Used Manifold EGR Cooler Purchased Second Opinion?

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Dave1UK, Apr 14, 2025 at 4:58 AM.

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  1. Dave1UK

    Dave1UK Junior Member

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    Purchased a used manifold and EGR cooler, it arrived today and gave it a inspection, there are some parts/areas which concern me. Not having one side by side (haven't removed mine yet) nor ever seen one before, apart from on YouTube not sure whether these things can cause an issue before going ahead with the removal and replacement.

    Engine manifold:
    • 2nd port from the left has a slight groove in the plastic inner and outer area probably about 1mm? The gasket isn't affected and would be replaced but wondering whether this would/could cause an issue due to not being a tight seal?
    • The small port holes seem overly big (bigger than I recall on YouTube videos?) as if through cleaning have been expanded or sanded/roughed down more than they should be?
    • Does that screw look normal or has it been snapped off?

    EGR cooler:
    • I recall reading some posts on avoiding certain cleaning chemicals for the EGR cooler as it's aluminium? So as not to react with it (no clue what could happen). Most of the inside parts are whitened like that as if caked/some residue? Is that normal?
    Thanks!
     

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  2. MAX2

    MAX2 Active Member

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    The cooler is made of stainless steel. It can be cleaned with various solutions for cleaning kitchenware or with an alkali solution.
    It will not be damaged by this.

    You need to clean the inside of the cooler, not the coolant supply lines.

    A small scuff can be corrected and the orange gasket can be replaced. The gasket provides tightness.

    The damage to the screw is not entirely clear. The angle is bad. Is it broken or unscrewed?

    What is the part number on the EGR valve?
     
    #2 MAX2, Apr 14, 2025 at 5:18 AM
    Last edited: Apr 14, 2025 at 5:25 AM
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  3. Dave1UK

    Dave1UK Junior Member

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    Good to know thanks!

    The inside doesn't look too clogged up thankfully so shouldn't be hard.
    Thing is I can return it and ask for a replacement wouldn't be a hassle for me. I will be replacing the gasket anyway as mentioned not worried about that. I am just concerned that the grove could create/be a weak point at some stage? Don't want to mess with filling/sanding it down to smoothen it or whatnot either, in case I mess it up/make things worse.

    Will get a better pictured in a bit as put it away in the garage now. It looked unscrewed, however seemed odd to have a bolt on one end and then require some sort of nut on the opposite side? Hence my query.

    I can read 25620-37110 from the photo just barely - again will double check and report back.

    Thanks!
     
  4. MAX2

    MAX2 Active Member

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    25620-37110 was later replaced by 25620-37120. I think it was in 2011-2012.
    Check which one you have on your car.

    INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR
    1. Install the manifold absolute pressure sensor with the bolt.
    Torque: 7.0 N*m { 71 kgf*cm, 62 in.*lbf }
    2.Connect the connector.
     

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    #4 MAX2, Apr 14, 2025 at 5:57 AM
    Last edited: Apr 14, 2025 at 6:45 AM
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  5. Dave1UK

    Dave1UK Junior Member

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    Was not aware of that! Is there a place I can check what the latest most compatible part would be? Have there been updates/different versions of the manifold or EGR cooler as well?
     
  6. MAX2

    MAX2 Active Member

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    A newer version usually replaces the older one.
    For example, the EGR valve replacement kit has a number 04004-58137 and is suitable for replacement as: 25620-37110, 25620-37120
    OEM Part Number GENUINE EGR VALVE KIT for TOYOTA LEXUS 04004-58137, 0400458137, 25620-37110, 25620-37120, 2562037110, 2562037120
    I didn't compare the contents of the insides.
    OEM GENUINE EGR VALVE KIT for TOYOTA LEXUS 04004-58137 25620-37120 2562037120 | eBay

    The cooler 25601-37010 is the same.
     
    #6 MAX2, Apr 14, 2025 at 6:35 AM
    Last edited: Apr 14, 2025 at 6:40 AM
  7. Mendel Leisk

    Mendel Leisk Senior Member

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    The EGR channels in intake manifold look fine, just in need of cleaning.

    still, this is a good example of the “bird in hand” adage. For starters, what you have on the car is all eminently cleanable. The ONE advantage of spare parts is the luxury to clean them in advance. Weigh against that the uncertainty of their condition.

    definitely hang onto everything.
     
