Strange knock and misfire at idle after EGR cleaning

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by PriusBackwards, Mar 17, 2025.

  1. PriusBackwards

    PriusBackwards New Member

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    Hello, first post here, seeking help with an at first intermittent MAF sensor code that has now progressed to rattling at idle that sounds like motor knock.

    Here's a list of everything that has been replaced since I purchased the car about a month ago.
    -EGR cooler, valve, connecting pipe and intake manifold cleaned with a pressure washer and nylon brushes.
    -2 week period where everything ran fine
    Car throws code for MAF sensor (po101 and P0171)
    -Cleaned MAF sensor, issue resolved for about a week after, then same codes displayed.
    -Replaced MAF sensor at this point (OEM DENSO replacement)
    -Replace spark plugs
    -After 2 weeks (last Friday) car started rattling really badly when coming to a stop (gasoline engine turning off) but drove smoothly on the highway.

    Here's everything I have attempted to do to fix the poor idle in the last few days:
    -Switch cylinder 2 coil pack to cylinder 4, no change in idle.
    -Clean fuel injectors, no change.
    -Add oil catch can, clean pool of oil in intake, no change.
    -Replace MAF for a second time (duralast), no change

    The only "smoking gun" I have is short term fuel trim values being +20%, I am afraid to idle the car longer to do O2 sensor diagnosis due to the bad knock. If there is any other scan tool information that would help with solving the problem, please let me know, I have a scanner

    Car is currently displaying the following codes: P0302 (cylinder 2 misfire) P0171 (system too lean) po101 (mass air flow sensor range bad)
    I am not burning coolant, have put 3000 miles on the odometer since buying it with no coolant consumption. After cleaning the intake manifold for the first time, I had no cold start rattles for 2 weeks.

    Consumes about 1/2 a quart of oil between oil changes but this may just be oil pooling in the intake because of the PCV design, I just installed a catch can and will have to wait to see results.

    Any help would be appreciated, I am thinking there might be a vacuum leak or EGR gaskets leaking, but I haven't seen much information on this happening to others which leads me to believe it might be something else. If anyone has a vacuum diagram or common leak points to check, that would be helpful as well.

    Screenshot_20250312-094122.jpg Screenshot_20250312-094034.jpg
     
  2. Lares_Mat

    Lares_Mat Member

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    I don't really have a clue, but you seem to scan with the OBDLink app, am I right?

    Try to do a "Report" - the icon in the lower right corner of the screen.

    You can see there the "Mode $06 - On-Board Monitoring" results with EGR flow and misfire counts at the different cylinders - maybe this directs you in some other direction?

    If you have the EGR clean, you should see an EGR flow in the range of 20 to 21 kPa.

    I'm puzzled with the engine nocking or rattling on shut down... Normally it shakes after starting...

    If it idles rough, it could be the EGR valve open (as it should be closed at idle).

    If the valve works right, you should hear two distinct clicks from the valve a second or two after the engine shuts off. If you do not here the clicks, I would suspect the valve sticking. (It is a primitive test, it is not telling you, the valve is fully OK, it tells you, the rotor is turning and reaching the closing point.)

    This above are simple checks I would make to see, if they give any clues ;)

    Mat
     
  3. Tombukt2

    Tombukt2 Senior Member

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    This is where I was with the 13 Persona for months I didn't even take it on the road anymore I just worked on it and fooled with it in the driveway and the other day the 10 and the 13 finally got towed away from here and the 13 with the JDM engine with less than $5,000 miles put on it in America and rattling again just like it did before the original engine shook itself to death and imploded right in front of me so we weren't going to have anymore of that and this engine just doesn't interest me that much so away it went never to be heard from again I hope The guy even asked me if I wanted it back when he fixed it I told him Lord have mercy No I wouldn't do that to anybody No sell it to somebody and pray to God they enjoy it He loves to fix these things I said well you should be busy for the next 5 years and he's in there Arabic dude It's always like the people you see on Facebook with all the battery stacked up on an Adobe floor and all that yeah he's from where that goes on so I don't know how much actual fixing they do but they seem to have a lot of fun.
     
  4. ASRDogman

    ASRDogman Senior Member

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    Did you change the spark plugs? Or at least switch the #2 plug to another cylinder?
    I got similar codes when I had a bad ngk plug. When I needed to accelerate quickly, it would
    stumble and I'd get a check engine light. I switched #'s 3 and 4 and the misfire code switched
    from 4 to 3.....

     
  5. Mendel Leisk

    Mendel Leisk Senior Member

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    What’s the miles?
     
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  6. PriusBackwards

    PriusBackwards New Member

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    209k. I can't tell if the head gasket has been replaced in the past. I will try some of the suggestions in the replies and update with any changes later tonight.
     
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  7. PriusBackwards

    PriusBackwards New Member

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    I'm an idiot left the EGR valve unbolted from the housing (or the bolts worked their way loose, I didn't use any threadlocker, will be doing that upon reassembly), I'm surprised it lasted this long without acting up. I unhooked the valve connector and the car ran fine, will be heading to the junkyard tomorrow to get new bolts. IMG_20250319_191407.jpg
     
  8. ASRDogman

    ASRDogman Senior Member

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    You don't need to use locktite. Just tighten the bolt/nuts down and you'll be fine.

     
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  9. Mendel Leisk

    Mendel Leisk Senior Member

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    Due to the head's being mangled? If you want to replace with aftermarket this has worked for me.
    (above link is amazon.ca. I believe this is equivalent at amazon.com)

    With the T-handle hex wrench I had on hand, it just sneaks by (the evap return tube) with the left-side screw. The hex wrench I'm using is 4 mm face to face:

    IMG_0316.jpeg
     
    #9 Mendel Leisk, Mar 20, 2025
    Last edited: Mar 20, 2025
  10. ChapmanF

    ChapmanF Senior Member

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    Or do you mean those attaching the valve to the cooler?
     
  11. PriusBackwards

    PriusBackwards New Member

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    Got it all put back together with the new bolts from the junkyard and loctite red, everything runs great after a 50 mile drive and I'm getting about 3mpg more than before because of the injector cleaning. My biggest tip for getting that bolt on the close side of the motor is to use a 10mm socket on a 1/4 socket drive to 1/4 hex drive adapter and driving the 1/4 hex end with a 1/4 socket. The skinny shaft should clear the various coolant lines with only the EGR cooler to manifold pipe removed and the 1 12mm nut and e-torx stud removed.
     
  12. PriusBackwards

    PriusBackwards New Member

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    The lower 10mm bolts (not the black plastic hex ones) were missing on mine, whether they somehow loosened and dropped or were never reinstalled is a mystery to me. The threads are on the EGR valve side and the bolts come up through the elbow with the e-torx stud from the bottom