Gen4 to Gen3 engine swap using gen 4 intake and egr, DONE!

Discussion in 'Gen 3 Prius Technical Discussion' started by Dave Hanson, Aug 13, 2019 at 11:22 AM.

  1. Dave Hanson

    Dave Hanson New Member

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    2010 Prius
    Model:
    Three
    My 2010 prius blew a head gasket @ 255,000 miles. So with the inspiration of Rafit and cnc97, I decided to swap in a generation 4 engine. I found one with 94,000 miles for $450 shipped on Hollanderparts(Car-part is another good site), half of what they wanted locally, me picking up not dropped off right under my hoist. New engine came with wiring, egr system, intake and exhaust manifolds but no throttle body(I reused my old one spinning it 180°). I wanted to use as much of the new parts as possible but knew the exhaust manifold was a no go without the downstream exhaust and at another $450 was out of the budget. So, I set out to see if my old exhaust manifold would work with the new egr system. Bolting it up, the old egr pipe on the exhaust manifold was the correct length but to low and bolt holes were twisted clockwise. After much deliberation, I took the plunge and heated the pipe up cherry red with a torch, first at the bottom to raise it most of the way, then in the middle to twist the flange and raise it into the final position. I was surprised that it went so well. Pipe post heating is in first picture. Using new intake involved: changing manifold absolute pressure (map) sensor wire connector and moving it down out of the way of the old air horn(also had to cut off its old mount)pic #2, pic #3 shows shortened intake pipe 1/2" and trimmed webbing to lower air cleaner box back down ware it belongs. Rest of pics show minor changes, mostly to wiring harness and finished product. IMG_20190809_070734.jpg IMG_20190809_070734.jpg IMG_20190809_070734.jpg IMG_20190809_073511.jpg IMG_20190809_071249.jpg IMG_20190809_071112.jpg IMG_20190809_073554.jpg IMG_20190813_084301.jpg
     

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  2. RMB

    RMB Senior Member

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    Did you open up the EGR system (cooler, pipe, and valve) to see how much buildup it has from your Gen 4 engine?
     
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  3. Dave Hanson

    Dave Hanson New Member

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    Three
    Yes and it was pretty clean inside,just a light carbon coating, which brake cleaner easily took care of. I wish I would have taken pictures, but I was preoccupied with getting it to work.
     
    #3 Dave Hanson, Aug 13, 2019 at 9:12 PM
    Last edited: Aug 13, 2019 at 9:26 PM
  4. Raytheeagle

    Raytheeagle Senior Member

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    +1:).

    Well done BTW(y).

    I’d be curious at 94k miles what it looks like;).

    Any info or pics are appreciated (y).
     
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  5. RMB

    RMB Senior Member

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    Ray, is there any previous data in comparison to this case? 94k and with light carbon coating on Gen4 EGR here.
     
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  6. Raytheeagle

    Raytheeagle Senior Member

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    Not that I’ve seen:cool:.

    I was trying to get @soldierguy to commit locally, but they traded it in for a VW:(.

    But I’d like to see some data rolling in (y).
     
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