I just acquired a new project vehicle

I appreciate you sharing your expertise with us on your (re)build. I can hardly wait for the next installment on your story. I hope you have continued luck with your project. Y'alls picture/stories are great.
Keep safe and careful.

GT

 

Amazing. Really.

 

Hi JelloSlug,

This thread is amazing. Thanks for sharing! If I had the space and know-how, then I'd love a project as yours. Until then, living vicariously has been an absolute pleasure. ...Cleaner, too!

 

I've noticed several recent posts regarding errors made by body shops while repairing Prius accident damage. I am impressed at how thoroughly you've researched the Prius during your project vehicle acquisition and repair, so you may already be aware of the following. If not, then the following list may be helpful as you are reinstalling the front-end:

• Engine coolant not filled and air purged out. Expect to use ~ 6 quarts of Toyota SLLC when refilling; dry system capacity is 9 quarts. The relay that controls the coolant heat recovery pump is located in the relay box mounted to the cowl; you can short the switched terminals to get the pump to run while you are refilling the system. It will take lots of time to get all air out; note the air purge valve on top of the radiator, driver's side. 6 mm Allen hex key needed to open the valve. Use inspection mode to force the engine to run continually.
• Inverter coolant not filled and air purged out. Probably need ~3 quarts of Toyota SLLC. The inverter coolant pump is running whenever the car is IG-ON or READY. You should not hear air in the system when the pump is running, and you should be able to see a step in the fluid level, looking at the reservoir mounted to the side of the inverter. The fluid level at the rear should be higher, compared to the fluid in the remainder of the container.
• Radiator fans installed incorrectly so that they are blowing air at the radiator rather than sucking air. Note that the two fans have different blade count. They spin in opposite directions - refer to the exploded parts diagram to see which fan goes where.
• Incorrect air conditioner compressor oil used, which causes a high voltage leak in the compressor and DTC to be logged.

 

Outstanding! There is good reason to expect that upon completion of the rebuild, the Prius will come READY, no DTC will be logged, and your wife can comfortably rely on that car for her daily commute or a long road trip!

 

Looking good! Do you give the inner fender wells a shot of blue?

 

When do you think it will be road ready?

 

Will you also be painting the exterior sheet metal at this time, or later? What is the process: will you paint the LF fender, hood, and front bumper cover while mounted to the vehicle or as loose parts? Is there need to paint the driver's door, the RF fender, or any other body parts? Do you plan to color sand the exterior sheet metal after it is painted?

 

How do you keep the lint and dirt specs off the paint? Assuming this is in your garage?

 

Sounds like a nice setup you have going there! Look-en Good.

 

You know, reading this, has given me hope that the era of 'shade tree mechanics' had not ended with hybrids and higher end technological cars. Thanks!

 

I've been following some of this thread and was wondering how much the wheel alignment is affected after this is completed. Will it be like new again?

Thanks
2003 Prius (when you never saw another PRIUS on the road.)