Another Trip to the DEALER !!!!!!!!!

[Weinerneck]

05 Prius with 77,500 miles, live in Western NY.

Have replaced both front Hub Assemblies in the last month, not sure if that's typical?

My wife had to take the car to the dealer again yesterday. Engine is bucking and the engine light can on. Shortly after that the air bag light can on, this has happened before but never stayed on so we could have it checked out. Also the traction light was coming on and off.

This is what the dealer put on the work order;

Job #1 Body Electrical
Customer states seat belt/air bag light came on and is staying on.
Check/Advise – Extended Warranty
Scanned computer, Pin point for code B1826 open in passenger seat squib. Found object shoved under seat causing damage to wiring. Repaired, cleared code, OK

Object shoved under seat causing damage was a ¼ inch high stack of sticky notes. Find hard to believe this was the cause, but what ever. Charge was $32.50

Job #2 Check Engine Light
Customer states check engine light on and is bucking/jerking – Check/Advise. Also Trac light is on. Scanned computer, Pin point for codes P0301 and P0302.
Found water in spark plug tubes causing misfire cylinders 1 & 2, remove all coils, reconditioned plugs reinstalled with silicone grease E

On the drive home it started again and the light came back on. They told my wife that it still is probably wet and would take a while to dry out. Not sure why they charged $65.00 if they knew it wasn’t fixed. One question I have, what are spark plug tubes? I have worked on cars before (the older ones) but not sure what they are referring to, this isn’t the wires is it?

I really have a bad impression about dealers and this isn’t helping matters any. I feel I’m stuck going to them for these kinds of problems but hate that thought. Any insight, suggestions or thoughts are welcome. Oh…….. by the way, they also told her that the transaxle fluid needs changed ($140 for this) and if it wasn’t it would not be cover under warranty. Check under “Changing Transaxle Oil” for the thread on that.

Thanks again,
Bill

[Godiva]

Do you have a different dealer you can go to?

[Patrick Wong]

Originally Posted by Weinerneck

Job #1 Body Electrical
Customer states seat belt/air bag light came on and is staying on.
Check/Advise – Extended Warranty
Scanned computer, Pin point for code B1826 open in passenger seat squib. Found object shoved under seat causing damage to wiring. Repaired, cleared code, OK

Object shoved under seat causing damage was a ¼ inch high stack of sticky notes. Find hard to believe this was the cause, but what ever. Charge was $32.50

Job #2 Check Engine Light
Customer states check engine light on and is bucking/jerking – Check/Advise. Also Trac light is on. Scanned computer, Pin point for codes P0301 and P0302.
Found water in spark plug tubes causing misfire cylinders 1 & 2, remove all coils, reconditioned plugs reinstalled with silicone grease E

On the drive home it started again and the light came back on. They told my wife that it still is probably wet and would take a while to dry out. Not sure why they charged $65.00 if they knew it wasn’t fixed. One question I have, what are spark plug tubes? I have worked on cars before (the older ones) but not sure what they are referring to, this isn’t the wires is it?

Hi Bill,

DTC B1826 "Open in Side Squib (P Seat Side) Circuit". This code means that the passenger seat side airbag has a loose connection. I'm not sure that the 1/4" object was responsible, but at least the connection was restored at a nominal charge.

DTC P0301 and P0302 mean that cylinders #1 and #2 have spark plug misfires. Prius does not have a distributor or high voltage spark plug wires. Instead, each spark plug has its own igniter. The engine ECU provides low voltage pulses to each igniter in the correct sequence and timing, based upon engine speed and load.

If you take a look at the engine valve cover, you will see the tops of the four spark igniters. Each igniter top is a dark rectangular shape with a wiring harness connector attached.

If you look closely, you will note that one small bolt secures each igniter to the cover, and that a rubber O-ring provides a seal between the igniter and the valve cover. The problem is that water can get past that seal and accumulate in the spark plug well (or tube).

The spark plugs are located several inches below the top of the engine valve cover. If water gets in, this will encourage the high voltage generated by the spark igniter to leak to ground instead of firing the spark plug, thus resulting in a misfire.

There are a few reasons why water might be present. One reason might be that the black plastic cowl has a seal between the two cowl pieces, and that seal is allowing water to leak onto the engine. Another reason might be that you washed the top of the engine and water entered the spark plug wells. Or it could just be that you drove through deep water which splashed onto the engine.

They should have dried the spark plug wells before releasing the car back to you. If the problem continues, the spark igniters for cyls 1 and 2 would be suspect.

Regarding the front hubs being replaced, if they were noisy then they needed replacement.

