2010 DIY head gasket repair help in Madison, WI

Hi to all you Prius vets. I am a Chat newby in Madison, WI. Please read my story an share your experience.

I have a 2010 Prius Gen 3 bought at 223K now with 293K miles with all the head gasket fail signs (code P0301, slow coolant loss and engine shutter at startup).

I will try to run my own compression test (in maintenance mode) and if 2 thru 4 cylinders show good I plan to do a driveway head gasket replacement with egr/intake cleanout.

For backround I've done full VW TDI engine pulls and builds. I have the time, a Toyota Corolla factory service manual, friend's backup car to run for parts and beer, nothin to loose plus the learning experience. I can get a low mileage imported engine from JDM for $1500 but have no hoist, or help (but could scrape up to $500 for a helper) for engine swap.

Will anyone who has done their own head gasket job please offer the big DO's and DONT's?

Can anybody in my area offer hands-free on advice if/when I get stuck? (choice beers supplied). That would be so great ! I

 

The How To video looks great scanning it, thanks. From a Prius taxi yard, these guys don't fool around. Using a Felpro head gasket and aftermarket other gasket set and head bolts. Will try to get a compression test to day.

 

Nice to be in the Chat, thanks.

I did talk with @erickbecky recently about an engine swap option. Good guy, might help me out if I get stuck on this HG job.

 

How to compression test a 2010 Prius?

The local Orielly Store compression rental test kit has no adapter for Prius 12mm spark plug.

What testkit or adaptors are people using? Will the Harbor Freight gas engine compression test kit work? The deep spark plug well is a problem too, or do I just tighten down a little, holding the hose, on the rubber O-ring (but I need that 12 mm adapter) ?

Any advice from your successful compression test is appreciated.

 

Compression test completed using Harbor Freight (gas ICE) test kit for $23 out the door, comes with the right 12 mm adapter for the Prius spark plug hole. Removed all ignition coils and spark plugs, threaded on the 12mm adapter and also secured it with electrical tape so not to loose it when unscrewing from the cylinder head. I screwed gauge/hose assembly hand tight into each cylinder, turned engine over for 3-4 seconds to reach maximum guage reading.Tests run for all cylinder with cold and warm engine

The results:

2010 Prius compression test
cyl cold warm
1 100 118
2 100 120
3 110 118
4 105 120

Comparing these figure to the available reference compression psi target of 118 PSI I would say the test values and variation look surprisingly good, for 293K engine mileage. Oil consumption has also been pretty low around a quart per 6000 miles.

I'll ask for your educated opinions out there on how these readings relate to the suspected head gasket coolant leak into Cylinder 1 producing the occasional P0301 code with engine startup shudder?

I plan to start the head gasket replacement job myself tomorrow with the aid of an excellent video suggested by ttou68 (see above).

My goal is to go another 50,000 miles and trade in before other major system failure. Transmission is smooth (fluid changed recently) and Hybrid battery cells are all in tolerance (using TorquePro app)

 

Dry test only. I'm thinking the test figures looked "good" and oil consumption is low enough to stick with this engine after HG job

The other easy preventive maintenance item i will do along with reconditioning the head and replacing all head gaskets & seals

- egr valve & cooler clean
- intake manifold clean
-replace thermostat housing assembly
-new PCV valve

Questions:

Is a new crank seal in the timing chain cover really necessary?

Am I missing any other Must Do items on my list?

Thanks

 

Yessir, my gasket kit includes new set of valve oil seals the machine shop will install for me and I will replace that crankshaft seal.

Any tips out there for properly retightening the crankshaft bolt with only a common torque wrench and no special tool?

 

I have made that Y-arm sprocket holder tool before for VW TDI work, but it's sitting in Virginia storage unit. May fab another one or just find a way to restrain the balancer then use the torque wrench.