EGR Cleaning: What did I get myself into?

A new gasket is only $3-4. A lot easier....
I bought new ones, so I didn't drop it. Had I not bought the gaskets, I probably would have dropped them!

 

I made the mistake of not having the intake manifold gasket. Had to wait 2 days for it. What a pain!
I have all the numbers for the next time! I probably could of reused all but the intake manifold one. It was completely flat.
But for under $10, why not change them? Hopefully, we both learn from out mistakes!

 

There’s a black hole underneath the engine.

Maybe that’s where my oil is going.

 

I didn't change any gaskets. I think the intake manifold gasket alone was over $30 CDN.

 

Did you check ebay for a gasket?

 

Huh, only $10~ for the intake manifold gasket, through US online retailer McGeorge Toyota, for example. Item #33 here:

Engine Parts for 2010 Toyota Prius | Toyota Parts

Still, just dropping into my local dealership (I very rarely resort to E-Bay; it can be worthwhile, but shipping and/or duty can nail you up here) I think it'd be at least double that in Canadian funds. I maybe asked; had that number $30 in my head, which might be right. The way it works, buying from Canadian dealership:

Take the most absurd, over-the-top price you can imagine. Then double that.

Our car only has 75K~ kilometers, and all the gaskets looked pristine, btw. Maybe if there's a next time, though.

 

Mine was 138,XXX, the gasket was flat, it would not have sealed.
You just have to be careful with ebay, I search at many places and see where they're from and what their
rating is.
The local parts store had one, but the price was only $2 less than the Toyota one, so I bought Toyota.
Plus I get a veterans discount. 10% Which helps.
I'm not sure if a private individual can ship something to Canada without a customs charge but that might
save you some money.
At least it's not something you have to do every 5000 miles!

 

Yeah if there's a next time I think I'd research sources, do the gaskets, the pliable plastic/rubber ones.

 

Our 2010 prius with 121k finally popped p0401 last week. This vehicle has been running the Ball jar oil catch can since 2015 with 75k. It took 1.5 hrs to remove intake manifold, egr cooler, egr pipe and egr. I was able to access the 12mm nuts and #8 torx studs with the windshield wiper cowl on with much frustration. I recommended removing the cowl to access the studs for the cooler. The intake manifold had a wet coat (no pool) of oil and carbon buildup from the pcv and egr systems. The occ prevented the pooling of oil normally found in the intake manifold with no engine knock to date. I would say the cooler was 35~40% clogged. I soaked and flushed the egr cooler with purple power. I did not use the # 20awg wire with drill to clean the cooler because it was not completely clogged like the egr cooler on my 2011 with 297k. So far with all the components cleaned up p0401 has not popped back up and the car is running smooth. I also replaced some filters. The manifolds were also cleaned using a 90 degree "o" ring pick. I was able to remove 95% of the build up you see below. Sorry forgot to take pics with all the parts cleaned.



You could see light shining through the cooler. 35~40% clogged.

 

Wow! Have you been using quaker state oil? Mine didn't look 1/2 that bad, anywhere.
I guess driving slower really helps.

 

Only the brave and adventurous do the egr cooler job woth the cowl on.

The reach around is a challenging bit but can be done.

 

It gets cold here in Maryland, longer warm up times and plenty of water in the crankcase. We also drive with the flow of traffic, 80mph at times.

 

Extension 3/8 1/4 ratchet was key player here. Those egr cooler 12mm nuts and #8 torx studs were removed with this tool along with 3/8 and 1/4 wobble extensions.
1/4 in. x 3/8 in. Dual Drive Extendable Ratchet
9 Pc Wobble Socket Extension Set

 

I’ve got the same ones linked above and they have found their use.

Still best to have the wiper cowling off for the cooler job, but if you got the tools, you’ll be ready for the challenge .

 

Definitely better to have the cowl off. I like to attack things from different angles and think outside the box. The toyota manual said to remove the engine from the bottom, I pulled mine from the top. Members here said there is no room so I had to post the pics. I really like the community here. We are all sharing our experiences to keep these cars on the road.

 

Sometimes we get to share those experiences in person too.

I was able to pick @leeb18c ’s mind at one of our local meet ups. He did the head gasket in place without removing the engine.

Always good to share.

 

What's wrong with Quaker State Oil? The reason I ask is I was blaming Quaker State Oil for a problem with one of my cars possibly sludging up the drain holes under the valve covers but after valve cover removal I found it to be spotless. I had to change my opinion.
The car was a 1989 Lincoln Town Car with 135,000 miles and always had Quaker State Oil in it. I searched the internet and found several places blaming Quaker State Oil for this problem but if it were true at least since 1989 I say BS.

 

Even trivial items, the Repair Manual will go overboard. For an oil change, it recommends to remove the entire engine underpanel (aka NO 1 ENGINE UNDER COVER). This I agree with, both to avoid damaging that flimsy access flap hinge, and to afford a better view, check for leaks, look at the CV joint boots, and so on.

But, it also recommends to remove the underpanel between the engine underpanel and the front bumper (aka FRONT SPOILER COVER). This is absurdly unnecessary: technically the engine underpanel laps under that second panel, but it is so easy to just tuck it under and in.

 

$9.99 with coupon, sale ends tomorrow.