EGR Replacement??

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Jamdemos, Jul 22, 2018.

  1. Jamdemos

    Jamdemos Junior Member

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    Was at the Toyota dealer the other day just getting a few things done, and the service tech that was assisting me asked if I've had the ERG device/valve or whatever replaced. Says that Toyota does this repair for free if the car is experiencing symptoms. Told me that If I haven't had it done to just come in one day and say that I've been having rough starts and that'll trigger him to replace the part. Saying that every Prius has this issue but not all show symptoms yet, that I should try and get it done before the replacement period expires....Does this make sense?
     
  2. Raytheeagle

    Raytheeagle Senior Member

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    All they do is replace the egr valve if P0401 is displayed.

    A more effective solution is to have te egr circuit cleaned from cooler trough the intake manifold.

    While the techs advice seems genuine, it only gets one of the parts in the system, leaving other failure points.

    Hope that helps(y).
     
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  3. bisco

    bisco cookie crumbler

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    take the free part and ask how much to clean everything while in there. how many miles on your car?
     
  4. Raytheeagle

    Raytheeagle Senior Member

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    You can give this a try, but be prepared for the bait and switch routine;).

    The free part gets you in the door, then to do the rest (if they even would) results in their boat payment being made for the month:cool:.

    Keep us posted (y).
     
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  5. bisco

    bisco cookie crumbler

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    other than diy, what is the alternative? private mech? how much is the free egr worth?
     
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  6. Raytheeagle

    Raytheeagle Senior Member

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    Private mechanic will do it, probably more likely if they do t have to clean the old one out;).

    If you price a brand new one, it runs north of $200:eek:.

    Salvage valves can be had for ~$50:).

    I’d pick up a cooler and valve, clean them both up, then source an independent in the area that would do the swap if not capable of diy ;).

    Not sure how far @farmecologist is away, but he might have a spare and might be able to share a source (y).
     
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  7. farmecologist

    farmecologist Senior Member

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    I got my spare on Ebay for $50ish. There are lots of salvage yards that sell on Ebay.
     
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  8. Mendel Leisk

    Mendel Leisk Titanic Social Director

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    You can clean it yourself, end-to-end, with zero outlay of $'s, just some effort and patience. Watch @NutzAboutBolts video, pinned at top of 3rd gen maintenance forum.

    Just on a phone right now, can post more tips, reference and info in a bit.
     
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  9. m.wynn

    m.wynn Senior Member

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    Check in with Carspec regarding getting your entire EGR circuit sorted. They have conveyed an understanding of the issue via their blog, and also stated that Mother Toyota wasn't happy with their publicizing said issue. A recent poster here stated that they are expensive, but if I were in the Twins and not DIY capable, they would be my go-to Toyota guys.

    Have a look at this blog post AND the highlighted links within it:

    2010+ Toyota Prius P0301, P0302, P0303, P0304, P0401, cold soak rattle noise (FINAL UPDATE)
     
  10. Mendel Leisk

    Mendel Leisk Titanic Social Director

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    A thread on intake manifold and EGR cleaning:

    EGR & Intake Manifold Clean Results | PriusChat

    And oil catch can install:

    Oil Catch Can, Eliminate that knock! | PriusChat

    The nutzaboutbolts videos:

    Nutz About Bolts Prius Maintenance Videos | PriusChat

    Regarding tools: you would need the usual collection, ratchet wrenches, sockets, extensions. Also long reach pliers (with tips bent at various angles is good), maybe some grab-it type tools.

    Also: a E8 Torx socket (likely requires 1/4" drive ratchet, and maybe an extension. An E6 socket is needed if you opt to remove the throttle body hold-down studs from the intake manifold (good practice if you're say banging it around in a sink for cleaning.

    A 12mm ratcheting box wrench is very handy for reaching the rear bolts/nuts of the EGR cooler to intake manifold connection.Watch out with that: there's a loose gasket in that connection, will readily drop down (to who knows where) once the bolts are out.

