1. Attachments are working again! Check out this thread for more details and to report any other bugs.

Replacing Tank Assembly/Reserve Tank

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by WesX, May 23, 2016.

  1. JC91006

    JC91006 Senior Member

    Joined:
    Nov 10, 2013
    16,482
    8,397
    0
    Location:
    Los Angeles, CA
    Vehicle:
    2008 Prius
    Model:
    II
    Surely this shouldn't come out of your pocketbooks to fix this.....that insurance company needs to do an adjustment on your claim....however much it'll be, until the problem is fixed
     
  2. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    I couldn't agree more. Unfortunately, this is an long uphill battle with the insurance company. The adjuster refuses to listen to anything anyone has to say and has stated that this wasn't caused from the accident so their hands are free and clear. I'm probably close to about $3k out of pocket for repairs.
     
  3. JC91006

    JC91006 Senior Member

    Joined:
    Nov 10, 2013
    16,482
    8,397
    0
    Location:
    Los Angeles, CA
    Vehicle:
    2008 Prius
    Model:
    II
    leaking fluid.....from a front end accident is most definitely their problem. You can escalate the claim and make a complaint to people higher up. Possibly contact the agencies that deal with insurance companies and issue a complaint there too.
     
  4. andrewclaus

    andrewclaus Active Member

    Joined:
    Sep 15, 2009
    993
    324
    0
    Location:
    Golden, CO
    Vehicle:
    2007 Prius
    It sounds like you might need a different mechanic. They can't seem to bleed the system correctly, and thinking the coolant control valve can cause the engine to overheat is just wrong--as evidenced by the problem continuing after replacing it.

    Did you monitor the level in the coolant reservoir between episodes at the dealer? It would be good to know if there was a steady small leak that eventually causes an overheat, vs. a sudden failure.

    Have they tried a coolant system pressure test? A cylinder leak down test?
     
  5. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    This is my next step. They are fully responsible as far as I'm concerned.

    The insurance company is blaming the repair shop and of course the repair shop is denying that it's their fault.

    I'm stuck in the middle of a rock and a hard place.
     
    #25 WesX, Jul 11, 2016
    Last edited: Jul 11, 2016
  6. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    I couldn't agree more. The Toyota dealer is bringing in a field engineer this week to look at it. They brought in specialty tools to bleed the coolant system, etc. The problem still exists.

    I unfortunately did not monitor the coolant level as it's only been literally days between visits to the shop. Not even long enough to put gas in. Lol.

    They have done a number of pressure tests. No leaks. They've bled the system numerous times, even overnight.

    I'm not sure if they've tried a cylinder leak down test. I could suggest it since they're asking me what to do next.
     
    #26 WesX, Jul 11, 2016
    Last edited: Jul 11, 2016
  7. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    Another update from the dealer after they've had it another 7 days.

    Was told they need to tear it apart. It's either the head gasket leaking, as others have stated in this thread, or it's a ABS actuator.

    Any insight on what to do next. I'm thinking it's time to get a new car or go up the corporate later of Toyota.
     
  8. andrewclaus

    andrewclaus Active Member

    Joined:
    Sep 15, 2009
    993
    324
    0
    Location:
    Golden, CO
    Vehicle:
    2007 Prius
    That would be like a doc saying to a patient with a fever, it's either the flu or your ankle is sprained.

    The ABS actuator has recently been covered by an extended warranty, so that work should be done on Toyota's dime. It may be a separate diagnosis.

    The head gasket makes sense, but a new gasket may not completely cure the car. It has overheated repeatedly, and in other cars that means a main bearing failure may be next.
     
    Patrick Wong likes this.
  9. Patrick Wong

    Patrick Wong DIY Enthusiast

    Joined:
    Mar 8, 2008
    18,200
    6,472
    0
    Location:
    Green Valley, AZ
    Vehicle:
    2015 Prius
    Model:
    Two
    What is the odometer reading on the car?

    If the engine head gasket is leaking, and you want to keep the car, you may be better off installing a used engine vs. trying to repair the existing engine as other damage may have occurred to the crankshaft, pistons, cylinders etc. from overheating.
     
