The front exhaust pipe assembly (heat exchanger) on my 2016 Toyota Prius leaked engine coolant internally into the exhaust system. Toyota has documented this condition in Technical Service Bulletin T-SB-0135-19 ("Low Coolant, MIL ON DTC P148F00, and/or Poor Heater Performance") for 2016-2019 Prius vehicles and released a redesigned replacement part (17410-37D40). In [October 2026], at about [97,000] miles, I found the engine coolant reservoir was emptying about every night (nearly a full reservoir) with no...
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external leak. A shop pressure test found no leak. Coolant collected inside the tailpipe after the car sat overnight, and white steam came intermittently from the exhaust while driving. The car stored code P148F00. On [redacted] a Toyota dealer ([DEALER NAME], [[redacted]]) confirmed coolant leaking from the front exhaust pipe heat exchanger, per T-SB-0135-19, repair order #[RO NUMBER], and quoted $1,870 to replace the front exhaust pipe with the updated part. My concern is that a vehicle losing coolant this fast can run low without warning and overheat while driving, which can cause engine damage or loss of power, and the white steam from the exhaust may reduce visibility for drivers behind. I also worry that coolant entering the exhaust damages the catalytic converter. The car has been serviced regularly, and the leak was not caused by an accident or impact. Toyota covered this repair under its emissions warranty for 8 years/80,000 miles, but my car is past that and Toyota has declined goodwill coverage (Toyota case #[redacted]). I'm reporting this so NHTSA can see that the failure is happening in vehicles outside that warranty period and can evaluate whether it is a safety defect. Vehicle: 2016 Toyota Prius, VIN [[redacted]] Component: Engine and engine cooling / exhaust system Crash: No. Fire: No. Injuries: No. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)