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Making an Air Filter for the Battery Cooling Fan

Discussion in 'Prius c Care, Maintenance and Troubleshooting' started by David Keevil, Sep 28, 2016.

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  1. David Keevil

    David Keevil New Member

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    Hey all!

    I'm new here with a 2016 Prius C2.

    I've been reading a lot about my new Prius (just shy of 300 miles now) and there have been many warnings about NOT blocking the intake vent for the battery cooling fan in front of the rear seat on the left side.

    Problem....... I have a Golden Retriever who goes almost anywhere we go.

    [​IMG]

    Anyone who has had or has one of these breeds knows that no matter how much you brush, groom and vacuum the beast..... They shed! Not only shed but they shed unbelievable quanties of light drifting fur!

    So, how to prevent the fan from clogging up with dog fur in short order?
    I don't want to decrease air flow to the fan but really what's worse?

    1.) A fan intake clogged with dog fur but that really only happens after pounds of the stuff made it through the factory screen through the fans squirrel cage and pushed into the battery cooling vents.

    Or

    2.) A replaceable filter that marginally decreases fan air flow?

    My logical answer is #2

    Now those who know me from thesamba know that I document and make a tutorial as I do a project..... So hang on folks! I hope this ends up being helpful!

    Dave
     
    #1 David Keevil, Sep 28, 2016
    Last edited: Sep 30, 2016
  2. Coast Cruiser

    Coast Cruiser Senior Member

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    I think that's a very good idea. I wonder why Toyota just didn't include an easily removable/cleanable vent filter as standard equipment.
     
    #2 Coast Cruiser, Sep 28, 2016
  3. Coast Cruiser

    Coast Cruiser Senior Member

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    The "cheap guy" solution... a square piece of window screen, held on by duct tape. :ROFLMAO:
     
    #3 Coast Cruiser, Sep 28, 2016
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  4. David Keevil

    David Keevil New Member

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    Well, it already had a factory window screen type product protecting the fan, but that is simply to coarse of an opening for the fur.


    You can see the fur build up on the intake screen already!

    I did a search on filter solutions but the ones that came up were for the larger models.
    There was a good one by member Rondodog about his fur control efforts.

    Fur and dirt causing major battery problems | PriusChat

    I built upon his concept only adapted it to the Prius C2

    All told, this mod took me 20 minutes to do.

    Dave
     
    #4 David Keevil, Sep 28, 2016
    Last edited: Sep 30, 2016
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  5. David Keevil

    David Keevil New Member

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    To get the intake grille off you need to,pry out the center of the push rivet, preferably doing so without damaging the push rivet.

    To do,this I used a simple "dental pick" tool, I got these at Lowes for a few dollars.......


    Here is a view of the panel with the intake grille, it shows one of the push rivets, there are two that must be removed......


    Using the sharp point of the dental pick tool, push it under the center of the push pin rivet, you will lift the center out of the rivet.......



    Here is the push pin rivet removed with the dental pick tool....... Remove them both.


    Now you need to pull the panel away from the seat base, it will,take some effort. The part at the door isn't fastened any longer and will easily pull away. DO NOT BREAK THE PANEL by pulling it only by the loose outer portion. Work your finger nails or a pry bar (screwdriver?) into the inner seam and pop it off. There are three (3) clips that are holding it on......


    You can see the three clips in this photo......

     
    #5 David Keevil, Sep 28, 2016
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  6. David Keevil

    David Keevil New Member

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    Dinner and camp fire time!!

    To be continued!

    Dave
     
    #6 David Keevil, Sep 28, 2016
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  7. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    I used a piece of vacuum cleaner motor material for a while. Probably fine, but I got worried that it might excessively restrict flow, so replaced it with a piece of window screen material. It looks similar to your pic of the stock screen:

    image.jpeg

    Maybe a little finer. The main thing, I think, is to have something in there. A coarse screen will catch pet hair, as evidenced above. And it gives you evidence, of how much it's dusting up.

    Additionally, you want to inspect and clean the actual fan, say every two years. It will get a fine dust build up. Run a wand style duster through all the ductwork too. Then hit everything with some sort of air jet.

    You want to do just as much dismantle as needed, likely no need to pull the fan right out to clean.
     
    #7 Mendel Leisk, Sep 28, 2016
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  8. Coast Cruiser

    Coast Cruiser Senior Member

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    David, those "push pin rivets" look exactly like the ones I removed from the plastic engine cowling (when I installed new horns.) I just pressed the center button, and they pop free. (Then I went to the dealer and bought a few extra. New ones seem to fit tighter when plugging them back in.)
     