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  8. Tombukt2

    Tombukt2 Senior Member

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    You need to unbolt the aluminum EGR valve off of the cooler and clean the cooler separately The EGR valve has an updated part that may work differently but looks the same and doesn't come with anything in the box that I remember It's just a tan cardboard box with a Toyota label and a EGR valve and maybe the two gaskets that go on each end of it or something that was it I paid $130 or something for it brand new in the box the latest updated part that Max posted above I have one right here still in the box and I used another one on a car and it didn't seem to make any difference
     
  9. Mendel Leisk

    Mendel Leisk Senior Member

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    The revised EGR valve, and revised intake manifold, seem like Toyotas lip-service attempt to “fix” Gen 3 EGR woes. And yeah, does squat.
     
  10. Dave1UK

    Dave1UK Junior Member

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    Had a look at the one in my car the part number I have is 25620-37120 this is the newer/revised one?

    The part number on the one I just bought is 25620-37110.
     
  11. Mendel Leisk

    Mendel Leisk Senior Member

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    …20 is the revised one, …10 the original. I have the latter, doing fine. Maybe just clean the one you’ve got, the …20 one.
     
  12. rjparker

    rjparker Tu Humilde Sirviente

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    The revised egr valve does fix sticking open, the real drivability issue. Aftermarket egr valves for Prius are particular bad and may stick out of the box.

    The revised egr valve kit is often 50% less than the valve itself and includes a gasket.

    Newer EGR Valve
    Egr valve updated Kit 04004-58137
    With 25620-37120 Updated egr valve.

    The revised valve is recommended for 2010-12 Prii.

    There is also an ecm software update recommended with revised valves or intakes which probably makes the most difference for head gasket preemptive maintenance. It will be different in Europe so the best advice is to have a dealer install the software. A European tsb was specific about the head gasket correlation.

    The revised ecm software is recommended for 2010-15 Prii.

    Toyota also sells a revised head gasket.
     
  13. ChapmanF

    ChapmanF Senior Member

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    The nick on the face of the intake manifold doesn't bother me, but the photo at an angle shows most clearly that the nick has edges where the plastic is raised above the flat face.

    I would temporarily remove the gasket and pare down those edges so nothing is left raised above the flat face. The slight nick can remain and the gasket should seal, as long as those raised edges aren't preventing the face seating down flat.
     
  14. xliderider

    xliderider Senior Member

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    The "broken" bolt or screw you are concerned about, is supposed to look like that. The side that looks broken is a locating pin or nub, the sensor is placed on it so that the hole is held in position, while a bolt goes in the hole on the opposite side to secure it.

    There is an o-ring under the sensor, you will feel the sensor resist pulling out and when you put it back in place. The sensor will definitely "seat" when it is inserted far enough into the hole in the intake manifold. That is probably why there is only a need for one fastener to secure it.

    FYI, that white residue you are concerned about inside the EGR cooler is just dried up antifreeze/coolant.

    SM-S936U ?
     
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  15. xliderider

    xliderider Senior Member

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    I also wouldn't be concerned about the knick on the intake manifold on either side of the orange gasket. The new IM gasket on reassembly will make a seal, unless that knick somehow goes down and under the gasket into the groove that the gasket is seated in (unlikely).

    Like Chapman said earlier, take a sharp tool and pare down the raised sharp edges of the knick and be done with it.

    You didn't post any pictures of the inside of the EGR cooler, other than the coolant passage. What is the condition of the EGR cooler, the main cavity that has the fins and is usually clogged with carbon and oil/greasy deposits?

    The spare EGR cooler I got looked really clogged and took days to clean out. 20210903_155916_1.jpg 20210903_155933.jpg

    SM-S936U ?
     
  16. Mendel Leisk

    Mendel Leisk Senior Member

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    Doesn't look that bad; what were you using. I'm itching to get in there again, try lye solution. :)
     
  17. xliderider

    xliderider Senior Member

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    Actually, I think I posted the wrong pictures. They are of what came out of the Prius with 124K on the odometer.

    The used cooler I got off eBay was much worse, full of oily, carbonized gunk. Probably used till the headgasket blew.

    SM-S936U ?
     
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  18. Dave1UK

    Dave1UK Junior Member

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    I ended up messaging the seller as it's a company and mentioned the manifold groove as well whether they have the newer EGR valve. They were happy to replace the manifold and said they would look if they have the newer one. Then they stopped replying, so just opened up a case on eBay and will be returning it.

    Will repurchase from a different seller with the updated ver. one as there's a lot around. Probably better if as you say it addresses the sticking open. Also again don't fancy messing with the manifold to smooth it out etc.

    Good to know, as that bolt/screw looked out of place.

    I asked the seller before purchasing whether the parts were heavily clogged they said they clean it all before sending off. The passages looked pretty good, will take a look again and post a photo.