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

Cylinder 2 Misfire - Is It The Infamous Headgasket Failure?

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by jumpinjivinjoe, Mar 10, 2019.

  1. jumpinjivinjoe

    jumpinjivinjoe Junior Member

    Joined:
    Jun 5, 2017
    19
    24
    0
    Location:
    Kennewick, WA
    Vehicle:
    2010 Prius
    Model:
    III
    When I first started my 2010 Prius today it did a pretty nasty rattle/knock/shake for a minute. And while it's done it in the past, it was particularly nasty this time. 222,000 odo miles.

    Driving was fine, but when I went to go home the check engine light came on with the code P0302 ... Cylinder 2 Misfire.

    I know the usual way to investigate misfires is to check or swap spark plugs, coil packs and injectors. But after looking through this forum it seems very likely that the headgasket blew. And I would rather not submit my engine to any more abuse if I can skip directly to confirming the headgasket.

    At 195,000 miles, I cleaned the EGR system including the valve and cooler. It was effectively completely clogged at that time. With a pressure washer I was able to clear the EGR cooler only 50-70%. I vowed to replace it by 245,000 odo. During this time, I also cleaned the intake manifold and installed an oil catch can.

    The engine coolant level is at the "low" mark. If it was lower than the low mark I would be more concerned.
    The engine oil does not seem milky on the dipstick.

    Here are my questions:
    1. How likely is it to be a headgasket problem considering this is a common problem in Prius?
    2. Is there a way to directly confirm headgasket issue? (And bypass troubleshooting the other systems) Video inspection of the cylinder for coolant leak? Combustion leak tester? Compression test? Leak down tester?
    3. Should I replace the headgasket or replace the engine? Why would I want to replace the engine if I can just change the headgasket?
    4. What causes the headgasket to fail? Clogged EGR system? Intermittent waterpump? Something else?
    5. Machining a warped head is relatively easy because I don't have to remove the engine, but how often is the actual block warped in the 3rd gen Prius?
     
    #1 jumpinjivinjoe, Mar 10, 2019
    Last edited: Mar 10, 2019
  2. Brandon_P

    Brandon_P Junior Member

    Joined:
    Nov 17, 2018
    16
    11
    0
    Location:
    US
    Vehicle:
    2010 Prius
    Model:
    IV
    As someone who just replaced the engine in my 2010 Prius with head gasket failure, I can attest to a few things.

    1. I can almost guarantee this is a head gasket failure. You are lucky, mine failed at 100,000 miles. These will fail, just if a matter of when. To inspect, you can buy a liquid to test for exhaust gases in your coolant. If the liquid changes color with the coolant, you have a head leak. Don't go to a mechanic and waste hundreds of dollars like I did to do what amounts to 5 seconds of work.

    2. The head gaskets fail without any regard to overheating or maintenance, it is a fault in the engineering of this car. The consensus is that the water pump gradually fails to produce enough coolant pressure or circulation and gradually starves the cylinders of coolant just enough to kill the head gaskets but not enough to cause an overheating. (In my opinion, planned obsolescence from toyota).

    3. Replace the engine. When the head fails it can cause pressure in the cylinders and mess up your rods, cause the engine surface to warp, or the head to warp. You don't want to waste 20+ hrs labor just to swap the engine anyway. Swapping the engine vs doing the head gasket is almost identical on cost so why not get something rebuilt with some kind of warranty?

    Make sure the engine that is swapped has updated heavier duty gaskets and also better head bolts. Even with those two replacements my mechanic still said they've seen premature failures on these engines without regard to the water pump or the intake manifold (although keeping these working with preventative maintenance can't hurt).

    At the end of the day, the Gen3 Prius is a lemon and Toyota should have to pay up. It's ridiculous in this day and age to see head gasket failures of this magnitude.

    SM-N960U ?
     
    GregC1979 likes this.
  3. jumpinjivinjoe

    jumpinjivinjoe Junior Member

    Joined:
    Jun 5, 2017
    19
    24
    0
    Location:
    Kennewick, WA
    Vehicle:
    2010 Prius
    Model:
    III
    Checked the spark plugs and they looked good.
    Inspected the interior of the combustion chamber with camera nothing too obvious.
    Did a leak-down test. No serious pressure drop. Only loosing pressure through crankcase.
    Perhaps the EGR system got clogged again and caused a misfire and perhaps I am overreacting towards the headgasket?
     
