05 Engine Replacement

I've decide to replace the engine in a 2005 Prius. For whatever reason it went bad around 110,000 miles. It was making some noise and then went all at once. I don't know the complete maintenance history of the car, but I know it was pretty regular. I also know the car was driven mainly highway miles and on A LOT of dirt roads. So, the oil may have needed more frequent oil changes.

Here's where I need some help. I found a low mileage engine in a salvage yard from a 2009 for $500. I know the 2004-2009 are the same generation, but what does that mean for me trying to swap engines. Does anyone know off the top of their head if I can swap the 2009 right in? I assume the mounting points and mechanical aspects will be the same, but what about the electronics? The 2009 will come with the intake. Can I use that, or am I going to have to take the old one off?

I'll dig through the schematics of the two years and see if I can notice anything obvious, but any advice is appreciated.

I'll take pictures and keep this thread updated as we go.

Thanks!

 

Things are starting to happen.

A picture of the car arriving at my friend's place where it will undergo the knife. And a picture of the donor car. 2009 with 23,000 miles.

I'll try to post a video file of the sound the car is making. It's NASTY.

 

A few more pictures of picking up the engine. It's light. Me and one other guy easily lifted it out of the back of the truck.

 

We are all mechanical engineers that work with engines. Of course we are going to do an autopsy

 

Listen at your own risk. It's pretty painful.

 

Some update pics. We are 5 hours in with 2 people working pretty diligently. Engine/transaxle is out and ready to be split to attach the new engine. Work continues tomorrow.

Pictures in order:
Inverter cover removed
Inverter removed
Subframe and steering rack dropped
New and old engines
It's so spacious in here!

 

As Hal and uart said, you can get them just about anywhere.
This one from Home Depot is similar to the one shown in the picture (fluorescent bulb)

They have some LED ones, but I haven't tried any of those.

 

Not many pictures taken today. We have the replacement engine in the car, but have most of the heater hoses and stuff to hook up. We spent about another 5 hours tonight, but a good chunk of that was spent looking through wiring diagrams and comparing wiring harnesses.

We found one connector in the 2009 harness that had 3 extra wires in it compared to the 2005 harness. Turns out they are redundant (already connected to other wires in the connector). We then had to check where those 3 extra wires plugged in to. If there are actual pins back at the computer where those 3 extra wires were, we would be risking shorting something out. When checked, those three extra wires don't have mating pins back at the computer, so, they are only needed for the 2009 computer.

We ended up using the complete 2009 engine/transaxle harness. Lets hope it all works! The picture below is of the new engine installed.

 

If you look at the 2nd set of pictures, the 2009 engine came with the harness on it and completely intact. So, a fair amount of time would have been needed to take the harnesses off both engines and install the 2005 onto the 2009.

The engine harness is 5 connectors that all go through one large grommet on the passenger side firewall. It was easier to unplug those 5 connectors and pull out the grommet than take the harnesses off the engines.

 

After several more hours and some electrical frustrations she's running! The 12V battery had died and needed a jump.

Once we got the engine in we had a heck of a time getting it into inspection mode so the engine would start with it up on the jackstands. I tried Patrick's method several times, but could not get the engine to start. I eventually held my foot on the brake and shifted it from neutral to park several times pushing the gas pedal to the floor twice between each one and suddenly the engine started :rockon:

Also, all 4 of the yellow "brake" lights came on.
From left to right they were:
1)Brake System Warning Light (exclamation point in a circle in parentheses)
2)ABS
3)VSC
4)The skidding car icon

We took the car around the block and the speedometer wasn't reading either. We thought we had inadvertently broken one of the wheel speed sensors or cut one of the wires. Then, as soon as the car hit 20mph, all 4 of the lights went off and the speed started reading. I'm not sure what that was all about, but everything seems normal now.

So, YES, the 2009 engine with its harness went in just fine to the 2005 without needing any sort of modification.

Here's video of her running with the new engine.