Advice on gen 4 engine into gen 3

Ok, none of the pros here mentioned anything about codes upto this point. Which means, if there are codes, it's not going to be specifically from putting a gen 4 engine into a gen 3 body. Great.

 

Ok, just finished watching the following videos. Each mentions an "oxygen sensor reading" code that came up and went away after clearing it.

That seems to be the only error code one can expect from this swap, which, again goes away by itself.

The third video demonstrate that the gen 4 engine is infinitely quieter and smoother, with a gain of about 3 mpg. This is the way to go.

(part 1 of 2)

(part 2 of 2)

 

Believe me. I tried. Would take me forever to find where he talks about what I'm looking for.

 

This reminds me, a few months back I hooked up my torque app and looked at the water pump readout labelled "WP run". It said it was off the whole time the car was running, but the coolant temp levels seemed to be within normal range and there was no code, so I just ignored it. I have it circled at the bottom on a screenshot of my app. Maybe this was a sign I shouldn't have ignored it. Better check my water pump when it comes off.

 

The garage with the gen 4 engine sent me pics of their engine posted below. I didn't expect the transmission to be included, but it is, and the whole thing looks to be in pretty rough shape. It's missing a coil and there's quite a bit of rust already on this newer engine. I'm guessing the earlier estimate assumes both the newer engine and tranny to be swapped in together, so the question is:

1. Will the gen 4 tranny fit into the gen 3 chassis?
2. Is it worth putting in this newer tranny if it does fit?
3. Should I even use this engine given its condition?

 

As expected, the tranny is not included in the job. The good new is, there was a discussion about the pictured AC compressor possibly being swapped in together if it fits. Anyone know if it does?

This is a great shop that deals with lots of Prius taxis and other alternative fuel vehicles. Spoke with Dave the owner and he said it can be done even before the new year. They are called Alternative Fuel Solutions Automotive, in Burnaby BC. They specialize in propane conversions, engine repairs, and fleet services. They also work with a ton of Prius vehicles owned by taxi and Uber drivers. So if you have a Prius in the greater Vancouver area and need any work done including an engine replacement on a gen 3 using a gen 4 engine, this place will be your best bet. They had a gen 4 engine available for my swap, which is awesome. I will post updates as they arrive.

 

Shop sent me a pic of my AC compressor which was destroyed by the thrown rod. Luckily, they had a compressor from another 3rd gen laying around, so they put that in. What a win.

They told me the car was ready at about 2pm today, which is a phenomenal turnaround time that totally surpassed my expectations. Stay tuned for more updates.

 

Got word it was done later last Tuesday. Picked it up the day after. Engine idled way quieter, and everything was as expected except there was a certain misfire-like hesitation at low RPM accelerations.

The problem was, I told the shop they can use the gen 3 EGR, but they actually kept the gen 4 EGR by bending pipes to retrofit the gen 3 intake and exhaust, which was a bonus for me, but they forgot to re-pin the connector for the newer EGR according to this thread. That's why there was a bit of misfire going on.




So I re-pinned the connector myself and the problem went away immediately. (If you DIY, make sure you watch this and do it right).


A bit of surface rust on the engine, but can't feel it performance wise. Vastly superior engine, good shop (AFS Automotive in Burnaby, BC), standing by their workmanship. Overall, a win for my situation.







On top of all that, I also got my AC recharged

 

Ok according to this I now have a vestigial EGR valve and no actual EGR going into my engine. How will this affect the longevity of this engine? I guess with no EGR the engine will run hotter, but just how much of a cooling effect doe EGR have? I guess I can monitor my coolant temperatures using my torque app and see how it matches up to others running the same engine with a working EGR?

 

I'd like to hear as well.

When I first unplugged the EGR valve connector to see if the car drove better without it, it did, but gave me a CEL right away. After re-pinning the wires and clearing the "EGR valve disconnected" fault code, the car drove well just like when it was disconnected, but there was no CEL.

I'm just guessing but wouldn't the ECU be able to make some air-fuel adjustments via the oxygen sensors (which would now sense more oxygen due to the EGR delete) to somewhat compensate for the lack of EGR?

It would also be useful to find out if other parts of the engine or vehicle are set up to detect a lack of EGR and throw a code in response to it.