warranty enhancement; P0401 EGR Valve

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

  1. Raytheeagle

    Raytheeagle Senior Member

    Joined:
    Jul 1, 2016
    10,532
    14,340
    0
    Location:
    Bay Area, California
    Vehicle:
    2019 Prius Prime
    Model:
    Prime Plus
    A used cooler can be had for $65;).

    As @Mendel Leisk went through the process, I would clean the valve and save $35 for that piece. The valve is easy to clean:). Since you can clean the cooler ahead of time and have it ready, it will reduce the labor charge;).

    Hope that helps(y).
     
  2. MilkyWay

    MilkyWay Active Member

    Joined:
    Feb 20, 2013
    736
    300
    23
    Location:
    MI
    Vehicle:
    2007 Prius
    Model:
    II
    Well I can't wait because 1) risky could blow motor and 2) I already took it to my mechanic in the morning and he doesn't have the space.

    So long story short was planning on just cleaning everything up but the egr tube was pretty clogged...intake gunked a bit....cooler looked bad, and EGR probably crap too.

    So ended up getting all the gaskets, cooler, and valve for around $565. This was through commercial account they wanted to charge $705 at first so ok discount. And my mechanic giving me good deal because we have some other repairs going on. He is only charging $50. Parts will be in tomorrow morning.

    I got a really good deal on the plug-in so this amount stings, but could be a lot worse.

    EDIT: I was with the mechanic and cleaning the cooler seemed risky. It really wasn't cleaning up that good. Plus we are both on time restraints. And lastly, the most labor intensive part was removing the cooler so figured might as well replace it instead of having to do it twice.
     
  3. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    40,416
    28,953
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    Oy vey. Well, if time is money, that's how it is.With an E8 torx socket, and the usual assortment of ratchets wrenches, you CAN DIY this yourself, without extra components, or even fresh gaskets (knock on wood), in about 12 hours if you rush, 24~36 if you're not rushed, and can let that cooler bubble away leisurely, with OxyClean soaks.

    Definitely hang onto the old parts.
     
  4. working1

    working1 Member

    Joined:
    Apr 1, 2013
    116
    99
    0
    Vehicle:
    2012 Prius
    Model:
    Two
    Just to clarify the March 31st 2017 date in the first post is unique to the purchase date of that vehicle. My purchase date was March 2012, exactly five years later. Later purchase dates should push the enhancement date out.
     
  5. DallasDad1000

    DallasDad1000 Junior Member

    Joined:
    Jul 19, 2015
    17
    2
    0
    Location:
    Dallas
    Vehicle:
    2010 Prius
    Model:
    III
    Well this occurred. I was told by Toyota of Plano the my CEL was due to the ERG valve. Then, the light came on again, due to the intake manifold. So I have spend $1500 in repairs getting those replaced. 1 week later, Longo Toyota of Prosper, TX is saying they need to replace the "back" of the ERG valve, not sure what that is. I am awaiting a call to get details. That said, the unlimited mileage warranty ended in March, 2017, and my car has 248K miles, so it is past the 150K recall. Not happy about it. Anybody with high mileage successfully get past these issues?
     
  6. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    89,469
    40,040
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    oh ya, there are threads here on diy. check out nutzaboutbolts videos. at 250k, i'm not sure what you are upset about.
     
  7. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    40,416
    28,953
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    The "back" of the EGR valve might be their way of describing the EGR "cooler". This is the most clog-prone piece, a rectangular channel between the exhaust manifold and the EGR valve, with an integral (coolant fed) radiator. You can just remove it and do hot/strong Oxi-Clean solution soaks on it. In about 8 hours you can have it like new. Or have the dealership put in a new one.

    For DIY, if you drain a couple of liters of the engine coolant, it'll drop the level below the cooler, and it'll be mostly dry when you remove it, apart from a little trapped at the lower back corner.

    Yeah, watch @NutzAboutBolts EGR cleaning video. You'll for sure need an E8 Torx socket, and an E6 will come in handy if you might want to remove the throttle body hold-down studs. Also a ratchetting 12 mm box wrench makes for easier access to the back of cooler nuts. Besides those, a full collection of ratchets and extensions is mandatory, and a 3/8" torque wrench (and perhaps a 1/4" torque wrench as well, if you want to avoid torquing at the extreme low end).

    upload_2018-1-10_18-1-5.png
     
  8. Raytheeagle

    Raytheeagle Senior Member

    Joined:
    Jul 1, 2016
    10,532
    14,340
    0
    Location:
    Bay Area, California
    Vehicle:
    2019 Prius Prime
    Model:
    Prime Plus
    The back of the egr valve could be the black cap on the egr valve which contains the electronics ;).

