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

MAF sensor and throttle body are clean?

 

Gas tank vapour lines verfied as hooked up? Third gen intake pic:

 

A failed start with only code 3190 and smell of gas is reminiscent of my experience (see above post). It strongly suggests a vacuum leak. In my experience the leak was causing the engine to run very lean and causing insufficent engine power.
Techstream data could reveal some information.

I've diagnosed a suspected vacuum leak before with carb spray - although the engine was running (small leak). With a large leak preventing an engine start you may need better tools - smoke generator. With the engine off you could inject smoke into the PCV elbow. That could show smoke coming out of an intake manifold gasket or EGR cooler. With engine on and a big enough smoke generator you should be able to see smoke being drawn into a vacuum leak. An assistant may be needed. Disclosure: I have only read about smoke generators and not used them...

 

Yeah. I was down last night. But I’m not giving up. Going to retrace everything again tonight. Mad and throttle body are clean. This is going to work. Im not putting old shit back on it if I don’t have too. I’ve made it this far.

 

Gen 4 Injectors. I will try gen 3 intake and throttle body tonight and see what changes. I know several have done this and used all the sensors and just swapped egr, intake and throttle body, so has to be somewhere in there.

 

It's the orange plug in the hybrid battery. We've all done it and it's so stupid.
- Fix That Prius!!!!

 

It’s in and slid over all the way. I double checked it.

 

Ok. I swapped to the older intake manifold and the throttle body. 3190 went away. Now I have cylinder 2 and 4 misfire codes. I swapped packs. Nothing i swapped plugs. Nothing. I noticed fuel on the plugs when i pulled them. Would a 10k mike motor have a faulty injector?

 

Just curious: does the 4th gen EGR pipe connect ok to 3rd gen intake manifold?

 

Yes. Lined right up.

 

Geez, I would stay with 3rd gen intake and throttle body then, and then the air box, air intake snorkel all fits, looks stock.

That's kinda eerie, because the 4th gen EGR pipe is different, ditto for the valve and cooler.

Hope you sort out your other issue, and thanks for all the info.

 

Make sure the intake gasket is still in place at those two cylinders. A bad injector at that mileage is possible, but the odds are certainly against it happening, one would think anyway.

 

The other question, did you change the whole rail, or take the injectors off the rail. If the upper o-ring gets torn, the fuel leaks past the injectors like it’s nobodys business. And it also causes a vacuum leak affecting only that specific cylinder. And you may not see fuel leaking outside the injectors either.

 

Yeah. Just injectors. Checked rail. Checked o rings. I’ll try again tomorrow. I’m beat for tonight.

 

Ok. Had to walk away from it a couple of days and work on the old beater truck. Back to the prius.

New EGR and old EGR obviously are different. The wiring in the plug was different. The new egr plugged into the old plug was causing it to hang open which was giving me the misfire codes. Tried using the old cap but the plungers are different size. Test drove a new prius and stopped off to the side of the road and tested the wires with a multimeter, repinned the plug and she purrs now. I am still on old IM and throttle body, going to try and make that switch back tonight. One problem at a time.

 

Go back to third gen EGR might be in the cards?

 

You literally can depin the plug, move three wires and it functions just fine. So I am sticking with the new egr.

 

Oh, ok. Missed this bit:

Again, you guys are pioneers.

 

The EGR is basically like an air valve, magnets adjust the valve open and closed. When it misfired it was stuck open. I happened to touch it and it was warm. I realized the power wire was in the spot of the signal and was commanding it to hold open. I took the cap off allowing it to close and the car ran fine. No codes except egr. Thats when it was time for a test drive. I want to make the rest work. 200k on this prius with a terribly designed IM and EGR with no help from toyota, dont want to go down this road again if I can help it.

 

We are very like minded, I was doing the exact same thing at basically the same time. My post is in the gen 3 technical discussion, so I don't know if you saw it.(not sure how to link it either) here is the picture of my exhaust manifold modification and another of the finished product. I'd be happy to help any way I can.