    My school of thought: use a torque wrench for the "significant" bolts (most torque spec's in the attachements), at least if it's practical (sometimes it's impossible to reach with a torque wrench). Some of the torque spec's are quite low, the throttle body hold down bolts/nuts for example, and the throttle body hold-down studs are lower still: with those a low range inch-pound 1/4" drive torque wrench is best.

    A few tips:

    You may need to raise the car and remove the engine underpanel, for access from below, or just in case you drop something: it might hang up, or drop all the way down to the engine underpanel.

    When removing the throttle body, it is not necessary to disconnect coolant lines; you can just lift the throttle body off and tie it to one side with twine or whatever.

    When removing the EGR, if you first drain a couple of liters of coolant into a clean container (at the radiator drain spigot, driver's side front corner, no panel removal needed, and car lifting not mandatory), you can avoid any need to clamp any lines (which is somewhat ineffectual), and will have no spillage. This drain will drop the coolant level enough to be below the EGR system. When lifting the EGR cooler off, there'll be a small amount of coolant trapped at the lower back corner: just lift it out without tipping, then pour that bit into your container with the other coolant.

    When everything is done, EGR reinstalled: pour that drained coolant back into the engine coolant reservoir. Leave the coolant vent open (it's atop the EGR system, has white knob) until coolant starts to flow out. Note, this vent was eliminated starting in 2012 model year, with those you might just leave a top hose loose till coolant starts flowing out.

    Cleaners I used:

    Intake Manifold: Brake cleaner, then Oxi-Clean, a strong/hot solution, fill the unit and let it sit, say an hour. Repeat a few times. Various brushes may help, including some thin pipe cleaner style brushes for the EGR capilaries (one at each intake port).

    Intake ports (on the engine): Brake cleaner on a cloth (do not spray). Use caution, avoid getting anything on the injector tips.

    EGR valve: Brake cleaner (avoid Oxi-Clean, since the body is aluminum)

    EGR cooler: Brake cleaner, then Oxi-Clean, sim to Intake Manifold. A thin copper wire may help, running it through the fins.


    And attached is a couple of Repair Manual excerpts, regarding intake manifold removal/install, and similar for the EGR system:
     
    #10 Mendel Leisk, Jul 23, 2018
    Last edited: Jul 23, 2018
  11. Bay Stater

    Bay Stater Senior Member

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    OP, the above info is very good advice from the regular PC members. (y) I can only add that if you plan to DIY, check out the various threads by PC members that have done the EGR assembly cleaning. Also check out @NutzAboutBolts videos. Good luck ;)
     
  12. Bay Stater

    Bay Stater Senior Member

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    Wow, I think you have all the bases covered! Including that awful loose EGR Cooler gasket. :ROFLMAO:
     
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  13. farmecologist

    farmecologist Senior Member

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    Nice article. Doesn't surprise me that Toyota wasn't happy as they have not been very receptive with any of these emerging defects ( post-recall inverter issues and EGR are the most blatant ).
     
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  14. sguerra923

    sguerra923 Junior Member

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    Any updates? My mechanic at toyota said the same thing. Did you ask for further cleaning?
     
  15. Dragonfly1993

    Dragonfly1993 New Member

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    Okay I just want to know what a good deal would be to have a private mechanic to the EGR cleaning and tune up, replacing the spark plugs would be? TIA
     
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  16. Raytheeagle

    Raytheeagle Senior Member

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    @RightOnTime had a private shop and does the job:).

    Maybe he’ll share what he charges (y).
     
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  17. ChapmanF

    ChapmanF Senior Member

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    I didn't see this go by last year.

    They do a bit more than just replace the valve (per T-SB-0027-16):

    • New EGR valve
    • ECM reflashed to at least firmware 34715700 (for 2010, see TSB for other years)
    • A little wire harness modification, for reasons I haven't quite figured out
     
  18. Mendel Leisk

    Mendel Leisk Titanic Social Director

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    A fix that does nothing to address the EGR cooler and Intake Manifold clogging is useless. And the symptoms Toyota describe are likely a too-far-gone case.
     
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