2010- 3x EGR Valves, Preventive Maintenance

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Prius_Angie, Jul 24, 2020.

  1. Prius_Angie

    Prius_Angie Active Member

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    Today's project is a 1 hour maintenance of 3x EGR Valve assemblies. With a quality Capri 1/2" impact driver, I opened up 3x EGR Valves for clean out (with brake parts cleaner, WD40 and Silicone spray) and preventive maintenance. 1:3 EGR Valve assemblies were stuck open; its stem was stuck open due to a large amount of carbon buildup. Pretty neat to see side-by-side the dissimilar views of a normally and malfunctioning EGR Valve assembly. A fully functioning EGR Valve stem can depress and bounce up without any external assistance. The malfunctioning EGR Valve was just stuck open. Using both force and chemicals, I was not successful in fixing nor cleaning out 1x malfunctioning EGR Valve assembly: pliers, degreaser, WD40, etc. The stem nudged back and forth about 3mm but not more. In the end 2:3 EGR Valve assemblies were salvaged and maintenanced.
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  2. wheezyglider

    wheezyglider Active Member

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    Good stuff. So would you think someone doing an EGR clean could be confident as long as the pintle depresses easily and returns freely? (Not that I wouldn't love an excuse to buy an impact tool :ROFLMAO:)
     
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  3. Ed Beaty

    Ed Beaty Active Member

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    Nice idea with the holes in the plank to imobilize the valve body. :)
     
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  4. ChapmanF

    ChapmanF Senior Member

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    The end you would be trying to 'depress' for that test is the end you need the impact tool to get to. If you leave the cap on, you have to reword your test to "pintle pulls outward easily and returns freely". But you would be trying to grab and pull a slippery round pintle sitting down in a recess. It's not easy to do. And pliers might mess it up.

    If you could grab it and pull. you would feel and hear a soft whirring of the motor as you pulled the pintle out. You might then need to push it back in also; it has a return spring, but won't necessarily just whir its own motor to return to closed position without a little help from a thumb.

    The 'impact tool' I would recommend for the job is something like the Lisle 62140. It doesn't twist the screws at all, just bonks on them while you gently and steadily turn with a wrench. That's all it takes. The kind of impact tool that imparts a twisting force has a higher chance of breaking one; they're not big screws.
     
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  5. Prius_Angie

    Prius_Angie Active Member

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    that IS the basic takeaway = liberal pintle movement
    i HIGHLY suggest people buy a legit impact driver. If you are undertaking this project, you NEED to be successful in not stripping those 2x screws. If you strip those screws, you have to take more drastic measures to getting them out, or ditch the EGR Valve itself. And those screws sit atop of hardened plastic. Its a bad design, they should've been bolts.
     
    #5 Prius_Angie, Jul 24, 2020
    Last edited: Jul 24, 2020
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  6. ChapmanF

    ChapmanF Senior Member

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    I've had traditional, twist-imparting "impact drivers" for decades, but only got the Lisle seized-fastener remover in the last couple of years. It works on a different principle, where it simply strikes the bolt on axis while you gently turn with a wrench, and it is one of those sort of life-changing tools in the rapid success it delivers with a greatly reduced risk of stripping or breaking the fastener.

    Whoever already has one tool or the other will probably use whichever one they have, but if I were starting and looking for an excuse to buy a tool, it would be the seized-fastener remover for sure.
     
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  7. wheezyglider

    wheezyglider Active Member

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    Ah yes I remember now prying it up with a flat blade (and wondering how much damage I was doing). That Lisle set looks nice, they make good stuff.

    And yeah, what were they thinking with that choice of fasteners? Tamper proofing??
     
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  8. ChapmanF

    ChapmanF Senior Member

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    They're just ordinary Phillips screws. I don't think the engineers had any extra goals in mind for them. They're just steel threaded into aluminum that gets hot, and they get very happy where they are.
     
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  9. Mendel Leisk

    Mendel Leisk Senior Member

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    If you could determine the dimensional details of those screws it would be very useful; you could replace them with a regular hex bolt, or torx socket. I'm guessing they're M5, coarse thread, about 16 mm long??

    The simplest way to sort all of this out: take one of the valves to hardware store, try a few metric bolts for fit.
     
    #9 Mendel Leisk, Jul 25, 2020
    Last edited: Jul 25, 2020
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  10. Raytheeagle

    Raytheeagle Senior Member

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    That's exactly what @m.wynn did:).

    A novel idea and functional(y).
     
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  11. Mendel Leisk

    Mendel Leisk Senior Member

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    Can you recall what they turned out to be?

    Maybe he'll see your flag and chime in.
     
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  12. Raytheeagle

    Raytheeagle Senior Member

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    That was about 3 years ago. I've slept since then:sleep:.

    But he sent me a pic:):

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    He's the outdoors type, so those are titanium bicycle water bottle bolts and a #10 washer;).

    Use whatcha got(y).
     
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  13. ChapmanF

    ChapmanF Senior Member

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    Or just bonkity-bonk the originals while loosening, they come right out.
     
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  14. Raytheeagle

    Raytheeagle Senior Member

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    That's what I've done about a dozen times, but there are solutions out there for those looking for alternatives(y).
     
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  15. Prius_Angie

    Prius_Angie Active Member

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    Great idea-- why should I settle. Added to my task list (when convenient). Thanks.
     
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  16. Prius_Angie

    Prius_Angie Active Member

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    For this procedure, I think your Lisle hammering tool is a better over my impact driver. Not all of my screws came out UNSCATHED. Its only a matter of time those screws get eaten up by the Capri impact driver. I think RTE's idea of a hex bolt is a better longer term fastening solution
     
  17. Mendel Leisk

    Mendel Leisk Senior Member

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    Maybe a very thing application of anti-seize too. I have an old toothbrush that's just sorta anti-seize "contaminated": I'll brush threads with it, just gives them a hint of anti-seize.
     
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  18. Prius_Angie

    Prius_Angie Active Member

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    aha, those look nice and fancy. I don't see this assembly being regularly maintenance but ~once/50,000 miles. New sturdy bolts should hold fastening integrity and should grant easy access & a quicker maintenance process. Thanks.
     
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  19. Raytheeagle

    Raytheeagle Senior Member

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    Readily available if you have a water bottle on your bike and have some washers laying around:).

    But once every 50k miles is what our old 2010 was on before we parted ways;).

    I'll check out our Primes EGR circuit at 120k miles like I did our old 2010. And that circuit will not be as easy to access:cool::

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    Not as simple, but worth the data and piece of mind(y).
     
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  20. Prius_Angie

    Prius_Angie Active Member

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    Sounds like a good idea; I'm a big fan of lubricating everything (where possible). On the pintle threads under the black cap, I placed an ample amount of white lithium grease.
     
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