cleaned EGR cooler and egr valve, exhaust leak now?

Are these EBay listings, salvage items? Because the EGR pipe, valve and cooler ARE available separately, as new items.

I would only change the pliable gaskets on the intake manifold, and even then only if they seem flattened or dried out. The metal gaskets on the EGR components I'd reuse, unless they're obviously bent or damaged.

Doing a tally of gaskets in my head:

Intake manifold to EGR pipe: one pliable, small O-ring style gasket, orange
Intake manifold to throttle body: one pliable, O-ring style gasket, black
Intake manifold to engine: one pliable, multi-opening style gasket, orange
EGR pipe to EGR valve: metallic gasket with clips
EGR valve to EGR cooler: metallic gasket with clips
EGR cooler to exhaust manifold: metallic gasket, no clips, easy to drop

This page has a lot, if not all, the parts no's and info:

Exhaust gas recirculation system for Toyota Prius 3 generation 01.2009 - 11.2011 - Toyota Car & Auto Spare Parts - Genuine Online Car Parts Catalogue - Amayama

 

I reused all nuts, studs, bolts, and metal gaskets with no leakage following reassembly.

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Very good write up, but you are missing one metal gasket... There is an elbow attached to the egr valve. If you look online to buy a new egr valve, the elbow comes attached with the valve. I have looked at the repair manual and can't find any info on torque specs or that the elbow can even be removed from the valve. I have looked on Toyota parts pages and can not find the part number for this gasket. I bought all the gaskets from Rockauto originally just to do the Egr cleaning... Then I found out my head gasket was already blown and bought the Head Gasket gasket kit from Toyota and I still do not have this gasket. I will include a photo of the gasket below. If anyone knows this part number or where one can buy this gasket... Let me know.

One thing I would like to know is the quality difference in gaskets from the 3D metallic cardboardish Fel-Pro gaskets vs the stamped metal gasket from Toyota and Mahle.

I ended up installing the Fel-Pro Head Gasket as it seemed of higher quality than the Toyota Head Gasket because it was the Toyota Head Gasket that failed... So why not try the Fel-Pro out... What's that saying? The definition of inanity is doing the same thing and expecting a different outcome... I mostly got the Toyota Gasket kit for all the gaskets I might be missing.. And low and behold.... I'm still missing this gasket!

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Ugh, flakey memory and 5 years since I was in there: you’re right.

you’re thinking to replace that gasket, the one in your hand? It looks pristine, fugedaboutit?

for the bolts between that elbow and valve, I agree: Toyota seems to have missed a torque spec. I would use 15 foot/pounds (which I likely did too), same as the rest.

 

Yeah I just wasted way to much time trying to track down that gasket. Thank God I didn't throw it away accidentally. I went to a Toyota dealership parts department to try to have them find it... They couldn't. I went to an auto parts store and had them look at about 14 gaskets that looked to be the correct shape, but none were the correct size.

From what I can see... The only way to get that gasket is to get a used or new EGR Valve... Which I think is ridiculous!

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Seems like Toyota deems the EGR valve is an “assembly”, the valve proper, the elbow, the gasket and connecting bolts: all one “part”. Frustrating if you lose/damage little bits of it.

is there some damage on the current gasket?

 

My original gasket has some damage on the edge and is a bit flattened out. I will try the original out.

I did find a gasket that in a pinch could work. The holes line up, but the main hole is slightly smaller than the original. I lined the gasket up with the parts and the smaller hole does not seem to block anything.

It is of the composite type of EGR gasket from Fel-Pro 70961 which works on a 2004 Toyota Tacoma Base L4 2.4L 2RZ-FE . The Mahle version appears to make a graphite gasket for that model and year.... So a metal version of this gasket is yet to be determined.

Please see the photos below to compare the gasket with the original.

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15 ft-lbs is too much! I just felt one of the bolts strip. I think the 15ft-lbs is for 12mm bolts.. These are 10mm bolts. It feels tight still, but If it leaks... looks like I'll be buying a new valve and a new gasket will be on it... Silver lining...

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Looking at the other 10mm bolt on the assembly, 7ft-lbs is what they call for.

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You could get a brand new one with the kit. It’s cheaper than just buying the valve by itself.
04004-58137 Egr Valve Kit
https://parts.mcgeorgetoyota.com/oem-parts/toyota-egr-valve-kit-0400458137

 

Ugh yeah: there are both 15 and 7 values in what I attached. The pipe to valve for example, is 7. And of course, they omit showing value for the “internal” bolted connection of the valve. Sorry.

 

If you did strip it’s very possible to fix that. If you have the money buy the egr kit I linked which will have the valve and all the gaskets. Next time don’t worry about torquing it down to spec. Just get it nice and snug and you’ll be fine. I did not torque anything other than the IM during my egr work. And everything has been good for 18k miles.