Repair
Rebuilt HV Battery Packs - Toyota Prius Hybrid et al.
(This blog focuses on our rebuild services; read the original blog on Gen 1 battery failure here.)
Rebuilt HV batteries for the Gen 1 Toyota Prius are a convenient and cost-effective alternative to brand new.
New ones cost $2299 list (which is a pretty reasonable IMO), but when you add up tax (9.5% in our dear city) and four hours in labor ($480 at LG; other shops/dealers will surely vary), you’re looking at three grand out the door. You know what you’re getting (the same thing you had) so life expectancy should be nearly the same. In our experience with *genuine* failures—cars that actually needed a pack, not just a wire harness (read the blog about P3030) or a cleaning (read the blog about P3009)—the probability bell curve peaks at 150,000 miles, tapering off in both directions.
Besides offering new assemblies (purchased directly from Toyota) Luscious Garage also rebuilds battery packs in house. I can’t honestly remember what prompted us to figure it out, two years and dozens of packs ago. It was probably a combination of plug-in conversion work (which inherently goes “out of the box” regarding HV batteries) and the drive to find a better way. (There is also a shop in North Carolina—Taylor Automotive, d.b.a. ReInvolt Technologies—also selling rebuilds, for which LG is the Bay Area installer. I’m not sure who was first, but, having spoken with Dave Taylor in person, our process sounds very similar.)
The benefits of rebuilds:
1. Rebuilt packs offer a significant cost savings. We sell ours for $1500 (38 modules at $36/each and a new sensing harness for $120); with tax and six hours labor (two additional hours to cover the building process, which is therefore untaxed) the repair comes to $2361. That’s over $600 less, which is real money.
2. The modules come from young Gen 2 Prius (sourced from early totals or plug-in conversions) which have an upgraded design over the original Gen 1 module (pic: metal sided is Gen 2, all plastic is Gen 1) with better heat dissipation and lower internal resistance. The difference is evident in the cars we service: all Gen 1s will have an HV battery failure; Gen 2s rarely do (despite many with very high mileage).
Thus, though the price is lower and the batteries are second-hand, we expect the rebuilt packs to last as long if not longer than the originals. For most Gen 1 owners, this confidence combined with the cost savings will drive the decision.
All packs are load tested to confirm battery health, and the results are included in the work order (learn more about battery testing here). If I may say so, we build mighty strong packs, with identical performance to brand new units.
All of our rebuilds are guaranteed for one year (the same as new from Toyota) but we have yet to have any come back (and we don’t expect them to).
REBUILT BATTERY PACKS:
Labor: $720
38 NiMH, Gen 2 Prius Modules @ $36.30: $1379.40
Sensing Wire Harness, 82165-47030: $119.43
9.5% Sales Tax: $142.39
Total: $2361.22
Click here to book an appointment
View of our HV battery service area:
Stacks of bad Gen 1 modules:
Gen 2 module stacks:
With low mileage and plenty of future:
Posted by Carolyn
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High Voltage Battery Test - Gen 1 Prius
High voltage battery testing is now available on first generation Prius, model years 2001-2003, a reliable means of determining battery health.
The test is run using the car’s own operating paradigm; we do NOT use the Midtronics HYB (Hybrid Battery System Analyzer) for lack of proven performance in the field.
Cost: $50
Time: 30 minutes
**We are still developing dynamic test methods for other hybrids.
First pic: Failing HV battery; note climbing Delta SOC (green) as SOC (blue) plummets.
Second pic: Good battery (one of our rebuilds, tested before delivery); note Delta SOC (green) does not change as SOC (blue) goes down. Max/Min block voltage levels do not diverge.
Posted by Carolyn
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Luscious Tire Service
The biggest perk of our new location: more room! For cars, staff, equipment, and parts (including tires). View of our “tire department”:
We’ve been keeping tires in stock for several years. Now we’ve collected mount and balance equipment (gorgeous Hoffman machines that were inexpensive, purchased second hand), a modest tire rack, and the accoutrements (valve stems, weights, etc) so we can perform tire replacement in house. This is hybrid land: very specific, nothing fancy. We charge $25 total for mount/balance and fees.
