EGR valve removal and cleaning

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by MeGuinness, Jul 20, 2016.

  1. MeGuinness

    MeGuinness Member

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    Guys ,anyone that has removed the black cap on the egr valve and accessing the shaft inside?
    I remove it but now when I'm fitting it back it doesn't seat properly and it push the shaft slightly in and the car rattle like hell ,what mi missing ?
     

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  2. Mendel Leisk

    Mendel Leisk 'Orrible Oracle

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    Check page "1958" (actual page 6 of 17) in the attachment. There's a particular install/torque sequence. I've not done it, but maybe that's the issue. Here also is a screenshot of that page:

    upload_2016-7-20_5-38-42.png
     

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  3. MeGuinness

    MeGuinness Member

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    Going thru the pdf,no indication on how to remove and refit the black connector cap!
     
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  4. Mendel Leisk

    Mendel Leisk 'Orrible Oracle

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    I guess the above is off the mark, describing the install of the entire valve, no mention of the disassemble of the valve, your case.
     
  5. MeGuinness

    MeGuinness Member

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    Is there a full pdf of the repair manual?
     
  6. Raytheeagle

    Raytheeagle Senior Member

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    Replied in your other thread with shaking and rattling. The weight spins on. Spin the weight on, hold it in place, then re-install the black cap.
     
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  7. JC91006

    JC91006 Senior Member

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    There's an extended warranty on the egr, why mess with it?
     
  8. MeGuinness

    MeGuinness Member

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    Recalls and extended warranty's don't apply to all countries.
     
  9. Caballo Prieto Azabache

    Caballo Prieto Azabache Junior Member

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    MeGuinness did you get the cap back on? Was your rattling issue resolved? (way to revive an old thread, I know :whistle:)
     
  10. Raytheeagle

    Raytheeagle Senior Member

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    He hasn’t been on in 5 weeks, so you might want someone else to chime in;).

    Some questions:
    • What issues are you dealing with?
    • How many miles on your Prius?
    To get the black cap back on, rotate the weight all the way on then hold it while you fit the black cap over it;).

    Keep us posted (y).
     
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  11. dbprius

    dbprius New Member

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    I am having a similar issue...

    I removed EGR and cleaned both the valve and cooler, but I am having an issue with how tight the magnet should be screwed on before replacing the black cap? The first time I screwed the magnet on, i did it fairly tight and it seemed to be at a point where the tightness was set and while the magnet could move back and forth 1/16 of a turn, it would not unwind on its own. The car drove great for about 1200 miles, then out of the blue it started to exhibit EGR issues. When I let off the gas on the freeway I felt shaking and a P0401 code popped up. I pulled over and unplugged the EGR so I could get home, and the issue immediately stopped and I made it home.

    When I got home I pulled the black cover off the EGR and the magnet self unwound, almost like it lost its initial setting.

    It would seem to me that the position of the magnet matters as it affects the spring tension or the valves ability to seal. If the magnet can self unscrew all the time, wouldn't it constantly be doing so every time the step motor engages the magnet (opening up the valve) and when power is removed wouldn't the magnet self unscrew as there would be the space to do so and nothing is keeping it in place? If it moves, I would think one of two things would happen: 1) it would change the spring tension which would cause EGR issues or 2) it would keep the valve stuck open, or too far open when engaged.

    Sorry for being long winded, but am I thinking about this wrong? Is there a "correct" setting or "locking point" for the magnet?
     
    #11 dbprius, Aug 4, 2019
    Last edited: Aug 4, 2019
  12. Raytheeagle

    Raytheeagle Senior Member

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    Welcome to Prius Chat (y).

    The magnet is there as the black cap has the electrified portion that causes the valve to change positions ;).

    You just need to make sure the cap is on and the only way to do that is to wind the magnet all the way on:).

    Good luck and keep us posted (y).
     
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  13. schmuber

    schmuber Member

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    For future reference: I don't think it's necessary to take apart the EGR valve. Just spray it with carb cleaner until it runs clear. Done it with mine a few times in the last 1/4 million miles with no ill effects.

    PS: Don't spray the plastic connector, of course.
     
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  14. meeder

    meeder Member

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    I just wonder why Toyota uses an EGR valve on these engines.
    The Toyota Auris we had which had the 1.6 Valvematic engine used the dual VVT system to create an internal EGR system. Wouldn't that be possible on the Prius or would that interfere with the Atkinson-like cycle that they use for it?
     
  15. Mendel Leisk

    Mendel Leisk 'Orrible Oracle

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    Yeah I agree: while removing the cap may expedite cleaning, it's also tough to do, and maybe trouble prone. I was able to clean everything without removal of the cap, just gently prying open the valve. Also, don't use Oxy on the valve, it's aluminum and will turn dull-grey I think. Not sure if that matters, but it's easy to clean with just carb or brake cleaner and brushes. Keep it purty.
     
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  16. Raytheeagle

    Raytheeagle Senior Member

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    No tougher than pulling the cooler out;).

    Much easier and you get to clean the seating position where the plunger resides (y).
     
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  17. Mendel Leisk

    Mendel Leisk 'Orrible Oracle

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    I "might" try it if I had replacement screws on hand. That'd pretty much guarantee it'd be smooth sailing, wouldn't need them.
     
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  18. Raytheeagle

    Raytheeagle Senior Member

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    @m.wynn had a better idea than screws;).

    I think it was a nut and bolt but I don’t remember:oops:.

    But there are options (y).
     
  19. dbprius

    dbprius New Member

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    Thank you for all the replies!

    I just went ahead and cleaned the MAP to check one more thing off the list.
     
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