Tuesday, February 7, 2023

CT200h - Intake, EGR valve and cooler assembly PCV swap & Lessons learned.

Nothing out of the ordinary here, this has been well documented. I didn't however need to take the plastic cowling, wipers and tray off. I was able to get to everything without doing so.  

Lesson learned:

So, this was interestingly annoying! I got the new egr valve with part number 25520-37120 which replaces the part number 25520-37110 that was currently on my car. Well, after swapping everything the car started but the 'Check Hybrid System' warning came on and I couldn't put it into gear and it wouldn't move. I reset the 12V battery and the hybrid battery with no change. On further research I found out that there was a TSB issued, L-SB-0015-16 in regards to the EGR Valve for 2011-2012. The TSB would update the ECU to accept the new EGR part. Considering that my CT has been serviced completely at Lexus till about 2020 I figured it would already be done. Anyway, dismantled my old EGR valve, cleaned it out, pulled the whole assembly out replaced the EGR valve from the assembly with the clean EGR cooler and reinstalled it. Plugged the batteries back up and all is well. 

Also, I didn't fill the coolant back up to 'Full'. Lost some coolant when I pulled out some of the coolant lines connected to the EGR cooler and throttle body. Instead of burping the system I usually just drive it for a bit till it reaches operating temperature and then park it and then next day fill coolant. The 'Check Hybrid System' message came up after about 5 minutes of driving but the car was still drivable so I attributed that to the coolant being low. Filled up the coolant the next day, reset the batteries again drove it around and no more light or issues. All's well that ends well. 

-AJ Abraham

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CT200h - Catch Can Install

 Was swapping out the EGR valve, cooler, intake and PCV valve so was the best time to install a catch can. To prep for this I had already 3D printed out a catch can holder that I found on thingverse, huge thanks to everyone who takes the time to share their work. I'll probably get one printed in carbon fiber later. 

After I found a good placement for it I drilled a hole, touched up the exposed paint with primer and then used a nutsert in the hole to hold the catch can holder. 

I cut the factory U piping from the PCV to the intake and used 3/8 barb fittings to splice into some 3/8" ID fuel hoses.  

The following pictures is just to denote how I routed the hoses  

During the actual install, I found out the front plastic engine cover didn't fit. I ended up trimming it to fit. 

All back together. Happy with how it turned out, will check on it to see how well it actually works over time.