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Update on Head gasket repair

Discussion in 'Gen 3 Prius Main Forum' started by priusbydefault, Jun 18, 2024.

  1. priusbydefault

    priusbydefault Junior Member

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    I posted on another thread about my HG repair among other repairs and I said I would post an update.

    I completed the job using the fel-pro head gasket including lapping the valves, cleaning egr valve, cooler and pipes, installed new spark plugs and coil packs and also installed an oil catch can on the PCV valve side (I'm thinking of installing a catch can on the valve cover side also but I'm not sure if it is needed). I also did a piston soak as the engine had started to consume oil at a rate of 1 qt. per 1k miles. It was evident that oil was being consumed on the #1 piston as that spark plug was oil fouled(that is also where the HG had failed)

    The engine started right up with no codes and runs smoother and stronger than before. Ive put over 1k miles on it and it has not consumed any oil.

    I noticed that the car was running longer on the ICE than on battery and was getting lower MPG's. A battery life expectancy test determined it's at 59.39% with a #7 weak block.

    Next project is to replace failing battery pack modules to lengthen life as much as I can.

    It's just one repair after another with this car and I regret having purchased it and should have stuck with Honda civics as my work commute cars. I feel taken by jumping on the hybrid, gas saving bandwagon. Any fuel savings have been negated even though I have done all the repairs myself. If I would have had toyota complete this repair including the failed ABS/Booster module, I would have spent about 10k by now not including the failing battery. I have no choice at this point to continue repairing it as I have too much invested into it and refuse taking even more of a loss.

    I also have a 2012 Prius plug-in that will benefit me all I have learned when I have to start repairing that one. Which has already had a HG replacement by the previous owner BTW. Lets just hope the work was done properly. It has similar miles on it.

    I just want to thank you all for your continued contribution to this forum by sharing all your knowledge and experiences. I would not have taken on such huge repairs without all that help.

    Sorry for not taking better pictures. I was overwhelmed at the time and I did not think about it. 20240531_220110.jpg 20240604_201553.jpg 20240531_220140.jpg 20240531_220119.jpg
     
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  2. priusbydefault

    priusbydefault Junior Member

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    I forgot to mention that I also cleaned the throttle body, intake manifold and MAF sensor
     
  3. priusbydefault

    priusbydefault Junior Member

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    Here she is all put back together with the oil catch can installed. 20240618_162110.jpg 20240618_162134.jpg
     
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  4. bisco

    bisco cookie crumbler

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    well done! thanks for the write up, please keep us posted. i traded my '12 plug in at 87k because of knocking and shaking.
     
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  5. Tombukt2

    Tombukt2 Senior Member

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    Yes the old Honda Civic would be a better car You're right or '04 to '09 generation 2 I have a 94 civic 1400. Great running car but not quite as reliable as the Prius unfortunately but still a great car and got near a million miles on it it's been through you know what and back and still fires right up Just put a fuel pump on it the other day My kid drives it as a beater.
     
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  6. Eddie25

    Eddie25 Active Member

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    what did you use for the piston soak?
     
  7. priusbydefault

    priusbydefault Junior Member

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    I've had 2 8th gen civics. My first had 220k miles when I sold it. Got it with 80k. I only replaced the starter when I got rid of it. The second had 26k mi when I bought it. Only replaced the fuel pump for less than $50 and wrecked it at 345k mi. Now my daughter has one and I do the maintenance on it. All she does is gas it. No problems for 2 yrs.
     
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  8. priusbydefault

    priusbydefault Junior Member

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    I used Berrymans B-12 and soaked it 5 times until all solvent had either drained down or evaporated during the course of about a week and a half that it was down for repairs. I also used about half a bottle of seafoam I had left over. Turned the crank by hand several times in between soaks. The last 2 soaks were done while the head was removed. Just leveled pistons and filled the cylinders. I noticed a shiny spot in cylinder #1 and sanded as lightly and evenly as I could with 600 grit sandpaper until shiny spot was gone to replicate a honing. I can't be any happier with the results.
     
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  9. Mendel Leisk

    Mendel Leisk Senior Member

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    Holy smokes: valves disassembled too! Not your first rodeo?
     
    #9 Mendel Leisk, Jun 19, 2024
    Last edited: Jun 19, 2024
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  10. Eddie25

    Eddie25 Active Member

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    Cool, I'm probably going to do a Berrymans soak soon. I'm nervous about it mainly since people seem to have trouble starting their engines afterwards and I'm wondering how being a hybrid will play out in that regard. I definitely wish I'd thought to do it when I had my head off recently. Did you have any issues starting? Did you lube the cylinders after the soak at all?
     
