Advice on gen 4 engine into gen 3

Have you looked up LKQ? That's who @Ragingfit used, sourcing a fourth gen engine. He video documented his transplant here (if you haven't already found it):

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

These (2016 model year) are all US dollars prices I assume:

LKQOnline

Well I see this:

Will you ship freight items to Canada or elsewhere outside the US?

LKQ Online will only ship to the continental 48 United States. At this time, we cannot ship to Hawaii, Alaska, Canada, Mexico, Puerto Rico, or elsewhere overseas.

Maybe you could ship to a "post box" service in Blaine. Maybe cost prohibitive, too complicated, but who knows.

 

Sorry, no clue. I'm just shy of 93K on our 2010, using it less and less, what with retirement and Covid. Plus I cleaned the EGR and intake some years back. Likely won't have your "fun".

I suspect you're right about locally sourced engines: there's tempting prospects from the States, but shipping restrictions/cost, and exchange can make it prohibitive. Plus if your purchased engine is a dud, local return/exchange has got to be easier.

 

I'm just guesstimating, would think if you retain third gen EGR components, intake and throttle body (as @Ragingfit did in this video series), then no Techstream needed. It seems to be the 4th gen EGR valve in particular that needed Techstream, and even then might be problematic.f The video you linked does use 4th gen EGR.

 

@RightOnTime is doing 4th gen engine transplants into 3rd gen, professionally. Gleaned from looking through my past Private Messages. Also I see I posted an assembly of engine overhaul related excerpts from the 3rd gen Repair Manual for him. Can't even remember doing it, but let's not get into that lol. Anyway, not sure if that's the pdf you've mentioned, or it's got more info. I'll attach it here.

And hopefully @RightOnTime will see this and chime in. The more conservative route, just utilizing 3rd gen EGR, is not that much of a backward step though. 4th gen EGR into 3rd does require heat-and-beating on the exhaust manifold, to change the position/orientation of the pipe that bolts to the EGR cooler. And again, it seems like the third gen CPU's are a little confused, dealing with 4th gen EGR valve.

 

Our SoCal Shop (Hybridpit) specializes on Gen 4 transplants and 3rd Gen Engine rebuilds.

With our experience, there is no need to reflash the ECU since we are keeping many 3rd Gen parts over to the Gen 4.

As for the EGR cooler route, it is best to use the Original Gen 3 cooler and assembly for less modifications to get the car running.

Good luck with your project!

 

I've always wondered how much *could* be brought over. Let's say you wanted to have the Gen4 adaptive cruise control, which is different than the Gen 3 ACC. Is that something that could be done without breaking the bank?

 

Their video might have been an hour but the job is at least a day. If you swapped gen3 for gen3.

Swapping a gen4 block has required gen3 egr, intakes, exhaust, controls, wiring mods, etc which is one reason most won't touch it. Even then lots of attempts have ended up with nagging problems. A rebuilt gen3 is arguably better.

 

Your will need transfer the harness and ECU over to the Gen 3 and then figure out the pin outs for each plug. Until we get a customer for that request- will try to do it

 

Only diff with later v engines is better piston rings. Not trivial, but not relating to EGR much. Watch @Ragingfit video series, to see 4th into 3rd, with 3rd gen EGR retained. Think I’ve linked it? It’s in Prius v mod forum. Long story, but basically the way to do a Prius hatchback as well.

 

All Prius v wagons are gen3 engines with the same issues except for excessive oil consumption remedied by revised pistons and rings in mid 2014 through 2017 blocks.

Many of us believe the better rings and pistons did reduce the head gasket failure rates, at least so far. Certainly the pistons and rings were important enough that Toyota provided free rebuilds for early excessive oil burners and did the 2014 mid year production change.

The major advantage to you would be an engine from a more recent year. A 2017 v engine is only four years old. However they are rare because a) Toyota did not make many, b) the Rav4 hybrid was a hot seller and c) many customers and mechanics already knew about gen3 design flaws by then.

There are system differences in a v wagon versus a gen3 hatchback. Better cooling of the engine and transaxle, a higher numerical final drive ratio, pitch and bounce control and enhanced ac. The first two may theoretically improve engine life, especially if you sourced a younger 2016 or 2017 v engine.

 

All Prius v engines are essentially gen 3 engines, have same Exhaust Gas Recirculation components.

 

None of the pro mechanics I know (dealer and independent hybrid specialists) have done a gen4 heart transplant into a gen3 car. But we hear about owners who still have codes and stumbling on their frankensteins. However if your gen4 shop has experience specifically doing it and can give you a verifiable reference, I would go that route. There were massive improvements on a gen4 system. The question is how much a gen3 conversion retains.

Here is a link on the gen4 engineering
Did 4th Gen fix 3rd Gen? | PriusChat