EGR & Intake Manifold Clean Results

Sorry, you: just thinking of connectors that might get missed at reassemble, triggering a warning.

 

Well so far after my little drive everything was smoothed out. When i get home from work tomorrow, i'll give an update. I'll stop by my local autozone and see if they can clear the CEL for me. But all hoses and connectors were put back together. next weekend i'll change the oil. I'm thinking about doing a seafoam cleaning. any ideas on that?

 

Don't know about seafoam. See if you can get codes read, not just dismissed. Could point you to the issue. I'm still betting something is not hooked up lol. Did you check that last one I mentioned, it's this:

 

That was actually one of the 1st connector and hoses I put on after lining up the intake. Let me go double check.

 

How many miles on your vehicle, Dan?

Pixel XL ?

 

133K
All connections and hoses are connected.

 

I perform a BG Products EPR treatment before changing the oil and have helped reduce oil consumption.

Something to try.

 

Read the CEL before clearing it

 

Thank you folks for all the work, photos, and Nutzaboutbolts videos on this topic.
Since it looks like almost ALL Gen III owners will have to do this or have it done within the normal lifespan of the car, could we have this thread made a sticky, moderators?

 

Here are some pics from the job i did since I can't upload pics 1 by 1 for some odd reason.
Library Slideshow by dan05979 | Photobucket

 

@Tideland Prius A sticky has been requested.

 

The intake manifold cleaning at least, is relatively easy, especially the second or third time. A pre-breakfast chore, lol.

The EGR valve and cooler, not so much.

 

You just need to do it a couple of times for practice .

 

Dan, kudos for cleaning out the intake manifold. This is one of the weak links of the engine.

The second weak link is the entire EGR system - it is a silent killer. The EGR cooler is the worst part of this system because it accumulates carbon (see post #69). The Prius ECU will not set a code if your combustion temperature increase by hundreds of degrees because of a partially plugged EGR cooler. It will also not set a code if one of the cylinders is hot and another cold because of uneven distribution of EGR gas. There are simply not enough sensors. I'd recommend the EGR system cleaning every 100k at a minimum.

My EGR cooler had about a third of the flow rate at 73k miles. I tested it with a garden hose.

 

^ Testing before and after is a big plus, if you've got the wherewithal. That was not reduced by a third, that was reduced to a third? Unreal.

 

Correct

Pixel XL ?

 

I've got the EGR pipe bolted on, basically to act like a pour spout, and because when the mainifold's set in the laundry sink the top of the pipe is level with the EGR "port exits".

I recall @Tideland Prius's posted pic of the 4th gen, how the EGR channels within the intake manifold branch one, to two, to four, vs third gen which I assume goes a simple one to four.

Anyway, when I pour in the Oxy solution through the pipe, and even with some rocking back and fourth, it seems the most frothing/foaming action is at the port closest to the EGR pipe, and the second has quite a bit too. Numbers three and four are pretty quiet.

This would infer the carbon build-up is most extreme at the pipe entrance, then tapers off towards the other end.

Third soak:


(Looking at the above, seems like #2 port from right end is the worst. This was even more pronounced with the next soak.

Wee bit thin Guinness:

 

Didn't you just know this is where it would go once Mendel hopped down from sitting on the fence? The least driven, most anally obsessed over turd gen on the planet now has an EGR flow rate higher than fresh off the assembly line... My dream used turd gen is only 3k miles and one border crossing away. Good work, man!..

 

I'm just wondering the OCC that Mendel has, how it can have oil in it. He doesn't lose any oil in the engine.

 

I've been wondering the same thing. Is it the heavier hydrocarbons from gasoline that resist combustion?

Great photography Mendel and glad it's working well! That engine's going to purr when you're done with it.

Pixel XL ?