    I’m sure the work order clearly describes the difference :whistle:.
     
    amos, Prodigyplace and Mendel Leisk like this.
  9. Kirt

    Kirt New Member

    Joined:
    Jan 21, 2018
    2
    3
    0
    Location:
    Arizona
    Vehicle:
    2011 Prius
    Model:
    II
    I begged Toyota (called HQ) today to allow the free EGR fix in my case because the rattle happened to me multiple times (including when my 2011 II was just 6 months old!) but I can't get it to happen when I'm filming. It also didn't happen on my first roll of the dice while at the dealership after receiving the warrantee enhancement letter. Tomorrow I go in to try to "win the lottery" again and hope that the rattle happens in front of a dealership tech. I spent 2 hours tonight with a camera set-up pointed at the engine, turning the car off and on about 50 times. Because a code only "may" appear, I'm afraid that if I don't get it on film, the rattle will happen, I will get no code, and Toyota will stiff arm me like they did before. HQ did absolutely nothing for me today in preparation of my appointment at Precision Toyota tomorrow in Tucson. They were no help and did not live up to their fancy satisfaction goals mentioned in the letter. Service manager at Precision didn't call me back in a week to talk about the situation as we lead up to the fateful appointment. I understand that the 50 starts in a row were unlikely to produce the famous symptom because it usually happens on a cold start but hey I just wanted a shot to win the lotto. When the rattle does happen, it is loud and terrible sounding, almost as if your engine has blown (not quite). It's happened to my Prius at least twice, probably more times. Dealer said if I could get it on video, they'd consider that "verification." I've got 6,000 miles left to try to get it on camera. I think that's ridiculous. Just do the fix. Based on how they've handled this, I'll never buy another Toyota. Greedy duufs.
     
    amos and Tande like this.
  10. JC91006

    JC91006 Senior Member

    Joined:
    Nov 10, 2013
    14,358
    7,124
    0
    Location:
    Los Angeles, CA
    Vehicle:
    2010 Prius
    Model:
    V
    Download someone else's video and it's as good as yours
     
    William Redoubt and amos like this.
  11. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    40,416
    28,953
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    It's simpler to just knowledge-up and fix it yourself, just pull off all the parts, clean, and reinstall. You can take your time, clean thoroughly, ditto for the intake manifold, including all the EGR passages. Put in an OCC too and you're good to go.
     
    amos, m.wynn and Raytheeagle like this.
  12. amos

    amos Active Member

    Joined:
    Aug 19, 2017
    285
    259
    0
    Location:
    los angeles
    Vehicle:
    2016 Prius
    Model:
    Two
    It will happen in cold or hot weather. Regardless of temperature. My knocks in the middle of summer.temps were over 100.check @Mendel Leisk advise. Save yourself all frustration from dealer. Not a bad solution at all.
    Besides that. If you worried bout warranty expired in 6000 miles you should know that if you went to a dealer for that issue and dealer found nothing , i think you have extra 12k miles for that specific issue. At least this what iwas told by california dealers
     
    Raytheeagle likes this.
  13. William Redoubt

    William Redoubt Senior Member

    Joined:
    Feb 13, 2016
    1,206
    1,145
    1
    Location:
    Coronado Island, California
    Vehicle:
    2016 Prius
    Model:
    Two
    Suggest consultation with Volkswagen for advice on altering codes ... Just sayin'
     
    Raytheeagle and amos like this.
  14. William Redoubt

    William Redoubt Senior Member

    Joined:
    Feb 13, 2016
    1,206
    1,145
    1
    Location:
    Coronado Island, California
    Vehicle:
    2016 Prius
    Model:
    Two
    Sometimes just bringing a friend with you to the appointment where the verification happens gets the results you want. If I get any static I just introduce the service writer/tech to Ben Franklin. They are usually very glad to meet him and he is very persuasive about pointing out the reality of my issue to even the most stalwart deniers.
     
    #74 William Redoubt, Feb 16, 2018
    Last edited: Feb 16, 2018
  15. William Redoubt

    William Redoubt Senior Member

    Joined:
    Feb 13, 2016
    1,206
    1,145
    1
    Location:
    Coronado Island, California
    Vehicle:
    2016 Prius
    Model:
    Two
    If they only want to charge you $120 they are not much of a real car dealer. Real dealers won't do anything for under $500.
     
  16. Joejoethejoey

    Joejoethejoey New Member

    Joined:
    May 20, 2019
    2
    2
    0
    Location:
    United Kingdom
    Vehicle:
    2012 Prius+ MPV
    Model:
    Active
    Hi All,

    Apologies for dragging this thread up from the past. I've recently suffered very similar symptoms to the EGR system faults. Engine stuttering during idling and low speed with the petrol motor only.

    Took it to Toyota dealer today in UK, they are asking for £1000 to repair. Anyone know whether this extended warranty was ever issued in UK and whether it's still valid?

    Mine is a Prius+ (Prius V)
    Year is 2012 model
    Mileage is 60,000miles
    No error codes on the dash at all.

    Thank you for any advice.
     
  17. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    40,416
    28,953
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    Cheap to DIY if you can. See tips/links up the page.
     
Loading...