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Airbox missing bottom gasket. Long term consequences?

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by LEARNER, Sep 11, 2021.

  1. LEARNER

    LEARNER Junior Member

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    Noticed my Airbox or Air filter assembly was missing the bottom port gasket or whatever it's called that seals the airbox to the engine air intake.

    I was doing a throttle body cleaning as well as cleaning the MAF sensor in response to P1121 (Correction P0171)

    Also 2-3 of the plastic tabs were broken off so the only thing securing it was the clamp tightened by the 10mm bolt.

    The last shop that I no longer use did one of those kit throttle body cleaning with the cans I believe about 2 years prior. Long story short I have good reason to believe it was done intentionally.

    Well the throttle body was caked with thick black deposits and the MAF was black but cleaned with the appropriate sprays and p1121 (Correction P0171) is gone.

    Lucked out finding Airbox from a Gen 2 Prius at Junk Yard in excellent condition but cleaned it out well with 90% alcohol I had and let it dry. A new one from Toyota is $805?????

    I did find a small sticker with bar code on it below the throttle body that I was able to get out with claw extractor.

    Does anybody know what the long term consequences of not having that gasket seal there in place?

    2004 Prius 250K miles and countless idle hours (Prius Camper) Acceleration is still strong and doesn't run bad although MPG 41mpg on Interstate doing 70 . Was getting 46mpg a year ago

    Tire pressures are correct but believe it needs an alignment, new spark plugs and new PCV valve which I don't think has ever been changed.

    Not burning oil. Use full synthetic and change every 3-4K miles No smoke coming from exhaust other than thin white smoke and start up briefly sometimes.
     
    #1 LEARNER, Sep 11, 2021
    Last edited: Sep 11, 2021
  2. ChapmanF

    ChapmanF Senior Member

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    I can't say that I remember such a gasket. You're sure it doesn't just cinch down on the top of the throttle body with a worm-drive clamp?

    What was the connection between your throttle body/MAF sensor and the P1121 cooling system code?
     
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  3. LEARNER

    LEARNER Junior Member

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    CORRECTION: Not P1121 but P0171

    I first realized a thick gasket was there when I got the Airbox from the junk yard 2007 Prius which fit perfectly on my 04 Prius although I had suspicions some type of seal should be there otherwise it's just hard plastic and clamp and nothing else which seemed sketchy.

    I did call Toyota Parts to verify it was the same air box. I'm sure those tabs help seat the air box but the ones on the back side were broken off (looked like by pliers) which allowed a small gap but it is possible the bottom plastic port of the airbox overlaps the air intake once seated which I can't really see.

    I looked up trouble shooting steps for P0171 that has other possible causes which MAF sensor was one and it was real black (now red). Not sure dirty throttle body was one but it was in great need for cleaning. The P0171 is gone and hasn't returned over a month now.
     
    #3 LEARNER, Sep 11, 2021
    Last edited: Sep 11, 2021
  4. ChapmanF

    ChapmanF Senior Member

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    Edit: posts crossed. If it was really P0171 all along, then the info below isn't needed, but I'll leave it because it shows how in fact P1121 can appear to mean throttle body or MAF sensor for other cars, not the Prius.

    A P0171 is a lean-mixture code, and if in fact there's supposed to be a gasket down there and there isn't, air entering the intake at that point, beyond where the MAF sensor can measure it, would be one of the classic causes of a P0171.

    Got it. :) What you did was you looked up P1121 in generic trouble code sites on the internet.

    The trouble is, all P1 codes are defined by car manufacturers, not by SAE, so the same P1xxx code can mean completely different things from one make or even model to another.

    [​IMG]

    As you can see from this page here, even Toyota has used P1121 to mean different things in different cars.

