1. Attachments are working again! Check out this thread for more details and to report any other bugs.

DIY engine replacement in a Gen 2...

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Oracle617, Jan 4, 2014.

  1. PollyDaPrius

    PollyDaPrius New Member

    Joined:
    Aug 2, 2017
    19
    5
    0
    Location:
    United States
    Vehicle:
    2004 Prius
    Model:
    Two
    Going to see how far the rabbit hole goes! All I need to know is how to unbolt that one of two non-bolt washer off the mount and then I'll soar through disassembly process. Was already reading through one of the manuals on techinfotoyota when you replied. Can record everything on my computer for later playback saving paper and ink, Thanks for tip!
     
  2. oil_burner

    oil_burner Active Member

    Joined:
    Feb 26, 2017
    249
    126
    0
    Location:
    Canada
    Vehicle:
    2006 Prius
    thanks for your thread, I am about to replace my engine but unsure about whether to pull it out of the top or the bottom. It sounds like if I separate it from the transaxle I may be able to lift the engine out of the top of the engine bay and avoid wrecking an axle if it does not separate from the transaxle cleanly? I don't understand why the design allows for the transaxle fluid to be open to the driveshaft with a seal there, what purpose could that serve aside from a failure point. Why don't manufactures just design that as a dry connection..?
     
  3. kutcht1

    kutcht1 Member

    Joined:
    Nov 25, 2013
    295
    81
    0
    Location:
    Andover, Minnesota
    Vehicle:
    2008 Prius
    Model:
    N/A
    oil_burner, I have thought the same thing with the axle seal when I was working on an older Mazda and I could not get the seal to stop from weeping some oil. My VW Passat has a bolt on axle and it is a much better design.
    TomK
     
    edthefox5 likes this.
  4. Oracle617

    Oracle617 Member

    Joined:
    Jan 4, 2014
    30
    35
    0
    Vehicle:
    2005 Prius
    Model:
    II
    Hi oilburner,
    If you're trying to get the engine out, the thing which stops you from pulling it out of the top is the AC pipe which runs over the engine. If you de-gas the AC, the engine will come out of the top with the transmission attached.

    Personally, I find getting the drive shafts into and out of the transmission such a pain, it's easier to split them on the inner CV joints, bag both ends to keep them clean and then lower the engine and the transmission to the ground together, leaving the 'cup' part of the inner CV joint attached to (and sealed in) the transmission.

    Good luck!
     
    Robert Holt likes this.
  5. Gary Hoffmann

    Gary Hoffmann New Member

    Joined:
    Oct 12, 2019
    3
    1
    0
    Location:
    Forest Glen, Qld,Australia
    Vehicle:
    2007 Prius
    Model:
    i-Tech
    The engine will come out the top, I have just done it twice to take an engine out of a donor car and replace the cooked engine in the other car. Unless you are a complete masochist take the inverter out first. You need to remove the pulley from the crankshaft also and much easier if you take off the inlet manifold. I found leaving the exhaust manifold on the engine and undo the 2 spring-loaded bolts on the exhaust swivel joint easier than trying to remove the exhaust manifold with the engine in the car. There is only just enough clearance to do it this way but it is doable.
     
  6. kutcht1

    kutcht1 Member

    Joined:
    Nov 25, 2013
    295
    81
    0
    Location:
    Andover, Minnesota
    Vehicle:
    2008 Prius
    Model:
    N/A
    After having removed an engine and transmission out of my 2008 and replacing myself I would without question take it out the bottom as it was designed by Toyota. It can be done from the top but not as easily and the AC would have to be drained and filled. It was extremely simple to drop both. What took the most time was draining all the fluid (engine oil, transmission oil, radiator/engine coolant, inverter coolant). The rest was extremely simple as I could do it again probably in one days time. I had use of a buddies engine hoist and I would suggest that as it made things easy to move around. Put the front of the car as high as I could, braced it with two wheels under the frame and rolled it out from the drivers wheel well.
    TomK
     
    donbright likes this.
  7. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    54,463
    38,101
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    I'm purely an armchair mechanic, and it is different gens, but with the 3rds you can just unbolt the AC compressor and maybe a few line clips, then lift it out of the way, for pulling the engine out from above. Not doable with a 2nd?
     
  8. kutcht1

    kutcht1 Member

    Joined:
    Nov 25, 2013
    295
    81
    0
    Location:
    Andover, Minnesota
    Vehicle:
    2008 Prius
    Model:
    N/A
    All the freon stays in the system on the GEN3 that way?
    TomK
     
  9. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    54,463
    38,101
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    Yeah. Interesting series of videos here. It's transplant of 4th gen engine into Prius v (under the hood is more-or-less identical to 3rd gen). He just unbolts compressor and moves it out of the way. He did the same transplant previously with a regular Gen 3 too.

    Swapping in a Gen 4 Prius' 2ZR Engine into the Prius v | PriusChat
     
  10. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    54,463
    38,101
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    Video #3, around 10:35
     
  11. kutcht1

    kutcht1 Member

    Joined:
    Nov 25, 2013
    295
    81
    0
    Location:
    Andover, Minnesota
    Vehicle:
    2008 Prius
    Model:
    N/A
    AFAIK, not in the GEN2. Cool design and why is this not used in ALL cars.
    TomK
     
    Mendel Leisk likes this.
  12. Mendel Leisk

    Mendel Leisk Senior Member

    Joined:
    Oct 17, 2010
    54,463
    38,101
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    Yeah I'm not sure. Looking through the Repair Manual, in the instruction for engine removal, there's this:

    upload_2019-11-20_16-0-21.png

    I''ve attached the full section, for engine swap. There's a fair number of references not embedded (a lot of work to chase them all down), but it covers the main points.

    I believe it recommends to drop the engine too. That seems a terrific amount of extra work though, through the top the main cross beam can be left alone.
     

    Attached Files:

  13. SteveLee

    SteveLee Active Member

    Joined:
    Sep 15, 2012
    645
    179
    0
    Location:
    North Carolina
    Vehicle:
    2010 Prius
    Model:
    I
    My son just pulled his 2012 Prius engine (blown head gasket for about a year so it was a mess) out the top and leaving the trans in place. Has now set in a 2017 replacement purchased from across the country. Still in the process of connecting everything but wow, I am very proud of him since he had little mechanic experience. But he was motivated, being a poor student, and refused to give up on his Prius. He used the previously mentioned Youtube series on replacing the Prius engine. Just wanted to mention it since that video series was mentioned.
     
    donbright and edthefox5 like this.
  14. edthefox5

    edthefox5 Senior Member

    Joined:
    Jul 25, 2007
    10,096
    4,795
    0
    Location:
    Clearwater, Florida
    Vehicle:
    2007 Prius
    Model:
    Two
    Sounds like a great son. very difficult for someone without alot of mechanic chops.