    #8 Coast Cruiser, Sep 28, 2016
  9. Coast Cruiser

    Coast Cruiser Senior Member

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    I forgot to mention, the fan cover in my Gen4 has only one Phillips head(?) screw holding it. I haven't removed it or looked in there yet. bisco told me I would be letting the MICE escape... :LOL:
     
    #9 Coast Cruiser, Sep 28, 2016
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  10. kevins007

    kevins007 Active Member

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    If you go to a store that sells fish aquarium filter material or look on eBay for it, you will find something that your looking for.
    Basically, you need a HVAC filter material. That filter material catches everything. Just remember to change it every month or so.
     
    #10 kevins007, Sep 28, 2016
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  11. David Keevil

    David Keevil New Member

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    Ok, back to it,

    As I said, screen is too coarse in my opinion.

    I decided that an inexpensive furnace /A/C filter would be ideal.
    The cheap ones don't filter as fine a particulate thus allowing greater air flow through the filter medium.


    I cut it with scissors to the size I wanted.....




    About 7" square......

     
    #11 David Keevil, Sep 28, 2016
  12. David Keevil

    David Keevil New Member

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    How to fasten the filter to the fan intake? It isn't difficult.

    I simply pressed it onto the foam around the intake screen, it sticks there quite well.....


    Notice the plastic intake fits snuggly to the fan screen, it is molded to fit......


    Once the grille is reinstalled the filter forms itself perfectly to the fan intake.....


    How long before it needs replacement?
    I don't know.

    I'll keep an eye on it and let you know.

    I'm happy with this filter, yes it will need changing or risk battery damage, but how much easier and cheaper will it be to take 10 minutes and simply replace a $10 filter every six months rather than a $2,000 battery and risk a break down somewhere?
     
    #12 David Keevil, Sep 28, 2016
  13. bisco

    bisco cookie crumbler

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    i hope that allows enough airflow. i like kevins007 aquarium foam better.
     
    #13 bisco, Sep 28, 2016
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  14. kevins007

    kevins007 Active Member

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    #14 kevins007, Sep 28, 2016
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  15. David Keevil

    David Keevil New Member

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    Kevin, thanks for that link!
    The "Pinky" filter looks like an interesting solution.
    I do wonder how well a filter designed for water filters air?

    I also do wonder about reduced airflow of my filter, I feel that for now it is better than clogging things up with loose dog fur.

    I am looking at 3M High Air Flow commercial filters. Easily found as a replacement filter for "dri-eaz" equipment. It is cleanable by compressed air or by vacuum for three cycles.

    I know that There is a good solution to this pet owner battery cooling air problem, it just needs to be found.

    Dave
     
    #15 David Keevil, Sep 29, 2016
  16. David Keevil

    David Keevil New Member

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    Looking at the grille for the fan, the molded recess would easily handle a "fluffy" filter cut to a circle and slipped into the recess.
    Now to find that least restrictive "fluffy" filter!

    Then if an easy to release clip was found for the grille panel, we'd be golden!


    Dave
     
    #16 David Keevil, Sep 29, 2016
  17. bisco

    bisco cookie crumbler

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    cotton batting? upholstery, interior design or quilt shoppe.
     
    #17 bisco, Sep 29, 2016
  18. David Keevil

    David Keevil New Member

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    I just came home from the pet store with this bulk aquarium filter medium.
    $7 for what is most likely a lifetime supply!

    It is very porous offering almost no resistemce to air movement. While I doubt it will trap much in the way of dust, my concern is dog fur, and it will most certainly stop that from passing into the fan and battery.

    When my Wife gets home from work I'll cut a chunk and slip it in. It should only take minutes to do so.



    Dave
     
    #18 David Keevil, Sep 29, 2016
  19. kevins007

    kevins007 Active Member

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    Perfect. Glad it worked out for you.
     
    #19 kevins007, Sep 29, 2016
  20. David Keevil

    David Keevil New Member

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    OK, with this post I'll put this to bed until I've racked up some miles and am able to report real world performance of the filter.

    The car came home, within 20 seconds I had the battery fan grille removed (Yes, it IS that easy to remove).

    I laid the fish tank filter medium on the grille and cut around it with a pair of scissors.

    I stuffed the filter into the round recess. I Photographed a scrap of the filter medium standing on edge next to the cut filter, it's a good 5/8" thick or better.

    Popped the cover back on and DONE!

    It honestly took longer to download the photos and write this post than it took to install the new filter, including cutting it to size and photographing it!

    I'll keep an eye on it and report how it is working from time to time.



    Dave
     
    #20 David Keevil, Sep 29, 2016
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