2012 egr cooler leaking

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by kevin mcfarland, Nov 3, 2025 at 4:45 PM.

  1. kevin mcfarland

    kevin mcfarland New Member

    Joined:
    Yesterday
    1
    0
    0
    Location:
    Pa
    Vehicle:
    2012 Prius
    Model:
    IV
    Just purchase a 2012 started seeing white smoke and that sickening sweet smell of antifreeze burning, before looking to replace head gasket I unplugged the EGR vale and no more smoke, upon further research, and discussions w/ other mechanics the thought was even after replacing the cooler by driving car w/ EGR unplugged The car gets better mileage better performance, with check engine light on. the thought process is since you are not reburning spent exhaust you have a cleaner running engine with no worries about the port clogging especially on 1st cylinder causing notorious head gasket issues. Curious on other thoughts out there? When Cars due for inspection wipe code plug in EGR valve to inspect.
    Also I was considering even bypassing the EGR cooler antifreeze lines What would be the effect, bypassing the cooler while keeping the EGR unplugged?
     
  2. Brian1954

    Brian1954 Senior Member

    Joined:
    Jan 31, 2021
    2,090
    812
    0
    Location:
    South Central PA, USA
    Vehicle:
    2011 Prius
    Model:
    III
  3. Mendel Leisk

    Mendel Leisk MMX GEN III

    Joined:
    Oct 17, 2010
    59,904
    41,170
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    I got kinda lost after that. What's the miles on it?
     
  4. rjparker

    rjparker Tu Humilde Sirviente

    Joined:
    Jun 6, 2008
    10,010
    6,195
    7
    Location:
    Texas Hill Country
    Vehicle:
    2012 Prius v wagon
    Model:
    Three
    Unplugging the egr valve is highly unlikely to stop white smoke especially if was antifreeze (eg coolant).

    Unplugging the egr when the egr valve is closed (normally closed at low rpm and shutdown) will create a check engine light but not much else you will notice. I might do it except the check engine light on all the time will mask other problems. Other hybrid issues have their own warning lights. The overheating warning light is separate but often just flashes once or twice when it's all over except the crying.

    Yes there is coolant in the egr cooler but it is a stainless steel heat exchanger with the coolant separated from the exhaust gas flow. Even if your egr cooler was leaking internally (something that is almost unheard of), closing the egr valve would simply stop coolant flow to the intake manifold. A leaking egr cooler would continue to leak coolant directly into the exhaust system. This would quickly empty the engine coolant reservoir (passenger side) and soon cause engine overheating.

    The frequent cause of coolant burning is coolant entering a cylinder through a head gasket leak. These leaks can be infrequent at first but are almost always accompanied by a severe startup rattle when they happen.
     
    Brian1954 likes this.