    Code:
        P1121 ACURA Throttle Position Lower Than Expected
        P1121 AUDI HO2S Sensor Heater Circuit Short To Ground Bank 2 Sensor 2
        P1121 BMW Pedal Position 1 Range/Performance Problem
        P1121 BUICK Throttle Position Sensor Circuit Intermittent High Voltage
        P1121 CADILLAC Throttle Position Sensor Circuit Intermittent High Voltage
        P1121 CHEVROLET Throttle Position Sensor Circuit Intermittent High Voltage
        P1121 DODGE Decreased Engine Performance Due To High Intake Air Temp
        P1121 FORD Throttle Position Sensor Inconsistent with Mass Air Flow Sensor
        P1121 GMC Throttle Position Sensor Circuit Intermittent High Voltage
        P1121 HONDA Throttle Position Lower Than Expected
        P1121 HYUNDAI Throttle Position Input - Abnormal
        P1121 INFINITI Electric Throttle Control Actuator
        P1121 ISUZU Throttle Position Sensor Circuit Lower Than Expected
        P1121 KIA Throttle Position Sensor Signal Invalid
        P1121 LAND-ROVER Accelerator Pedal Position Sensor Range/ Performance Problem
        P1121 LEXUS Accelerator Pedal Position Sensor Range/Performance Problem
        P1121 LEXUS-2 Coolant Flow Control Valve Position Sensor Circuit Stuck
        P1121 LINCOLN Throttle Position Sensor Inconsistent with Mass Air Flow Sensor
        P1121 MAZDA Throttle Position Sensor Inconsistent with Mass Air Flow Sensor
        P1121 MERCURY Throttle Position Sensor Inconsistent with Mass Air Flow Sensor
        P1121 MINI Pedal Position 1 Range/Performance Problem
        P1121 NISSAN Electric Throttle Control Actuator
        P1121 PONTIAC Throttle Position Sensor Circuit Intermittent High Voltage
        P1121 SATURN Throttle Position Sensor Circuit Intermittent High Voltage
        P1121 SUBARU Neutral Position Switch Circuit
        P1121 SUZUKI Throttle Position Sensor Intermittent High Voltage
        P1121 TOYOTA Accelerator Pedal Position Sensor Range/Performance Problem
        P1121 TOYOTA-2 Coolant Flow Control Valve Position Sensor Circuit Stuck
        P1121 VOLKSWAGEN HO2S Sensor Heater Circuit Short To Ground Bank 2 Sensor 2
    
    The "toyota-2" meaning, about the coolant flow control valve, is the only thing P1121 means in a Prius.

    If it hasn't come back for a month since you cleaned the throttle body and MAF sensor, then you have a nice clean throttle body and MAF sensor, and your coolant valve hasn't acted up this month, but they're not connected. :)

    This is the main reason why doing generic searches for trouble codes on the internet can often lead you into a bunch of wasted time, and the repair manual for the car (more info) is the most sensible place to look. Certainly for the manufacturer-defined codes.

    If you're looking up a standardized code (one in the SAE-defined P0, C0, B0, or U0 ranges), then a generic internet search is less of a gamble. But you'll still get more directly useful information by looking it up in the manual.
     
    #4 ChapmanF, Sep 11, 2021
    Last edited: Sep 11, 2021
  5. LEARNER

    LEARNER Junior Member

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    Correct. I looked it up for Prius Gen 2. Possible Engine Coolant Control valve but can be other possible causes that I am going through. (P1121)

    Yes I found that out before searching codes alone.

    The main thing though trying to find out the potential consequences of not having that gasket or molded rubber or synthetic material that fits perfectly in the bottom port of the air box where the throttle body is underneath it.

    I don't if you would call it a gasket as it is thick and has a ledge or ridge that fits perfect in that bottom port providing a much more air tight seal than without it. How much? I don't know.
     
  6. ChapmanF

    ChapmanF Senior Member

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    I wasn't there for the search you did, but P1121 in a Prius refers strictly and only to the Gen 2 coolant flow control valve. The listed trouble areas are that valve itself, clogging of the cooling system, or a faulty ECM, full stop. (And that last one is just to cover the case where you find there's absolutely no problem with the valve or the cooling system, and some failure in the ECM must be causing the code; pretty much not a thing that happens, only the list would be logically incomplete without it. :)) They didn't list the coolant valve/sensor wiring, but of course that's part of the circuit too.

    If you found a source that said there were "other possible causes" in a Prius Gen 2, then you found a source where somebody else had made the mistake of looking up a P1 code in the wrong places. That kind of thing happens too. It can be surprisingly difficult to put things like that to rest.

    I think I do remember that thing now that you describe it further. Sort of the stuff of door weatherstrips. And I agree, I don't see it offered as a separate part, not in figure 17-03 and not in figure 22-11. That's kind of frustrating.

    You could almost make the thing out of some door weatherstrip stuff, except for how to join the ends.

    With it missing, I would be expecting pretty much classic symptoms of unmetered air, including lean mixture drivability issues and P0171 codes.

    Maybe three or four wide rubberbands? I sometimes get some good ones on broccoli.
     
    #6 ChapmanF, Sep 11, 2021
    Last edited: Sep 11, 2021
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  7. LEARNER

    LEARNER Junior Member

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    Yes that is what I had read before I had decided for a hybrid mechanic to check it out before just having a new engine coolant control valve installed.

    Well I'm just happy to have found the Air Box with gasket thing for $18 instead of paying $805 for a new one from Toyota. That's as much as a New OEM AC Compressor.
     
  8. ChapmanF

    ChapmanF Senior Member

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    Does that mean you found a "hybrid mechanic" who believed P1121 had "possible causes" other than the coolant control valve and sensor, in a Prius? Funnier things have happened....

    $18 is a good price. Less fuss than gluing up door weatherstrip.