warranty enhancement; P0401 EGR Valve

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by working1, Jul 6, 2016.

  1. working1

    working1 Active Member

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    Primary Coverage extended (depends on first use date) to 5 years and no mileage limitation. Secondary Coverage 10 years from date of first use or 150,000 miles.

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    #1 working1, Jul 6, 2016
    Last edited: Jul 7, 2016
  2. bisco

    bisco cookie crumbler

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    wow, i had no idea there was a problem.
     
  3. mracko

    mracko Junior Member

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    I received mine yesterday. Glad to see it, but I am already past the secondary coverage. I've been dealing with these symptoms for about 67,000 miles,(currently have 158,000 miles), but the car has never popped the P0401 DTC. I have however gotten several related to the spark plugs, even with new ones installed. I am going to ask about looking into it when I am in for my oil change.
     
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  4. cproaudio

    cproaudio Speedlock Overrider

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    I received my notice last week too. I don't have the code but will the dealer replace it to prevent future issues.
     
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  5. Lightning Racer

    Lightning Racer Active Member

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    Sweet timing. I haven't been home in months, so I haven't seen this in the mail. But my car has had the P0401 code on and off since March, and now it's solid on. A couple weeks ago, it also started hesitating at low throttle at times, though tapping the EGR valve and cooler with a wrench seems to cure it for a short time. I got a quote from Luscious Garage a while back thinking I could drive back across the country before getting the work done, but now it looks like I can get it done for free here in NH before my drive back to CA and AK.
     
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  6. Lightning Racer

    Lightning Racer Active Member

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    I misread this the first time too, maybe because I read your post. You are NOT past the primary coverage yet! It's unlimited mileage until March 31, 2017!
     
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  7. Rebound

    Rebound Senior Member

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    It doesn't matter if you're past the secondary coverage, because it isn't March 2017 yet! You're covered. :)
     
    #7 Rebound, Jul 17, 2016
    Last edited: Jul 17, 2016
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  8. szgabor

    szgabor Active Member

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    I have expreienced the symptoms once maybe twice neither times was any code (checked with my scanner) and surely not reproducable.

    At least once, I know I just moved the car and it did not finished warm up. Then next day (maybe 16 hours later) when started it up I had something of a rattle/noise and shaking for about 5-10 second then run smooth ... again no code

    This was describe numerous times in PC.

    So not sure how this can be useful.
     
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  9. qdllc

    qdllc Senior Member

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    Details on how to know if it applies to you? I did a VIN check on the recall website, but nothing came up. Of course, this might not be a "recall."
     
  10. szgabor

    szgabor Active Member

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    Thyia
    This is NOT a rcall therefore you will NOT find it there.
     
  11. Ginto

    Ginto Junior Member

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    I am going to test this coverage (waiting on call back from the dealer)... my concern after reading a bit closer is they refer to sticking EGR valve... not the clogging of the cooler portion of the EGR valve, that lots of people are experiencing.
     
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  12. MeGuinness

    MeGuinness Member

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    Is this USA only .?
     
  13. Mendel Leisk

    Mendel Leisk Sand Pounder

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    Nothing here in Canada for ours, well so far.
     
  14. qdllc

    qdllc Senior Member

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    Is there a way to see if one qualifies for this? Is everyone supposed to be covered?
     
  15. szgabor

    szgabor Active Member

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    My notice says something about units made btw certain dates ..... have to check.
     
  16. szgabor

    szgabor Active Member

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    My notice says something about units made btw certain dates ..... have to check.
     
  17. Lightning Racer

    Lightning Racer Active Member

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    I assume that Toyota has determined that the EGR valve is the main problem and that EGR cooler clogging is probably more of a symptom. Maybe it is usually self cleaning during normal operation if the EGR valve doesn't stick. Maybe once the EGR valve sticks, the cooler needs some cleaning, but it can be reused. A recent poster here described using compressed air to clean the EGR cooler, so maybe normal flow of hot exhaust is enough to clear it. The carbon stuff I found when I disassembled the EGR pipe and intake manifold back in January was dry and loose - flowable - until it hit oily parts of the manifold. Toyota has known about the problem for years, and I assume that they solved the issue by model year 2013, since only the 2010-2012 model years are covered by the enhanced warranty. I can't imagine that Toyota would risk paying for the warranty work, directed by their carefully written TSB (2nd edition, first was from 2013), without being 100% sure that the P0401 DTC doesn't pop right back up again after all the parts are put back on. Also, I got a quote in May for the work from Luscious Garage in SF, everyone's favorite independent hybrid shop. They said that the EGR cooler doesn't need replacement, but they clean it - I presume they just follow the TSB like the dealers do.

