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

FYI - the pipe is easy to clean. The valve is a pain (though not as bad as the cooler). So I would order the valve to go along with the cooler.

 

Yup I got all the same parts as the OP. Just got these today from Walmart.


iPhone ?

 

+1 engine seems much smoother after EGR replacement. I was getting a mild resonation through the car when going up hills before where pwr was all the way. Now it's toned down a good bit. The improved engine performance makes the mpg drop odd though. Running ~38 where I was 41-42 prior to EGR (already low). No CEL clues so far.

 

I love you! Planning this job this weekend. My catch can doesn't have anything inside it though. Is that how it's supposed to be?

 

So is the Prius Gen3 engine just incredibly dirty the way it's designed? I've never contemplated just taking the manifold off and cleaning it as maintenance on other cars. Sometimes a can of the foam cleaner down the intake and leave it at that of course.
My MPG on my Prius v is about 39.9Mpg over the life of the vehicle @ 135k. Looking at the lifetime graph, MPG has gradual decrease but hasn't seemed to decrease notably.

Looks like a full weekend of work for me to do EGR and intake. Wondering if intake is worth the hassle. EGR photos are enough to convince me that I should do that soon.

I did replace the PCV and since then, oil consumption seems to have increased slightly which was surprising.

 

I just finished cleaning the egr system, intake, and installing a OCC on my 2012 prius with 167k. I would definitely clean the intake, make sure you clean the small holes where the exhaust gas recirculates. Like everyone else on here I had a lot of oil in my intake.

Here are photos of what mine looked like.

 

You guys think 5ft is enough or better with 6 (2x3)? like this: https://www.amazon.com/LDR-Industries-516F385-Fuel-Line/

 

You can buy it by the foot, off a spool, at local automotive retailers. It's impossible for responders to know how much you need. Maybe you could do a "dress rehearsal" with garden hose or similar, measure what it takes. For sure just get a couple of feet surplus.

 

It should, if it was needed. Appropriate % of egr improves BSFC.

 

Ugh, even when I look it up, I'm still lost:

Brake-specific fuel consumption - Wikipedia

 

Fuel consumed per unit mechanical energy out. Units of pounds per hp-hr or grams/kw-hr, typically.

 

I translated it to maybe if you believe hard.

 

Finally I made it! EGR is clean. Second time I was more prepared. Dawn soap did not work for me, neither oven cleaner, but high pressure car wash did marvels in 5 minutes! Probably around 80% open now, but way better than zero as it was.

Posted via the PriusChat mobile app.

 

Nice job. Regarding the first picture, does it not seem that the gasket was leaking, there being a lack of a distinct boundary around the soot?

 

Good point, I haven't thought about it. There was no gasket on that end (the exhaust end) between the EGR cooler and the pipe going out..

 

Maybe there was a gasket but it dropped off when you lifted off the EGR cooler? That's what happened to me, and I would dub it a design shortcoming. The corresponding gasket between EGR valve and pipe has clips (similar to a brake pad shim plate) that hold it in place, but the gasket between cooler and exhaust has none.

In any case, there should be a gasket there. It's #8 in this link:

EGR System for 2010 Toyota Prius | McGeorge Toyota Parts

In my case I located the gasket, it had fallen partially down through the engine components below, but hung up somewhere.

 

Thanks, I ordered one. However I really don't feel like taking it apart again.. though, I feel I'm getting good at it. still painful
Btw I meticulously checked not to lose that gasket, and I was also surprised not finding it there