EGR/Intake Manifold Cleaning...Then It Happened...

2012 Prius v/3:

A few weeks ago I did the full EGR valve, cooler and intake manifold cleaning. The cooler was about 70% occluded. I did a gravity water flow test to determine this between dirty and clean. First I used the pressure washer which did great at blowing things out. The next day I sprayed straight Purple Power cleaner inside the cooler and suddenly thick dark tar like substance started running out. Purple Power did an AMAZING job of removing all the buildup on the three components. Super pleased. While I was cleaning these parts my helper asked if I wanted him to clean the intake ports on the engine (head). Sure.... This is where things may have went downhill...

I instructed him to push blue paper towels down into the ports to prevent liquid and stuff from falling/running towards the valve seats, etc. I also provided him with two cleaners, one being the Purple Power. He was working like a mad-man and when he stepped away to get more towels I took a look and was very pleased with the progress. Until... I happen to step over while he was cleaning the last one. He had a small stainless steel brush and was using it and the cleaners to remove the carbon, suet residue. Still not a bad thing as he was very careful with keeping things clean. However, It was then that I noticed that he was also scrubbing the TOP of the intake port, including the fuel injectors which sits right there! ............sigh.......

I stopped him and he confirmed that he had cleaned the other three the same way. I packed fresh blue towels into the intake and sprayed the tips of the injector (best I could) with carb cleaner. Everything was reassembled with new gaskets and the engine started right up and was a little rough for about 5 seconds, then smoothed out. Actually idled much better than before the cleaning. An Oil Catch Can was also installed.

I noted over a couple of weeks while driving around town my MPG's seemed a bit low. This past weekend we did a 600 mile trip. Typical load and speeds. I normally average out between 40 & 42 MPG For the first hundred miles I got 32 mpg per the computer. I stopped and bought a bottle of Techron Fuel Injector cleaner, dumped it in and topped of the gas. Over the remainder of that tank the MPG's got close to 35. When I refilled I added a bottle of Techron Fuel Cleaner. The last 220 miles of the trip I averaged 36 MPG.

So.....While I can't see a clean EGR/Manifold system causing this, I am left to believe that the injector tips (that were scrubbed with a stainless brush) may have been damaged and has caused this sudden drop in MPG performance. The engine seems to actually run stronger but the MPG's are WAY off!

I would welcome your input and suggestions regarding my situation. Thanks!

 

Chapman,
Thanks for the info...appreciated. I really want to pull the injectors and check them before leaving on my 4 week, 7K mile trip...but my departure time is too close. Thankfully no codes and it is running good/better than before the EGR cleaning. I just hope the MPG's continue to improve. I will certainly report on this after my trip. Thanks again!

 

Thanks for the info. I really do feel like some damage has been done... I have to give my friend kudos for doing such an amazing job of cleaning the intake ports...and at the same time wish I had been watching closer! While I use the onboard computer for quick MPG's I do track every tank of fuel, miles and MPGs figured by math...not computer!

I really hate that I don't have time to pull the injectors before leaving on our trip next Wednesday...the clock is ticking! I will be watching everything closely.

LOL...glad to hear that @frodoz737 fixes planes...I do the same...well...I fix my homebuilts! ...and I do need a phone repaired! ...can't touch that! LOL

Thanks again for the support and info...sincerely appreciated!