Prius Gen 3 Major Maintenance: EGR, manifold, spark plugs, Oil Catch Can

Hi Yall,

Finally did a major maintenance on my 2013 Prius at about 113,000 miles and wanted to report in my experience. And big thank you to the prius owners on this site with their contributions of tips, tutorials, videos, and pictures.

Big Thank You's to:

• NutzAboutBolts
• danlatu
• Mendel Leisk
• 1A Auto Parts
• Jeff Honeywell

Background:
Bought prius used at 106,000 miles in 2019 September. Prius only had one previous owner, who followed the regular maintenance and oil change schedule.

Goal:

• Complete maintenance in 2-day span 1/19-1/20/2019
• Clean EGR circuit (EGR pipe, valve, cooler)
  • Due to short timing, I decided to replace with new EGR valve and cooler
• Clean air intake manifold
• Clean throttle body
• Replace PCV valve
• Clean MAP and MAF sensor
• Install Oil Catch Can
• Change spark plugs

New Parts Cost: (pruchased online though McGeorge Toyota)

• EGR Valve (#25620-37120): 219.14 (msrp:332.89)
• EGR Cooler(#25601-37010): 248.11 (msrp: 376.88)
• Gasket between EGR pipe and valve (#25634-37030): 2.58 (msrp: 3.71)
• Gasket between EGR valve and cooler (#25627-37010): 2.61 (msrp: 3.74)
• Gasket at EGR cooler intake (#25685-37010): 2.54 (msrp: 3.65)
• Gasket air intake manifold (#17177-0T020): 10.93 (msrp: 16.17)
• Gasket between EGR pipe and air intake manifold (#25628-28010): 2.04 (msrp: 2.93)
• PCV Valve (#12204-37010): 4.52 (msrp: 6.48)
• PCV hose (#12261-37060): 8.58 (msrp: 12.69)
• Spark plug x4: 35.64 (msrp: 52.80)
• Shipping: 21.41
• Total: 558.10

Other parts:

• Ruien Oil Catch Can 400 mL: 25.50
• 3/8-inch fuel 3-feet x2: 11.94
• 3/8-inch ID Brass Hose Barb Splicer: 4.26
• 5/8-inch hose clamp x5: 5.00
• o-ring 5/16" OD x 3/16" OD x 1/16" 6-pack: 2.48 (for OCC's dipstick)
• Total: 49.18

The experience:

• Total time: 16 hours
• ~Tip 1: have a system to keep your parts, bolts, nuts, etc organized. I keep organized by separating between major tasks
• Tip 1 pic:

1. Remove Top and Bottom Cowl
   • Refer to:
2. Removed Air Filtration Set
   • Refer to:
3. Removed EGR Pipe
   • *Gasket Warning
   • Used 1x Brakleen non-chlorinated can for easy cleaning
   • Pic Below: Dirty EGR pipe
   • 
     
   • Refer to:
4. Removed Air Intake Manifold
   • Used 3x Brakleen non-chloirinated can for cleaning
   • Pic below: Dirty Manifold
   • Driver side:
   • 2nd from driver side:
   • 2nd from passenger side:
   • Passenger side:
   • Refer to:
5. View of engine
   • Used 1x Brakleen non-cholorinated for cleaning engine bay openings
   • Pic Below: Dirty engine
   • 
   • Clean engine:
   • Driver side:
   • 2nd from driver side:
   • 2nd from passenger side:
   • Passenger side:
   • Refer to:
6. Separating Throttle Body from Air Intake Manifold
   • Used CRC throttle body & air intake cleaner for Throttle Body
   • 
   • Pic below: opening throttle body to see dirty oil/junk in air intake manifold
   • 
     
   • Refer to:
7. Separate MAP sensor from Air intake Manifold
   • Used CRC Mass air flow sensor cleaner for MAP sensor
     
   • 
     
   • refer to:
8. Remove EGR valve/cooler combo
   • *This is tough. Also installing it back on is tough
   • *Gasket Warning: gasket in the back can easily be dropped when taking out the EGR valve/cooler
   • ~Tip 2: There's a 12mm bolt at the EGR's bottom bracket that is tough to get to. Get some sort of socket combination that gives you 3-inch clear space.
   • Pic for Tip 2:
   • Pic below: Dirty EGR valve and cooler
   • 
     
