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Clean EGR Manifold, Pipe, Replaced Fuel Injectors, Still Shudder

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Tony D Mafia, May 20, 2023.

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  1. Tony D Mafia

    Tony D Mafia New Member

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    Hello All!

    Thanks in advance for any Advice. Replaced all Spark Plugs and Engine Coils. Did a Thorough Manifold Cleaning, and Pipe Cleaning (Gas Mileage jumped by 180 mi/tank).

    Replaced all fuel injectors carefully (Used engine grease and Dialectric grease). I didn't replaced the Orange gaskets that the fuel injectors sit in on the engine side.

    Took Prius out for a Spin, still shuddering at low speeds. Is this just aerated fuel working its way out of the system? No codes were yet triggered.

    Thoughts? Should I replace the engine O rings that the fuel injectors sit in?
     
    #1 Tony D Mafia, May 20, 2023
  2. JC91006

    JC91006 Senior Member

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    How many miles on your car? Any evidence of bad head gasket? When you cleaned the intake manifold, did you clean the 4 small passages that were probably clogged with carbon?
     
    #2 JC91006, May 20, 2023
  3. Tony D Mafia

    Tony D Mafia New Member

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    Great Questions. 245K. No evidence as of yet. Just refilled the Tranny Fluid, and holding the level, plus changed oil and no evidence of discoloration, and never has overheated. I did Clean the 4 passages and the Manifold VERY thoroughly.

    After the Manifold Cleaning, I got a 4th Cylinder Misfire Code--Cleaned all 4 injectors while I waited for the new injectors to arrive. I got a "Multiple Cylinder Misfire" Code after the cleaning, after running great for about 20minutes.

    I installed the new injectors last night, 30sec shudder upon starting, then ran phenomenally for about 10 minutes, before the shudder started to slowly return. No Codes Yet.
     
    #3 Tony D Mafia, May 20, 2023
  4. Mendel Leisk

    Mendel Leisk Senior Member

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    By "Pipe" you mean the stainless steel pipe that bridges between intake manifold and EGR valve:

    How about the EGR valve and EGR cooler (colloquial name for the largish radiator contraption between the EGR valve and exhaust manifold).

    I'd second @JC91006 : miles is paramount. Ditto for cleaning of those small EGR passages in the intake manifold.

    Also: neglected EGR leads to head gasket failure (well that's my theory, but I take some flak for it...). Once the head gasket's commenced failing, no amount of EGR cleaning is going to "heal" the head gasket; you need to address the failed head gasket first, THEN get on the EGR cleaning ASAP thereafter, to avoid a repeat.

    Pic of EGR Pipe, Valve and Cooler (highlighted, in order, left to right):

    upload_2023-5-20_7-12-50.png

    See first couple of links in my signature for more info on EGR cleaning. If you're on a phone turn it landscape to see signatures.
     
    #4 Mendel Leisk, May 20, 2023
  5. Tony D Mafia

    Tony D Mafia New Member

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    THANKS FOR the advice. I'll check out the EGR Cooler cleaning info you have on your links.
     
    #5 Tony D Mafia, May 20, 2023
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  6. Mendel Leisk

    Mendel Leisk Senior Member

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    What’s the miles?

    sorry, answered above. That’s a LOT, you will find a massive amount of carbon in the valve and cooler.

    Best prep for head gasket being kaput though. Leak down test or boroscope inspection to see.
     
    #6 Mendel Leisk, May 20, 2023
  7. Tony D Mafia

    Tony D Mafia New Member

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    Thanks a lot for the "heads" up. I'll follow your instruction for the egr cooler and valve and we'll go from there.
     
    #7 Tony D Mafia, May 20, 2023
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  8. Tony D Mafia

    Tony D Mafia New Member

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    Hey Everyone,

    Replaced the EGR Valve. Cleaned the EGR Cooler Thoroughly. When I unplug the EGR System Car runs well, once replugged in still shuddering very badly when I accelerate. Thoughts?
     
    #8 Tony D Mafia, Jun 5, 2023
  9. Tony D Mafia

    Tony D Mafia New Member

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    I've reopened the EGR Manifold and ReCleaned it. Missed quite a bit. Those four little holes were packed solid, I'm ashamed/relieved to admit. Also swapped out PCV Valve while I was down there.
    Glad to have learned everything I learned, including being able to take off and clean EGR Valve and Cooler. All of this stuff seemed COMPLETELY OVERWHELMING at first, but I feel so much more able and connected to my prius now.

    I'll let you know how it runs tmoro. Thanks for all of the assistance.
     
    #9 Tony D Mafia, Jun 5, 2023
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  10. Tony D Mafia

    Tony D Mafia New Member

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    She's Running Great now. If anything else pops up, I'll log back in!! Thanks for all of your help!
     
    #10 Tony D Mafia, Jun 6, 2023
    CR94 and Mendel Leisk like this.
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