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

@Ragingfit freespans 3rd Gen EGR from the exhaust connection to the pipe that bolts to the intake. Just passes by the 4th Gen engine without touching it. He needed to grind off one extraneous lobe on the 4th Gen head to miss the EGR.

 

Right, and there's never going to be a manual that says "here's how you make this thing work in that other car", that all has to be worked out. It's just that even so many of the explanations concocted for why such-and-such thing is happening would be better explanations if they at least started with the information already available.

and hope what they're telling you is well founded.

Edit: it comes to me that sources like manuals are really most usefully read for what they tell you about what's there, how it's meant to work, etc., than for what they tell you about how to do something.

Even in the parts where they're telling you step-by step how to do something, it's still more useful to read that for "what is this suggested procedure telling me about what's there, how it's meant to work, etc.?"

It just kind of dawned on me that that's more or less how I've been reading the things as long as I can remember, but hadn't thought about it exactly that way before.

Not to mention that the manuals here are not all just how-to-do-stuff procedures to begin with. A lot of what's in there just flat out is explaining what's there and how it's meant to work. And when a situation comes up where something isn't working as it's meant to, it's a handicap to be without that information.

 

#340 showed the pintle lift of a -37110 valve, 6 mm.

I didn't measure the pintle diameter that day, what was I thinking? It's 13 mm:



Looks like a pretty simple, straight-sided cone shape. No fancy lathe work to give it any special position-to-flow curve. They wouldn't need it; they've got 110 steps of position control, so they can do whatever curve they want in the firmware and just reflash it if they change their minds. The cone does have a slight lip to stop it when fully closed.



@michaud85, am I right that you have used a Gen 4 valve and cooler, but you are feeding it from the Gen 3 exhaust, where it comes off at the exhaust manifold, upstream of the catalytic converter?

In its natural habitat on a Gen 4, it would be fed from a pipe downstream of the cat, an arrangement known as 'catalyzed EGR' or sometimes "clean EGR". That both changes the chemical composition of the gas and lowers its available pressure, so Toyota might have had to upsize the -37140 valve, the cooler, or both, to get the rates they wanted. With that cooler and valve put on a Gen 3 manifold, the higher pressure upstream of the cat could lead to excess flow.

Or did you somehow adapt a Gen 4 manifold and the takeoff from after the cat?

It would be good to have the dimensions of the -37140 pintle to compare here.

 

@ChapmanF what valve diameter is being measured above; looks to be around 11 mm (not 13)?

 

I count 13. Look for where the 0 on the vernier scale lines up.

 

Yes, my engine components completely gen 4. It blends into car via

Gen 3 exhaust manifold to gen 4 EGR cooler
Gen 3 damper and trans to gen 4 flywheel
Gen 3 wire harness to all gen 4 sensors

Nice information about where the gen 4 takes the gasses from, clearly gen 3 comes right off head pressure which is for sure higher that after cat.

I'm peeping around eBay for gen 3 EGR cooler and valve combos., Looking to buy if anyone is interested in selling one.

I am not sure if I am going to go back to gen 3 EGR or try playing around with some sort of restrictor plate design. What do you guys want to see happen? I really don't care at this point I almost feel like it will be the same amount of effort to restore cooling lines and all that shit as it would be to custom fab a restriction gasket/plate.

Pic is gen 4 engine with gen 4 cooler, but it shows how you have to make a T to connect coolant lines back into gen 3 system. Working on that side of the car is so tight, anything you can do ahead of the drop needs to be done. I dropped motor with exhaust manifold installed and I had some wood protecting the windshield.

 

Haven't read through this thread, but there's a thread posted on a successful Gen 4 to Gen 3 engine swap here (the title actually says the opposite, Gen 3 to Gen 4):

https://priuschat.com/index.php?threads/216305/

Posted via the PriusChat mobile app.

 

Cooler also looks physically upsized from Gen 3, innit?

I guess the title is down to how you look at it ... the engine in the car was a Gen 3, now it's a Gen 4.

I asked them to share what they did for EGR, but haven't seen anything yet.

The bees' knees would be to somehow hack in a pipe from after the cat and feed the EGR with catalyzed gas, as it's designed for in Gen 4. If there's any way to make such a pipe fit. And I guess it wouldn't be smiled on in California.

Can any of this be done in California?

 

In CARB’s Engine Change Guidelines (PDF), item II.1 requires that (among other parts) the transmission must be the one from the certified configuration of the donor vehicle—here, the fourth-generation P610 transaxle, not the third-generation P410—and item IV.7.a says the calibration (i.e., software in the engine control module) has to have been certified for the donor engine, meaning you’d have to use the fourth-generation ECM.

I’d be glad to hear from anyone who has taken theirs to a BAR referee and had it passed, though.

 

I think this warrants being repeated.

"As it turns out, the water pumps between the 3rd & 4th generations are not compatible (the way thermostats are). They discovered this when they tried to bleed air out of the coolant system and were unsuccessful - the pump sounded rough, and they triggered a water pump code. Apparently the spline on the 3rd Gen water pump is longer than the one on the 4th Gen."

- Jacob Bonner

This may save a few swaps. Thank you for adding to our knowledge.
Also, when you're out of ideas, taking it to the dealer can get you started again. I approve.
- Fix That Prius !!!

 

Still going strong!!!!
No problem.

 

If you go back to 3rd gen EGR, maybe look for another exhaust manifold too? Maybe not a high demand used item, and if you can get one for $50, save putting yours through another beating, which might do it in.

 

Haha I threw away the damn EGR but I kept the "backup" gen 3 water pump for no sound reasoning whatsoever. Glad someone determined that should be tossed in the scrap pile as well.

Thanks for sharing.

 

I have been lurking on the forum for quite sometime reading and learning a lot. My car needs a head gasket and possible head confirmed by Lexus dealer. I have a 2011 Lexus CT200H, I want to swap in the 4th gen engine into my 3rd gen, but i can not find or (maybe i searched incorrectly), if it matters which 4th gen engine it needs to be, IE (FU,EU engine, or 5th digit B.n)? I apologize if this has been discussed all ready. I have found a 2016 Prius engine with 1.8L (2ZRFXE engine), Prius (VIN FU, 7th and 8th digit), VIN B (5th digit) for $650.00

Thanks for the help.

 

Obviously, none of them would do, since the No. 1 Engine Cover Sub-Assembly has the wrong logo.

More seriously, there has been only one major type (2ZR-FXE) and displacement (1798 cm³) of engine for all fourth-generation Prius (2016–) cars, which in the U.S. have had VINs that begin with JTDKARFU, JTDKBRFU, or JTDL9RFU. There were some changes to the engine design for model years 2019 and later, but I don’t know if any of them would affect use or installation of the engine in a third-generation car.

 

Well if it make things better I have owned 2 Prius both with 300,000 miles before I sold them. I found one with 50,000 miles this morning at a local salvage yard. I am going to pick it up this morning. Thanks for the help!!

 

Please start a thread for this swap, and post lots of pictures, as this could be the first gen4 engine into a ct200h.

It will be exciting to see the process as it progresses.

 

I'd get an engine from a 2016-20 Prius with the 5th letter "B". - Fix That Prius !!!

 

Why would B be better? Not disputing it, just wondering why.

Some info here on interpreting the VIN:

Toyota Parts | How To Decode Your Toyota's VIN Number - Toyota Parts Blog

The 5th digit is the "series".