Gen4 to Gen3 engine swap using gen 4 intake and egr, DONE!

My 2010 prius blew a head gasket @ 255,000 miles. So with the inspiration of Rafit and cnc97, I decided to swap in a generation 4 engine. I found one with 94,000 miles for $450 shipped on Hollanderparts(Car-part is another good site), half of what they wanted locally, me picking up not dropped off right under my hoist. New engine came with wiring, egr system, intake and exhaust manifolds but no throttle body(I reused my old one spinning it 180°). I wanted to use as much of the new parts as possible but knew the exhaust manifold was a no go without the downstream exhaust and at another $450 was out of the budget. So, I set out to see if my old exhaust manifold would work with the new egr system. Bolting it up, the old egr pipe on the exhaust manifold was the correct length but to low and bolt holes were twisted clockwise. After much deliberation, I took the plunge and heated the pipe up cherry red with a torch, first at the bottom to raise it most of the way, then in the middle to twist the flange and raise it into the final position. I was surprised that it went so well. Pipe post heating is in first picture. Using new intake involved: changing manifold absolute pressure (map) sensor wire connector and moving it down out of the way of the old air horn(also had to cut off its old mount)pic #2, pic #3 shows shortened intake pipe 1/2" and trimmed webbing to lower air cleaner box back down ware it belongs. Rest of pics show minor changes, mostly to wiring harness and finished product.

 

Yes and it was pretty clean inside,just a light carbon coating, which brake cleaner easily took care of. I wish I would have taken pictures, but I was preoccupied with getting it to work.

 

Update, fixed a drivability problem with the help of Sandog58, who happens to be doing the exact same swap. Had to swap the red and purple wires going to the egr. Why Toyota did this is baffling and it's truly amazing that Sandog58 figured it out. Here is a picture of the plug before the red and purple wires were swaped.

 

Really don't notice any changes in power, the electric motor provides most of the torque for acceleration, anyway. Just runs much smoother than the old one, now that I got the egr wiring straightened out. Also, still running the old 255,000 mile catalytic converter so that's not helping things. Have driven less than 300 miles since the swap but my gas mileage still seems also to be the same at about 45. If I can sell my old cleaned egr system and intake(both available in the private sale category), I probably will buy a gen4 catalytic converter and do the entire gen4 swap. On a side note, I did take apart my old engine and aside from the slime from the blown head gasket, it was in remarkably good shape. Rings were all free, still crosshatching on cylinders, bearings all looked good and that's after driving it 25 miles home, with my wife and daughter. It was missing badly and the temperature light was no most of the way but we made it. Didn't think it was worth fixing after that and wanted to see how far I could take the gen4 swap anyway.

 

I'll try to pop the hood and get a comprehensive list of all the modifications I made. Off the top of my head.
1. Add ; Do this before installing engine, not like I did.
2. Swap red and PURPLE wires on EGR valve connector.
3. Good
4. Add 3/4 pex tee in water line to accommodate lose of connection on new egr cooler. Routing I used, I will have to check out, Sandog58 would have the routing as Toyota did it on gen4, my tee is in a different place. I did this for faster heater core warm-up.
5. Add L bracket on valve cover bolt so you have 2 supports on air box. You loose the one on the intake manifold.
6. Move and change wiring pug for MAP sensor, wires are old yellow to purple, gray to blue and black to black. Cutoff old mount on intake manifold, it interferes with the air horn.
7. Drill out ground connectors and bolt one to passenger and one to drivers side of head.
8. Remove mount, saving water hose connector, of vacuum switch going to gas tank. It moves toward the passenger side to make room for the top air box mount.
9. Miscellaneous wiring harness changes for slight sensor moves and for new lower radiator hose route. I used the new wire loomes on the top of the engine with the old wires because I thought that they gave it a more finished look.

 

This is how I connected my hoses, with gen4 egr cooler. What gen4 parts are you using?

 

Excuse my poor penmanship, should be temp. sensor/ bleeder. Of course, Toyota got rid of the bleeder on post 2010s.