Engine swap question

Good Work

Maybe the Gen IV swap will be worth the pain to the elite few because of the fuel economy?

 

hopefully a Nutzaboutbolts' video will be coming out on this

 

I'm very happy for you!

 

I just like how gen 4's ICE comes on after 54 mph, turd gen will only go up to 43 mph then ICE kicks in. Maybe hire someone to swap the engine for me, gen 4 looks aesthetically awful but I'd take the engine over gen 3 engine any day.

 

That likely has more to do with differences in the transaxle than in the engine. So for the next challenge project, retrofitting a Gen 4 tranny to a Gen 3? Should leave lots of extra room for air horns or something (an aux battery perhaps?) at the left side of the engine compartment....

-Chap

 

You've answered a lot of my questions about the Gen 4 engine swap into a Gen 3. Here's the result of my swap into a 2012 Prius v. I was able to use the head after modifying a few things.

 

@Ragingfit : Using Gen 4 EGR cooler you likely have a misfit connecting to the (Gen 3) exhaust. Hopefully a gap, not interference, and then it's a matter of fab'ing an adapter to bridge the gap? Or was there no misfit?? That would be interesting...

 

A V might be a bit different than a normal Gen III

 

I used the gen 3 intake, EGR and EGR cooler. Had to cut a nub off the head that interfered with a gen 3 EGR cooler pipe.

 

A v's engine bay is a Prius engine bay - same everything until the cat and exhaust pipe.

 

Does the EGR cooler, valve and pipe then free-span between intake manifold and exhaust connection? Or are some of the boltings in-between compatible? I think even free-spanning it would be stiff as heck, but just curious.

Good info btw.

 

Yes, the EGR cooler is not connected to the block or the head. It is VERY stiff and does not move. You may be able to get the dreaded bottom bolt / stud & nut into the head but I don't want to. Also, I had to use the Gen 3 exhaust manifold because I did not have a gen 4. I'm getting a gen 4 exhaust manifold today to test out the possibility of using the gen 4 intake manifold, EGR and EGR cooler on my car. I suspect there will be a misalignment at the cat. We'll see. Stay tuned!

 

It's not a straight forward swap. There are 5 or 6 modifications you have to make. This is what I did; I used the gen 4 engine, head, water pump, thermostat, fuel rail, injectors, coils, spark plugs, valve cover & sensors. I did not dismantle the engine in any way. I wanted to use all the new stuff that came with my salvage engine because it had 3200 miles on it. I could NOT use the Gen 4 intake manifold, EGR or EGR cooler, and I did not have a Gen 4 exhaust manifold. I will try all the gen 4 stuff, but the point that things don't line up just moves down the line. You must change the flywheel / damper, thank you cnc97 for that one. You must lengthen the wires going to the temp sensor on the head because it moves forward. You must remove the "S" shaped lower (driver's side) radiator pipe and replace it with a 1" galvanized pipe, 8" long or use a Gen 4 lower radiator hose. You must cut a 3/4" to 1" nub off where the EGR cooler mounts to the new head to make room for the OLD EGR cooler. The EGR cooler is held only buy the exhaust manifold and the intake manifold. It is SOLID! You must relocate the ground terminals to the engine. I had to drill out the terminal holes and bolt them to the front. Finally, you must install a 1/2" PEX T in one of the coolant lines because you loose a hose connection when you remove the "S" shaped pipe. I`made the T between the coolant tank, head and throttle body. I will be doing another GEN 4 swap, into a 2012 Toyota Prius v at the end of August and hope to video the entire process. Stay tuned, and tell your friends. Thanks for your interest. Sincerely, Thomas E. Bourassa - Fix That Prius!

 

You, cnc97, inspired me to do the swap. You did all the research. You answered all the questions. I knew it was going to work because you went there first. Thanks for leading the way.

 

Looks like the engine swap from high mileage Gen 3 with Gen 4 motors is going to be a common thing now thanks to our new pioneers.

 

Hopefully not too common. It's still heart surgery