1. Attachments are working again! Check out this thread for more details and to report any other bugs.

Engine swap question

Discussion in 'Gen 3 Prius Technical Discussion' started by cnc97, Jun 29, 2018.

  1. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    One note to anyone else that sees the post and wants to do this. The “port” below the VVT solenoid is just the post the engine cover sits on. It is not open to the inside of the valve cover.
     
  2. Rmay635703

    Rmay635703 Senior Member

    Joined:
    Oct 16, 2016
    2,609
    1,624
    0
    Location:
    Somewhere in Wisconsin
    Vehicle:
    2013 Chevy Volt
    Model:
    N/A
    That’s why I go to a decent U-pull, they aren’t always the cheapest but I pull what I want, how I want, run it by them on the way out, usually ends up cheaper because they don’t needlessly pull stupid stuff off damaging seals that they will never sell anyway.
     
  3. Mendel Leisk

    Mendel Leisk EGR Fanatic

    Joined:
    Oct 17, 2010
    56,667
    39,220
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    @cnc97 This is a 4th gen engine? The EGR mount will likely need some adapting, just of top of my head. Good luck with this project. (y)
     
  4. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    Yes. Gen 4 engine. There are open threaded holes on trans end of the engine. The Gen 3 engine in my car has studs in the open holes. Looks like just moving the studs around. All the sensors look to be in the same places with same connectors. I won’t be able to use the Gen 3 engine cover. And they could not find the Gen 4 cover that came off the one I bought.
     
    Mendel Leisk and JC91006 like this.
  5. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    I did pull the oil filter out of this engine. Very clean. Appeared to be OE filter. No debris in the oil that drained out. I saved it in a clean mason jar and poured it over a magnet. Since I’m putting 3, maybe four days into this, I wasn’t taking any chances.
     
    Grit, JC91006 and Raytheeagle like this.
  6. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    Gen 4 coils are plug and play on the Gen 3. I pulled one off the Gen 4 I bought and plugged it in to my car. It fired across the plug gap. There is plenty of wiring as the Gen 3 coil for cylinder 4 is canted, but the Gen 4 coils have the connector pointing straight rearward.
     
    Rmay635703, Grit and JC91006 like this.
  7. Aaron Vitolins

    Aaron Vitolins Senior Member

    Joined:
    Feb 28, 2014
    1,612
    1,144
    0
    Location:
    Franklin TN
    Vehicle:
    Other Hybrid
    Model:
    N/A
    Your
    You're my hero! I'm so excited for this project! My father and I replaced my sisters 2010 engine due to headgasket failure and high oil consumption. We bought a very low milage prius plug in engine. Runs great and wasn't too terrible of a job. I'll be sooo interested to see what type of mpg you'll get with the updated 1.8! Beyond happy!
     
    Grit, Shane Burns and mjoo like this.
  8. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    The yard told me 8100 miles on the 17 this engine is out of. The plugs look great and the oil was very clean. I have not found any reason to doubt them yet. Looking at mine, I think I will have to reuse my intake, as they broke the map sensor off of the donor engine. Surprisingly they only cut the two hoses feeding the heater core. Every other coolant hose connection was just taken apart.
     
    Aaron Vitolins and JC91006 like this.
  9. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    So the following realization just came to me. I want/need to get this done so I can take it to the local Toyota dealer for service. So I can see if they notice my Gen 3 has the heart of a Gen 4.

    I think I might let them change the trans fluid just for kicks
     
    ITBland, Grit, Shane Burns and 3 others like this.
  10. Shane Burns

    Shane Burns Member

    Joined:
    Oct 30, 2015
    94
    125
    0
    Location:
    SoCal
    Vehicle:
    2005 Prius
    Model:
    N/A
    Following. I’m getting excited on your engine swap!
     
  11. Grit

    Grit Senior Member

    Joined:
    Aug 22, 2017
    6,173
    4,077
    1
    Location:
    Wilkes Land
    Vehicle:
    2012 Prius
    Model:
    Four
    Im rooting for ya, and may follow suit.
     
  12. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    At 430pm on Tuesday the fun begins. I don’t have to be back to work until Friday morning. Weather looks to be in my favor. I’ll be so glad to get my car back together.
     
    amos, Shane Burns, mjoo and 1 other person like this.
  13. Mendel Leisk

    Mendel Leisk EGR Fanatic

    Joined:
    Oct 17, 2010
    56,667
    39,220
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    Have to say, I'm waiting for the "pin to drop" as the Brits say, when things don't fit up, due to 3rd vs 4th gen variations. The EGR connection will be interesting, not sure how that's going to work. That said, think good thoughts, hopefully you can "engineer" through any difficulties. (y)
     
  14. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three

    Since the yard took the EGR cooler and manifold with converter, I’ll be reusing the Gen 3 items. Looks to be moving a couple of the studs around to bolt things back up. I have all the engine sensors except the MAP sensor that they broke off of the manifold. I looked into getting that sensor, but I will just reuse the Gen 3 intake. Im 92.5% sure that things will go according to plan. I still have a few things to look into, but I have to wait until my car is apart to see if things are going to work. The exhaust gasket matched the new one I had at work. If I didn’t have to work tomorrow, I’d get started tonight. I know that if I start, I won’t quit until it’s running.
     
    amos and Mendel Leisk like this.
  15. mjoo

    mjoo Senior Member

    Joined:
    Nov 9, 2016
    1,134
    1,324
    12
    Location:
    Michigan
    Vehicle:
    2010 Prius
    Model:
    III
    That should be the least complex plan. I'd try bolting on 3rd Gen exhaust and intake manifolds and EGR system to new engine externally to test for fitment. Once tested strip it down again and install the new engine.

    It shouldn't take more than a half hour to test with a cordless drill/ impact wrench.

    Pixel XL ?
     
  16. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    I can literally have the intake off in 10 minutes without electric tools. The exhaust will be a little more challenging. Going to work on that tonight a little bit.
     
    mjoo likes this.
  17. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    The intake does fit. There are some adjustments that would be required to use the Gen 4 intake. So I will use the Gen 3. Looks like I will have to change over the oil dipstick tubes between engines.

    Since I had the wiper cowl off, I held my phone down and got a pic of the hole in my block. I can tell you that my engine threw enough oil to overwhelm my OCC. It was full along with my hoses going to it.
     

    Attached Files:

    Rmay635703, Mendel Leisk and mjoo like this.
  18. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three

    Absolutely bolting Gen 3 manifolds to it for photo op before installing the engine. If anyone seeing this has suggestions of pics to take, send me a PM or post them here. The more information I can provide will only help the next person doing their own swap.
     
    mjoo likes this.
  19. padroo

    padroo Senior Member

    Joined:
    Jan 11, 2008
    2,763
    2,251
    13
    Location:
    Chesterton, Indiana Another third world country.
    Vehicle:
    2016 Prius
    Model:
    Four
    Looks like a big difference in the intake manifold design, I wonder why?
     
    m.wynn and Mendel Leisk like this.
  20. cnc97

    cnc97 Senior Member

    Joined:
    Mar 13, 2018
    1,422
    1,532
    38
    Location:
    Evansville, IN
    Vehicle:
    2010 Prius
    Model:
    Three
    I know that where I had my OCC hoses routed interfered with intake. And oil dipstick tube is bent differently. As far as design, I don’t know. Does anyone with a Gen 3 have the “replacement” intake noted on the TSB for the startup knock?