2010-2015 Prius // EGR Valve // Intake Manifold // DIY // Removal - Clean & Replace

In this video I remove the intake manifold and EGR valve on my 2010 Prius. I had previously replaced the EGR cooler and at the time I didn't realize that the EGR valve needed to be cleaned or replaced too. I had also cleaned the intake manifold but I decided to replace the EGR valve and intake manifold so that I could quickly swap out the parts and then take my time cleaning the old parts and have them ready to swap again.

The intake manifold can be swapped in about an hour without any problem once you've done it. It's very easy to do and the tiny passages from the EGR valve can get plugged up pretty easily. I'm going to be able to dunk the entire intake manifold in a degreaser multiple times and make sure it's clean like when new.

The EGR valve is attached to the EGR cooler and to remove it the entire unit has to be loosen to get a wrench around the bolts that hold them together. The lower back bolt on the EGR cooler is widely know as "the bolt from hell" because it's very hard to reach. This time I left it off so that I can swap out these parts quickly and easily. I got the idea from some other people that did the same thing. The EGR cooler & EGR valve are connected together with 2 bolts. There are 2 bolts from the exhaust that bolt to the back of the EGR cooler. The EGR cooler also has an upper bolt that holds it tight to the engine. The EGR valve also has a stud and nut holding it to the engine with 2 more bolts attaching a metal tube that bolts to the intake manifold. None of these parts move in any way so leaving off the very hard to reach stud and nut won't make any difference.

A little more information on the lower "bolt from hell" which is a pain in the butt. It's actually a stud with a nut. This time I couldn't get to the nut to remove it so I worked on the stud since it was easier to reach. With this method I was able to back it out for the final time. The hoses and HV hybrid cables are just in the way trying to get a wrench or socket into place.

I hope that this summary helps for anyone that wants to tackle this. These 3 pieces are critical to keeping the Prius in good running order and need to be kept clean. My plan is to swap them out every 50k miles as they should be easy to swap now that the "bolt from hell" is gone.

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EGR Valve Kit OEM # 04004-58137
Intake Manifold OEM # 17120-37054
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Chapters-
00:00 Intro & Explanation
03:49 Removing Wiper Cowl
10:50 Removing Intake System
15:11 Removing Intake Manifold
18:53 Removing EGR Valve
25:26 Installing New Updated EGR Valve
28:25 Installing Intake Manifold
31:20 Final Wrap Up

If you are cleaning your old parts these wire brushes can help clean the passages. Use a good degreaser to soak the parts and I found brake cleaner to also help. The EGR cooler has to be soaked so the brake cleaner helps between soaking.

Long Narrow Wire Brushes - [ Ссылка ]=
Wire Brushes - [ Ссылка ]=

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