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

Too late I guess. I already paid for the Gen 4 engine from a local JDM place. Should be delivered later tonight. The engine looks to be in good condition, no leaks that I could see, low miles, no cross threaded drain plug. Plus it's coming in at a little over $1800 with delivery included. To get a similar build from Hybrid Pit would be over $2600 plus whatever the delivery fee is and however long the lead time is. I'm hoping to have mine up and running by this weekend because it's really tough being a 1-car house.

I did think about replacing the head gasket but reviewing the videos and such, this should be faster and "easier". I'm willing to take a chance. If I still have issues, I can always attempt to change the HG on the old engine.

 

You do have to use a lot of your gen3 engine on the gen4 to make it fit including the egr system. Plus some wiring and cooling system changes.

 

Just going to throw in there the Gen 4 block Gen 3 head swap I did never overheated. Possibly due to NOT having to reroute coolant lines required to use the Gen 3 EGR cooler with the Gen 4 head? I’m just guessing here. But I did have to flush the “mechanic in a bottle” out of my system with vinegar/distilled water and clean a glob of junk out of the thermostat in the Exhaust Heat Recovery Tank.

 

with the Nexpower V2.5 car still gets 610-625 miles per tank on flat ground driving easy.

 

Hey Durham neighbor!
Your situation kinda looked similar to mine years ago. I picked up a 2010 with about 140k miles back in late 2018. I had a 200 mile daily commute to to my job on base and needed something other than my thirsty V8 that takes Premium

Features wise, I still miss the solar sunroof and leather and interior room (along with not being noticed when I hover around 90mph), but dealing with why I wasn't seeing the MPGs this was supposed to have, coupled by the oil consumption, EGR and then eventual HG issues, I decided to do the Gen4 swap in mines- mainly because an Engine Swap looked much easier than HG repair on my own.

@Ragingfit videos along with the posts here in this helpful forum are what I primarily used.
In the end I couldn't nail down the overheating issues after the build and I had my buddy who used to be a Toyota Master Tech who now runs his own shop take a look at it. I enjoyed the idea of surprising him on what I did with this Gen4>Gen3 chassis. After he spent some time checking the install over and bleeding it a few times, he figured in the end the engine I got from an ebay seller junkyard in Cali was just bad- it was pulled from a roll over...which may be why it cost me $1000 shipped from CA<>NC.

I still hang out here keeping up-to-date on the TurdGen and 4th Gen issues and casually look for CT200h's with busted engines to snag and am willing to do this swap again, as overall although this swap looks like a massive undertaking, it's not that bad of a garage project to take on. This was my first engine swap and largest project I've ever completed and afterwards I can say that I did have a lot of fun and learned alot and have bragging rights on my growing mechanic hobbyist skills.

Will your engine come with some of the attached accessories? I was able to sell the injectors, wiring harness and egr on ebay to make some money back spent on the engine.

Keep is updated on your progress and we'll try to advise as much as we can

 

When I tackle this again in the future, I will be sure to sit down and analyze your posts to see how you've done yours..From what I remember, I stuck w the Gen3 cooling only because the Coolant Re-Routing diagrams shared here and on YT were confusing to me at the time and I just wanted to get this swap done w the least amount of hassle

 

If considering an engine swap, maybe just spring for a brand new 3rd Gen short block, have a machine shop go over the (existing) head.

that’s essentially what @cnc97 did, albeit using a salvage 4th Gen, using everything from the head gasket down.