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NEW!!! Service Bulletin for Engine Knocking at Startup T-SB 0012-10

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by seilerts, Jan 12, 2012.

  1. Grit

    Grit Senior Member

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    Would that mean to check your oil level? Don’t be like the last two people on my signature.
     
  2. Tande

    Tande Active Member

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    Oil level is fine......doesn't use a drop .......
     
  3. toyolover

    toyolover Member

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    I am not a techno guy. May I ask what is OCC? Where do you install it and how much does it cost? Can you provide product links?
     
  4. ASRDogman

    ASRDogman Senior Member

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    Oil Catch Can. If you do a search for OCC, you'll find several thread here about them.
     
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  5. Mendel Leisk

    Mendel Leisk Senior Member

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  6. Raytheeagle

    Raytheeagle Senior Member

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  7. toyolover

    toyolover Member

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    This will be interesting. I have my G3 for 11 years and I am loving it still. Since the third of fourth year, the dreadful knocking noise would appear two or three times on each winter season. Like most everyone else, I immediately turned off the engine, wait 10-15 seconds and restart it. In most cases, it would not knock again. Yet this is possibly the only thing I am quite worry about. Even though it has 200,000+ km on it, I plan to give it my most tender loving care for another decade.
    94 pages- piece of cake. LOL.
    Does anyone in Toronto who had it installed at a garage which you can refer me to? How much does it cost?
     
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  8. Mendel Leisk

    Mendel Leisk Senior Member

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    Have you ever cleaned out the EGR? At 200K kms, and knocking, I would address that first.

    The simplest way to see where you're at, is to check the degree of carbon build up in the EGR pipe, a stainless steel connecting pipe between the EGR valve and intake manifold. Watch @NutzAboutBolts video #16 here:

    Nutz About Bolts Prius Maintenance Videos | PriusChat

    Two or three other videos linked there too, for the full cleaning of the intake manifold, full EGR clean, and Oil Catch Can install.

    Good thread:

    EGR & Intake Manifold Clean Results | PriusChat

    Another:

    Oil Catch Can, Eliminate that knock! | PriusChat

    Some tools worth having:

    E8 Torx socket (mandatory)
    E6 Torx socket (optional, but good to have, to remove the throttle body studs from intake manifold)
    3/8" ratchet wrench, regular and long handle, flex head, you can never have enough (or 1/2 plus reducer)
    1/4" ratchet wrench, or 3/8" to 1/4" reducer
    Ratchet extensions: you can never have enough
    Long needle nose piers, straight and bent tip
    Ratcheting 12mm box wrench (optional, but makes disconnection of the EGR cooler from exhaust easier)
    Torque wrench (3/8" and 1/4" both good to have)
    Floor jack and safety stands (or ramps): basically some method to raise front, if you need to take underpanel off, which you may need to, both for access and to recover dropped items.

    Comment regarding clamping of coolant hose, mentioned and or shown in videos:

    1. When removing the intake manifold for cleaning, you do need to lift the throttle body off the intake manifold. Still, the coolant hoses connected to the throttle body have ample slack, enough that you can leave them connected, and just tie the throttle body to something adjacent, say the inverter wiring harness.

    2. When removing the EGR cooler, removing coolant hoses is necessary, but if you drain 2 liters/quarts from the radiator drain spigot prior (into a clean container), the coolant level in the system will be dropped below the EGR components, and you won't spill anything. Just be sure to not tip the cooler when lifting it off (and catch the rear gasket): there are a few tablespoons of coolant trapped at the lower back corner.

    Pour that into your previous drained coolant, and when done pour it back into the reservoir. If you've got the coolant bleed bolt (2010, 2011 model years), leave it open while pouring the coolant back in, till coolant starts coming out. For later model years, leave the topmost coolant hose on EGR disconnected till coolant starts coming out. Also, might help to burp the main radiator hose as you pour the coolant back in.
     
  9. Raytheeagle

    Raytheeagle Senior Member

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    Ah boiler plate :).

    How many times this week have you whipped it out :whistle:.

    I bet we're is at least a page or 2 of the boiler plate in this thread if we totaled it up (y).
     
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  10. Mendel Leisk

    Mendel Leisk Senior Member

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    With my attention span more'n likely lol.
     
