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

Yes I had the OBD2 Craftsman that I posted pictures of in the previous posts. maybe it's an older model but it didn't show me any temperature readings. Just codes.

Posted via the PriusChat mobile app.

 

Hey all, looks like it's time for me to join the club. 2011 CT200h in need of new engine. Just read through all 29 pages and wanted to verify thoughts on best option going forward.

Gen 4 engine (A/B)
Gen 4 plugs & coil packs
Gen 4 water pump
Gen 4 t-stat (jiggle pin removed?)
Gen 3 intake manifold
Gen 3 wiring harness
Gen 3 exhaust
Gen 3 EGR system
Gen 3 flywheel and damper

I believe that covers the essentials other than a coolant line that needs to be teed in and a sensor wire that needs to be extended. Will have to read through everything again and watch the full video series. But wanted to make sure I was on the correct path. Seems like this is the simplest and most trouble free swap combination.

Please let me know if I've missed any major details, and thanks to all who have posted/shared in here as it's an amazing resource.

 

I used everything on your list except coil packs. I used gen 3 coil packs. Didn't buy new ones, car had 220,000 mi and they still work fine. Runs like a champ. The guys here were a great help and the video was spot on!

 

Did you already start your swap? I will check in once in a while and answer any of the questions that I can. The guys took their time out to help me so I will try to give back! Good luck it's not so hard

Posted via the PriusChat mobile app.

 

This is in regards to overheating issue after swap. Huge thanks to @cnc97 and @Ragingfit

Two things need to be made sure.
(1) @cnc97 - The important thing about the jiggle pin (in thermostat), or hole left behind when you cut it, it must be up, not down. Otherwise, the purpose of it being there is defeated.
(2) @Ragingfit -

Sergiy Kovalevych10 hours ago
Installed a 2016 prius engine in to 2010 prius. Burned two electric coolant pumps(an impeller stuck melted), because of overheating of the engine. The coolant system was creating air bubbles. The problem was very difficult to figure out. The solution was very simple. The level of an expansion tank hose ,which goes from the connection on the engine head to expansion tank must be only up!!! No sag or dip of the hose. By the correct hose leve the bubbles will freely come out to the coolant expansion tank, will not go back to the engine head or to the cabin heating coil. Driving vehicle around 20000 miles (1 year). Didn't have any problems anymore. Good luck guys.

 

Had an opportunity to tear down a Gen 4 engine. Can you spot the difference?



Gen 4 on the right

 

Water jacket looks kinda different

 

Could be miles variation in part, but yeah. Right pic says to me: “just doing my job, nothing to see here”. Left pic not so much.

Excuse my ignorance, but intakes towards bottom of pic right?

 

Looks to me like the Gen 4 head is cast differently, with that bottom water jacket passage cast as three small openings rather than one long one. Maybe a little more support behind the gasket?

I would hate to think miles variation could make a difference like that.

 

On top

 

Looks like less or finer soot generated in Gen 4. Globs of soot in gen 3 - attaching to and flaking off gen 3 head. From the soot deposits it looks like Gen 3 head gasket separated from head between cylinders.

moto g power ?

 

Yes indeed! Gen 3 had a leak in cylinders 1, 2 & 3

 

Here is another pic of the Gen 4 block



Those Toyota Engineers really did their homework

 

Why was the gen 4 head off?

The gasket had little pin bubbles, or is that beads of something ?

 

Miles on the Gen4?

Miles on the Gen3?

 

So with the 4th Gen Headgasket they eliminated some of the Triangle coolant ports and replaced it with a small circular port

 

Used Gen 4 had a bad main seal that was leaking. Motor has 30k on it

 

30k on Gen 4

130k on Gen 3 (water pump went out but Owner continued to drive the car)

 

Next layer of the onion: what did the water pump that came out of the Gen3 look like (I.e. did the impeller breach the containment, magnet delaminate, impeller blade shear off, etc)

And the gen4 engine was from a wreck?

All pieces to the puzzle.

 

Triangle holes for a circular port? That doesn't seem like a benefit. Poor hydrodynamics and stress at the ends of the triangle? Did Toyota go out of their way to create a lemon?

I wonder if a Gen 4 headgasket would benefit a Gen 3 engine...