Unknown problem after some work i’ve done, please help

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by ToyotaCoyotta, May 15, 2025 at 9:04 PM.

  1. ToyotaCoyotta

    ToyotaCoyotta New Member

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    Check youtube video first:


    There were no major problems with the car, except for one issue: when sitting in traffic, if the battery discharged and the gauge dropped to two bars, a slight vibration would appear when the gasoline engine kicked in. During the time it took for the battery level to rise from 2 to 3 bars, the engine didn't run completely smoothly (but nowhere near as rough as in the video).

    P.S. This issue was present both before and after the LPG system installation.

    I've also noticed that when pressing the gas pedal harder uphill, there's a slight pulsing sound (not reflected in the RPMs, which rise smoothly), so I didn't pay much attention to it.

    Recently, there have been two instances while driving where the car suddenly lost power, as if the gasoline engine had shut off. I continued driving on the battery until it fully discharged, and the car came to a complete stop. After turning the car off and restarting it, everything seemed fine. Diagnostics showed two error codes: Poor Engine Power and Engine Failed to Start. After clearing the codes, the car drove normally again.

    Today, trying to address these potential issues as a preventive measure, I:
    - Replaced the EGR cooler and EGR valve (both were cleaned and shiny).
    - Installed new spark plugs (one of the four plugs was hard to unscrew and had some slight corrosion).
    - Changed the transmission fluid.
    - Reassembled everything, but now it's clear something is wrong when starting the engine.

    I kindly ask for your advice on where to start looking for the problem. What might I have done incorrectly, and where should I check?

    No error codes are showing on startup.

    Car details:
    - Toyota Prius 2009 XW30, 2ZR-FXE 1.8, gasoline-LPG
    - Spark plugs used: Denso Iridium IXEH20TT
    - Transmission fluid: ATF T-WS Ravenol

    Current mileage - 141000 kilometers (not miles)
     
    #1 ToyotaCoyotta, May 15, 2025 at 9:04 PM
    Last edited: May 16, 2025 at 4:45 AM
  2. Brian1954

    Brian1954 Senior Member

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    Check for vacuum leak.
     
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  3. rjparker

    rjparker Tu Humilde Sirviente

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    Sounds like a gen3 1.8L misfire, usually caused by a leaking head gasket.

    Given you tore down the egr, check all vacuum and pcv hoses.
     
  4. Grit

    Grit Senior Member

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    All this information but no miles driven? Oh well, off to another thread.
     
  5. Mendel Leisk

    Mendel Leisk Senior Member

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    What is “”LPG”, when did its installation occur, and what did that entail?

    video sounds like head gasket failure. What is the extra hose apparatus for? Maybe: Liquid Petroleum Gas??
     
  6. rjparker

    rjparker Tu Humilde Sirviente

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    LPG as an engine fuel is primarily propane which is more common in cars overseas like the op. He said the problem was there before the lpg conversion.
     
  7. BiomedO1

    BiomedO1 Senior Member

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    Probably liquid propane gas; it's a popular conversion in countries that has no oil. It's cheaper than gasoline over there.

    The problem existed before the conversion; but rather than fix the problem first - they converted it. So now the question is the conversion tuned properly or is it adding to the existing problem or did it get worse on it's own???
    Don't know how they were going to properly tune and balance the propane injectors with a potential head gasket issue; but that's just me.......
     
    #7 BiomedO1, May 15, 2025 at 11:26 PM
    Last edited: May 15, 2025 at 11:48 PM
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  8. ToyotaCoyotta

    ToyotaCoyotta New Member

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    It has 141000km driven
     
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  9. Tombukt2

    Tombukt2 Senior Member

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    It's a Prius forklift. This is what forklifts run when they're inside a lot LPG liquid propane gas conversions they can be problematic sounds like he's got a head gasket leak and this expensive conversion holy cow amazing.
     