  10. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    I have the letter from Toyota for the ABS actuator, so I'm sure that won't be a problem.

    I am, however, very worried about the engine after this problem has been going on for so long. I feel at this point the car is just going to nickel and dime me every few months. Maybe not, but after dumping in $2500 in repairs plus another $2-3k if I get the head gasket fixed, I probably could have bought a different used Prius.

    I think it's time to trade her...
     
  11. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    The odometer is roughly 130-135k. I forget at this point. I haven't seen the car in literally weeks.

    I thought about putting in a used engine but I can only imagine the work and cost involved with that. I'm sure the problems from the engine overheating repeatedly is going to cost me a lot of money in the long run.
     
  12. dolj

    dolj Senior Member

    Joined:
    May 14, 2012
    7,651
    3,860
    0
    Location:
    Wellington, New Zealand
    Vehicle:
    2007 Prius
    Model:
    N/A
    If you were able to source a good (lower mi) engine and have it swapped in, there should be no further problems due to the overheating. All those problems will go away with the old engine.
     
  13. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    Sorry, should have clarified. I meant with the old engine. At this point from it overheating, it's gonna have issues down the road.
     
  14. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    Just got the call from the dealer. They ripped it apart and found that it needs a new head gasket and the cylinder head is warped.

    Sounds expensive.
     
  15. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    Just got the call that it will cost roughly $1900 to replace the cylinder head and gaskets.

    Would it be better to buy a used motor and swap it or should I have the cylinder head replaced? Or should I buy the gaskets and cylinder head and replace those separately?
     
  16. Patrick Wong

    Patrick Wong DIY Enthusiast

    Joined:
    Mar 8, 2008
    18,200
    6,472
    0
    Location:
    Green Valley, AZ
    Vehicle:
    2015 Prius
    Model:
    Two
    If you can DIY, you could remove the head and send it to a local machine shop for rework.

    This assumes the block is not warped. If the block is warped then a used engine would be the way to go.
     
  17. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    I've actually inquired about this because of the advice from this thread. I was told they checked the block and the head and the block was fine but the head is warped and needs to be replaced.

    I just feel at $1900 I could do the engine swap instead. I could probably have the head rework done also.

    At this point I'm beyond frustrated and become completely soured with Toyota and their work.
     
  18. andrewclaus

    andrewclaus Active Member

    Joined:
    Sep 15, 2009
    993
    324
    0
    Location:
    Golden, CO
    Vehicle:
    2007 Prius
    All the bearings, pistons, rings, connecting rods etc at this point would be suspect. The whole engine block overheated, not just the head.

    It took them a long time to diagnose the problem, and they made some really basic mistakes along the way. I'm Monday morning QBing here, but a head gasket would have been the second, if not the first test I did (see post #7). Do you expect them to get the fix right this time? If at all possible, get a better mechanic on this job.
     
  19. WesX

    WesX Junior Member

    Joined:
    Mar 7, 2011
    20
    0
    0
    Location:
    US
    Vehicle:
    2009 Prius
    Model:
    N/A
    I agree 100%. I don't know why the head gasket wouldn't have been one of the first things to check. They did say they couldn't tell it was leaking from the head until they pulled it apart.

    I told them to put the car back together and I'll have someone else do it. They charged me the labor time to rip the engine apart. They didn't replace the ABS actuator even though the field engineer said it was going bad. This particular Toyota dealership is an absolute joke.

    I think it's time to call Toyota cooperate. Does anyone know who to contact? Should I call the 1-800 number? Do you think it'd be a total waste of time?
     
    #39 WesX, Aug 6, 2016
    Last edited: Aug 6, 2016
  20. andrewclaus

    andrewclaus Active Member

    Joined:
    Sep 15, 2009
    993
    324
    0
    Location:
    Golden, CO
    Vehicle:
    2007 Prius
    I'm not sure how to contact corporate, but if you can document the errors in this thread, like a Toyota-trained mechanic telling you the CHRS tank caused the engine to overheat, you'll have some ammunition. Good luck with this one.