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Not just another p0401.. PICS!

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by khoda355, Oct 30, 2015.

  1. khoda355

    khoda355 Junior Member

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    Question for you guys.

    I have a 2010 with over 200k I am getting the same code.

    I took out the EGR, the tube and the intake manifold cleaned them all..( was real bad) and am still getting the same code.

    What would be next to check?

    Tech stream is saying egr flow insufficiency. Min 0.99 max 655.35 test value is 0.48

    So this means my egr is working but there is a clog someplace else?

    Here are some pictures so people can see what these egr look like after 200k

    Thanks!
     

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  2. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    You had the EGR right out, so assume you cleaned from the EGR back to the exhaust manifold?

    This is alarming, think Toyota's got their head-in-the-sand on it. :rolleyes:
     
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  3. Former Member 68813

    Former Member 68813 Senior Member

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  4. mrbigh

    mrbigh Prius Absolutum Dominium

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    PCV valve replaced???????
     
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  5. Former Member 68813

    Former Member 68813 Senior Member

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    any engine with EGR will have that problem. i think this is worse in oil burners.
    also, cars like prius are more likely to hit high miles like 200-300,000, so we hear about it more.
    i cleaned mine at 70,000 miles and it was not excessive.
     
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  6. khoda355

    khoda355 Junior Member

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    I cleaned the egr only. Not the big long square looking like thing that goes to the exhaust. Was thinking that the egr would be only clogged?
     
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  7. khoda355

    khoda355 Junior Member

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    Well if I could get a reading from tech stream then I was assuming it was working?
     
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  8. khoda355

    khoda355 Junior Member

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    Just took it out right now cleaned it and tested it and got it back on

    The tube was bad! So maybe this will be it!
     

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  9. khoda355

    khoda355 Junior Member

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    After cleaning the PCV it's looking way better... Still not fixed but! Test value has gone from 0.48 to 0.91!

    So need to get it up just a little more.. Any ideas? Maybe sea foam?

    Thanks !
     
  10. Former Member 68813

    Former Member 68813 Senior Member

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    wrong assumption IMHO.
     
  11. khoda355

    khoda355 Junior Member

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    Dang that other thing what ever the name is... Looks like a pain to get out. There are coolant lines that go to it too?

    So is that the step I messed up on? Need to rip that out to get this fixed?

    Again no one think sea foam would help to get it up just a little more to pass the smog test?

    Thanks!
     
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  12. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    I've looked at that more upstream component, looks like a back breaking mess, with lots of coolant lines attached. Good design Toyota!
     
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  13. khoda355

    khoda355 Junior Member

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    Yes this is why I do not want to have to pull it out.... On top of that need to get the expensive coolant, I'm sure it will drain a bunch since there are so many lines!


    But it looks like this is my only option.. Or take it to a shop and spend 5-600
     
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  14. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    Clamp the lines? You'll still introduce air though. I wonder: could you disconnect it from exhaust manifold and clean without disconnection of coolant lines? Maybe too difficult?
     
    #14 Mendel Leisk, Oct 30, 2015
    Last edited: Nov 5, 2015
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  15. khoda355

    khoda355 Junior Member

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    Looked at that... The lines are not long enough to do it. That would be just too nice! Haha...

    Thinking my only option is to rip it out and then bleed the coolant and all after too.

    Just wanted to see if anyone had any other ideas possibly!
     
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  16. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    To get at the very back bolts is best from below, still a reach though. I just happened to notice when doing an oil change.
     
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  17. khoda355

    khoda355 Junior Member

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    Thanks!


    Thinking Monday in going to start this... Really want to see what it looks like inside... I hope this is the last fix...
     
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  18. khoda355

    khoda355 Junior Member

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    Well if anyone is following this.... Here is a little update.

    I would say if you were planning on doing this yourself you would need to get the car as high as possible. The bolts that are holding the exhaust tube in the back of the egr are a pain to get off! They are a size 12. Then you have two 3 coolant lines to cut off or will be taking a shower in it. Other then that it's just a pain to get the bolts off, super tight space to work in.

    Here are some pictures, it was completely blocked up. Can't even see a light with a flashlight from the other end. Have it soaking in some carb cleaner see how that works but I think it's going to be best to get another one. I really feel that this should be covered in the unlimited mileage warranty for people who have smog to deal with.... If not then the car should have this to start with! Or at least a better design that allowes for it to be removed and cleaned. It is a mini radiator.... Super super tight, they must know that this would be happening just with time..

    Anyways here is the pics!
     

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  19. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    A hearty thanks for taking this on! Does not sound like fun.

    What's the miles again? Of course, Toyota's dead silent on this.
     
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  20. Former Member 68813

    Former Member 68813 Senior Member

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    OP, thanks for the feedback. I'm thinking coolant replacement interval should be a good time to take the whole EGR system apart for cleaning.
    It's surprised we don't see more of these problems reported at 200,000 miles. BTW, is this a case of an oil burner?

    Edit: the problem will be even more common in the new generation:

    “The efficiency will be realized by improving the EGR (exhaust gas recirculation) limit from 21 percent (current model) to 28 percent,” reported Nikkei Technology Online. “The thermal efficiency of 40 percent would be the world’s highest for a mass-produced gasoline engine.”


    2016 Toyota Prius Engine To Boast 40 Percent Thermal Efficiency - HybridCars.com
     
    #20 Former Member 68813, Nov 2, 2015
    Last edited: Nov 2, 2015