an hour and a half drive for me.
     
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  11. jerrymildred

    jerrymildred Senior Member

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    Yes, that's what I was referring to. I'm not familiar with any hybrid shops up in Ocala. Sorry.
     
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  12. Another

    Another Senior Member

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    You could call these folks
    Hybrid Service and Repair - PALS Ocala Auto Repair
     
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  13. PriusHead05

    PriusHead05 Member

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  14. alftoy

    alftoy Senior Member

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    PALS sure has a lot of 1 star google reviews, not sure I would suggest a mechanic unless I used them myself. Esp since a lot of those 1 star reviews mentioned $2000 repairs.

    Nor do they specialize in hybrids, they seem to specialize in everything even diesels and classic cars.
     
    #14 alftoy, May 21, 2022
    Last edited: May 21, 2022
  15. alftoy

    alftoy Senior Member

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    3 hours drive and 4 gal gas to Tampa to get a definitive diagnosis cheaper than getting ripped off, at least until you can find a local Prius specialist.
     
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