2011 Prius Head Gasket Failure

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by The Critic, Feb 28, 2019.

  1. Avi's Advanced Automotive

    Avi's Advanced Automotive Independent hybrid repair shop

    Joined:
    Jun 28, 2012
    758
    339
    0
    Location:
    Los Angeles, CA
    Vehicle:
    2005 Prius
    Model:
    Three
    It has the large o-ring that stays on the block, but you might want to get an OE one as the one it comes with doesn't like to stay in the block. The other ones can usually be reused and are not a big problem if they fail.

    Posted via the PriusChat mobile app.
     
  2. Avi's Advanced Automotive

    Avi's Advanced Automotive Independent hybrid repair shop

    Joined:
    Jun 28, 2012
    758
    339
    0
    Location:
    Los Angeles, CA
    Vehicle:
    2005 Prius
    Model:
    Three
    Some pop and some don't. I never really paid attention to which ones do and which ones don't. All I know is I don't remember ever felling one was loose. I did have one break off inside the block. That was fun.

    I've never had problems with the threads in the block, so I doubt you do.

    Posted via the PriusChat mobile app.
     
    Robert Holt and The Critic like this.
  3. Mendel Leisk

    Mendel Leisk Titanic Social Director

    Joined:
    Oct 17, 2010
    36,311
    25,117
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    I think I've got this right, but don't take it to the bank without another read over:

    BECK/ARNLEY GASKET KIT 0323038
    OE Number Description QTY
    11115-37051 GAKSET, CYLINDER HEAD 1
    17173-37010 GASKET, EXHAUST MANIFOLD 1
    17177-37030-A GASKET, INTAKE MANIFOLD 1
    11123-37041 GASKET, VALVE ROCKER COVER 1
    96721-24015 O-RING, OIL STRAINER 2
    96721-19010 O-RING, OIL LEVEL GAUGE 1
    96723-24020 O-RING 1
    90301-07037 O-RING, FUEL INJECTOR 4
    90913-02101 GASKET, SET 8
    90913-02111 SEAL, VALVE STEM 8
    11159-37010 SEAL, BEARING CAP SIDE 1
    11193-37020 GASKET, PLUG TUBE 4
    13552-37010 GASKET, CHAIN TENSIONER 1
    16258-37010 WASHER 1
    23291-73010 INSULATOR, INJECTION 4
    90210-06013 WASHER, VALVE COVER BOLT 1
    90430-12031 GASKET, OIL PAN DRAIN PLUG 1
    90430-35001 GASKET, OIL FILLER CAP 1
    22271-37010 GASKET, THROTTLE BODY 1
     

    Attached Files:

    SFO likes this.
  4. Caballo Prieto Azabache

    Caballo Prieto Azabache Junior Member

    Joined:
    Mar 27, 2012
    11
    6
    0
    Location:
    Ventura County, CA
    Vehicle:
    2012 Prius
    Model:
    IV
    Avi how much do you charge at your shop for this repair? My 2012 Prius at 170k miles has now also developed the head gasket failure.
     
  5. The Critic

    The Critic Resident Critic

    Joined:
    Oct 28, 2005
    2,948
    1,847
    0
    Location:
    SF Bay Area, CA
    Vehicle:
    2011 Prius
    Model:
    Three
  6. Caballo Prieto Azabache

    Caballo Prieto Azabache Junior Member

    Joined:
    Mar 27, 2012
    11
    6
    0
    Location:
    Ventura County, CA
    Vehicle:
    2012 Prius
    Model:
    IV
    I called Avi, fair price including parts and labor (he replaces the water pump as well).

    I believe I will be taking a stab at it, I have most of the necessary tools.

    Critic, thanks for the parts/cost breakdown and all the tips. I was looking forward to seeing some of the attachments you posted, however, the links are not working (at least not for me; for attachment 166855 I receive an error indicating that the attachment could not be found ).

    Mendel, thanks for the video and repair manual attachments, I am taking notes.

    Avi, thanks for the heads up on the water pump, I ordered an AINSI from Japan off ebay.
     
  7. The Critic

    The Critic Resident Critic

    Joined:
    Oct 28, 2005
    2,948
    1,847
    0
    Location:
    SF Bay Area, CA
    Vehicle:
    2011 Prius
    Model:
    Three
    Which attachments are you looking for?
     
    Raytheeagle likes this.
  8. Caballo Prieto Azabache

    Caballo Prieto Azabache Junior Member

    Joined:
    Mar 27, 2012
    11
    6
    0
    Location:
    Ventura County, CA
    Vehicle:
    2012 Prius
    Model:
    IV
    It looks great, and the machine shop seems to be fast! How long did they take? By looking at the time stamps, was it only one day?
     
  9. Caballo Prieto Azabache

    Caballo Prieto Azabache Junior Member

    Joined:
    Mar 27, 2012
    11
    6
    0
    Location:
    Ventura County, CA
    Vehicle:
    2012 Prius
    Model:
    IV
    Critic, did you use the two FIPG tubes? I'm debating whether purchasing one or two.

