2019- heat exchanger done- cap popped off

Discussion in 'Gen 4 Prius Care, Maintenance and Troubleshooting' started by C Clay, May 5, 2026 at 8:43 PM.

  1. C Clay

    C Clay Member

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    This car is new to me and has 200,000 miles on it. It just started the issue with the coolant loss and the heat exchanger.

    I did the bypass underneath the car, that seemed pretty easy. I read that the port to the heat exchanger should be capped off?

    Well, I did that, but I didn’t secure the caps and one of the caps popped off under pressure. Should I have vacuumed or tried to blow out all of the coolant from the exchanger? It’s actually in the catalytic converter isn’t it? Do you just have to wait for it all to burn off and then cap it off? I don’t remember reading this.
     
    #1 C Clay, May 5, 2026 at 8:43 PM
  2. ChapmanF

    ChapmanF Senior Member

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    It's in the exhaust pipe, behind both catalytic converters.

    (In gen 4, the first catalytic converter is built into the exhaust manifold. So the exhaust pipe starts with the second catalytic converter, followed by the heat exchanger.)
     
    #2 ChapmanF, May 5, 2026 at 8:45 PM
  3. C Clay

    C Clay Member

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    Just asking a hypothetical question- if the cap popped off- would that imply that the system is sealed, ie- that there is no failure in the heat exchanger?
     
    #3 C Clay, May 6, 2026 at 9:04 AM
  4. C Clay

    C Clay Member

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    I’m trying to figure out the pros and cons of this device. What is the effect of bypassing? Just that one might struggle for heat?
     
    #4 C Clay, May 7, 2026 at 7:39 PM
  5. ChapmanF

    ChapmanF Senior Member

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    Engine takes a bit longer to warm up.
     
    #5 ChapmanF, May 7, 2026 at 8:35 PM
  6. rjparker

    rjparker Tu Humilde Sirviente

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    If the exhaust heat exchanger failed there is now an exhaust leak into your "capped" coolant lines. I would probably securely cap it.

    You should also ensure the thermostatic valve is secure in an open position to reduce exhaust restriction.
    IMG_1383.jpeg
     
    #6 rjparker, May 7, 2026 at 9:04 PM
    Last edited: May 7, 2026 at 9:14 PM
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