EGR Cleaning: What did I get myself into?

Hmm finally reached the end of this saga. The Mods should change the title, it seems a bit ominous to a very important maintenance guide-just personal opinion
I would like to thank all the posters of videos and advice including stuff from the manual for improving information specially mentioning part number-(Us poor folk in Ozland are considered incapable of DIY stuff and the Big T doesn't like sharing part numbers etc so it can be a bit of a hassle). Also thanks to every one who mentioned tool types and sizes.
Main car is a diesel Passat and recently did the whole EGR valve and intake manifold clean on it-That was really gunky and I used degreaser for it which worked really well. Also a Liquimoly diesel engine decarb worked wonders specially with the pipe extension and a slight pressure nozzle. The last thing I thought I would need to do was a similar thing in the Prius. Never heard of a catch can for petrol but here we are.

I have a 2009 ZvW30 Itech Prius around 127k Kms, purchased used at around 1.5yrs and 10000 Km ago, in Pristine condition with relatively low Kms around. Have noticed once engine is warmed up and if I drive around 55km/hr in the power band just after the eco midline, the car starts to make a shuddering noise, goes away if I press the accelerator. No engine codes thrown but came up here to get information and have been reading up on things. Have cleaned the MAF and the engine air filter and that has helped. No idea about the service done earlier on but have ordered spark plugs{-Unfortunately ordered the TT ones- Denso Iridium TT (IXEH20TT)but based on the comments last few pages will return them and get NGK Iridium}, a few tools and the gaskets. Intend to change the PCV valve as well and whilst I was not initially keen on a catch can before, intend to get one for sure now. May just extend the pipe out for now and put it in once I get it but will try and put it close to the section of air intake entering the throttle body so almost at level of PCV valve if I can.


I intend to do the transmission oil as well. Have jacks for the front and will try and borrow some for the rear from someone., so looking forward to getting the hands dirty again, will keep you guys posted and update with part numbers etc in case it helps others from OZ.

Will book in for the engine oil change so I can get an official stamp. atleast for this year to keep em happy as they did the good will replacement of the Inverter during a recent recall. The car's inverter literally died on the day it was booked to have the software update lol.

Stay safe ppl

 

There were reports earlier of the valve binding after cleaning the bottom of the plunger. It was recommended to add a drop or two of oil - either motor oil or WD-40.

I haven't cleaned it from the top yet. It's definitely not a good idea to add a non dielectric lube to the electrical end (stepper motor) portion of the EGR or you could short it.

 

I just did this, again, with the help of a friend, on my niece’s 2011 Prius with 218k miles. Her car has only had oil changes, tires changed, and the ice battery changed once. Still running like a champ. I decided to give the car some much needed tlc. She just had the oil changed, so all I had to do was change the air filter, cabin air filter, the spark plugs, pcv, clean the intake manifold and throttle body, clean the egr pipe, egr, egr cooler, drain/fill engine coolant and inverter coolant, drain/fill transmission fluid, topped off brake fluid and windshield washer fluid, clean the hybrid battery fan and ducting, clean the engine bay, buff out the headlights. My friend got an extra egr and cooler to help us in the process of keeping our cars and family/friends Prii running strong. After the first few times doing this, we will probably pick up an extra intake manifold and egr pipe to expedite this process so we have clean ones ready to go.

For those of you wanting to know the best way to clean your egr out, carb cleaner and a brush. For the egr pipe and egr cooler, pressure washer is the way to go. The pipe, you can spray some carb cleaner and push a rag/paper towel through it too. The egr cooler, pressure washer is the way. You may have to shoot it for a little bit and watch out for the back spray. I usually follow up with some carb cleaner too, and then let it drain/dry out on its own. As long as you can see light through it, you’re good. For the intake manifold, I spray it out with isopropyl alcohol and wipe it out. It’s plastic, so you can wash it out with soap/water too. I just use alcohol to spray it out since it dries quickly.

Here’s some pictures. You can see the before/after egr pipe, dirty/clean egr and cooler, dirty pcv, etc. I forgot to take a pic of the engine bay after. Nice and clean, no rat poop and snail shells, no dirt or spilled oil, so much better. Now it’s ready for another 200k. Oh, and the brakes are still original with tons of life left!

 

Always nice to help others .

And glad the pressure washer worked.

 

Wow, the intake manifold was blocked solid!

 

Yeah that insufficient EGR flow detector (P0401) is almooooost ready to trip. Real soon now.

 

That would have been a great car to have collected some 'before' data from, in this thread over here.

A little late now, I guess.

 

yeah, yeah. Ran out of time and had to give the car back. Only had the afternoon to do all of this. Next time when I change out the shocks and struts, I’ll bleed the brakes.

 

Quite an impressive job!

 

Impressive Michael! You saved her so much money and extended the life of her Prius, they're such good cars.

How long did it take you?

 

we got started around 11 and finished around 3-4. Then I went home and spent another 30-40 minutes taking care of the hybrid battery fan clean out, and about 20 minutes buffing out the headlights. So, 6 hours I guess. We weren’t working fast, just shooting the breeze and wrenching.

yeah. Her car needed it. Only set her back about $175 for parts and fluids. These cars are great. I always recommend these cars. Plenty of space inside, gas saver and almost maintenance free.

 

And it feels great doing it!

 

Thanks for the tips and instructions.
In Oz use " clean boost" instead of Oxi.
Liquimoly have a decarbonizer with a small pipe attachment. It helps spray the degreaser, brake fluid or what ever you want in a fine pressurized mist.
Helps clean the valves.
Nothing worked for the intake manifold though for me.
Car working smoother.
Only transmission fluid left to change. Will do that on a lift if I can arrange it.

 

Four jackstands, or ramps for the front and jackstands at the rear, will work.

If you're going that route and are untested I can post a pic showing some very stable/ solid jackstand bearing points, superior alternates to the scissor jack proscribed bearing points.

 

Never used brake fluid for carbon build up. It eats paint, maybe it eats carbon too???

Gunk works for the instake. It does a GREAT job! Cleans up with water.

 

Yeah, that would be great. I only have 2 jacks unfortunately but will try and get another pair off of a friend if the stands are well positioned.

 

The four red rectangles are the points I use. With the rear they're turned 90 degrees, just seats better that way.



Some pics of the stands iin position:

 

Ok, thanks. These look good. I have misplaced the crush washers forWfor the transmission. I will get a new set.and borrow a other pair of jack stands

 

Thanks for all the help guys. The transmission fluid really jumps out fast, spilled over me as I removed the bolt from the housing. The fluid was very dark too, compared to what I put in.
Mileage improved as well so all things considered well worth the effort.