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New Owner Cleaning EGR Passages

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Dduelin2, Jun 3, 2024.

  1. Dduelin2

    Dduelin2 New Member

    Joined:
    May 13, 2024
    16
    5
    0
    Location:
    N Florida
    Vehicle:
    2013 Prius
    Model:
    Three
    I'm new here having bought a 2013 Prius Three about 3 weeks ago. I am the DIY sort with 50+ years experience wrenching on my cars, boats, motorcycles but I know I don't know it all and I really appreciate the plentiful resources here at Priuschat. I am sure there are many helpful owners here but a shoutout today for @Mendel Leisk. The links in his signature have already helped me to familiarize common service tasks. My new to me car has 189,xxx miles and somewhat of a full service history. I have records from day 1 and I am the third owner. The car was serviced primarily at two Toyota dealers up until the day it was sold wholesale. It runs great and has no codes stored. In about 900 miles I cannot discern any changes in the coolant or engine oil levels. Happy about that. Runs smooth and transitions back and forth between engine and EV operations smoothly. This morning I pulled off the EGR tube to see the type and amount of carbon buildup the rebreather system has at 189K. There is no record the EGR valve and chamber have been cleaned to date and I gather that is an important item to keep clean to help avoid head gasket problems. I was pleased to see the soot in the pipe, outlet of the intake manifold, and inlet of the EGR was absolutely dry. The pipe and EGR inlet had the barest minimum of soot, very clean but I used some flexible brass brushes and brake cleaner to clean these passages out. Now the inlet manifold had more but still dry and sooty. There was about 1/8" build-up on the inside of the intake manifold outlet. I did not pull the manifold today but connected a flexible 3/8 ID vinyl hose to a handheld vacuum cleaner and used the hose round and round and in and out to scrape the surfaces clean for the two or three inches that are accessible. I captured all the soot I removed from the tube and manifold and it came to less than 1/2 teaspoon (pictured). It's much like minute bits of charcoal. No oiliness what so ever. What can I expect the inside of the EGR chamber/cooler to look like based on the pipe and manifold?
     
  2. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    55,378
    38,616
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    The cooler and valve will like have you saying “OMG this should have been done sooner”.

    I’d start by removing the nut on the lower bracket of EGR cooler. This can done in advance, without having to pull off anything else, and the car will still be functional. Just because it’s a pain to get to.

    In advance you can also:

    1. remove the stud that nut screwed onto, and again, leave it off. You’ll need an E8 Torx socket for this. It’ll be very tight, due to dissimilar metals, and its difficult location. I used a diminutive 1/4” drive ratchet wrench, and a lot of patience; it took at least 15 minutes, backing it out one click at a time.

    With this stud removed, you’ll later be able to pull the EGR cooler straight forward and out, leaving it’s rearmost studs on, and they will keep the rear gasket from falling, getting lost.

    2. Remove, clean, lube and reinstall the stud/nut combo, that attaches the EGR valve.

    3. Ditto for the bolt at top of EGR cooler.
     
    Dduelin2 likes this.
  3. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    55,378
    38,616
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    Torque values for all those can be found by clicking the first link in my signature, which has Repair Manual excerpts. Both the top signature link and the next down are worth a read before diving in. (on a phone turn it landscape to see signatures)