Replaced complete EGR system w/photos

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by dame3780, Jan 5, 2019.

  1. farmecologist

    farmecologist Senior Member

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    I'm in the same boat. I'm not completely sold on the catch can yet. Yes, it might keep things 'cleaner'. However, I'll probably be doing the EGR and manifold maintenance every 50K miles or so. Therefore, I'm not sure the catch can is warranted. I do have one though if I ever change my mind. (y)
     
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  2. JC91006

    JC91006 Senior Member

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    The OCC will keep everything really clean, catch all the excess oil going to the manifold. But I can't see myself emptying the OCC, I'm too lazy for that LOL. The car was designed to be operated without the OCC and if you clean out the intake ports every 100k miles it shouldn't need the OCC. Of course, you should clean out the EGR pipe every 50k to ensure the system doesn't get choked up with carbon buildup.
     
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  3. Mendel Leisk

    Mendel Leisk Sidewalk Supervisor

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    What bothers me: maybe that oil you see accumulating in the intake manifold is only part of it. How much might just breeze through and combust, maybe carbon-coating various components?
     
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  4. JC91006

    JC91006 Senior Member

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    As the cars get older, they will be coated with all kinds of things you don't want. I do my maintenance according to how long I think I'll keep the car. If I think I'll have a car for 10 years, I do all the necessary maintenance to get me there. If you intend to keep the car for 20 years, then you might have to step up the maintenance and do a little more.
     
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  5. farmecologist

    farmecologist Senior Member

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    That's what the engine flush is for ( see other threads ). :D
     
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  6. Mendel Leisk

    Mendel Leisk Sidewalk Supervisor

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    I'd rather nip it in the bud though, always preferable.
     
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  7. farmecologist

    farmecologist Senior Member

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    Either that or folks are too anal about it ( just kidding ) (y).

    As for myself, I was just too lazy more than anything last summer. My front suspension rehab on our Prius v did me in over the summer I think!
     
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  8. Raytheeagle

    Raytheeagle Senior Member

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    +1;).

    Stop something before it happens:).

    Excellent mantra(y).
     
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  9. Bill Norton

    Bill Norton Senior Member

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    That's the nature of Crankcase Ventilation getting burned up in the combustion.
    Always has been since PCV was regulated in 1961.
    Is the oil vapor and moisture that much of an issue compared to the gallons of gasoline that get burned up and pass through the combustion process?

    Using an Oil Catch Can you can capture some of that oil vapor and moisture and keep it from pooling in the big, goofy, plastic Gen3 intake manifold that has large low points, evidently out of the flow enough for it to gather and pool after shut down.
    Which most likely is the cause of 'Cold Start Engine Knock'. (Very bad thing. Bad for head gaskets, Yo.)

    Is there a good description of how the new/improved intake manifold is different from the original?

    The first time I hear cold start knock I'm going to flip my lid !!:mad:
    I hope my driving patterns of never doing short runs keeps this from happening....:whistle:
     
    #89 Bill Norton, Jan 9, 2019
    Last edited: Jan 9, 2019
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  10. Mendel Leisk

    Mendel Leisk Sidewalk Supervisor

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    I've seen some low-res pictures, IIRC it was a cross-sectional view of fourth gen intake manifold. I'm assuming fourth gen manifold is carrying on the revision commenced sometime during 3rd gen, perhaps at the 2012 model year mid-gen revision.

    I also noticed in @NutzAboutBolts manifold cleaning video (he has a 2012), he notes that pushing in some sort of pipe cleaner brush, the EGR inlet passage only goes a few inches.

    On my 2010 with original intake manifold, the EGR inlet passage goes the full width. It's basically a "gallery", with capillaries off to the four intakes.

    From all of the above, I believe the revised manifold truncates that full-length gallery, branches into two intermediate size passages, which both have two capillaries.

    So, kinda like exhaust manifold description (but in reverse), the old is one-into-four, and the revised is one-into-two-into-four. The consensus though: the revision did not help much, if at all.
     
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  11. Bill Norton

    Bill Norton Senior Member

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    So, was the claim the new intake manifold design was 'just better' without specifying that it was for the 'Cold Start Knocking' problem in particular?
    What you are describing is different EGR passages, which won't help with pooling oil/water vapors after a shut down, especially in humid/cold conditions.

    Could it be: what is happening with Cold Start Knocking is a build up of classic 'Carb Icing' only on the walls of the intake manifold at low pressure areas where the intake air gets chilled enough to form ice during high humidity/low temp conditions?

    The EGR only warms the IM a little and only in the zones where it runs. Plus it's been 'cooled' somewhat by the EGR cooler,, .

    (I had a throttle body ice up after shut down, but didn't know it until after work my throttle pedal was stuck. The car started but when I forced the throttle open it stuck open!!! I had to shut off the engine. Then I started the car in 1st gear and went for it!! The throttle body had coolant hoses running through it to warm it. After a few minutes the ice melted and all was normal ever after!)


    This is just a WAT ,, but,, what if owners that sometimes get Cold Start Knock tried a Warm Air Intake Mod?
    It would only be needed seasonally.
    Some of Eco Modders claim this will improve Fuel Economy.
     
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  12. Bill Norton

    Bill Norton Senior Member

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    .....EDIT.....
    >Then I tried a '93 Honda Civic VX rated at 51 mpg hiwy. Rare expensive model, 1% of production.
    It had an expensive '5 wire Lean Burn O² sensor'. Loved that it had AC!
    EDIT:
    >Completely forgot my 2000 Honda Insight ! It was the first car to beat the Metro with a 71 mpg hiwy rating! (before the EPA downgraded their numbers)

    Had it about 3 years. Started to realize it didn't have room for 2 suitcases for a trip to the airport....
    It got totaled when someone turned left in front of me in city traffic. Their airbag went off,mine didn't!

    >Tried 2 different VW TDI diesels ...

    I know,,, who cares....:sleep:
    But the theme here is I hate sending my American Dollars to OPEC. (y)
     
  13. CR94

    CR94 Senior Member

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    I've heard it once, one of the first cool mornings last fall. I also avoid "doing short runs," so that's not a fool-proof solution.
     
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