    I just had the ZF3 enhanced warranty work done this morning at Irwin Toyota in Laconia, NH. The invoice was paid entirely by Toyota, and they followed the TSB (presumably T-SB-0027-16 from March 31, 2016). The invoice says that they used the EGR valve kit (updated EGR valve, gaskets for the EGR valve, pipe, inlet) and an EGR cooler gasket. They also reprogramed the ECU and modified the wire harness as per the TSB. I've only read pages 1-5 of that 10 page TSB, since that's the only part that has been posted in this forum. But the need for the cooler gasket suggests that they had the cooler off and inspected and cleaned if necessary. I didn't have a chance to speak to the mechanic.

    The car drove nicely for the 40 mile drive back from the dealer. Like I wrote higher up in this thread, I had the P0401 DTC on and off since March without any other symptoms until earlier this month. Then the check engine light stayed on and I started getting hesitation at times with the engine on and P0303/P0304 pending codes for misfires. I assume that the misfires/hesitation was caused by the EGR valve being stuck open at times. I checked and noticed a pending DTC for P0302 (misfire, cylinder 2), but since I never noticed a misfire on the drive home, I think that will clear itself. If misfires start happening again, I'll remove and clean the intake manifold, or replace it with the newest revision of the intake manifold, but I think it should be good, having cleaned it just 7,000 miles ago.
     
    #17 Lightning Racer, Jul 27, 2016
    Last edited: Jul 27, 2016
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  18. co_prius_3

    co_prius_3 Member

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    I just got my EGR extended warranty notice in the mail today. I took the car in back in 2012 due to the cold weather knocking on startup and in traffic. At the time they thought it was the intake manifold, based on T-SB 0012-10. I never had the work done because the knocking seemed to go away. It only happened twice the first winter. Sounds like it would be worth getting this fixed, just in case.
     
    #18 co_prius_3, Aug 8, 2016
    Last edited: Aug 8, 2016
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  19. co_prius_3

    co_prius_3 Member

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    I called the dealer. They won't do the repair under warranty unless they find specific codes or can reproduce it. Since the knocking hasn't happened in years, I'll have to wait until it happens again before it makes sense to have them look at it. Too bad it's not a recall, which would allow everyone to get it fixed.
     
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  20. DumbMike

    DumbMike Active Member

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    Due to some bad timing, here's what happened to me. About 2 months ago, the check engine light went one. I took my Prius to Pep Boys, they hooked it up and said it was the P0401 error, some EGR issue, but couldn't be specific without doing a diagnostic test. I looked it up on the internet, and some videos say to clean the EGR pipe. I did that. The check engine light stayed on. I disconnect the battery, and the check engine light goes out. But a couple of days later, the check engine light goes back on. I also get my registration renewal request, requiring a smog test. I'll have to put all of this off until I return from being out of the country for about a month. Upon my return, I tried cleaning the EGR pipe again. Nothing (thought about the definition of insanity). I disconnect the battery, the check engine light goes out, but comes back on real quick. Then lo and behold, I get the notice from Toyota. I take my car to the dealership, the service guy asks if my check engine light is on. I say, yes and that it gives the P0401 code. He says they will run the diagnostics. 4 hours later, the agent says my car is fixed. The documents say they replaced the EGR "valve." Check engine light is off. I can get my car smogged.

    Now for the bad part. While doing all of my weird stuff, as stated, I decided to disconnect the battery. For this repair, don't do that. Or, don't do that if you will immediately get the car smogged. Immediately after the repair, I took my Prius to get it smogged. It failed, something about they couldn't get a reading from the car's computer. The guy told me this happens when the battery is disconnected and the computer doesn't have enough time to fully get turned on (whatever that means). The guy says to drive it about 100 miles and bring it back in for the free re-test. That evening, I drive around to put 120 miles on the Prius. The next day I have it retested, and it passes.

    Maybe more important, I register my Prius. Good for 2 more years.

    Mike
     
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