Gen2 motor replacement

Discussion in 'Gen 2 Prius Main Forum' started by Kentucky Gen2, Oct 26, 2018.

  1. Kentucky Gen2

    Kentucky Gen2 New Member

    Joined:
    Sep 11, 2018
    7
    11
    0
    Location:
    Kentucky
    Vehicle:
    2008 Prius
    Model:
    II
    I am a little slow posting this, but my Gen2 (2007) engine swap was a success. It was all DIY, with no previous experience, and no manual. The removal was done out the top with the transaxle connected. I just read a few threads on here and went at it. First, I had to remove the “new” motor from a salvage vehicle with 84k on it. That was good practice for removing the bad motor out of my good car. The hardest part for me was removing and installing the brake controller and mounting bracket. Other than that, everything was pretty straight forward. While the “new” motor was out I swapped some parts that I had installed on the bad motor leading up to the untimely death at 186k miles. I also replaced the catalytic converter with one I purchased off Amazon. I did purchase a copy of TechStream to use once the “new” motor was installed. Car started on the first try and only threw a P0118 code for the coolant. I followed the fill and bleed procedure, but there must have been a little pocket. The AC compressor was left connected as was the brake reservoir. The only tool I had to purchase was a socket for the axle nuts. I only ended up with one extra 10mm bolt left over, not sure where it goes!

    This was the first time I had removed an inverter, so it was cool seeing the inner workings. I had to work around some bad weather, so it took a few days longer than anticipated. All said it wasn’t that bad and is definitely doable for the average DIY person.

    It wasn’t all roses, as I did manage to crack the windshield installing the motor. As I was dropping it in the exhaust shield swung back and hit the bottom of the glass. I would suggest taping a pool noodle or some foam on the bottom of the windshield to help prevent this.

    Thanks to everyone that posted instructions on the various threads, they really helped.
     

    Attached Files:

  2. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    87,416
    38,912
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    congrats and well done!(y)
     
  3. Patrick Wong

    Patrick Wong DIY Enthusiast

    Joined:
    Mar 8, 2008
    18,114
    6,119
    0
    Location:
    Green Valley, AZ
    Vehicle:
    2015 Prius
    Model:
    Two
    Nice work!

    1. What was the reason for removing the "brake controller" (which I assume is the brake actuator that has several brake lines connected). Was that to provide adequate clearance when removing the engine/transaxle?

    2. What caused the original engine to fail?

    3. What parts did you swap between engines?

    4. A great suggestion regarding use of the pool noodle to cushion the windshield edge. Thanks for sharing that experience which might enable another PC member to avoid that problem.
     
    #3 Patrick Wong, Oct 27, 2018
    Last edited: Oct 27, 2018
    Aaron Vitolins likes this.
  4. Center of Gravity

    Center of Gravity Junior Member

    Joined:
    Mar 18, 2017
    24
    2
    0
    Location:
    New Orleans
    Vehicle:
    2008 Prius
    Model:
    Three
    Congratulations Kentucky. You are now a member of the team. You have a cost savings future in front of you.

    The only thing I would have done differently, would be to get the entire assembly back to the exhaust manifold exit, with the axles and come in from the bottom.
     
Loading...