Death Rattle... clean manifold & EGR, new plugs, no change

I would block the egr tube temporarily and see if the rattle goes away. The egr should be closed at low rpms or it can cause misfires. The misfires can cause a loss of sync with the transaxle causing the noise.

 

When the traction battery doesn't need charge, the engine idles. Runs around 1000 rpm not doing any work to speak of.

When the traction battery needs charge, MG1 produces it, and that puts mechanical load on the engine. Still runs around the same rpm, but now it is doing real work. Goes back to idling when the battery is back up to a target charge. Those changes do come on and off very much like a light switch.

Running the A/C will use energy from the traction battery faster, so it reaches the point sooner where the engine load increases to charge it.

Anything that lets the engine run smoothly at no load, but with misfiring at slightly higher load, will have the effects you describe.

 

You can force charge the HV battery to full and test. Force charge the HV BATTERY to full by putting the car into drive, holding the brake down and flooring the accelerator.

Once the HV battery is fully charged, put it in inspection mode and let it idle. See at what point on the battery State of Charge meter reaches when the loud knocking starts.

You can run the test again with the AC blasting and see if the knocking comes on at the same battery SOC (low).

I would suspect there isn't enough fuel getting to the car. So my guess would be a bad fuel pump or injectors. Or maybe you don't have enough gas in the car

 

This is well-traveled ground here in Prius land.

You might take a look at this article, with special attention to "Why the knock" on page 4, before giving your final answer what you think it feels like.

 

Read my post again.

 

To those of us who may not know, ie me, can you please share how one might block the EGR tube?

REVVL V+ 5G ?

 

There's a YouTube video where a small putty knife is slipped between the EGR valve and tube to block off the flow to rule out an EGR valve that is stuck open or partially open.

Posted via the PriusChat mobile app.

 

Here you go.

 

Did you get the small EGR passages, one at each intake port?

 

Thank you for the direct link!

Be advised there seems to be a revised EGR valve:
04004-58137 (kit with gaskets except)
25685-37010 (EGR Cooler Gasket #1)

Intake manifold:

17120-37091
I just noticed this wording and interpreting:
"If current part number is 17120-37090, do NOT replace". I interpret this as meaning what you should see emblazoned on port #4, -090 when shopping for the part on the used market....

I suspect the updated manifold to be 17120-37090, and the -91 is the kit. (So many half truths out there).....

References:. T-SB-0103-12 Rev2, and T-SB-0027-16. (I keep learning as I go, didn't know the Rev# was important before).

If you are OC like me just pay Toyota $20 and look up what the latest is: techinfo.toyota.com .


REVVL V+ 5G ?

 

Actually there is little evidence or even support outside of Priuschat for the clogged egr head gasket thesis. Hearing it repeated over and over again from a single source and then believing it is a problem.

An egr is designed to be closed at low speeds and at wide open throttle. If it is not, misfires are common. This is the typical egr issue across most internal combustion engines that mainstream mechanics understand. Since you had been in the egr yesterday, the piping should have been pretty fresh.

 

I've got a recollection, trying to corral all the 3rd gen intake manifold iterations (part no's); think I threw in the towel around 5... Just clean what you got works for me.

Why are my ears burning...

 

I was talking about a certain media network. Since you are in Canada you don't have to choose sides. Especially if you keep the oil changed, the egr spotless and the car garaged.

 

Hell, I can't even find excuses to drive it. Was supposed to do an airport run, but they've got someone else now.

 

@rjparker Well I would not personally know as I'm not a mechanic by trade, but if it sounds like the engine is tearing itself apart I assume it actually is, (or what sounded like an animal being burnt inside and jumping around in my case)...

I even accidentally forgot to add oil once in my last oil change. Engine ran perfect for the one minute or so it took me to realize why the red oil (genie) lamp was lit, and turned it off. Should have sent a video to Mobil that their Annual Protection was that good....

Since I believe @ChapmanF found them on NHTSA somewhere, I'll try to post the important pages...

REVVL V+ 5G ?

 

Down in Texas we fire up the car to pick up the mail. Seriously. My mailbox is a mile away with a 200 foot elevation drop. Lightning storms are interesting from our vantage point. This was two weeks ago.