Hey All,

Just to preface this, I have never posted in this forum before, but plan to going forward. I have only been active on Ct200hForum.com as I didn't know of this forum until recently. My posts over there are under my username Jeffh. I am the original owner of a 2011 CT200h with 270,000 miles, and on my second engine, and second hybrid battery. I have a somewhat extensive knowledge on this car, but I wouldn't be where I am at today without the help of the members of this and the other forums.

After reading the posts on this forum and Prius chat about the EGR Cooler being the ultimate cause for Head Gasket Failure on top of other issues, I have decided to do something about it. I removed my EGR Cooler this weekend and experimented with it, and think that I am going to get into the business of reconditioning them. Lexus has been constantly failing us. Wanting to charge me $600+ for a part that clogs and causes failures by design at this point, the same problems happening with these engines since 2010. I have found new/used EGR Coolers online for about $250, and am personally looking to get into the $120-$160 range included US shipping and new gaskets (with an added core charge) depending on how much I can refine my process. I plan to offer at least a 6 month warranty.

Here is where you, the people, come in. I am looking for anyone out there who has replaced their cooler and has an old one lying around. I know it is a long shot, but I will pay for shipping, and will offer 50% if you need an EGR Cooler in the future. If anyone has any spare valves, I will take those as well, no matter how damaged. Don't have any concrete plans to do the valves, but if there is enough interest, I will see what I can do.

My name is Jeff and I made an email so anyone can reach out with questions EGRFixer@Gmail.com

Also comment below with any questions or suggestions. I'm not doing this as a means of income, as I already have a full time job I spend too much time at. I just would rather give people an option than to sit there and clean it for hours or to give any more money to Lexus/Toyota.

 

I think it's very admirable that you are doing this to help others out.

Question:. How involved is the actual process of doing this? Meaning if I get your rebuilt kit and how involved is it to swap this out? I can change my own motor oil, transmission oil, change out the radiator, and other odds and ends around car, but not "a full engine rebuilt".

 

Welcome Jeff!

Thanks for offering up your services on EGR cleaning. Definitely needs to be done on a regular interval. If you don't mind me asking, what process do you plan on using: ultrasonic, oven cleaner, oxyclean, pressure washer? I have found the ultrasonic cleaner did the best job with the least amount of work. I know lots of people use a PW on the cooler...but I wasn't sure how they held the cooler, vice maybe? the PW didn't work well for me, maybe because it was too clogged and made more of a mess then I was willing to deal with. I definitely suggest people get a spare egr system so they can put clean parts in while the other set is being cleaned. No loss of time on the road.


Also, don't forget to post this over on the 3rd Gen Prius page on priuschat. Always a lively discussion over there on EGR stuff.

 

Here's the procedure for the Prius. It's tedious but doable.

 

Definitely closer to radiator change than engine rebuild. Honestly, it is just more time than anything. It isn't particularly difficult. The hardest part for me was to disconnect the cooler from the exhaust manifold, and once you figure out the "angle of attack" so to speak, it honestly is just step 1, step 2, step 3. You have to remove the wiper and cowl, which is way easier than it sounds. Like it took me forever to get the cooler off, but putting the whole car back together took 30-45 minutes. The part that was terrible for me was the soaking, and spraying and cleaning, so I think the plug and play option is what is really going to trim down the time for this job. I know I tore the torx end of one of the studs off, and one of the screws that hold the plastic cover on the valve, so if there is enough interest, I may carry the specially screws that would be hard to find, and sell them at cost. Also, if anyone buys the kit, I will give you my personal cell number, and you can text me if you get stuck, and I can walk people through it.

It's more supporting the community than anything. I called Lexus the other day to replace the stripped screw from the plastic cover on the valve, and they said I would have to buy an entire new valve for $800. I'm just sick of them ripping people off.

 

Yeah, when you finally take it out, you feel so accomplished, and you realize now comes the hard part. lol To just take it out and swap it is definitely the dream, and I think it makes sense at this price point. When I took mine out, I wasn't getting any brake cleaner to go through. I previously cleaned the pipe, and after a couple thousand miles, it was getting residue again, so I know there was airflow. I used 6 cans of brake cleaner, and a power washer, until I remembered that My work has a massive in-ground ultrasonic cleaner. I put it in there, take it out and pressure wash, and run another cycle in there. They come out really well, which is why I will offer a warranty. I have a friend that works in metals and coatings, and I want to experiment with possibly coating the fins and seeing if I can get more longevity, but I guess it's better to clog the cooler than that tiny passage in the intake manifold. I also want to experiment with making the inlet tube post-catalytic converter, but that's a lot of heat, but likely a lot less residue. The only thing that stops me from doing this, is that I don't know how many people would even care. Most people who own these cars will be oblivious about the issues with their car until the rod shoots out the side of the engine like mine did.

I appreciate the heads up on Prius Chat, too! I posted over there last night, as well. We will see how they receive it.