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Head Gasket Replacement on Gen 3 prius

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by prius@noob, May 14, 2022.

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  1. prius@noob

    prius@noob Junior Member

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    Prev post: Should I replace the engine? | PriusChat

    So, I took the vehicle to a mechanic who essentially confirmed the issue is head gasket with a leak down test. He's unable to replace it for the next 3-4 weeks, so I decided to work on it myself. Will begin tomorrow.

    Following this video by Gasket Masters for step by step guidance

    Planning to rent out a few tools from Autozone to work on the vehicle like the torque wrench, torque sockets (need size 8), needle nose pliers etc. Just found out you could pay a deposit for some specialty items and return them for a full return! (Yes, I'm that brand new here.)

    Once I get the head, I plan to get a machine shop check it for leaks/cracks etc. I'm planning to order a replacement head gasket kit tomorrow night (suggestions welcome) if I can successfully remove the head.

    IThe reason for this post is to ask for any advice on thing I might have overlooked regarding videos, tools etc. Also I'll be taking some picture as I go along to update this thread and maybe post a few questions I might have.
     
    #1 prius@noob, May 14, 2022
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  2. PriusCamper

    PriusCamper Senior Member

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    I'm impressed you're taking on this challenge! Very brave... I will be following in your footsteps soon as I have a friend with a Gen3 headgasket that's bad but just barely and the car has been fine around town for small trips so been putting it off.

    Hopefully your success in this effort inspires myself and others to be successful too... Please keep posting your progress in this thread so we can all follow along and help out remotely.
     
    #2 PriusCamper, May 14, 2022
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  3. Tombukt2

    Tombukt2 Senior Member

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    I hope it goes well for you if doing it like this that is your cheapest route unfortunately make sure the head gets shaved at the machine shop or sanded on the big flat belt sander to make it flat use all the poisons and whatever that you want from the list right here see what happens best you can do once I got mine torn down in the head gasket replaced the number two rod quickly broke and the thrust direction engine still spun missed like crazy compression and two was zero of course the rod broke very low so the engine would still spin the number two was trashed so I got a Japan domestic market engine and it's running beautifully I should have started with that
     
    #3 Tombukt2, May 15, 2022
  4. prius@noob

    prius@noob Junior Member

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    Could you elaborate on this? Just curious about full engine replacement cost in case I fail in this endeavor
     
    #4 prius@noob, May 15, 2022
  5. Tombukt2

    Tombukt2 Senior Member

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    It's been done here a few times. JDM engines new jersey.bellville I think. About 1400 or less delivery to NC USA. That's engine n trans .looked brand new too
     
    #5 Tombukt2, May 15, 2022
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  6. prius@noob

    prius@noob Junior Member

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    UPDATE: took me almost 8+ hrs to get to the valve cover. The tire and crankshaft bolt gave me the most trouble. Kicked and hit the tire to no avail, put the bolts back on and drove for a few feet, then kicked a few more times to get it loose. Purchased an impact gun for the crankshaft bolt (felt like I was breaking something :D). Other stuff was pretty standard.

    Got stuck while trying to remove the motor mounts @ 9:10 in this video. Do we need to remove the motor mounts? (I'm guessing yes, to get to the timing chain?). Tried taking out the upper bolts 1st (on the motor mount) and they were too tight. Can we use the impact gun to remove them? Any advice here is appreciated!

    Will take a break for a day and get to it tomorrow evening.

    image2.jpeg image5.jpeg
     
    #6 prius@noob, May 16, 2022
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  7. Tombukt2

    Tombukt2 Senior Member

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    Breaker bar on bolt to ground kik starter bolt loose. at least here it is. Some People have fits over this kinda stuff.
     
    #7 Tombukt2, May 17, 2022
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  8. Mendel Leisk

    Mendel Leisk Senior Member

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    You can most certainly use an impact to remove stubborn bolts.

    for rust glued wheels:

    raise car till tire is slightly clear, remove all lug nuts but one left loose at top of pattern, place wood block against inside face of tire, and smack block with sledge hammer. Apply light coat of anti-seize to hub face, to prevent in future.
     
    #8 Mendel Leisk, May 17, 2022
  9. prius@noob

    prius@noob Junior Member

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    @Mendel Leisk Thank you for the info, will look into it when putting everything back together.
    Will definitely use an impact power tool as I'm not strong enough to get it done by hand.

    Since, I have your attention, could you recommend a replacement head gasket? Would like to purchase new head bolts too incase these are at the end of their life (207k miles).

    Planning to remove the head completely today, to get it to a machine shop.
     
    #9 prius@noob, May 17, 2022
  10. Tombukt2

    Tombukt2 Senior Member

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    Fel-Pro PT one of the best head gaskets out there I've been using them for 30 years but don't take my word for it I want to see a shot of the number two piston hole with the Piston all the way down and it's bored and all the way at the top if you like
     
    #10 Tombukt2, May 17, 2022
  11. Mendel Leisk

    Mendel Leisk Senior Member

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    No personal experience, but if I was going to do this I'd get the Toyota gasket kit, it includes head gasket and replacement gaskets, o-rings and seals for pretty much everything pliable inside the engine. Valve stem seals. And while there are repair manual specs for the head bolts, to check if they've elonginated, got "skinnier", just replacing them is simplest/safest.

