4th gen engine swap

Oklahoma is a ways from you, but not too far... This mobile mechanic: http://www.instagram.com/skimmilkhybrid/ used to do Gen3 to Gen4 engine swaps in people's driveways in one day for a $1500 charge. I think he charges more now. Also these days he's working on Gen3 rebuilds because he doesn't like the reliability of the JDM Gen4 engines. But if you can find a quality used Gen4 engine from a wrecker you're definitively within his service area.

 

I’d be more inclined to just do a head gasket job. If it turns out there’s a bent piston arm, or if you’ve got runaway oil consumption, and dependent ont cylinder wall condition, THEN consider either:

1. replacement pistons and rings
2. Short block replacement
3. Install of rebuilt 3rd Gen engine (say through Hybrid Pit Stop)

4th Gen engine engines have proven prone to overheating, and there’s never been a solid resolution to this.

do ensure the EGR system, including intake manifold, is thoroughly cleaned.

info in my signature; on a phone turn it landscape to see signatures.

 

It’s not really a complete gen4 swap. You end up using the gen3 intake, exhaust, egr system and wiring harness with custom mods. The cooling system is different on the smaller auxiliary lines going to the heater, exhaust recirc, egr and throttle body. Some call the result a Frankengine and there is no doubt the dealer wants nothing to do with it even afterwords when you might want repairs.

If you lived in OKC and the “mobile” swap guy was nearby, maybe a swap would be good. As I understand it, he works out of his house and distant callbacks became quite the challenge. Part of the problem is almost everything is used and could fail. It’s not like you are getting a new or even rebuilt engine with a Frankengine gen4/3.

So most pros and dealer mechanics recommend a rebuilt gen3 rather than a gen4 swap.

Update:
Towing it to Southern Calif or OKC makes little sense when you have to wait a few days and then drive it back. I would look for small shops that specialize in hybrids or Toyotas in Albuquerque. If low cost is number one over reliability, consider a JDM engine at one of the specialist shops. Better might be a Hybridpit rebuilt engine shipped to your shop. Either will save several thousand versus a dealer rebuild which usually includes a new short block.

Looking at local reviews I might start with this one.

 

First thing's first...
Stop starting it.
They call it the Prius DEATH rattle for a reason!

Your car has 175,000 miles on it and you've gone through one head gasket.
This means that you are 3/4 of the way through your car's economic lifespan.
If your car is in exceptionally good shape for a 2011 then it's worth fixing - but putting a G4 engine in a knackered-out G3 doesn't seem to be a very wise move, to me.
If your car is in 'average' shape it might not even be worth fixing.
The G3s are my favorite Priuses - and I still think that (warts and all) they're the best - all things considered - but they're 2 generations behind the current model - and they're NOT getting any younger!
Take a hard look - especially before setting out on a four-figure journey to getting this car back on the road again!!
Turning an old-not running Prius into a FrankenPrius by putting 3/4 of a G4 engine into a G3 seems......a very odd and very costly detour in your route.

If I woke up in your shoes I'd take Mendel's recommendation, below to heart, especially the part about fixing the things that caused your head gasket to let go in the first place.

Oh - and I'd give you back your shoes.

Good Luck!

 

If it comes to an engine swap, I think Hybrid Pit Stop ships their rebuilt engines. Not for free, but something to consider.

ah, mentioned above.