  11. Tombukt2

    Tombukt2 Senior Member

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    The berrymans just super cleans everything I'm not sure what it's doing for the oil control rings and cleaning that mess up but hey it's better than running water down there which will clean nothing. Least to berryman's has a chance to cut up some of that dried oil that gets coagulated around those oil return rings or oil control rings. It'll do what it can to get around the compression rings a little bit and try and undo some of the gum and nonsense the holes those stuck to the Pistons that's about it ideally in the old days and older Toyota motors if I had the head off it was another 45 minutes to take the oil pan off remove the rod caps push the pistons out of the top of the block clean the Pistons right in the driveway with real safety clean cleaner with gloves because that's stuff would eat your hands up It was real cleaning as it is not today pop new rings on three piece oil control rings clamp the pistons and the ring compressor pop them back in the lightly honed and wiped boards dry no pouring a bunch of lubrication in the hole and all this and that putting them up wet and sloppy You put them up dry the ring seat the first five travels they make up and down the bore and you're ready to go revving in 30 minutes not 400 mi of break in but that's just me. Your piston soap will be pretty much uneventful If you do this correctly and let it sit overnight with the drain plug off most all of your liquid will run past your slugs and rings fall into the pan run out into the drain pan you have sitting under the drain hole so most of what you poured in if you were watching will wind up down in your little tray then it sits all night and most of that stuff out gases and well pretty much dries. Then when you install your plugs and coils and what have you everything should be ready to start when it starts give it a little gas let it smoke and do its thing that should clear run that oil to 2000 miles and then change it and that's what you wind up with.
     
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  12. rjparker

    rjparker Tu Humilde Sirviente

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    Yes that is a come to Jesus realization on a high mile gen3. Almost all other hybrids before and after are better but with a gen3, buying new and selling around 150k was the value strategy. I only had inverter failure with a no warning stranding by that point.

    It is interesting Toyota initially covered pistons, rings, inverters and brake boosters for free. They revised the intake, head gasket, egr valve and ecm logic along the way. Only the free inverter still exists for most gen3s.

    Amazing what can be done when faced with little alternative. The more recent hybrids like my 22 Rav4 have a return to sump “catch can” built in with a no hose pcv installed between the head and intake directly through the intake gasket. One of many improves since 2016’s gen4 design.

    Rav4 hybrid with 2.5L “gen5” engine
    IMG_5162.jpeg IMG_5163.jpeg
     
  13. Mendel Leisk

    Mendel Leisk Senior Member

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    For the first 60k miles, or 5 years, whichever comes first. I doubt anyone achieved the 1 quart consumption in 1100~1300 miles (Toyotas criteria for doing the repair), within that mileage.

    I’d like to be a fly on the wall, at the meeting where they settled on 60k; likely lots of chuckles.
     

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    #13 Mendel Leisk, Jun 19, 2024
    Last edited: Jun 19, 2024
  14. rjparker

    rjparker Tu Humilde Sirviente

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    Based on dealer mechanics I know a lot of gen3 piston and ring jobs were performed under 60k and some until 125k for those who bought Toyota’s Platinum extended warranty prior to the 3/36 expiration.

    5 year 60k was the standard powertrain warranty.
     
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  15. priusbydefault

    priusbydefault Junior Member

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    This is my first time disassembling a car engine like this. After watching many videos and being able to get my hands on the shop manual online, it gave me the confidence to tackle this job. I work with my hands and have been repairing many things including vehicles all my life. It also helped that I took 2 weeks vacation from work so I could take my time with the repair. It was a not a walk in the park though.
     
  16. priusbydefault

    priusbydefault Junior Member

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    I did not have any issues starting the car. It stumbled a bit and was a little noisy for like a second before it built oil pressure and smoothed out. It also smoked like crazy for about 5 minutes haha. I was a little hesitant starting it dry but I decided to in the end and didn't seem to affect anything.
     
    #16 priusbydefault, Jun 20, 2024
    Last edited: Jun 20, 2024
  17. priusbydefault

    priusbydefault Junior Member

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    Even Toyota realized that sending all those crankcase fumes directly in through the fresh air side of the engine isn't the best design. Glad to see it.
     
  18. priusbydefault

    priusbydefault Junior Member

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    Yeah that is way too early of a time frame. It was just a way of them showing "good will" when they knew the issue would pop up further down the road.
     
    #18 priusbydefault, Jun 20, 2024
    Last edited: Jun 20, 2024
  19. priusbydefault

    priusbydefault Junior Member

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    Wow that is way to early to be going in for a job like that. What were the qualifying factors for Toyota to approve a repair like this?
     
  20. priusbydefault

    priusbydefault Junior Member

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    Yeah that is a laughable attempt at taking responsibility for a factory defect as most complaints online that I've read and watched videos about oil consumption are it happening around the 150k mile mark. That seems to also be the mile count were most HG failures seem to hover around.
     
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