Persistent P0401- dealership says replace intake manifold

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by PriusNovice911, Nov 21, 2019.

  1. PriusNovice911

    PriusNovice911 New Member

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    2010 gen 3 177K; AV MPG: 41

    P0401 1st code: 167K Jan 2019
    EGR Valve Kit, EGR cooler, gasket replaced by dealership.

    P0401 lights up again 167K
    intake manifold cleaned and inspected with bore scope, 4 spark plugs, 4 coil packs replaced. PCV valve replaced - hybrid specialists repair shop.

    P0401 lights up again @171K (Has been on since July 2, 2019)
    intake manifold cleaned again by dealership July 2019 and they Recommended intake manifold replacement @$1370.00 (said cleaning wouldn’t do it)

    The check engine light will go on and off-mostly on and throwing P0401 code.There is a rattle/knock on very slow acceleration that persists in engine about 60% of the time. Dealership at first said they didn’t know what could be wrong as everything has been cleaned or replaced. Then recommended the intake manifold replacement after 3 visits back.

    I HAVE SPENT over $5,000 on repairs and 3 hybrid recharged batteries ($1799) in the last 14 months. I bought it 9/17/2018 with 166,759 miles on it for $5300.00.

    I cannot stomach the $1370 for a new intake manifold. Any other option?
     
  2. bisco

    bisco cookie crumbler

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    welcome!

    check the toyota owners website, i thought there was a free intake manifold upgrade if you have symptoms, but i could be wrong.

    what's going on with the hybrid batteries? are they new oem replacements?
     
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  3. PriusNovice911

    PriusNovice911 New Member

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    thank you! i will check this for sure. I have not heard of this manifold upgrade. that would be amazing... as to the battery - the original went dead last year and i had a revitalized battery put in which has had to be replaced twice by the company that revitalizes them. Luckily its under warranty but that's an issue if i move or travel.. it only lasted a year and they replaced it today. (the first replacement idk what happened it was 2 days after they installed it).
     
  4. wheezyglider

    wheezyglider Member

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    Something doesn't add up. Did they give you a written quote? The MSRP on an intake manifold from Toyota is under $400. I see the updated "Intake Manifold Assembly" (17120-37054) listed at ToyotaPartsDeal.com for $225.28. Even includes the 3 gaskets. So how are they charging $1000+ for labor? Even a beginner would do this in under 2 hours.
    Watch the @NutzAboutBolts video on cleaning the intake manifold to get an idea how easy it would be to replace yourself.

    That said there's no guarantee this will solve your P0401. In fact I think it's unlikely to.
     
  5. PriusNovice911

    PriusNovice911 New Member

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    what else could need fixing with this code? i've been driving it for 4 months and it seems completely fine. they have checked it multiple times and i swear they were just guessing with the IM. They gave me written quote but it just said $1370 wasn't itemized and I was pretty irritated so I just left. I have watched that video already too - and that's a no go for me. thanks for the heads up tho
     
  6. Mendel Leisk

    Mendel Leisk 'Orrible Oracle

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    How the coolant level? Just wondering the head gasket is in the process of failing. No attention was paid to the EGR or intake manifold prior to the first code lighting up?
     
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  7. JC91006

    JC91006 Senior Member

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    From your description, you have yet to clean out the EGR system.

    The first item that is on your OP is an extended warranty program where they replace the EGR valve and Cooler gasket. They did not replace the cooler.

    The first thing you should do is clean out the EGR circuit. EGR pipe and the cooler. If you feel you can't clean it properly, then just replace the cooler with a new one. If this were my car, I would probably request Toyota corporate to pick up the tab for the new cooler, since the p0401 was a warranty enhancement that the new EGR valve didn't fix
     
  8. Grit

    Grit Senior Member

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    Keep eyes on the coolant level. If it going down then you gotten a leak in the head gasket. That will tell you to either replace the engine or car and not have to spend on anything else.
     
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  9. PriusNovice911

    PriusNovice911 New Member

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    Not that I know of. The coolant level is and always has been great. Can I get the HG checked? Is there a way to tell if it’s failing?
     
  10. PriusNovice911

    PriusNovice911 New Member

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    The entire EGR system was replaced brand new by Toyota after the first check engine light as posted in my original post including the cooler :)
     
  11. Tim Jones

    Tim Jones Active Member

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    That's why I have a thread on here telling people don't buy a gen 3 with miles on it unless you can do your own work. I was ridiculed by a few for the post but I know first hand. Luckily for me I can do the work that would have cost many thousands..... and even though a couple of these that were recalled I broke down at very bad times.....(long distances from home) plus traction battery, plugged egr system, master cylinder, accumulator, water pump, inverter, and now trani needs replaced. I like the MPG but wouldn't do it again. I didn't need another car but wanted a v for the heck of it.... what a pain in the v................
     
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  12. Mendel Leisk

    Mendel Leisk 'Orrible Oracle

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    Don't conflate the Prius line with all the automotive woes making the rounds though. I remember one time I was in the process of jumping companies, and a coworker cautioned: don't think it'll be all wine-and-roses at the new place; they all have the same BS.

    The best you can hope for is more tolerable BS.
     
  13. Tim Jones

    Tim Jones Active Member

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    I know my v pretty well now..... I just don't recommend if you plan on keeping for a long time and can't do your own work... still kinda tuff to work on and I have techstream.... ECE water pumps, timing belts, alternators, starters are pretty easy versus hybrid...
     
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  14. Mendel Leisk

    Mendel Leisk 'Orrible Oracle

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    Those two brake components on the firewall intimidate me more than the head gasket. I was hearing an odd grunt noise for a while, just before coming to a stop. Strangely it stopped, just when I booked an appointment for the dealership to have a look. Hasn't come back. Yet...
     
    #14 Mendel Leisk, Nov 23, 2019
    Last edited: Nov 23, 2019
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  15. PriusNovice911

    PriusNovice911 New Member

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    I think this is good advice based on a lot of other things I’ve read too. Unfortunately it’s the only transport I have and I can’t buy something else right now. I may try to sell it tho idk
     
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  16. Grit

    Grit Senior Member

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    My next vehicle will be the cybertruck from musk, it’s bullet proof.
     
  17. Tim Jones

    Tim Jones Active Member

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    Contact me anytime..... happy to help if I can...
     
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  18. JC91006

    JC91006 Senior Member

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    Did you pay for the cooler? Or was all this warranty work they did?
     
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  19. Raytheeagle

    Raytheeagle Senior Member

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    Except the glass:p.
     
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  20. PriusNovice911

    PriusNovice911 New Member

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    All warranty at dealership
     
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