Swapping in a Gen 4 Prius' 2ZR Engine into the Prius v

Well there's a problem, the oil'll get out there...

Oh, I didn't know that. I kinda lived down in our crawlspace, for a few months, refurbing the carrying and return ducts on the forced-air system. Would get hand cramps sometimes. Should have taken along bananas.

Torx E8 sockets (usually 1/4" drive) for the EGR studs, and E6 for the throttle body studs (if you opt to remove them from intake manifold).

 

thank you mendel, what surprises might I find in the throttle body area? should it be taken apart for cleaning while down? or is there something more specific i'd be looking for?
took to egr/cooler apart .it was disgusting! then I indexed the egr valve and removed that little motor cover. the armature came unwound, so I spun it back down and reassembled. hoping all will be well.....does someone know a bench test to actuate the valve after cleaning?

 

Ugh, that's a bad EGR. Besides flow restriction, I'd think there's precious little cooling happening.

I would clean the intake manifold thoroughly, remove the the MAP sensor (to the right, below throttle body) beforehand. Maybe spritz it with MAF sensor cleaner. It seems fairly durable (spends it's life in an oily cesspool) but be careful, it's over $200 IIRC. Just go over the throttle body and blade with a cloth soaked with carb cleaner, good time to do it.

I did Oxi-Clean soaks on the intake manifold, and you want to pay close attention to the EGR passageways (one per intake port).

Watch @NutzAboutBolts videos, pinned at top of 3rd gen maintenance forum; he covers all these cleanings.

How are you going to pull the motor, same as @Ragingfit?

 

thanks Mendel for your response, not sure how the egr system is supposed to work(cooling,etc.) but just one look @ that carbon build up and even I knew it wasn't/couldn't work as so carefully engineered. But, before I can thoroughly clean the intake manifold, I must first "drain out 'Toyota's' oil bath-air filtering solution" hopefully for the last time... what does "IIRC" stand for please? ok, I identified those small holes in the manifold where it contacts the engine, the four holes plugged with oil & FUNK...I will definitely take your advise and watch said videos on cleaning manifold. as far as motor extraction, yes, just like Ragingfit, but I don't plan on unbolting ex manifold from head. every thing has been spot on. My wife's prius would still be just setting in the front yard getting mowed around, if he hadn't taken the time to put this video series out where I could see it for myself, I truly shall owe him a huge thank you once completed. I can't wait "to like the woods!"

 

Yeah, it's a long way from new condition, and that can't be good.

IIRC (stands for: If I recall correctly), when @Ragingfit was pulling the engine, he looked around back kinda bemused, discovered he'd forgotten to remove the exhaust.

I had this quote as a signature for a while, loved it:

"Well we're not out of the woods yet, but uh, certainly feeling ok about it... Starting to like the woods." - raging fit

I like that one of yours too, about "mowing 'round the Prius", lol.

 

Wow your egr looks like mine did before I started cleaning. That means there is a lot, no I mean a ton, oh hell that is REALLY $&!? Clogged!!!!

You definitely need to get as much buildup out as possible. Make a soak to soften it, but you will need to poke a wire through to get the most surface area for the solution to do it’s job. Or, find a shop that will clean it for you chemically or with an ultrasound (I think it’s time I get one for Father’s Day this year)

Since your still working on the engine, let someone else clean it, it will go faster.

And that is a pretty engine. Is the top valve cover plastic or just painted black?


-Spiral

 

I took the “Murphy’s Law” approach and removed the exhaust. I didn’t like the proximity to the windshield that it would bring. And as it was, if you attach the chain at the wrong point, the hoist could be in the windshield too.

 

Oh I and I wouldn’t apply voltage to the egr to test, just pull the cap and push it open manually.


-Spiral

 

Just remember the impact screwdriver to avoid stripping the heads of the screws.

 

Potassium tablets help prevent cramps.

 

He got it open. And something maybe "sproinged"? But he got it all back together.

I decided to let the screws win. Maybe would be more agressive IF I had replacement screws. Then it would go smoothly, of course.

Anyway, I found I could gently pry the valve open, shoot brake cleaner (or carb cleaner, probably better) through, run a flat tip screw driver gently around the circumference, and get it clean without opening. I think.

 

Through the use of an impact screwdriver, I know I got the valve and the seat cleaned.

Another nice tool for the garage that gets used sparsely but when you need it, you have it .

 

You mean a manual one, that you hammer? I've got one, still seemed kinda borderline, if it was going break loose or much, so I backed off.

I'm done, think that EGR system will outlast me.

 

thanks for the responses, I had to stop and get a subway sandwich & go get a stereo that can tune in CLASSIC ROCK to help me push through this ever-mounding pile of more & more B.S., this EGR has put the brakes on this swap for me & has me side-tracked, not happy at all !
Mendel, I've been making that circle around the Prius for about 18 mths...my wife,.
Spiralhelix, thanks for the response and suggestions. The valve cover is plastic. When the EGR gets clean should I be able to see thru it like you would a radiator? right now you can't see a LED light thru it !! Should I be concerned about the catalytic converter now? if it's clogged or damaged will there be a "code" to identify it as problematic? if it is damaged or clogged, will it hurt this "surgery" that's being performed?
So there's no tricks to the reassembly of the EGR motor? "UNBELIEVABLE!"
cnc97, I will watch ever-so-closely to that SPECIAL windshield during removal & will try to remember to take pics of the clearance I have, or the lack thereof. Oh yea, just for the record, I hate MURPHY, his brother, sister, father, mother, especially his mother!
Raytheeagle, ALL phillips heads get the IMPACT treatment here, thanks for the heads-up.
mikefocke, bananas just taste better I guess, but at least there's a pill for THAT as well!

 

Once you get the egr cooler cleaned, you should be able to pass a flashlight through one side and see it in the other side.

If not, it ain’t there yet.

Power through and you’ll get there. I’m a 90’s alternative guy (what I grew up listening to). Crank it up and you’ll get there.

 

this fuel line... Dejuvue or what (ragingfit, part 5/ 7:05-7:50) at least I know it can be done! Right now, I just want it off, whatever it takes, give me gas in the eye, both eyes, if that is the necessary sacrifice to move forward....might be slow though during recovery time

 

He had some little plastic pieces that help, disconnecting the fuel line?

 

yes sir, I agree. I had taken note of those and purchased them (harbor freight #63595), but his was a "one piece", mine is now a "two piece". so no gas in one or both eyes, just a pure beating down today. "I'll Be Back!"

 

I took an EGR motor apart, cleaned it, and it was still broken. It never worked after that.