Hello all, I need some help/advice on what to do in my situation. I am currently working on removing the EGR cooler, and was able to get the top bolt and stud off the rear connection (to the exhaust manifold pipe), but the lower one I'm in some serious poop. The bolt came off fine, but when trying to remove the stud with an E8 socket, the tip sheared off and now I have no way to remove that stud. Am I completely screwed here? Any help would be appreciated! Attached is the part that sheared off, for reference. Thank you!
Presumably you’ve got the nut and stud off at the upper/front location, at the EGR valve? If you can now manage to remove the stud at the lower cooler bracket (the hard to reach one), and the bolt at the top cooler bracket, you’ll be able to pull the cooler/valve forward and off, with that (broken) lower, rear stud still attached. Once that’s done it’ll be much easier to deal with. Go REALLY slow and careful backing out that lower cooler stud, dissimilar metals and time mean it’ll be stubborn. And it’s a bear to get to; you may need to loosen adjacent wiring and/or coolant line brackets. I used a 1/4” drive Jet Ratchet, was only enough room for one click at a time, and took about 10 patient minutes to back it out, stubborn till almost completely out. But yeah, if you can get that lower cooler stud out, then the rearmost studs can be left in. Don’t reinstall the lower stud/nut; just leave it off permanently. Not sure, but that one MIGHT be same length as one you broke. For ref, here’s the one I took off (a long time back) from ours: I suspect it’s shorter, but worth checking. If it’s not a match for the broken one dealership can get one in for you. Another stud that may be identical to the broken rear one, is that upper/front one, at the valve: check its length against the rear cooler stud you did manage to remove. It can be left off, at least temporarily, swapped to the rear location, which is much more critical. I’ve got a hunch that one IS the same length. With one stud left at the rear of cooler, the EGR valve/cooler assembly will not quite clear a bolted-down tube (coolant I think) above, but if you remove the bolt holding that component, it can be shifted up just enough to be clear. If you haven’t disconnected any coolant lines yet, if you drain 2 quarts of coolant from the radiator drain (into a clean container), when you do pull the lines off the cooler everything will be virtually dry. When all is back together, pour that coolant back into reservoir. It’ll be a little high but should settle down with a few days driving.
Judging by the part no's on this page: https://www.amayama.com/en/catalogs/toyota/prius/3-hatchback-right-xw30-2009-2830/engine-fuel-system-and-tools-1/exhaust-gas-recirculation-system-52 The two rear studs on the cooler are unique, not swappable with either the stud at the valve, or the the stud at the lower cooler bracket. Here's a screen grab from above link: But yeah, if you can get that lower stud backed out (901260-0856), then you WILL be able to pull the EGR valve/coolder assembly out, with the broken rearmost stud still installed.
Thank you kindly for your reply!! I was able to successfully (and actually somewhat more easily) able to remove that lower nut and stud you mentioned (the one the can stay removed permanently). This definitely allowed me to pull out the cooler with that other lower/broken stud still attached. Now it’s on to the cleaning steps for everything (cooler, EGR, intake, etc.). With mine being a 2015 and having almost 130,000 miles, there was a small pool of oil under under the throttle body and loads of crud in the cooler and associated passageways. Even though I’m in a CARB state, I have a catch can ready to go and will try to install on that cross beam under the intake manifold to hide its presence. And great timing as I received my registration renewal in the mail and a Smog test is being required. Again, thank you for your information and help!
Also, according to the US Toyota parts website, the rear studs (901260-8052) are no longer available to be ordered. Being Sunday, all Toyota parts departments are closed today so I can't call around to see if they are able to order them. This is just in case I decide to get that stud out somehow and replace it with a new one.
