car won't go into maintenance mode/won't run after EGR cleaning

Most likely a cable is not on 100% or the pcv or other hose is disconnected.

 

You have to have parking brake on to get into maintenance mode; did you do that?

maintenance mode due to coolant refill?

 

may I ask how long it took you to do the EGR and associated area cleaning? I'm considering it and am hoping to get some feedback.

 

Second time around, started after lunch, and had everything "done" by evening, except reassemble. Started that the next morning, done by lunch. First time will take longer, due to a lot of unknowns. Read through the first couple of links in my signature; there's further links in those links, plus tools required, tips/tricks.

There's prep things you can do in advance, the car is still functional. Main one would be to take the nut off the lower EGR cooler bracket. Better yet, remove the stud that nut goes on (takes an E8 Torx socket). Both these items can be left off, permanently. The reason to do this in advance: it's a royal pain to access, will really bog you down.

Something else to do is just the EGR pipe cleaning, the pipe that goes between the EGR valve and the intake manifold. This can be done in a couple of hours, and you can button up.

You can do the above plus the intake manifold in one session, which will break it up. Combined with the pipe cleaning, maybe 3 hours. it is not necessary to disconnect coolant lines from throttle body, no need to deal with coolant spill.

For the EGR valve/cooler removal/cleaning, you do need to disconnect coolant lines, but if you first drain two liters coolant (at the radiator drain) into a clean container, it leaves the EGR components pretty much dry. When done you can just pour it back into reservoir; it'll settle down with a few days driving. You will also need to remove wipers/linkage/motor, and the metal cowl below.

For all of the above, check out the links in my signature. There's links in them to @NutzAboutBolts videos, everything relevant, like the wiper removal, EGR pipe Cleaning, intake manifold cleaning and EGR valve/cooler cleaning.

Consider an Oil Catch Can install as well, info at top of my sig.

 

The first time is a real pain. For me, it was accessing all of the coolant hose clamps and hoses around the EGR cooler.

Removing the clamps are very difficult, especially when there's hardly any room around where you are trying to get at. Using a cable operated hose clamp tool was key in the tightest spots. Long reach, angled needle nose pliers were my other go to for clamp removal.

Even after releasing the hose clamps, the hoses are often stuck on the fittings. Small spaces makes it difficult to get any grip on the hoses to wiggle and pull the hose off.

Here, I had to use a combination of hose picks, pry tools, and hose pliers to get the coolant hoses off.

Posted via the PriusChat mobile app.

 

Putting a flat-blade screwdriver or small pry bar at the edge of coolant hose on the spigot, and pushing firmly in the direction it would pull off, can help to unglue them. Do this at several points on circumference if possible.

again, if you’ve drained a couple of quarts of coolant (at the rad drain) beforehand, everything will be dry, when the hoses come off.

 

Sometimes a coolant hose pick gives an even easier angle.