   • Refer to:
9. Remove PCV Hose
   • 
   • refer to:
10. Remove and Install new PCV valve
    • need 22mm socket to remove pcv valve
    • I did not use any thread locker (e.g. loctite blue 243 or red 271)
    • 
      
    • refer to:
11. Assemble Oil Catch Can
    • Layout:
    • 
      
    • gasket for OCC's dipstick:
    • refer to:
    • 
      
    • Oil Catch Can, Eliminate that knock! | PriusChat
12. Cleaning:
    • Clean engine bay intake: Used 1x Brakleen non-chlorinated. did not spray into the engine bay intake. sprayed onto blue shop disposal towel and then wiped/rubbed away grime
    • Clean air intake manifold: Used 3x Brakleen non-chlorinated
      • Don't forget to clean the small hole in each manifold opening
      • 
    • Clean throttle body: Used throttle body cleaner
    • Clean MAP sensor (on air intake manifold near throttle body location): Used MAF cleaner. Only sprayed directly
    • Clean MAF sensor (in air filtration set): used MAF cleaner. Only sprayed directly
    • Clean EGR pipe (the pipe between air intake manifold and EGR valve): used 1x Brakleen non-chlorinated
    • replace old gaskets with new gaskets
13. Assemble new EGR valve and new EGR cooler together:
    • refer to:
14. Install new EGR combo:
    • *This will be tough
    • ~Tip 2: There's a 12mm bolt at the EGR's bottom bracket that is tough to get to. Get some sort of socket combination that gives you 3-inch clear space.
    • Pic for Tip 2:
15. Install OCC
    • attach OCC's "In" fuel line end to PCV
    • After air intake manifold is tightened, then attach OCC's "Out" fuel line end to air intake manifold
    • Run OCC fuel line of your choosing
    • 
16. Assemble throttle body and MAP sensor on air intake manifold
    • refer to:
    • 
      
17. Place air intake manifold on the engine's 2 stud bolts
    • I suggest not tightening nuts/bolts for air intake before EGR pipe
18. Install EGR pipe in between EGR valve and air intake manifold
    • refer to:
19. Install and tighten up bolts for intake manifold
    • refer to:
20. install OCC "Out" fuel line ned to air intake manifold
21. install air filtration set
22. Started up car
    • Since I lost coolant when taking apart air intake manifold and EGR valve/cooler, I let car startup and engine warmup
    • I got warning light, probably to the air in coolant system
    • I opened the cap of the coolant reservoir (the reservoir on the passenger side)
    • I also turned up high heat (no AC) in car
    • Warning light went away
    • Good to go! Though, I will have to top off the coolant later.
    • 
      
    • refer to:
23. Change out spark plugs
    • I did not use anti-seize for the spark plugs
    • I did use dielectric silicon paste for the bottom of ignition coils
    • Driver side:
    • 2nd from driver side:
    • 2nd from passenger side:
    • Passenger side:
    • 
      
    • refer to:
    • 
      
24. Started up car
    • Had engine warning light show up, but then it disappeared
25. installed bottom and top cowl
26. Test Drive! Drove car around the neighborhood and highway. Everything seems to be good!

Results:

• So far, prius drives smoother
• Will update on whether gas mileage improves

Helpful Documents:

• EGR maintenance manual
  • Intake Manifold Gasket Leak ? Toyota Prius 2010 | PriusChat
• Air Intake maintenance manual
  • Oil Pooling in Intake Manifold | PriusChat

Tips:

• ~Tip 1: have a system to keep your parts, bolts, nuts, etc organized. I keep organized by separating between major tasks
• Tip 1 pic:
• ~Tip 2: There's a 12mm bolt at the EGR's bottom bracket that is tough to get to. Get some sort of socket combination that gives you 3-inch clear space.
• Pic for Tip 2:

Hope this helps!

 

Check out thingverse and type in search "Prius Oil Catch Can Bracket"
Prius Oil Catch Can Bracket by Danlatu - Thingiverse
props to @danlatu for this design.

I have to say, maybe due to my family's 3d printer or plastic material, the bracket might've shrunk due to cooling of plastic during printing.