[Weinerneck]

Originally Posted by Godiva

Do you have a different dealer you can go to?

45 minutes west of us (haven't tried that one) and just over an hour east of us where we bought the car. Guess we'll have to try that route.

[Weinerneck]

Originally Posted by Patrick Wong

There are a few reasons why water might be present. One reason might be that the black plastic cowl has a seal between the two cowl pieces, and that seal is allowing water to leak onto the engine. Another reason might be that you washed the top of the engine and water entered the spark plug wells. Or it could just be that you drove through deep water which splashed onto the engine.

If it was water (I have my doubts) I will have to look but the cowl seal seems most logical. Haven't driven through deep water or washed the engine.

Originally Posted by Patrick Wong

They should have dried the spark plug wells before releasing the car back to you. If the problem continues, the spark igniters for cyls 1 and 2 would be suspect.

They said it might happen again and would need dried out some more. She didn't even get out of town and it acted up. I know it's hard to say but do you think it might still be wet?

Originally Posted by Patrick Wong

Regarding the front hubs being replaced, if they were noisy then they needed replacement.

They definatly were noisy, know complaints on that job. The dealer problems started after we told them we didn't want the transaxle oil changed @ $140.

[richard schumacher]

Originally Posted by Weinerneck

The dealer problems started after we told them we didn't want the transaxle oil changed @ $140.

Mmm, that might actually be reasonable. Some here have found by analysis that the transaxle oil benefited from a change as early as 60,000 miles.

[Michou]

From a Toyota Technical Service Bulletin:

Some 2004 and 2005 model year Prius vehicles may exhibit a M.I.L. “ON” condition with
Diagnostic Trouble Codes P0300, P0301, P0302, P0303, or P0304. A possible cause for
this condition is water collection within one or more of the spark plug tubes from a leak at the plastic cowl cover.

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is
in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s
in-service date.

* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.

If you have an extended warranty you should be able to get this covered under it.

With regard to changing the transaxle fluid, our shop changes transaxle fluid on both the Gen I and Gen II Prius every 30K. This seems far more suitable than 100K or even 60K as the fluid is pretty much black when changed on vehicles at 30K miles.

Best,

Michou

[Patrick Wong]

Originally Posted by Weinerneck

They said it might happen again and would need dried out some more. She didn't even get out of town and it acted up. I know it's hard to say but do you think it might still be wet?

Since a couple of days have passed, I am wondering whether you still have a problem. If so, maybe a return visit; or a visit to another dealer would be in order. It could be that the spark plug igniters for cyls 1 and 2 will have to be replaced.

Regarding drying out the spark plug wells, I would have expected the mechanic to use compressed air to blow out each well before removing the spark plugs. The water accumulation in the well might have damaged the igniters so that they continue to cause misfires.

If you feel like DIY, remove the igniters from cyls 1 and 2 (which are closest to the passenger-side fender). You can improve your access by removing the relay box mounted on the cowl. Then disconnect the wiring harness connector and remove the small bolt on each igniter. Pull up the igniter and carefully inspect for burn marks, cracking, moisture, etc. on the insulated body of the igniter. Look at the high voltage terminal and the surrounding plastic inside the igniter to see if you note any problems.

[patsparks]

I have come across cracks in insulators which may only become evident when wet or humid. A good fix for cracked insulators is to clean with thinners then paint with white paint. Other colors might work but I know white enamel works great.

[Weinerneck]

Originally Posted by Michou

From a Toyota Technical Service Bulletin:

Some 2004 and 2005 model year Prius vehicles may exhibit a M.I.L. “ON” condition with
Diagnostic Trouble Codes P0300, P0301, P0302, P0303, or P0304. A possible cause for
this condition is water collection within one or more of the spark plug tubes from a leak at the plastic cowl cover.

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is
in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s
in-service date.

* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.

If you have an extended warranty you should be able to get this covered under it.

With regard to changing the transaxle fluid, our shop changes transaxle fluid on both the Gen I and Gen II Prius every 30K. This seems far more suitable than 100K or even 60K as the fluid is pretty much black when changed on vehicles at 30K miles.

Best,

Michou

Hi Michou,

A friend of mine found this for me at work online at ALLDATA. My wife called the dealer that did the work and talked to the service manager and he said he was unaware of this problem. Seems like they should be the ones that are up on this stuff and the customer shouldn't have to point Service Bullitins out to them. Any way....... she has an appointment first thing Monday morning, hopefully it will get taken care of.

With a thanks to Patrick, Michou and everyone else that post or replies to this forum. This is a great resource and I'm glad I found it, everyones help is Priceless!!

Bill