So I'm going to clean the Intake Manifold, anything else?

change your oil to 5w20 to slow consumption

 

Why do you feel that would help?

 

I have done all of what you are about to attempt, except clean the PCV valve, but I think you meant replace. This is a $7 part at the local Toyota dealer.

Make sure the inlet ports from the egr system are cleaned in the intake manifold. These are small holes that have a tendency to clog, restricting air flow from the egr system.

If you are pulling and cleaning the egr pipe, you said the egr valve has been replaced, correct? If so, that would only leave the egr cooler, but that is a little more involved and require draining the engine coolant. If the egr valve was not replaced, I would pull it off of the cooler and take a look down through to see condition of the cooler. Typically there is buildup on the plunger that can cause the valve to not work correctly.

Only other things to do would be throttle body and MAF sensor cleanings.

I have a slow oil consumption issue at 140 k ( a quart every 6500 miles) and have tried some other things, but to answer your question, that's what I would do in addition to your proposal. Long term you will want to investigate the egr cooler, and I found a fair bit of deposits in mine at 120 k. Gas quality had a hand in it, but the egr system will have buildup over time.

Keep us posted.

 

Thicker oil will help. High mileage oil formulations would also help. The OP is in the middle of PA where winters can be cold, so the oil can't get too thick. I have switched to 5W-30 but I live in the Bay Area of California where it never gets below 25 F in the winter. It slowed the oil consumption some but did not solve it.

 

Here's Repair Manual info on the EGR pipe, valve and cooler removal/install. I've never touched it, well just took the pipe off. Ray is the man.

 

STOP: Don't do anything.
First, go to the My Toyota website and register your vehicle's VIN number. You may qualify for a free EGR valve replacement. Let the dealer do the free work. It's an unlimited mileage replacement until next March:

warranty enhancement; P0401 EGR Valve | PriusChat

 

In the original post, I read it as the OP had the warranty replacement done for the egr valve due to the P0401 code being displayed.

 

Sounds like a productive Saturday.

How long did it take you to do the job? Did you clean the MAF sensor and throttle body( or at least inspect )?

If you have a code reader, inspect the codes causing the check engine light to illuminate. If not, a trip to autozone will get a diagnosis. Not sure if they can clear it, but at least you will know what the code is and research it. Most codes have been discussed here, so continue to use this as a resource. A good device to add to your garage is a code scanner, as they work on cars newer than 1996. Here you will see threads for scanners for hybrid cars, but I have a basic scanner and will upgrade at some point. It does the basics well and works with my iPhone.

As far as the other questions:
1) how did you clean the intake manifold? Did you just rod out the holes or use a cleaner?
2) have you used fuel injector cleaner before, or is this the first time?
3) how many miles since the cleaning and what type of driving? You say the mileage is low, but could that be due to the terrain or short trip?
4) did you torque the manifold to the specs @Mendel Leisk supplied?
5) you said the PCV valve looked fine, but how did it sound and / or function?
6) you said the ice is running in the driveway but this could be due to the warmup cycle. Was the car sitting for a period of time prior to going out and starting it?
7) if the job could have been planned in advance, changing gaskets is "suggested" but ultimately you are on the air side of the engine so the worst thing that could happen is a vacuum leak. I do not think you have emissions testing there, I know my parents who live in Luzerne / Wyoming county only have to make sure their gas cap seals correctly, so even if there was a slight air leak, you have no emissions test to worry about unless the check engine light is associated with it. Easy way to tell if there is a vacuum leak is with ether around the areas you touched as part of the procedure ( the ether will get sucked in and cause a slight engine rev and leak found). But I am sure your brother in law mechanic mentioned that in addition to his other commentary .

Sounds like this was successful. Keep us posted.

 

No, not at all. I re-used the IM gasket when I did mine 2 years and 26,000 miles ago. It also looked and felt fine and no intake leak to this point. When I repeat the procedure I'll use a new one so as not to push my luck, but they are certainly re-usable at least once.

 

Good, sounds like you definitely fixed something.

I do not know if these codes clear themselves or not. The easy way to clear it is to pull the 12V battery ground, wait 3 mins, and reconnect. You'll have to reset your clock, but that's about it.

If you want the best code reader, you need an old, Windows 7 laptop, and a $20 cable/software combo from eBay called "Techstream / MiniVCI." Just search eBay for TechStream. The software is 32-bit only, so you should try to find an old Windows 7 laptop.

Definitely no idea why the engine turns on or off at random; Prius does that kind of weird thing for all sorts of reasons. Let's assume that's normal. Let's also assume that if your car is burning a quart every 1,000 miles, you're going to smell a little burning oil now and then.

Now, here's the real problem: Your car probably isn't burning oil because of the spark plugs or the intake. It's probably the valve seals or the rings. So switch to a higher viscosity, like 5W-30. And monitor the oil level carefully. Your engine can last a long time in its current state, as long as you don't let it run low on oil. Keep oil on hand and check the level every week.

 

Win 10 also comes in 32 bit. Have no clue if that would mean it would work with techstream.

 

I've seen some posts from people who went through insane contortions to try to get the 32-bit MiniVCI driver to work in Windows 10, and some of them got it to work, but it looks like a pain to me.

Also, my $20 purchase looks like Chinese pirated software, so I just bought an old laptop for $100 and use it for nothing but Techstream and avoid the possibility of a malware infection, and getting grease on my daily laptop. Plus, my daily laptop is a Mac.