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Intake Manifold Gasket Leak ? Toyota Prius 2010

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by C Athula, Nov 29, 2014.

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  1. C Athula

    C Athula New Member

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    Dear Members,

    I have a prius gen 3 (2010) with the mileage of 65,000 KM. Recently the car has started indicating the error code P0171 (System Too Lean Bank 1).

    I did below mentioned tests as recommended by the mechanic, replaced the air filter, checked the spark plugs, throttle body cleaned, checked for vacuum pipes for any leaks (except the injector cleanup).

    Unfortunately, still i am getting the error even when it is erased from the ICU.

    After resetting the error, it is not showing until the engine gets wormed-up into some level. From the engine cold start, i can run the car about 15 - 30 mins with the engine power without the MIL indication.

    Today, I did notice something in-between the intake manifold and engine head (Orange color rubber part), i think it should be the manifold gasket but I am not too sure whether this is normal and causing the error.

    Appreciate the kind help in this and thank in advance for all the members.
     

    Attached Files:

    #1 C Athula, Nov 29, 2014
  2. C Athula

    C Athula New Member

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    Adding HD video for clear view

     
    #2 C Athula, Nov 29, 2014
  3. IMkenNY

    IMkenNY Im just being nosy

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    That's the gasket and its normal, if you want to try locating a intake leak (not a common problem), you can try spraying carburetor cleaner around the intake area and listen for a idle surge (engine running of course).

    I would try cleaning the maf sensor with CRC maf cleaner, its located on the upper right hand corner of this picture of the air box.
    Ebay picture link below:
    2010 2013 Toyota Prius Air Cleaner Assy Airbox Intake Mass Air Flow Sensor | eBay
     
    #3 IMkenNY, Nov 29, 2014
  4. Former Member 68813

    Former Member 68813 Senior Member

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    I had 2003 corolla with the same problem and had to replace the intake gasket to fix it. However, it was a very common problem in that car as they used a defective gasket in the factory. Since it's a rare issue in Prius, the problem or may or may not be the intake gasket. While the gasket is cheap, it takes some time to replace it. You need to check/clean MAF, check for any intake leakes downstream to MAF and any exhaust leaks upstream to oxygen sensor first before attempting to replace the gasket.
     
    #4 Former Member 68813, Nov 29, 2014
  5. C Athula

    C Athula New Member

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    #5 C Athula, Nov 29, 2014
  6. C Athula

    C Athula New Member

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    Thank you my dear members. I think it is worth trying both options. I'll give you update later.
     
    #6 C Athula, Nov 29, 2014
    kevtan likes this.
  7. C Athula

    C Athula New Member

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    I did clean all the stuff.... including EGR and piping which was clogged very badly. I took the entire intake manifold and its attached components out, such as sensors, throttle body, EGR piping and valve. of course the EGR valve was heavily blocked including the piping and tiny breathing halls in the intake manifold which mixes the cold air with exhaust air was also partially blocked. .....so i did clean them well and assembled them back and make sure any intake leaks not to happen. So far this is what i did.

    1.) Cleaned the air Flow Sensor,
    2.) Cleaned kind of a sensor mounted to the intake manifold (may be the heated air sensor, not sure)
    3.) Replaced a new air filter.
    4.) Checked and clean all the spark plugs with suitable sparking gaps.
    5.) Cleaned the EGR valve.
    6.) Cleaned EGR piping.

    After fixing all these I ran the car in my usual daily routine and i feels there is a slight improvement in the performance.
    However, appearing the MIL (p0171) was not resolved but the frequency of appearing it has reduced.

    As i noticed, most of the occasions where the car is moving just above the ECO line with the slight engine power (just above the middle line of the EV to Engine Power display) this is happening.

    Can someone tell me any area to check ?
     
    #7 C Athula, Dec 9, 2014
  8. tv4fish

    tv4fish Member

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    #8 tv4fish, Dec 9, 2014
  9. C Athula

    C Athula New Member

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    Dear Friends,

    I think i have found the problem which is really an unexpected situation at this level of millage of my Gen III prius (2010 - 62,000 Km).... i never thought that fuel injectors can be blocked this early. 20141213_093312.jpg
     
    #9 C Athula, Dec 13, 2014
    edthefox5 likes this.
  10. bisco

    bisco cookie crumbler

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    you must get some seriously bad fuel down there. is there a fuel filter? i wonder if a bottle of fuel treatment every now and again would be helpful?
     
    #10 bisco, Dec 13, 2014
  11. C Athula

    C Athula New Member

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    Best Average Fuel.jpg
    Soon after cleaning the injectors, the engine started to perform like a new, no error codes anymore Got the best millage after longtime 22.6kml (53+ MPG) in regular driving...!!!
     
    #11 C Athula, Dec 14, 2014
  12. frodoz737

    frodoz737 Top Wrench

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    Good find.
     
    #12 frodoz737, Dec 14, 2014
  13. edthefox5

    edthefox5 Senior Member

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    Wow. Better pictures of the pintle area of the injectors please. They look really dirty. Maybe byproduct of the EGR sludge? That EGR sludge is a known issue and man it gets really clogged up doesn't it? So maybe good idea if you clean the EGR take a look at the pintles also. Very good stuff thank you.

    Don't understand why no misfire though. That will throw you off the path for sure.

    Good find!
     
    #13 edthefox5, Dec 16, 2014
    C Athula likes this.
  14. cocot007

    cocot007 Junior Member

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    How did you clean them?
     
    #14 cocot007, Apr 17, 2015
  15. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    I'm wondering if the badly clogged EGR could be the cause of the clogging injectors. Clogging EGR is starting to look like a regular, inevitable issue with 3rd gen.
     
    #15 Mendel Leisk, Apr 17, 2015
  16. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Good to hear you figured out your car's problem.

    It is interesting to see the RHD JDM model display in your photo is the mirror image of the LHD North American display with regards to the location of the fuel gauge and speedometer, vs. the hybrid drivetrain power indicator and traction battery state of charge gauge.
     
    #16 Patrick Wong, Apr 17, 2015
  17. wetback1

    wetback1 Junior Member

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    #17 wetback1, Nov 13, 2015
  18. kevin75

    kevin75 New Member

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    Hello I have same problem.Could you please show how did you take out injectors ?..Thank you
     
    #18 kevin75, Oct 18, 2017
  19. Prodigyplace

    Prodigyplace 2025 Camry XLE FWD

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    You will not get a response. That user has not been here for 3 years.
     
    #19 Prodigyplace, Oct 18, 2017
  20. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    Here's the section from the Repair Manual, covering fuel injector removal, inspection and install. You apparently need to remove the EGR valve and cooler for this, so I've attached that as well.
     

    Attached Files:

    #20 Mendel Leisk, Oct 18, 2017
    Too Many Prii, kevin75, Raytheeagle and 1 other person like this.
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