EGR & Intake Manifold Clean Results

@trojandnc how many miles on it?

 

136,000.
The engine light came back on this morning so I broke down and took it to the dealer. They told me it was the code for the Mass Airflow Sensor which they have to order. We'll see.

 

At least now you have the tools you need for the next time.
I would suggest a pressure washer and Oven Cleaner.
The pressure washer does a decent job of clearing it out, and the Oven Cleaner will
actually CLEAN the cooler. Don't use the Oven Cleaner on the EGR valve or intake manifold.
Use Gunk. It's a LOT cheaper than using all the break/carb cleaner.
Did you clean the egr valve? And the tube attached to it?

Did you remove the intake manifold and clean out the oil and run a brush and gunk through the
4 small holes on the manifold near where it attaches to the head?

That is the whole EGR Circuit. If you ONLY did the cooler, than you've only done half the job.
It's a lot easier to remove the intake manifold.

Doing the cooler is a good start and could save the head gasket!

 

You should just get some MAF cleaner, and spray it over it. It probably has oil on it.
You should also clean the MAP sensor.

 

Thanks for the reply:

Update: I picked it up from the dealer this morning with the replace MAF and all seems well so far. So looks like I didn't tear anything up with the EGR cooler project.

Hopefully this can get me by until the fall, or at least until I can get a day in the low to mid 70's vs 105 heat index like this past Sunday.

I did clean the EGR valve and the pipe that runs from EGR to the intake manifold and the exhaust side port that connects to the bask side of the cooler.

I didn't do anything with the front side of the intake manifold, only where it connected with EGR tube/pipe.

I feel like just getting a reman cooler that is already cleaned and go back in a replace it while cleaning out the intake manifold. Since I don't have a garage and live in a condo I gotta dodge heat and rain. But now I feel better with doing it as this my second time taking of the all the upper windshield wiper stuff (replace the spark plugs last year).

Thanks for the advice on the oven cleaner and the GUNK.

 

Thanks for the reply. Picked it up from the dealer today with the replaced MAF. Don't know where the MAP is though, but will look it up.

This little car is easy enough to work on that I may just find a sibling with some miles on it to keep it company. ;-)

 

You are welcome!
There are small holes on the intake manifold that come from egr to allow the engine
suck the exhaust gases into the engine to kinda be reburned.
They get clogged. So it would be a good idea to pull the manifold off and gunk them down
and use a bore brush or small bottle brush to clean them out.
And oil collects in the bottom of the manifold that needs to be cleaned out.
Consider installing an Oil Catch Can to collect a lot of that oil.

The intake manifold is a lot easier and faster than the egr cooler!
And a 2nd cooler is really nice to have! I got one from a junk yard for $55, including shipping!

 

I’m going to do that. I’m going to have to redo it again because something is just not right. The car is louder now. Kinda sounds similar to an exhaust leak that seems to be from the area of the cooler.

When I was spaying the cooler with BrakeKleen the liquid was barely going through. I had to call it because it was getting dark on Sunday evening and I needed the car for work Monday and hoped I could at least get the cooler back mounted before I headed in. I ended up putting everything back on in a little over an hour total so I’m pretty comfortable in the disassembly and reassembly but my lil “PP” has never been that loud.

 

You know, for about $100, you can get a covering. It's easy to set up and can cover the whole engine area.
So at least the sun isn't beating down on you...

 

Oh, so the cooler is still partially clogged...
Get a $100 pressure washer, or borrow one if you know some one who will lone it to you,
then you can clear it out. Then go to the dollar store and get a can of oven cleaner.
That will make the job go a lot faster.

Did you use new gaskets or reuse the old ones? All the gaskets you need are inexpensive,
it's worth getting new ones. Maybe the gasket at the bottom of the cooler slipped out of place
and that's where you're getting the exhaust noise.

I know it's hard when you have limited area and time to work, but it's alway best to take that little
extra time with certain areas that are more difficult to get to.. Been there, done that!

At least you know what's involved so it will go faster and easier the nest time.

 

Thanks for both recommendations! Probably look on FB marketplace for both. Because $100 here and $100 there adds up quick when your trying to be cheap.

 

So, I took everything back off today and cleaned the egr cooler real good (and, unfortunately, broke my windshield in the process).

Anyway as I’m preparing to put everything back on, I pick up the rear egr cooler gasket that it is split on one side. But, of course, the bad gasket is the last thing in the line!

Do you know of anything that I can use to maybe make another one?

 

How did you break the windshield cleaning the cooler???
Did it happen taking out off, or putting it back in?
Either way, sorry it happened.

Did you use a pressure washer and oven cleaner?
I know of no way to make one of those gaskets.
That's why I don't reuse gaskets. One of the parts stores might have the one you need.
If they do, get two. one for next time. And I'd get the whole set, and you have 60,000+ miles
to get them.
I save the old one, JUST in case....

 

I would get the real part. Pretty sure you're looking for item #8 here:

EGR System for 2011 Toyota Prius | McGeorge Toyota Parts

My guess would be swing of ratchet handle?

 

That is correct!

Do you know if that gasket can be put in just by removing the two bolts and studs that connect the rear of the cooler to the pipe that leads to the exhaust or is the only way by removing the entire system?

I would think that because the lower bolt/stud under the cooler and blocked from the top seems to be designed for access underneath the car and would also give direct access to the two rear studs, that hopefully I would be able to remove those rear studs and create just enough space to slide a new gasket in place.

That would mean I would only need to remove the windshield wiper motor and cowel stuff to get to it.

 

Thanks. I was tackling the lower bolt on the side of the engine block above the lower stud and blocked from the side by the cooler.
Was using an 11-inch double boxed ratchet wrench and wasn’t thinking that the “black” ledge I was under was actually the windshield. And went the blot broke loose the wrench caught the edge of the w/s and the rest is history.

Have set an appointment with safelite on Thursday for new one. $426

 

OUCH! Well, I came close a few times myself! Speed will get you!
I had to step back and count to a thousand by sixes to relax and slow down.

Do you have full coverage on the vehicle? If so, they will probably pay for a replacement.

 

I have full coverage but carry $500 deductible.

 

That doesn't matter. Replacing the windshield shouldn't cost you anything.
I forget exactly why, but the insurance company must replace it for no cost to you.
That's how it is in Florida, it may be different in whatever state you are in. But it would be
worth checking on.
And they aren't suppose to be able to raise your rates for it...

 

I just did an EGR clean, and I'm hooking things back up right now. Would you guys be able to tell me if this would be the correct hose connection? Sorry, I haven't figured out how to post pictures directly to Priuschat, so I'm linking to imgur.