Gen3 Engine Swap

There's a thread that explains how to swap a 3rd gen engine with a 4th gen engine. That's the route I plan on taking when it's my turn

Gen 4 to Gen 3, what you need to know | PriusChat

 

Ditto to Solar Blue. A handful of people in Priuschat have done it and got it down. Trial and Error helped to eliminate what not to do and in what order to do it. I suggest you review the link posted above. Its a lot of work and you will have some codes to eliminate at the end. But the reviews of the successful completion are wonderful.

 

There's also a few 4th gen into 3rd transplant done. Good video series here by @Ragingfit :

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

(It's a v in the above videos, but the engine bay's pretty much identical I think.)

The approach he takes is likely safest; he retains 3rd gen intake and exhaust manifolds, EGR components. There's one wire extension needed, and some coolant plumbing rework.

Reasons for using 4th gen:

1. Pistons/rings improved
2. More low miles and cheap engines available

 

That thread also mentions that such a swap may not be approvable in jurisdictions that follow CARB or CARB-like emissions standards; too many design and tuning differences, such as the different type of EGR. (Taking it from after the catalyst, as in Gen 4, changes both its pressure and its chemical composition and effect on combustion; the engine calibration is designed for one type or the other.)

 

Yeah @Ragingfit retains third gen exhaust manifold and EGR. Still, I think if an inspector looks in a 3rd gen engine bay and sees an unfamiliar engine, he's going to be getting dour; it'll take some talking, lol.

FWIW, if I EVER get there (which I doubt), I think I'd put in a new (3rd gen) short block and have the head rebuilt, and new gaskets/seals all-round. Doing that, wouldn't hurt to take it out in two stages: firt the head and manifolds, then the block?

 

Right ... supplying uncatalyzed exhaust gas, through valves designed for that (so far so good), to an engine designed for catalyzed (hmm), being managed by an ECM programmed for uncatalyzed (double hmm). The inspector could be understandably skeptical.

 

generally In the US you are always allowed to swap in a numerically Newer engine than the failed engine . Period.

When you smog if everything is functional you pass
end of story.

It would be extremely unfortunate if the ability to replace an old engine From decades Past with a new unit would become illegal.

Many a relic from ancient times has a 350 in tow. I can guarantee there are only very bad things that would happen if you are stuck not only with OEM but with only exactly the year your car was manufactured . In fact it would be a horrific environmental disaster.

If such an issue were pressed in a legal fashion I would fully support the individual with any necessary assistance to ensure the case thrown out.

 

That's very generous of you. You would probably start by reviewing the CARB Engine Change Guidelines by following the link I supplied in #5.

 

JQ74, if you get serious about doing a swap I have a 2012 Gen3 engine I purchased from a wrecking yard that has 568miles on it. I purchased it when I bought my 2010. I sold the 2010 with 280K miles on it and still have the engine and trans in my shop. Its on my list to put up for sale. You are close enough that if you have interest please PM me.
I get others swapping in the Gen4 engines into the Gen3 cars since there are many out there that are cheap and the belief is they don't have the piston rings issues that the Gen3 motors had. But if you have 200K on your existing car, I would feel pretty good this engine could last you that and longer if taken care of, and would be a quicker swap.

 

2015 for sure has revised pistons/rings, and part of the year 2014, but don't know how you could tell from the vin.

 

My advice to the OP is to take the offer from High Milage. A gen 3 engine with only 568 miles on it? Hellz yes!

 

Revised piston rings does not keep from oil burning and EGR issues. GEN4 motor with retaining the GEN4 EGR is the way to go, if your gonna swap a motor.

 

Yes and I read that similar to requiring a red car to stay red, there are a multitude of problems with that Unfortunate logic as cars age,
And many arguments could be made to get it thrown out, especially as cars age beyond 20 years.
Hopefully someone has the guts to press it to the top so at a minimum an age limit for exemption is forced (not a fixed year in the past)

As a policy Forcing as many cars into the wrecker as possible due to minor issues (like a missing cat) or forcing them into other states are both reprehensible.

 

That has proved problematic? You have 3rd gen computers trying to make sense of 4th gen EGR?

 

I tend to believe it's not so much the rings, but the valve guide seals that are causing
the brunt of the oil burning...

As always: result may vary!

 

Toyota's TSB says otherwise. Their remedy involves replacing only the rings and pistons.

Bad valve guide seals are a common problem on older cars when the seals become less pliable. My Gen-3 was less than 5 years old when it began burning oil.

 

As I stated:
I tend to believe it's not so much the rings, but the valve guide seals that are causing
the brunt of the oil burning...
I did NOT say the rings DID NOT cause oil burning. I said the valve guide seals
are the bigger problem.

There are a few people here who have replaced the valve guide seals when they
did the head gasket. Hopefully they can provide some feed back when they have
some miles on the engine.
Since they didn't change the piston rings, only the valve guide seals, if oil consumption
goes down, then there is more information about what is causing more oil burning.

As always: result may vary!

 

@The Critic replaced valve seals when he did his head gasket. I think. He sent the head out to a machine shop.

Maybe he'll comment.

 

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