My 2013 Uber vehicle died after making a loud noise.

OK quick update as I have to take my wife to work.

Got a call from the dealer this morning, before I had any caffeine . They did a fuel system bypass, which included cleaner for the injectors. They discovered that the PCV valve hose had come off (it was missing a clip). The SM told me that the Pop I heard must have been this hose popping off. The engine is now running, and the Hybrid Battery is OK.

I informed him that I did an EGR + EGR Cooler + EGR IM pass ages cleaning, and that I replaced the PCV valve myself with a Toyota part. I have been monitoring EGR Flow Insufficiency, and was concerned that it had been dropping.

So as it stands, I owe $300 +tax, and they recommend a recalibration of something, and replacing "the Purge Valve". The SM thinks that since I have Techstream, I can do it myself. I have a lot of questions, but I am not awake yet.

 

I dropped my wife off at her work, and then went over to the dealer to get an answer while I was in that neighborhood.

Here is what I was able to piece together, using the SM as interpreter:

Apparently, the PCV hose fell off at some point. There is supposed to be a clip, and when I replaced the PCV valve as part of cleaning the IM, I apparently did not put the clip on the hose. I find the need for a clip surprising, since the hose has vacuum in it, but who knows. This loose hose caused a huge vacuum leak to the IM. Whenever the ICE was called apon to charge the Hybrid battery, it would cut out after 20-30 seconds as a result of the leak, but not throw a check engine light. Not sure when the hose came off.

So basically, last Thursday, my car was running mostly off battery, since the ICE was only running 20-30 seconds at a time, and could not keep up the charge. No explanation for the loud bang, but it happened just as the Hybrid Battery was completely depleted. Reconnecting the hose with a clamp, the Tech discovered the ICE would run fine, and it can now charge the Hybrid battery. I would have expected that when I needed to go up a hill, I would have noticed a loss of power when the ICE cut out, which it did not.

The tech also found a hose from the Evap Purge valve was off (not sure which side). The tech recommended replacing the purge valve, and re-calibrating the system with Techstream. I suspect that recommendation was made before the Tech knew I had done an EGR service. Again, I would have expected a Check Engine light with an Emissions code for this.

I drove the car home, and everything was normal. They had fully charged the Hybrid battery, so I got like 68mpg on the way home. Still no explanation that I can believe for the loud bang that was heard.

So the really great news is that the major systems including the Hybrid Battery, the Inverter, the ICE are all doing fine. They send their best wishes to your spouse and kids

Total damage to my wallet: $320. Total damage to my self confidence: very hard to measure.

I still have my spare vehicle (2001 voyager minivan 180k) up on jackstands. It overheated while my wife was taking it to work Saturday. Cold radiator, and no heat, Thermostat replaced last year. I assumed it was the water pump, because the impellers are known to break off on these pumps, turning the pump into a idler pulley. I had a new pump sitting around that I never got around to installing. Got the old pump out, and it was an upgraded pump with metal impellers, and was fine. Strange thing: new thermostats are double the price they were last year.

So I have left the 2017 parked at the dealer, so I could drive the 2013 home. When I PU my wife at work at 6PM, she will drive the 2017 home.

 

I generally do the same thing. I don't remember there even being a clamp on that hose.

I also store bolts in the threaded holes they came out of. Not always possible, but if it is possible, I don't have to figure out which bolt goes in which hole.

 

Now that you mention it, I sort of recall the thin wire clamp. I would have most likely left it on the hose as I mentioned above, but possibly not. I guess that the oily mess that comes through that hose means that a clamp is required, in spite of the vacuum.

I am still surprised that there was no CEL with such a large vacuum leak. It does not make sense that the hose came off at the time I heard the bang. The HV battery went to zero in 200 feet after the "bang" at about 25mph.

 

Your reply had me google "Atkinson cycle engine". I had been under the impression that an Atkinson cycle engine had a multi-piece connecting rod, which I think was part of Atkinson's original 1880's design. I have seen videos of Gen3 engines that died with bent single piece connecting rods, so I was confused.

The following link explains why the delayed intake valve closing at the beginning of the compression stroke makes it more efficient than the Otto engine. It only makes sense in a hybrid, because the Atkinson cycle has poor performance during low RPM. What surprises me is that the Atkinson valve timing is not used in fixed speed applications like backup generators, or engine driven sump pumps.

What Is the Atkinson Combustion Cycle, and What Are Its Benefits?

 

I did not install an OCC. I plan to install one someday, but the Trans fluid and Inverter coolant changes are ahead of it in line. My surprisingly clean spark plugs at 95k, and lack of oil consumption have made an OCC a lower priority for me.

When I get to installing the OCC, I was hoping to splice into the existing hose.