Problem - Just back from Replacing EGR and Cooler

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by KellyDean, Jul 1, 2022.

  1. KellyDean

    KellyDean New Member

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    Hey there, folks! 200K 2013 Prius - Decided to just replace the EGR valve and cooler instead of cleaning it. If anyone can help me before tomorrow, I appreciate it. Shout out to everyone on here who talked about the need to do this job! He said the old cooler was indeed very, very clogged. When this is said and done, my hope is my MPG and performance gets better. I've pretty much followed all advice on here and this was the last thing.

    Now, on to my question:

    They replaced both - Toyota parts but with my shop. But when I got in the car and accelerated, I could hear a type of gurling noise. Later, it seems to be more of a rumble. So, I turned around and he took it for a spin and said he thinks it's an exhaust leak. He's right. I can smell in coming from the engine pretty strong. They said they'd be happy to give it a look again tomorrow early AM - It's a good shop but I was clear that I know it wasn't like that before. It has to be something to do with the work. So, to save time, is there anything I can suggest to them to look for or do you think they'll probably know already? I just want to sound somewhat informed. What's common? What to check?

    Thank you again. - Kelly
     
  2. KellyDean

    KellyDean New Member

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    I would like to add that I just drove it down the way to pick up wife from work. Starts fine, no noise unless I'm giving it gas. I opened the vents going up a small hill and we got a good blast of exhaust. No check engine light. Still that sputtering type noise - hard to describe. I feel like this is something gasket o-ring related but what do I know? haha That's why I'm here.
     
  3. xliderider

    xliderider Senior Member

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    Probably forgot to put one of the gaskets in place before assembly. Or, didn't properly tighten one or more nuts or bolts to spec resulting in your exhaust leak and performance issues.

    Did you ask for the original EGR cooler and valve back? Those are good to have, as they can be cleaned and ready to go for the next time, or sold to someone who needs to service their EGR system.

    Others will chime in shortly about the need to clean the intake manifold EGR passages as well. Also, the EGR pipe between the EGR cooler and the intake manifold at 200K will be pretty much occluded as well.

    Posted via the PriusChat mobile app.
     
    #3 xliderider, Jul 2, 2022
    Last edited: Jul 2, 2022
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  4. Tombukt2

    Tombukt2 Senior Member

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    It would seem a couple hours driving would put a little bit of black on the inlet or the outlet of the intercooler the part you just replaced That's only connections they had undone with the slide that out so if there was an exhaust leak I would think it would be one of those two places and when you run your hand across it it should produce a black mark on your hand and I wouldn't think the exhaust would be enough there to make all that noise but I guess it's possible it's a pretty big it's a 1 in hole almost maybe they left the gasket out?
     
  5. Mendel Leisk

    Mendel Leisk Underfoot

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    It's really easy to drop the rearmost gasket on the EGR cooler, when removing it. Maybe they did that, then didn't realize there WAS a gasket there, and reassembled without gasket.

    Did they clean the intake manifold btw? It has EGR passages.

    There's a couple of pdf in the first link in my signature, relating to torque values for EGR components and intake manifold. Plus tips that may be helpful.
     
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  6. bisco

    bisco cookie crumbler

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    unfortunately, this thread illustrates the rock and hard place toyota has put their customers between
     
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  7. Mendel Leisk

    Mendel Leisk Underfoot

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    The EGR warranty extension notice I got has the underlined phrase “While the majority of vehicles will not experience this condition…”.
     
  8. bisco

    bisco cookie crumbler

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    maybe true? idk, priuschat is not a good place to judge. but even so, tell us why toyota
     
  9. KellyDean

    KellyDean New Member

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    Hey! I'm a big fan of yours! Haha and of course the other gentlemen who I will reply to when I'm not on this phone.

    Because of this group, I actually warned him of that very gasket way back there. It's in my shopping cart at Toyota for pick up if needed. Also, the cooler (I don't believe) came with that one, so it's very possible it dropped and he never knew it existed.

    They spent yesterday trying to find a reason why it wasn't related to their work and finally said they will pull it apart again first thing tomorrow. I wonder if could have dropped and it's still down there. Wish they would have taken mine, (which is really everyone here)s advice and were more mindful. Could be on the shop floor too.

    When I get home, I'm going to slide under and see if I can find where that gasket may have fell. I also took the liberty of writing down the torque specs and printed the diagram, highlighting all the gaskets. I'm sure they're going to LOVE having a customer coming in like a know-it-all, but I know they don't normally work on this type of car so it's a good learning experience.

    Talk to y'all soon with an update. :) Kind regards
     
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  10. CR94

    CR94 Senior Member

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    That's in the notice about misfires due to EGR valves sticking open. Applicable?
     
  11. Mendel Leisk

    Mendel Leisk Underfoot

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    Not sure. Thoughts:

    That warranty extension is useless, since codes and/or shakes (the prerequisite symptoms for claims) don't manifest 'till it's way too late.

    That phrase ("while the majority...") is rubber-stamped on practically every missive I've got from them. My 2 cents: using the phrase in the warranty extension for EGR issues, Toyota is lying through their teeth.
     
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