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Gen 4 into Gen 3 swap fail

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by C-in-DC, Jan 14, 2023.

  1. C-in-DC

    C-in-DC Member

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    I’m getting the following fault codes:

    P0102
    P0113
    I guess clean the maf sensor and change the air filter
    P0403
    trying to repin the egr plug didn’t work.
    P0402
    I hope this is due to the above
     
  2. ChapmanF

    ChapmanF Senior Member

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    Are people still trying to repin the EGR plug?

    Do not do that. It was a mistaken idea from the get-go.

    For whatever reason, after somebody may have come up with that wire swap as a covert way of completely scotching EGR to mask an excess-flow problem when using the Gen 4 components, it started getting "explained" on PriusChat as Gen 4 having somehow changed the pinout of the valve, which is baloney.

    This has been known now for, like, three years. It needs to stop circulating as a thing people still try to do.
     
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  3. johnnychimpo

    johnnychimpo Active Member

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    same gasket as it will be obvious if it leaks. if it does and you are in a pinch clean it and use the grey gasket seal both sides should work to get you through. anywhoo sounds like your pump issue is related to the water pump impeller. likely melted and warped you hence the horible sound. in my book of shot pumps once you can hear the pump its over. buy an new one. I would never trust a pump the makes sound it will be a short matter of time before it leaves you stranded on the way to the hospital..not where you want to be. I am in the process of testing this brand of impeller its only 40 bucks. will report back soon as short of the logo like asin and toytoa pbap to asin dang near same thinsg. Like i said bleed it bleed it bleed it. never over 203 in maintenance mode you will find you over heat bleed bleed then stress test. if car cant cool itself in maintenance mode it dont stand a chance driving regular. mark my words!
    impeller is called pbap on amazon
     
    #83 johnnychimpo, Jan 30, 2023
    Last edited: Jan 30, 2023
  4. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    All of these cautionary tales have me thinking, IF it's ever my turn, it'll be a new short block*, reuse the head, and the gasket kit of course. Per @cnc97 .

    * According to The Car Care Nut, as soon as Toyota acknowledged the "low tension" piston ring problems, they also stopped sales of short blocks; ensured they all had the revised pistons/rings before resumption of sales.
     
  5. C-in-DC

    C-in-DC Member

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    I got 92-95 in maintenance mode. Maybe I shouldn’t have made that second hole in the thermostat when I cut the jiggle pin since I’m on the east coast.

    The pump is new. If it goes out I’m putting the 2016 one in.
     

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  6. C-in-DC

    C-in-DC Member

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    I understand. I was trying to use the gen 4 EGR initially so I swapped the wires per that thread. Later on I found the threads about how that wire swap was hogwash, so I pulled the wires out and pushed them back in their original locations to use the gen 3 EGR. Looks like putting them back didn’t work.
     
  7. C-in-DC

    C-in-DC Member

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    I found a leak on the small hose that connects to the new tee from the the degas tank. Somehow the clamps being all together near the front of the EGR caused them to puncture that hose via rubbing. I replaced it with a 3/8” sae hose. Not sure if I’ll get a new Toyota replacement or not.
     
  8. C-in-DC

    C-in-DC Member

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    did you see gasket masters video on gen 4 head gaskets ? The future is bleak lol. Apparently they’re getting tons of such work orders now.
     
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  9. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    It’s just a “short”? I saw that, a little sceptical; hopefully they’re not doing head gasket when it’s the exhaust heat recovery. o_O
     
  10. cnc97

    cnc97 Senior Member

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    If I ever find myself owning another Gen 3, that’s exactly what I will do, use the Gen 3 head on a Gen 4 block. Except I’ll remember to make sure all 16 valves seal before I bolt it down. LoL
     
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  11. C-in-DC

    C-in-DC Member

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    I was finding the gen 4 for 2200 in this area. Is that how much you can get a new short block?
     
    #91 C-in-DC, Jan 30, 2023
    Last edited: Jan 30, 2023
  12. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    New block is $1800 USD plus change if I check parts.Toyota site, and then go to the nearest-to-me US dealership (Foothills Toyota, in Washington State, about 50 miles distant). List is $2200 and change.
     
  13. C-in-DC

    C-in-DC Member

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    On the Toyota parts site I see the opposite. it’s 2,200 on the site and at a dealer about an hour from me it’s sold for 1,866.89. Would love to make this my new side hustle but it looks like I’m a few years too late.
     
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  14. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    That’s what I was trying to say, maybe awkwardly: list price higher, dealership lower. And yeah, bottom line: $1800 and change USD is what you’ll need to spend. Plus sales tax.

    you do need to transfer over what Toyota calls “upper oil pan” or words to that effect.
     
  15. C-in-DC

    C-in-DC Member

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    So the changes Toyota made from gen 3 to gen 4 to correct overheating were to the short block assembly only?
     
  16. ASRDogman

    ASRDogman Senior Member

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    I believe they made changes to the head also, bu tnot sure what it was.
     
  17. C-in-DC

    C-in-DC Member

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    Any recommendations on what to do with my old gen 3 engine? Is it Worth it to fix the head gasket and sell? What did you all do with yours after the swap?

    Mine doesn’t have a hole it but I’m assuming it would have to go to a machine shop because all four cylinders were taking on coolant.
     
  18. ASRDogman

    ASRDogman Senior Member

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    What year is it? You could update to the 2015 pistons and rings, and hone out the cylinders.
    It would depend on what shape the walls are in. How many miles on it? Was it burning oil?
    And if so, how much?
    If they are evenly worn, and no flat spots, and still have the cross hatch pattern,
    honing would probably work with the new pistons/rings.

     
  19. C-in-DC

    C-in-DC Member

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    I actually had never heard of the oil burning issues until I joined Priuschat so I was one of the few fortunate to not have them(or maybe I just didn’t notice). It’s a 2010 engine And has 231,000 miles. If there’s money to be made I definitely would want to fix it. Not an experienced mechanic so I don’t know how much it would cost to have a machine shop repair any warpage. All four pistons were taking on coolant so you can imagine how much it was shaking and how long I was driving with a blown head gasket. Would’ve done the swap a year earlier if I had figured out it was the head sooner (mechanic told me it was a piston misfire and that I needed to change all of them).

    The engine is in my company’s warehouse now and the office manager is indirectly telling me to get it out asap.
     
  20. C-in-DC

    C-in-DC Member

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    Crap! Getting a cylinder 1 misfire now. Code p0301.