Slightly shaking engine and rattling noise on acceleration

Attached is a diagram and gasket list from when I did the whole intake cleaning. Go to Toyotapartsdeal.com for gasket pictures. If you are just going to do the EGR to cooler gasket, might be better to go to the Toyota dealer and shipping will be pricy for one gasket.

 

Not for the egr. This was a gasket list for the complete job. The egr cooler to valve is a metal gasket. Could you use something else? Probably but each of the gaskets on the list was $3 or less ( other than the intake manifold). Why not use the same gasket and avoid some other issue (air leak caused by incorrect gasket then throw a code).

 

was your rattling problem resolved, any update on the problem? As I'm experiencing a similar trouble.

 

I'm also experiencing a rattle with 2010 Prius when battery is low and engine charging and light acceleration. Rattle sounds like diesel or engine knocking but no change in rate of acceleration/engine power.


Was cleaning the EGR system the fix?

 

That's one potential solution( but rather involved). But we'll need more info. How many miles on the clock? Any codes thrown? Any other problems? You get the idea.

 

154k. No codes. Just came from mechanic. Other issue is oil consumption.

 

How much oil consumption? What other maintenance work have either you or the mechanic done? Did he have any thoughts on the problem?

 

Glad it worked out for you.

Those small passages are the egr inlets to the intake. Great design, right ? Toyota did a redesign of the manifold in 2012? and may have addressed some of the issues. IMO, the egr inlets should be on the upper side of the intake manifold, given the Atkinson engine naturally passes oil, which only enhances the issues in these small passages.

Thanks for the update!

 

This is rivalling catalytic converters for problems.

 

At least this problem has a less expensive solution. Replacing cats can get pricey, where at least this problem is a couple of gaskets and your time.

 

I wonder if clogging intake manifold cascades the issue, accelerating clogging upstream, in the EGR valve, and the dreaded cooler? The latter really concerns me: hard to access, needing to disconnect coolant lines. Pretty much a design fail.

 

Good question. I would think so, but there are several ways to look at it:

1) that is the point of entry into the intake manifold, and it all starts there.
2) it clogs further back and then since there is no or reduced flow through the small passages, they collect some of the passed oil.
3) driving style / fast highway speeds lead to incomplete combustion generating more deposits and collecting on all surfaces.

Not sure which it is. the next planned maintenance I'll do will be at 200 k (75k after first complete intake cleaning). Plan on pooling a lot of tasks together:

Intake manifold, engine coolant, egr and egr cooler, MAF sensor, pcv valve and throttle body.

This will be a couple of years out, but will help with understanding the dynamics.

 

I'm a bit absent minded, forget what I've discussed and with whom, but anyway: I've heard it's not a bad idea to have a replacement egr valve and cooler on hand, be prepared just swap it out if it's hopeless. In particular the cooler.

 

No worries, I sleep and get a mental reset .

What you suggested is what I have done ( I think is a great idea): I have spares that I am compressed air cleaning now to be ready for 200k. Salvage or auto recyclers have them cheap, and will ensure you have a good clean intake system once done and not rush through a cleaning to get it back together. But clean what you get from the second hand source, as they will not know to look for it .

 

Some have used a warm parts washer ( I have a small 2 car garage in suburbia and park both inside so my space is limited ).I did what you did: carb cleaner then let cleaner sit for a bit. I then let sit out in the sun for a bit to ensure all the carb cleaner evaporated. An air test after cleaning will tell if the passages are free or not.

 

Forgot to ask when say oil consumption is "normal", could you elaborate. As in how much oil is being consumed and what grade of oil are you using?

Trying to get a feel for level of loss and associated issues in my own preventative maintenance planning. My oil consumption on Mobil One 5W-30 synthetic is one quart every 6,500 miles with 136 k on the clock.