LG’s inventory, and our recommendations for individual hybrid models:
2004-2009 Toyota Prius: Goodyear Assurance FuelMax
Size: P185/65R15 88H
Price: $114.00
With tax and install/fees: $149.83/tireWe maintain a big pile of these tires as they move quickly; very popular, a really nice match for the car.
Read the original tire blog about why we love the FuelMax...
We also keep a small selection of used tires in this size, ones with 50% tread life or so, for certain circumstances.
2001-2003 Toyota Prius: Dunlop SP10
Size: P175/65R14 84S
Price: 105.00
With tax and install/fees: $139.97/tireBecause of its relative weight (HV battery and motors in a small package) max pressure rating is critical on this model, to 50psi. Otherwise the tires will not last. Higher pressure also increases fuel economy. The Dunlops are a less expensive alternative to the Bridgestone Potenzas (which we no longer carry). Ownership cost is the name of the game with Gen 1s.
2003-2005 Honda Civic Hybrid: Dunlop SP20 FE
Size: P175/65R14
Price: $81.00
With tax and install/fees: $113.69Again, owners of older model hybrids (the Gen 1 Civic in this case) are looking for value and these tires hit the mark. Dunlop provides competitive prices without compromising the quality to maintain good fuel economy.
2000-2006 Honda Insight: Bridgestone Potenza RE 92
Size: P165/65R14 78S
Price: $112.00
With tax and install/fees: $147.64The Gen 1 Insight, like the Gen 1 Prius, needs a very specific tire that can be inflated high to last. The Potenzas come in the right size, are the stock equipment, and maintain MPGs: the primary reason people drive these classics.
Toyota Highlander, Camry: Goodyear Assurance Fuelmax
We do not keep these in stock, but can get them a day or two in advance. Email us for current pricing or to make an appointment
LG orders from the Tire Rack and Goodyear wholesale. Our prices are competitive with most full service shops (or lower), but not with Big O or Costco. We are not tire dealers who buy by the truckload. Likewise we do not offer lifetime tire repair or other gimmicks to sell you brake jobs or more tires. Nothing’s free! But the person willing to compare prices or order their own tires will often come out a little better. Go for it! We will still install any tire for $25 out the door.
Likewise we can buy for other make/models, just give us a heads up to order in advance. Use the contact page for appointments...
One hybrid word of warning: avoid cheap tires, they will kill your fuel economy. Hybrids need “low rolling resistance”. For more:
Tire Rolling Resistance, Part 1 via TireRack.com
Tire Rolling Resistance, Part 2 via TireRack.com
Tire Rolling Resistance, Part 3 via TireRack.com
Posted by Carolyn
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Prius P1121: Coolant Flow Control Valve Position Sensor Stuck
The second generation Prius, model years 2004-2009, uses a 3-way valve to control coolant flow between the engine, the hot coolant storage tank (thermos), and the heater core. Thus it’s involved in heating the passenger cabin (when requested), as well as reducing cold start emissions (with the coolant storage system). 
Anything that has to do with emissions illuminates the “check engine” light; if something goes wrong with this valve, the “check engine” light comes on.
The valve is prone to sticking, and Toyota has issued a technicial service bulletin (TSB) on this problem: EG001-08 M.I.L. “ON” DTC P1121
The fix is replacing the valve. It’s mounted along the driver’s side frame of the engine compartment, near the radiator, and can be removed by elevating the inverter and pulling the valve out from the top. With good use of hose clamps, the job can be performed without loosing more than a spash of coolant.
Warranty time for valve replacement, as listed in the TSB, is 2.1 hours. Luscious Garage charges 1.75 hours.
Labor, 1.75 hours: $210
Valve Assy, Water, P/N 16670-21010: $78.59
Qt Super Long Lift Coolant: $5
Total with tax: $301.53
Posted by Carolyn
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Full Service Prius Key Programming
Luscious Garage is registered with the National Automotive Service Task Force as a certified California Locksmith. Thus we have full access to Toyota key codes and reprogramming. The prices for services are as follows:
New key fob (unprogrammed): $192
Used key fob (previously programmed): not available at this time
**Customers may provide their own fobs (purchased off ebay, for instance)
Programming immobilizer/wireless/smart functions, with new key purchased at LG: $30
Programming immobilizer/wireless/smart functions, used key: $100
Each additional keys: $50
To book an appointment, use the contact page.