    The attachment has Toyota part no's for the gasket kit and head bolts.

    Also check out the two links in my signature saying "head gasket".
     

    Attached Files:

    #11 Mendel Leisk, May 17, 2022
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  12. Tombukt2

    Tombukt2 Senior Member

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    The bolts were so reasonable I felt silly not getting them I know in some of these Fancy pants motors at companies make now they're not reusable they're one time use I didn't bother to check into that I just ordered the new ones as the parts people recommended it for this open deck engine
     
    #12 Tombukt2, May 17, 2022
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  13. prius@noob

    prius@noob Junior Member

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    Link to the part you like?
    I agree with your point and will check out the links/attachments. Thank you!


    I'm likely going this route too. Thank you!
     
    #13 prius@noob, May 17, 2022
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  14. prius@noob

    prius@noob Junior Member

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    All 3 bolts on below mount bracket are very hard to get off. Tried with a 300lbs impact wrenches and a regular 5 inch socket wrench (The only size I had), lubed it with WD-40 and tried again, with no luck. I'm gonna try with a loaner breaker bar and give it another go tomorrow.
    Is there something I'm missing?

    EDIT:
    The other question I had: It's pretty hard to reach the studs on the EGR cooler (The back ones and the one under a bunch of stuff). I have normal sized hands and find it hard to reach there. Took me a good 30 mins and got the a flex head size 6 socket on the stud and is immediately fell off. Looked at the video when Gasketmasters remove the head and EGR cooler (bottom and back studs) is not attached to the head he pulled out.

    Can I leave the cooler in there? Removed all other bolts and the valve cover is already out. I know cleaning the cooler is a recommended task, I was wondering if I can leave it alone for now.
    MountBracket.png
     
    #14 prius@noob, May 18, 2022
    Last edited: May 18, 2022
  15. ttou68

    ttou68 Active Member

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    04112-37254 is the part number for Toyota Kit... Do a search online for a local Toyota dealership online part store and it's usually discounted and less than retail price..

    I'm currently sourcing parts for a head gasket and other repairs for a Prius 4 myself, and found Felpro HS26515PT1 gasket set is a little hard to find them in stock if you're in a hurry...

    I use Felpro headbolts Fel-Pro-ES72434


    Posted via the PriusChat mobile app.
     
    #15 ttou68, May 18, 2022
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  16. prius@noob

    prius@noob Junior Member

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    @ttou68 Thanks for the part #. Made my search easy...
     
    #16 prius@noob, May 18, 2022
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  17. prius@noob

    prius@noob Junior Member

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    Update: got the pesky motor mounts off with a breaker bar and also got off the egr cooler with outmost difficulty.
    While removing the water pump, fluid gushed out and it looks suspiciously similar to coolant. Is that normal?
     
    #17 prius@noob, May 22, 2022
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  18. bisco

    bisco cookie crumbler

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    yes, it is coolant
     
    #18 bisco, May 22, 2022
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  19. rjparker

    rjparker Tu Humilde Sirviente

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    I would not depend on the Gasketmasters video or even advice here to achieve a functional engine at the end. At least get access to the online version of the Toyota Information System and print out each procedure before you jump in. Tearing down the engine is a whole lot easier than getting it back together properly.

    There are a few "can't mess up" steps ahead including the engine timing (often misaligned even by semi-experienced diy). That error can force a major teardown after you are done. The gaskets often require sealant only in specific places. Measuring the piston rise is important to hopefully avoid a broken rod after you are done. The Toyota repair steps and their referenced procedures will help but even those assume a fair amount of experience.

    https://techinfo.toyota.com/techInfoPortal/appmanager/t3/ti?_nfpb=true&_pageLabel=ti_home_page&goto=https%3A%2F%2Ftechinfo.toyota.com%3A443%2Fagent%2Fcustom-login-response%3Fstate%3DQCuKqagab_UqnvdiQhd8SLu33d8&original_request_url=https%3A%2F%2Ftechinfo.toyota.com%3A443%2F
     
    #19 rjparker, May 22, 2022
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  20. prius@noob

    prius@noob Junior Member

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    Update:
    Got off the head completely. I was mostly smooth sailing once I got the EGR cooler and motor mount bolts off.
    I do have a few questions, Does the gasket look worn out or bad (Can't really tell, not experience).
    Please do take a look at the pictures and let me know if there's other stuff I need to check out before putting it back on.

    Also, I broke something right underneath the egr cooler (refer to pics please). Can I get the part number or name of part so I can look for replacement?

    Planning on cleaning the EGR cooler while I get the head checked out at the machine shop.
     

    Attached Files:

    #20 prius@noob, May 23, 2022
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