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  11. toyolover

    toyolover Member

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    Thanks and really appreciate it very much that you took the time to give me such details. I know some basic of it but not sure if this is something I can or want to do myself. I will still study this more in depth for my knowledge but would like to just find a mechanic who has done that for another Prius before to do the job for me.
     
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  12. Mendel Leisk

    Mendel Leisk Senior Member

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    Yeah it will be expensive, and likely frustrating, I don't think the typical mechanic is doing this on a regular basis. If you're capable of doing an oil change, have a few tools, you can do it.

    The coolant level isn't dropping? That's a good sign. Start with inspecting the the pipe between EGR valve and intake manifold. Also you could clean the throttle body. Both of those are relatively easy, get your feet wet.
     
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  13. cmderks93

    cmderks93 Junior Member

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    Last days I finely did clean the egr system with egr, cooler, hose from engine to intake, intake itself and throttle body.

    What a mess! I do now believe that the dealership did actually clean the intake, but no way they did clean the rest of the egr, especially not the cooler.

    I've used hit water with dishwasher soap. It cleans very good. But the cooler was clogged. So finally I've used the pressure washer to blow it all out.

    Everything put back together, toped up with coolant and give it a shot.

    Now it's rough idling, the rpms goes up and down all the time. I've let it run a minute or so, and turned it off, I can't do anything now, because it's evening first.

    What are your suggestions to check? I did notice during cleaning the egr does leak somewhat at the top. (Where the electrical motor is) I did blow at one end, and did open and close the egr with the little piston. But somehow at the top there escaped some air. Is this normal?

    Kind regards,

    Casper
    IMG_20200908_175713.jpg IMG_20200909_150540.jpg IMG_20200909_150551.jpg IMG_20200909_150556.jpg IMG_20200909_151007.jpg IMG_20200909_151026.jpg IMG_20200909_233425.jpg IMG_20200909_233431.jpg IMG_20200910_132816.jpg IMG_20200910_132829.jpg IMG_20200910_144847.jpg IMG_20200910_144854.jpg
     

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  14. ASRDogman

    ASRDogman Senior Member

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    Are you sure you put the gasket on the top of the cooler? Did you tighten the bolts/nuts?
    That would be the reason you have a leak. Unless you mean coolant leak?

    It sounds like you have an air intake leak. Double check that you have ALL the hoses and make
    sure they are connected. If the engine rpm's are bouncing around, it's probably because the sensors
    can't figure out how much air is getting into the cylinders.

    Also, make sure you have all the electrical connections connected. It's easy to miss one,
    or not have it plugged in all the way.

     
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  15. cmderks93

    cmderks93 Junior Member

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    Thanks for helping me out.

    I'm pretty sure all the gaskets are in place, but thinking now that the gasket between the cooler and egr is placed upside down. (Don't know if it matters)

    Sorry, but don't know how to clarify what I mean with the egr leak. I'll try to explain with some pictures later.

    Can I check for air intake leaks with brake cleaner? Don't have any other right now.

    I'll double check all this stuff later this morning. It's 6 am now.

     
  16. ASRDogman

    ASRDogman Senior Member

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    Yes, you can use brake cleaner, or carb cleaner. Spray around all air intake fittings.
    While the engine is running of course. If it's sucking air, the idle will go up.
    With the engine running, you should be able to feel the exhaust blowing out.
    Maybe the gasket slipped and is only half way in place.

    Let us know.

     
  17. cmderks93

    cmderks93 Junior Member

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    Well, all nuts and bolts were good, no difference when spraying brake cleaner. Solution was pretty simple, just a battery reset.
    Maybe because I did disconnect and clean the throttle body?

    Drives like a new one!

     
  18. ASRDogman

    ASRDogman Senior Member

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    That's great! And it was simple! :)
     
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  19. cmderks93

    cmderks93 Junior Member

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    Yes, so simple that it's not the first thing we think about!

    Thanks for helping!
     
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  20. cmderks93

    cmderks93 Junior Member

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    Oh no. The car drives good, better gas mileage, bit still with the shaking problem directly after the ice kicks in after a stop. So, I can now assume, it was not the egr system.... But wat is...