  4. Groundpounder17

    Joined:
    Mar 4, 2019
    104
    77
    0
    Location:
    AR
    Vehicle:
    2014 Prius
    Model:
    Three

    All very good questions. I have a blown head gasket on my 2014 and am awaiting parts from Toyota. In the mean time I will be disassembling, cleaning EGR and getting things ready.

    I’m very curious as to the root cause of the head gasket failures. I had a 79 FJ40 that had well over 600,000 miles on it. I want Toyota reliability to come back and this head gasket issue is puzzling
     
  5. The Critic

    The Critic Resident Critic

    Joined:
    Oct 28, 2005
    3,193
    2,319
    0
    Location:
    CA
    Vehicle:
    2011 Prius
    Model:
    Three
    1) At your mileage, there is a strong possibility. You mentioned that the coolant level was low, but without knowing where it was previously, there is no baseline to work off of. I would fill the coolant level to the full mark so that you can have a reference.
    2) Keep a pressure tester connected to the reservoir overnight and recheck each cylinder for coolant in the morning.
    3) If the engine is clean, does not consume a significant amount of oil, and the bottom-end is still good, then a headgasket repair is a viable option.
    4) No one really knows - we all have our own theories. On mine, the headgasket itself had a broken seal and between 1 and 2 and one of the head bolts got a bit loose.
    5) Usually the block is fine, but be very careful about what you use to clean the surface. I suggest sticking with plastic razor blades and CRC gasket remover. You can use a fine-grade wire brush sparingly if needed. OEM head gaskets need a surface finish of <30rA to seal.
     
    mjoo, CR94, RMB and 2 others like this.
  6. jumpinjivinjoe

    jumpinjivinjoe Junior Member

    Joined:
    Jun 5, 2017
    19
    24
    0
    Location:
    Kennewick, WA
    Vehicle:
    2010 Prius
    Model:
    III
    So after not getting a solid confirmation of headgasket failure through video inspection of cylinders and leak-down testing nor oil in coolant or milky oil, I decided to first replace the EGR cooler and clean the other EGR components. I had cleaned them about 20,000 miles ago, but was unable to completely clean despite using brakecleaner, ultrasonic cleaner and 0 degree tip pressure washing. The EGR system was once again very clogged.

    I replaced the EGR cooler and I cleaned the valve using Seafoam Deep Creep Penetrating Oil which was recommended by the auto-parts store for cleaning carbon (very effective by the they way and I suspect it would be helpful for cleaning the EGR cooler as well).

    Well I just drove around 800 highway miles and the clean EGR system seems to have fixed my cylinder 2 misfire!
     
    mikey_t, mjoo, RMB and 6 others like this.
  7. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    107,693
    48,945
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    congrats!(y)
     
  8. Grit

    Grit Senior Member

    Joined:
    Aug 22, 2017
    6,112
    4,040
    1
    Location:
    Wilkes Land
    Vehicle:
    2012 Prius
    Model:
    Four
    Great news, no more misfires.

    As for cooler, save money and time with pressure washer. At our last meet up Raytheeagle cleaned 3 coolers in 15 minutes compared to the traditional half day soaking and rinsing.
     
    RMB and Raytheeagle like this.
  9. Raytheeagle

    Raytheeagle Senior Member

    Joined:
    Jul 1, 2016
    11,251
    15,476
    0
    Location:
    Bay Area, California
    Vehicle:
    2019 Prius Prime
    Model:
    Prime Plus
    Sometimes a half day is a good result ;).

    It could take more than a day or longer:cool:.

    But we’ll employ the solution that is much less than that and allows 2 circuits to be cleansed at a meet up:).

    Probably 2 more to do at the next meet up, so be ready(y).
     
    RMB likes this.
  10. Mgoddard92

    Mgoddard92 Junior Member

    Joined:
    Dec 15, 2022
    22
    9
    0
    Location:
    California
    Vehicle:
    2013 Prius
    Model:
    Three
    I have this infamous problem after just doing the head gasket, I also had the 0261b code but didn’t know if it was caused by low coolant, so I did the head gasket and reset the codes, drove the car for about 30 miles in 40 degree weather (never overheated) and the p261b returned. Now ordered the water pump and thermostat.

    is it possible the 30 mile drive took out the head gasket