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EGR Cleaning: What did I get myself into?

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Bay Stater, Jan 1, 2018.

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  1. Bay Stater

    Bay Stater Senior Member

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    Did this assembly breathed?
     
    #61 Bay Stater, Feb 27, 2018
  2. Bay Stater

    Bay Stater Senior Member

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    For those that have done the EGR assembly replacement and cleaning the related parts, did you disconnected the 12 volt battery first? Did you disabled the traction battery too? Thanks for any advice. :unsure:
     
    #62 Bay Stater, Mar 3, 2018
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  3. mjoo

    mjoo Senior Member

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    Yes and yes. The traction battery is most important and easier to disconnect

    Pixel XL ?
     
    #63 mjoo, Mar 3, 2018
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  4. Raytheeagle

    Raytheeagle Senior Member

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    Nope to both.
     
    #64 Raytheeagle, Mar 3, 2018
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  5. m.wynn

    m.wynn Senior Member

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    Nope and nope.
     
    #65 m.wynn, Mar 3, 2018
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  6. kc410

    kc410 Active Member

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    I've done the whole EGR system twice, swapping in new/clean EGR Cooler + valve & cleaning the EGR pipe & intake manifold each time.
    I do not disconnect the 12V batt. or disable the traction battery.

    The second swap out came after ~10K. The ICE started setting an engine lean code & running as if it was lean. Eventually I found the EGR valve stuck open about 1/16". After swapping in the now cleaned original valve & cooler the Prius is back to perfect at 236K.

    An interesting observation: 10K miles on my ~220K engine resulted in the EGR cooler being >50% plugged. I'm using a quart of oil every 3-4K. For me, the purpose of installing an OCC was to stop a substantial amount of oil from reaching the combustion chamber. In my case the OCC(s) are trapping <5% of the oil the ICE consumes I also find that my best OCC is the intake manifold. I have an OCC installed & after that I have an inline air line filter installed. Both collect small amounts of oil, but the real efficient OCC is the intake manifold!
     
    #66 kc410, Mar 4, 2018
    Last edited: Mar 4, 2018
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  7. Bay Stater

    Bay Stater Senior Member

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    Today is the day! EGR system restoration and other cleaning tasks.(y)
    IMG_20180310_104648212.jpg IMG_20180310_111100270.jpg
     
    #67 Bay Stater, Mar 10, 2018
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  8. Bay Stater

    Bay Stater Senior Member

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    1st task wiper removal and spark plug replacement.
     
    #68 Bay Stater, Mar 10, 2018
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  9. Bay Stater

    Bay Stater Senior Member

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    Wiper assembly finally removed. I have to thank @NutzAboutBolts for those fine DIY videos. I knew what to do! Step by step.
    IMG_20180310_120919459.jpg IMG_20180310_120904567.jpg IMG_20180310_113650306.jpg IMG_20180310_115709167.jpg
     
    #69 Bay Stater, Mar 10, 2018
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  10. Bay Stater

    Bay Stater Senior Member

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    Spark plugs done. The old spark plugs look good. No signs of oil burning. Funny that I had to fish the spark plugs out. :ROFLMAO:
    IMG_20180310_124453506.jpg IMG_20180310_131340333.jpg IMG_20180310_124855754.jpg
     
    #70 Bay Stater, Mar 10, 2018
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  11. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    Now just the easy part, hehe...

    Take the intake airbox off too, I think? And again, I'd recommend to drain 2 liters of coolant at the radiator spigot, then the EGR cooler removal can be spill-free, as long as you lift it out carefully.

    Are you going to pull the intake manifold off too? In for a penny, in for a pound? FWIW I didn't replace any gaskets, and it worked out. Only 70K kms in my case though.
     
    #71 Mendel Leisk, Mar 10, 2018
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  12. Raytheeagle

    Raytheeagle Senior Member

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    No magnetic spark plug wrench in your tool chest:whistle:?
     
    #72 Raytheeagle, Mar 10, 2018
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  13. Bay Stater

    Bay Stater Senior Member

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    Cleaned the throttle body, and EGR pipe. Drained some coolent to prevent a mess. IMG_20180310_164358010.jpg IMG_20180310_154216104.jpg IMG_20180310_154229594.jpg IMG_20180310_163910727.jpg IMG_20180310_164428743.jpg IMG_20180310_164358010.jpg IMG_20180310_154216104.jpg IMG_20180310_154229594.jpg IMG_20180310_163910727.jpg IMG_20180310_164428743.jpg IMG_20180310_163608486.jpg IMG_20180310_163615375.jpg
     
    #73 Bay Stater, Mar 10, 2018
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  14. Bay Stater

    Bay Stater Senior Member

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    I don't even have a socket that has the built-in sleeve.
     
    #74 Bay Stater, Mar 10, 2018
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  15. Bay Stater

    Bay Stater Senior Member

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    Yes to all.
     
    #75 Bay Stater, Mar 10, 2018
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  16. Raytheeagle

    Raytheeagle Senior Member

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    Sounds like you might be in for a belated birthday present ;).

    It is a handy tool (y).
     
    #76 Raytheeagle, Mar 10, 2018
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  17. Bay Stater

    Bay Stater Senior Member

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    I now have the intake manifold off. In process of cleaning it.
     
    #77 Bay Stater, Mar 10, 2018
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  18. Bay Stater

    Bay Stater Senior Member

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    Intake manifold before cleaning.
    IMG_20180310_170942563.jpg IMG_20180310_171754240.jpg IMG_20180310_171033609.jpg IMG_20180310_171023991.jpg IMG_20180310_171749147.jpg
     
    #78 Bay Stater, Mar 10, 2018
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  19. Bay Stater

    Bay Stater Senior Member

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    Intake manifold after cleaning.
     

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    #79 Bay Stater, Mar 10, 2018
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  20. Bay Stater

    Bay Stater Senior Member

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    PCV next.
     
    #80 Bay Stater, Mar 10, 2018
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