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

Another Head Gasket Story

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Singh Saab, Mar 29, 2023.

  1. Singh Saab

    Singh Saab Junior Member

    Joined:
    Sep 12, 2021
    38
    12
    0
    Location:
    CA, USA
    Vehicle:
    2018 Prius Prime
    Model:
    Prime Premium
    Hello All
    We had the motor on our 2013 Prius replaced at about 180,000 miles from a failed head gasket. Fast forward to now the CEL light came on and showed the code P0302 (Cylinder 2 misfire).
    I took a look at the EGR and intake manifold and both were heavily clogged with carbon build-up and engine oil.
    I made the assumption that the technician that replaced the engine with a used engine also replaced the EGR & intake manifold, however they did not. So I replaced the following:
    • EGR valve
    • EGR cooler
    • EGR pipe
    • Intake Manifold
    • Engine Cooling System Thermostat
    • PCV Valve
    After replacing all of this I left the auxiliary battery unplugged overnight. The next morning the engine knocked for a little bit and then subsided. I drove the car around for about 20 minutes and everything seemed relatively fine. After about 3 hours I went out to check the coolant and oil both were stable.

    Next day we took the car out and had A/C on. When the hybrid battery charge dropped to two bars the engine kicked on it knocked badly but then subsided. We came back and a little bit later turned the car on to move it and the engine knocked badly and constantly, however the knocking stopped when I put it into a reverse, neutral or drive. I checked the coolant level and it had dropped significantly but the oil level is still the same. So now it is parked and will not be moving.

    Some other things I did about 2,000 miles prior to this is the following:
    • Replaced all spark plugs
    • Replaced all coils
    • Drain & fill transmission fluid
    • Drain & fill engine coolant
    • Drain & fill inverter coolant
    • Replaced Engine Water Pump
    • Replaced Front Strut Assembly
    • Replaced Front Sway Bar Links
    • Replaced Front Headlamps

    My assumption now is to replace the head gasket but I am not sure. Any recommendations on what else I can check or do before moving forward?
     
  2. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    7,797
    1,349
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    I'm confused by what you are saying did the engine in fact get replaced in this car yes or no.? It will pretty much obviously be used unless you paid close to $10,000 or $8,500 or something crazy then you could have an open deck engine with a new center section which houses the crank rods pistons etc essentially a new engine personally I wouldn't opt for this and it's cost but that's me. I'm guessing you had a used engine from a junkyard installed which if you're in the United States pretty much any engine you find for a Prius is either going to have a whole lot of miles on it or it's about ready to explode like the one that you took out of your car The only option here for me in the States is to get a JDM Japan domestic market engine from Asia shipped here and put that in my car because there are some things that are at play here but we don't need to go into all that now so more than likely you got an engine that was close to the miles that was of the engine coming out so unfortunately not such a good play. So now what is it you want to do replace the head gasket on the inherently weak open deck design you have that option It will probably be more money thrown away. If it were me at this stage of the game and the car is reasonably clean and I'm stuck and I need to keep it I would be ordering the 13 1400 dollar JDM engine from the JDM importers that you can Google right here on our phone and see these companies there is one in the US close to where you live or not too too far look into it maybe Good luck.
     
  3. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    54,474
    38,106
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    In summary: the EGR system got royally clogged, the head gasket let go, you had the engine replaced (with salvage engine), and left the EGR system clogged. The first failure was at 180K; what are the miles now?

    Regarding your current actions: all the EGR cleaning or replacement after the head gasket has blown will not turn back the clock.

    Did you keep the old coils? They're probably good.

    Ditto for the old intake manifold and EGR components; hang onto them and clean them.

    My suggestion for future: keep on top of the EGR cleaning (no need to replace everything), regularly. See first two links in my signature.
     
    #3 Mendel Leisk, Mar 29, 2023
    Last edited: Mar 29, 2023
  4. Singh Saab

    Singh Saab Junior Member

    Joined:
    Sep 12, 2021
    38
    12
    0
    Location:
    CA, USA
    Vehicle:
    2018 Prius Prime
    Model:
    Prime Premium
    Yes engine was replaced at 180,000 miles with a used engine from LKQ. The replacement engine had 80,000 miles on it.
     
  5. Singh Saab

    Singh Saab Junior Member

    Joined:
    Sep 12, 2021
    38
    12
    0
    Location:
    CA, USA
    Vehicle:
    2018 Prius Prime
    Model:
    Prime Premium
    Car is now at 240,000 miles.
    Replaced the car at 180,000 miles with a used engine that had 80,000 miles on it.

    Replaced all the ignition coils.

    This was a special case other wise we have three other gen 3 prius that I usually clean up the EGR & Intake.

    Took out the spark plugs today and cylinder 2 spark plug was pretty dark compared to the other 3 cylinders.

    Planning to open up it up and see if it is the head gasket and it there’s any damage (bent rods, while in block, etc.)

    LMK what you all think.
     
    Mendel Leisk likes this.
  6. Singh Saab

    Singh Saab Junior Member

    Joined:
    Sep 12, 2021
    38
    12
    0
    Location:
    CA, USA
    Vehicle:
    2018 Prius Prime
    Model:
    Prime Premium
    An update:

    Took everything apart and the head gasket did indeed fail at cylinder 2.

    The height of pistons 1&4 and pistons 2&3 is the same, would it be safe to assume there are no bent rods?

    Also does anyone know how the wiring is for the coolant sensor temperature on the engine head. I forgot to disconnect the connector and ripped the connector off of the wires. Will fix just not sure which color wire goes into which part of the connector.
     
  7. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    7,797
    1,349
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    It's very difficult actually to tell if the rods are messed up if there's a slight tweak of bend etc very difficult to see I didn't see it on mine and went to look at it I think twice while it was sitting in the shop with the head off etc The kid had called me saying there was a divot on top of piston too I went to look and it was just a scratch and I proceeded to explain to the kid that the scratch wouldn't be a problem but if that scratch turned into a crack that would allow gas to penetrate through the crown of the piston that would be a no-no like you could clean the piston top off and take a vacuum cup out of your mighty vac and stick it over the little divot crack that you see pull a vacuum on it and see if it pulls air through the crack If not it's probably just a scratch I mean nothing's been dropped down the spark plug hole there's no metal missing off the head or valves etc etc It's not like a 6 l somebody dropped an exhaust nut down the intake while it was running. Haha
     
  8. rjparker

    rjparker Tu Humilde Sirviente

    Joined:
    Jun 6, 2008
    7,478
    4,374
    7
    Location:
    Texas Hill Country
    Vehicle:
    2012 Prius v wagon
    Model:
    Three
    So the second engine has 140,000 miles on it and blew again. Lower mile failures are starting to be common as these things age.

    As Tom suggests, there is no guaranteed way to know if a small amount of metal fatigue or crack has started but you look for the obvious deviations and spend the money to have the head inspected, cleaned and rebuilt. All the egr cooler cleaning in the world does nothing for the real issues, bad rings and resultant carbon build up in the intake manifold and head. Some replace the intake with the improved design and get a new start there as well.

    If someone had successfully convinced you to go with a professionally rebuilt engine for $4,000 installed the first time you would be a happy motorist now. Depending on your location which for some reason you are hiding. There could be a great shop five miles away but the community can not help you find it. We have had diyers do head gaskets three times before they get it right. Be careful with the timing, missed connectors and sealing.
     
    #8 rjparker, Apr 6, 2023
    Last edited: Apr 6, 2023