NEW!!! Service Bulletin for Engine Knocking at Startup T-SB 0012-10

Well, it's certainly not GOOD for the engine.

 

At the very least it can't be good for the engine mounts.

The dealer ordered the part based on the TSB. They still want to reproduce it before installing.

 

Considering the "Hammering" that goes with this issue........it's ONLY a matter of time!....:boom:

 

I just find it funny (or rather, sad) that for some of you, it's just a phone call away whereas others like vinnie are having a hell of a time getting them to perform the TSB.

If I live in an area where the issue is a common occurrence, I'd call 20 or so dealers and drive however many miles to whoever is most responsive and is willing to order the parts to get it fixed at once.

 

I'm glad to give you comic relief. I am about to call some Las Vegas locations...

I'll just warn everybody to avoid the St George (UT) location if they want to maintain their sanity and not jump through the hoops I have (I must be a sucker for abuse) for no apparent reason.

 

double post for some reason..see below

 

Well...I just got my Prius back this evening. They replaced the manifold..ect per the TSB. They kept it an extra day because they wanted to see if it would happen again. I walked out to their back lot where they had my Prius and started it up. Once the engine kicked on it rattled for about 2 seconds. I didn't have my video camera or anything running...so I have no proof. I decided to just drive it home and do another cold soak test on it over the next few days. I noticed the dealership had washed my car so I'm not sure if that had anything to do with it or not.

On a side note.. I know another poster in this thread or another mentioned he performed the manifold replacement himself and didn't need the "Super Long Life Coolant" (SLLC) per the TSB. On my copy of the work order I noticed that the dealership also did not list or use that part but did list Manifold Assy. Intake and gasket, EGR Pipe. So those parts were used.

I should have an update after the cold soak if the brief knocking was an anomaly or if the manifold replacement didn't fix my issue.

 

Not sure what part of the manifold we are talking about. Can someone show me a picture?

Thank you!

 

Oh man, the circus continues. You might want to conduct at least three checks before you assume it's fixed.

 

I agree. I'm really hoping it was just a weird coincidence. Other posters said it fixed their knocking issue so...keeping my fingers crossed.

 

We've heard of fake oil changes, etc. Maybe they did a fake TSB?

 

Are you asking, "What part of the manifold needs replacing?"....if yes, then the answer is "The entire intake manifold; it's one piece"....

 

I highly doubt it. But if I can 100% confirm it happens again I can always take it to another local Toyota dealership to have them confirm the TSB was performed / done correctly. There are a bunch of them here in the Puget Sound / Seattle area, this one just happens to be 10 minutes from my house.

 

I picked mine up on Friday and they did the change of intake manifold. They also replace the plastic under the engine. Seems to run the same as before and also gets about he same mileage. Took mine to Toyota of Olympia and they gave me no problem at all.


TED

 

Went to my dealer for the covered oil change and maintence check and told them I had experienced the engine knocking problems assoicated witht the TSB service and they said they ran a full diagnostic and the car checks out fine. Also they gave me the option of leaving it for a few days and they said the mechanic has to verify that its happening in person. Of course I need my car daily so I can't do that... On top of that the mechanic totally readjusted my seat so I now have to mess with it to get it back to my optimal setting...

 

Just an update to my earlier post. I did one cold soak test and my Prius started up without any issue. So it appears the new manifold install per the TSB is working.

 

Sounds like some minor moisture build-up occurred during installation and it won't happen again as it's now sealed thanks to the new design.

 

First, thanks to all the great support from one another. I've lurked here often, but first post.

This morning, 24 degrees F, parked outside, wife starts car and loud, loud knocking for about 10 seconds. By the time I got outside to tell her to shut 'er down the engine had quieted to normal. However, engine light was on. (Maybe that's the secret to getting the a code to prove it meets the TSB parameters; just let it run.) This had happened once before last year (we're in Kentucky, so not too many rafter-poppers in a winter), but I shut off immediately and when I restarted there was no knock.

I jumped on this forum and lo-and-behold there was the new TSB posting at the top of the thread. Perfect description of problem and potential solution. Also learned about the motor mount issue on cold starts, which explains another sound I've heard on very cold morns. Printed off both TSB links and picked up the phone.

Since the dealer can't order the IM until they confirm the diagnosis I'm going to have to leave it with them for a couple of days. Had to schedule a week out in order to get on line for a loaner.

BTW, my local dealer is "Toyota South," in Richmond, KY. Despite the disses that I've seen about other dealers I have to say these folks are all at the top of their game. Great customer satisfaction.

As far as engine damage, this is, as I understand it, a knock resulting from water condensation at the EGR tube collecting in the IM, then getting sucked into cylinders on start-up. I used to be a mechanic way back in the dark ages. A common trick for de-carboning pistons was to use a spray bottle to squirt water down the carburetor throat while revving the engine. Depending on engine timing there could be a significant knock and clouds coming out tailpipe. But, it was a sure-fire way to cure engine dieseling. (Anyone under 40 probably has never heard of such a thing.) Hmmmm, a built-in piston de-carboner. Maybe it's a good thing.

I'll jump back on in about 10 days and let you know what transpired with the dealer.

 

My experience with the (otherwise good) dealer was that they "couldn't reproduce it on the premises" so no intake for me they did, however, inexplicably reproduce the harshness on cold start, and promptly ordered an engine mount I wasn't even concerned about that one! I really want the knocking fixed...is there a "how to" guide to making it knock?

I think I have it figured out but, I can't keep it at the dealer, it needs to be in my driveway. I asked the service advisor and he said taking a video "would help but" they won't fix it if it doesn't knock "on the premises".

 

I've experienced this problem with my 2010 twice in the past three winters. I had my car in for an inspection last week and brought a copy of the TSB with me. I wasn't expecting a warm reception.

The kid who checked me in told me they would have to reproduce it there, which of course is nearly impossible.

Once the inspection was complete, the kid told me he spoke with the service manager who was familiar with the problem. He told me they ordered the parts and would call me when they arrived.

I've had some not so nice things to say about this dealership (Conicelli of Conshohocken) in the past, but they certainly redeemed themselves with this one. I have 57500 miles on this car so I figured this was my last (and only) opportunity to take care of this.