  10. Tombukt2

    Tombukt2 Senior Member

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    The old original Toyota 3r and 8R were originally forklift motors for Toyota forklifts then they were shoved in cars to be sent in the states in like 70 for the first gas crunch so they took the LP gas setup off a lot of these and made them gasoline for federal specification in a little car called a Celica. Funny thing is they never ran really well okay not really well
     
  11. rjparker

    rjparker Tu Humilde Sirviente

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    In many countries like the op lives, LPG can be 40-50% the price of gasoline, primarily because of tax reduction on LPG. They often have LPG stations everywhere. In the US LPG has no price advantage or wide availability.
     
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  12. BiomedO1

    BiomedO1 Senior Member

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    LPG is used mainly for cooking over there; not hit with road or infrastructure taxes.
    I believe the state of Utah, used to do a lot of these conversions - until it wasn't economically feasible any more. It's less energy dense than gasoline; so half the range of gas powered cars.
     
  13. Tombukt2

    Tombukt2 Senior Member

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    Oh yeah we have these cars in North Carolina as government cars not all of them but a bunch of them no Prius but they have Prius but just in standard gas trim a lot of Chevrolets and some trucks they got with the LPG conversions and it's a bunch of extra parts bolted up and all that business so I guess troubleshooting can change a little bit.
     
  14. rjparker

    rjparker Tu Humilde Sirviente

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    Per afdc.enery. gov
    • Propane contains 10-15% less energy per gallon than gasoline. This means a vehicle might see a 5-10% reduction in mpg when switching from gasoline to propane.

      Octane Rating: Propane has a higher octane rating (104-112) than gasoline (87-92), which can allow for more aggressive [optimized] engine tuning and potentially improve fuel economy.

    A converted vehicle is usually setup for bi-fuel meaning it can switch between LPG and gasoline.

    A Prius with its knock sensor will take advantage of higher octane. The value of higher octane gasoline in the US is negated by the price of high octane fuel.

    Here is a first hand Dominican Republic non-optimized experience:

    IMG_8290.jpeg
     
    #14 rjparker, May 16, 2025 at 1:26 PM
    Last edited: May 16, 2025 at 2:28 PM
  15. BiomedO1

    BiomedO1 Senior Member

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    Yep; and no talk about failing to pay their fair share of road and infrastructure taxes back then either!!!!!:(:mad::whistle:
     
  16. ToyotaCoyotta

    ToyotaCoyotta New Member

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    This thread turned into lpg discussion, but I dont mind at all.

    I have possibly found what could be the issue, Before dismantling the car I had extra EGR cooler along with egr valve, I cleaned them with oven cleaner, egr cleaner, Karcher strong pressure and could have broke something inside it,
    Apart from that I have cleaned the EGR valve, and one of the end is electronical part that has two screws, one of them screwed easy and the other one has broke like butter, i had to cut a minus sign in order to unscrew it, inside there was a bearing and spring which i took away to check if its not dirty, nothing was there so i screwed it back, I did exactly the same with the part that I tried to replace, and same exact thing happened, one screw was easy, other broke like butter. Someone told me that they cant be unscrewed because they are percisely calibrated in factories and if you unscrew it you can already throw it away.


    I am gonna buy a third one tomorrow and try to replace it without unscrewing or touching the bearing with spring part at all, ill appreciate any comments on what you think about this
     
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  17. bisco

    bisco cookie crumbler

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    we're fascinated by unusual (over here) energy sources
     
  18. ToyotaCoyotta

    ToyotaCoyotta New Member

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    what do you mean? im from lithuania fyi
     
  19. Brian1954

    Brian1954 Senior Member

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    There is nothing calibrated on the EGR valve. You can take it apart and put it back together again with no problems. You just need to make sure the valve is in the closed position when you put it back together.

    You are probably thinking of the position sensor on the throttle body. That sensor is factory calibrated and sealed. You do not want to take that sensor apart.
     
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  20. Tombukt2

    Tombukt2 Senior Member

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    Yes run the EGR screw down to asssemble. Or break shiet.