Disassembling a very Rusty intake to clean manifold

They're a lot cheaper here ($2~3 CDN apiece):
https://www.amayama.com/en/catalogs/toyota/prius/3-hatchback-right-xw30-2009-2830/engine-fuel-system-and-tools-1/air-cleaner-27

I've ordered from them several times; never any problems, nor extra duty (at least on the small items I've got, one shipment close to $100 CDN). You will incur a shipping charge. Ensure they're all from one source (typically either Japan or UAE), to not have two shipping charges.

I would register with them, load up a "cart" and see how it goes. Try both UAE and Japan. If they're close, I'd maybe go with Japan.

I did a trial cart, on West Coast Canada, not sure if I got them all; from UAE shipping charge was around $15 CDN.

Gotta grumble, regarding road salt. That stuff is causing financial carnage. There's gott be some way to scale back on the use of road salt, or find an alternative.

 

Figure out a good tool to cut the wires/bars and replace them. It's not worth the hassle trying to get them to work again. Once the hose clamps are removed there's no way the rust/corrosion will interfere with disassembly.

 

Use large diameter panduit straps and the gun to squeeze them tight All you'll ever need If you don't squeeze them too tight and try to kill them you can even pretty easily get them undone and put them back on again although that's the least of your problem generally speaking they'll hold up a lot better than these clamps and then when you want you just cut them loose and have three or four at the ready to reinstall ends the whole shebang. I'm sure in the aftermarket you can also get aluminum alloy clamps from the people that make the cold air intakes You know that all the kids put on the Hondas they should have a whole page full of what look to be billet clamps God knows what they're made of but they're not steel that supposed to rust I don't think.

 

Lol, I don't even know what that means... But it sounds awesome...

 

Panduit straps simply put some people call them zip ties The police use them as instant handcuffs when they don't carry a lot of metal If you get big ones like that are used in the HVAC industry there is wide as those clamps are around those rubber hoses on the intake You use a squeeze tool to install them tightly and they'll be tighter than those clamps which isn't necessary I'm just saying. You can also release them with a scratch all or a little tiny Klein screwdriver and reuse them as needed Panduit is the proper name for zip ties. Maybe it's the company that actually made them or whatever that's what I've always called them. Just like most people don't know what crocus cloth is unless they're over 65. But oh well that's just the role of sandpaper The narrow stuff that plumbers use to clean off the end of the pipe before they sweat the two pieces of copper together.

 

. I always called them Ty-Wraps but the US supplier was Panduit.

 

Zip ties to me.

Posted via the PriusChat mobile app.

 

Ty wraps don't fall apart in the sun. No Walmart or Harbor Freight stuff went to the moon.

We used Panduit wire ducts ("Panduit") in custom wiring for industrial controls. Allowed efficient troubleshooting and upgrades in one off designs.

 

An industry early on when these things first became available I remember the sales people the manufacturer reps and what have you calling these things can do it straps they came very narrow all the way up to I don't know today but back then about 5/16 of an inch wide pretty stout like about the width of some of these clamps were discussing here. Other than that zip ties and I do remember the TY wrap name.

 

You've got to be running like a gun cleaning brush up down that long 3/4 inch or so hold that runs all the way down the manifold that the EGR port connects to and then you've got to run brushes down those EGR ports that are centered in each port if you will there's a hole there that you need to clear that goes down to that 3/4 passage that runs all the way down the manifold that needs to be cleared by invasive brushing followed by blasting through with air maybe some decent cleaner but the brush is going to do the trick that's going to open up that passage back like it was which is the goal here.

 

For the small diameter EGR passages in the intake manifold, Google drinking straw brushes; lots of stores, Canadian Tire, Amazon, have them. I got these:

Straw Brushes - Lee Valley Tools

I suspect PineSol is quite basic/caustic? Rinse the stuff out VERY thoroughly, and maybe spritz any of the metal embeds with WD40 or similar, or you’ll have corrosion starting.

For the intake manifold best to stick with brake cleaner since the embedded metal is not stainless.

 

My first question would be, are you positive you didn't have those before, and they weren't just harder to see because of old gasket leavings or whatever?

Somebody else may chime in, but if I'm looking at the things you mean, they look too ... regular ... to be dings from the machine shop. Each one is exactly opposite a bored hole visible in its little arc-shaped passage, and my first guess would be they are artifacts from whatever tool at the factory bored those holes.

 

It must be the terrorists

 

I’d agree, those chips look original.

So did they machine the head? It looks like it (to my untrained eye).

 

Everything is “probably” fine. I believe there’s chain inspection instruction in the repair manual (full engine section is last link in my signature). Ditto for chain guides and tensioner. Would be good to replace tensioner gasket. Toyota gasket kit includes this gasket I think. Car Care Nut (YouTube Toyota Master Mechanic) says to look guides over for wear, but they tend to be very durable.