    Thanks,
     
  10. The Critic

    The Critic Resident Critic

    Joined:
    Oct 28, 2005
    2,948
    1,847
    0
    Location:
    SF Bay Area, CA
    Vehicle:
    2011 Prius
    Model:
    Three
    They originally estimated two business days but their other jobs were on hold due to parts being on order. So they had my cylinder head completed same day.
     
  11. The Critic

    The Critic Resident Critic

    Joined:
    Oct 28, 2005
    2,948
    1,847
    0
    Location:
    SF Bay Area, CA
    Vehicle:
    2011 Prius
    Model:
    Three
    My tube dispenser tool broke the first tube so I had to use both tubes.

    One tube is probably enough but it does not hurt to have a second one on hand.
     
  12. Mendel Leisk

    Mendel Leisk Titanic Social Director

    Joined:
    Oct 17, 2010
    36,311
    25,117
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    I'm curious: you didn't remove the engine? Assuming no, you applied the FIPG to the cover not the engine? From start of application to install, where you under +3 minutes* (from commence of FIPG gasket)? And then install and torque the myriad bolts by +15 minutes*? I would assume you did the applications of FIPG at the engine seams on those seams, not on the cover?

    I guess long story short, what were your impressions, the Repair Manual instruction vs realities of the the cover install?

    * Repair Manual stipulation, maybe a little nuts?
     
    The Critic likes this.
  13. Raytheeagle

    Raytheeagle Senior Member

    Joined:
    Jul 1, 2016
    9,274
    12,554
    0
    Location:
    Bay Area, California
    Vehicle:
    2019 Prius Prime
    Model:
    Prime Plus
    You need a second set of hands on the guide pins ;).

    Through the tire well and works well(y).
     
    The Critic and Mendel Leisk like this.
  14. Mendel Leisk

    Mendel Leisk Titanic Social Director

    Joined:
    Oct 17, 2010
    36,311
    25,117
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    Yeah that's how they worked in that video.
     
    Raytheeagle likes this.
  15. The Critic

    The Critic Resident Critic

    Joined:
    Oct 28, 2005
    2,948
    1,847
    0
    Location:
    SF Bay Area, CA
    Vehicle:
    2011 Prius
    Model:
    Three
    The engine was not removed for the Head Gasket repair.

    FIPG 103 was applied to the cover. FIPG 103 was also applied to the engine on the six seams. No, I did not use the coolant-specific FIPG on the coolant contact areas - I do not know any tech that does. I also did not measure the thickness of the FIPG beads but from experience, I applied an adequate to slightly excessive amount based on the size of the sealing area.

    It probably took me around 5 minutes to get the FIPG applied and the cover seated onto the engine. From experience, FIPG is not super sensitive in this area. I had the bolts snugged up within several minutes after that point, but I did leave out the bolts for the water pump and the engine mount until 10-15 minutes afterwards. Even without the water pump and engine mount installed, there are enough bolts on the timing cover to maintain pressure on the sealing surface. The important part is to have both surfaces 100% clean, oil-free and to not disturb the BEAD of FIPG when mating the cover to the engine.

    Doing the repair with the engine removed is probably ideal but it wasn't worth the extra time to me.
     
  16. The Critic

    The Critic Resident Critic

    Joined:
    Oct 28, 2005
    2,948
    1,847
    0
    Location:
    SF Bay Area, CA
    Vehicle:
    2011 Prius
    Model:
    Three
    Not sure what happened to the original pictures, but I think these were the ones that were posted.

    IMG_4673.jpg
    IMG_4676.jpg
    IMG_4680.jpg
    IMG_4669.jpg
     
  17. jack black

    jack black Active Member

    Joined:
    Jan 5, 2018
    198
    122
    0
    Location:
    USA
    Vehicle:
    2010 Prius
    Model:
    I
    Hi The Critic,
    i'm a big fan of your posts here and on BITOG. Strong work on this! it sucks to know the HG problem can happen despite the extensive maintenance you did. is this also an issue in corolla cars with similar engines?
     
    Raytheeagle and The Critic like this.
  18. The Critic

    The Critic Resident Critic

    Joined:
    Oct 28, 2005
    2,948
    1,847
    0
    Location:
    SF Bay Area, CA
    Vehicle:
    2011 Prius
    Model:
    Three
    Thanks. If you look over on Toyotanation, there are reports of HG failures on the corolla as well. But it is not as common, but perhaps the corolla section does not have the same user base as this forum. In my conversations with technicians, the HG issue affects corollas as well.
     
    Raytheeagle and jack black like this.
  19. mjoo

    mjoo Senior Member

    Joined:
    Nov 9, 2016
    826
    1,029
    12
    Location:
    Michigan
    Vehicle:
    2010 Prius
    Model:
    III
    The 2zr-fe engine (Corolla) has no external cooled EGR. It's internal.

    Pixel XL ?
     
    #79 mjoo, Apr 16, 2019
    Last edited: Apr 16, 2019
  20. jack black

    jack black Active Member

    Joined:
    Jan 5, 2018
    198
    122
    0
    Location:
    USA
    Vehicle:
    2010 Prius
    Model:
    I
    it has a HG though.
     
Loading...