Engine rattle and lack of power

Bookmark these videos by @NutzAboutBolts :

Nutz About Bolts Prius Maintenance Videos | PriusChat

For a first step, I would check out the EGR (Exhaust Gas Recirculation) pipe (video #16). This is a connector pipe between the EGR valve/cooler and the intake mainifold, relatively easy to access, and it's condition will give you some insight as to the rest of the EGR system, upstream. The EGR system has been turning out to be very prone to clogging, and is a strong possiblity to be involved.

If the pipe has significant clogging, and in any event, the next step would be full cleaning of the EGR circuit (video #17)

Also while there you can clean the throttle body (video #14).

It's also an opportune time to clean the intake manifold (video #24)

Another thread, on EGR:

EGR & Intake Manifold Clean Results | PriusChat

The EGR system can clog the intake manifold, and another source is the PCV (Positive Crankcase Ventilation) valve, bring gasses over from the zone above crankcase. Good thread on that, and installation of OCC (Oil Catch Can):

Oil Catch Can, Eliminate that knock! | PriusChat

Some reference material attached:

 

Welcome to Prius Chat .

Some questions:

• Did your Prius throw any dash lights that need to be read?
• Does your mechanic have Techstream?
• Any history of accidents with your Prius?
• Did you drive your car for a short distance prior to this event?

Keep us posted .

 

^This. The one time I've experienced a rattle at start up, the day previous I had rolled the car out to the driveway, and had the engine start up for a matter of seconds. This should not have to be a behavior you have to avoid, but it apparently is. Why is not clear yet.

If you need to move the car a few feet, try to do it in 10 second bursts, using the few (reliable) moments of EV when starting the Prius cold. Theoretically there's an EV mode button, but in practice I've found that's NEVER available with a stone-cold engine, which is the one time I could really use it.

If 10 seconds bursts aren't going to do it, leave the engine running, let it warm, say for at least 5 minutes.

 

Did you try to power it down and start it back up?

 

Is your mechanic familiar with the Prius?

 

I’ve experience this rattle that you’re describing as well. I left the Prius in the garage for a week without driving and when I turned it on, I heard a rough rattle in the engine compartment. It’s probably something that’s choking the engine while it turns on. It’s runnjng normal and no check engine light. It’s probabyl a normal symptom of these types of Prius, I still can’t figure what it is since it hasn’t cause a check engine light. This is probably the second time I’ve experience this symptom.

 

Interesting clue. One thing I can think: a cold-start engine will be running rich. Maybe one of these years there'll be something conclusive, what's causing this. Do post anything your mechanic comes across.

 

Did your mechanic have the cooler out of the car? Just seems like that happened kinda fast? Or maybe he was in progress when you posted?

I work like a crippled snail, and that would have taken me at least 24 hours, going full-bore (which I never manage), to adress the complete EGR system, from the connection to exhaust manifold, through to the intake connection. It's also good to do the intake manifold while you're at it.

 

Same question here, I'm about 9k miles til 100,000 miles and it's at that point when it needs to be done, not looking forward to it.

 

The signs will be subtle, much like battery degradation over time .

What I noticed prior to doing our egr swap at 120 k miles was the mpg slowly degrading over time. I started to troubleshoot causes and then when I had my old man out here (a set of experienced hands that would be here for a bit of time in case I ran j to issues), we swapped out the cooler.

At 120 k miles the cooler wasn’t completely clogged, but it was restricted .

I will be doing the cooler swap the weekend after Easter (along with a nice list of other preventative maintenance) if you are interested in participating / watching @grid .

 

What Ray was referring to is the "infamous" cold start rattle that Toyota is aware of. It only happens under certain circumstances; mainly after the car is restarted a number of hours after a very short engine start up (like moving it out of the garage). It sounds horrible but seems to be relatively harmless according to Toyota. It's caused from a buildup of moisture in the air intake system so a longer run time (and warming up) doesn't cause it. It also needs to be cooler weather which promotes water condensation.


There are examples on youtube:

 

All it took for me to dive in, at 72K km's, was the clamor here, I'm easily stampeded. I did have one cold-start engine knock event.

 

@wespoprius Hello from Chicago as well! I just purchased a 2013 with 103k yesterday. Getting ready for some major maintenance as Mendel suggested to hopefully keep it running great for many miles.