.:: Hybrid Pit • Buena Park, CA | Gen 3 to Gen 4 Engine Swap ::.

Discussion in 'Gen 3 Prius Accessories and Modifications' started by m3pare, May 16, 2020.

  1. m3pare

    m3pare Senior Member

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    Just want to give a shout-out and very big thank you to Roger and Andrew over at Hybrid Pit! These are the go-to guys if you are looking for a quality hybrid shop in Southern California. They gave our 2011 Prius a second chance at life with a practically new Gen 4 engine.

    Backstory — My sister's 2011 Prius had been consuming more and more oil over the years as the mileage rose up and over 200,000. No biggie... I figured I’d just keep an eye out and check the oil level more frequently for any needed top-offs. I changed to a slightly thicker 0W-40 oil from Ravenol to slow down the consumption rate from about 1.5qt every 5K miles to about 1.0qt. As it approached ~211,000 miles, the car began consuming a little coolant as well. I’d top it off about once a week, and about ~1000 miles later, it ended up needing to be topped off every couple days. MPGs dropped to an all time low of 32-33. A couple hundred miles after, the engine had finally given up and had a constant rattling/shaking as the ICE fired up. The head gasket was officially done.

    At this point, I figured it’d be best to park the car and weigh out our options. We could sell the vehicle for pennies on the dollar for a newer Prius, rebuild this current engine, or swap in a used lower mileage engine. My sister isn’t too fond of the Gen 4 styling so she definitely wanted to keep her Gen 3. I looked on Craigslist for used 2010-2015 engines for sale via dismantlers and part-outs. To my surprise, the Gen 3 engines still go for a good chunk of change even with higher mileage. I also visited a few different hybrid shops around the LA/OC area, inquiring about engine swaps/rebuilds, and looking to see the quality of workmanship being done to these Prius’. At the end of the day, I was ultimately disappointed at the quality of work by these well-known “professional” hybrid shops. The final products looked messy and rushed, to say the least.

    Finally, I gave Roger at Hybrid Pit a call. I’ve been to his shop before and have been a previous customer for a sway bar and coilover install. Being a smaller facility, I figured they only service regular maintenance and aftermarket installs... they don’t want to deal with an engine swap. Turns out they’d done a few swaps already for other customers in the past! I asked for Roger’s advice, what route to go with... and he mentioned he’s been looking for a candidate to swap in a newer Gen 4 engine.

    After crunching some numbers, we set out to look for the new heart of my sister’s 2011 Prius. It wasn’t long before we found one with only 8,000 miles! Coming from a rear ended 2016 model, it was a no-brainer to go pick it up. Shortly after, I towed the car over to Hybrid Pit and the masterminds began tearing apart the engine bay. Within a couple days, I received a text message that the new engine was already nestled inside. Now we just had to finalize which route to go for the EGR. Do we backtrack and re-use the Gen 3 components, or do we utilize the Gen 4 EGR for max efficiency? As far as we knew, no one else had successfully utilized all Gen 4 parts without any issues or CELs. The team at Hybrid Pit was determined to be the first.

    As we scoured through the forums, it seemed like much of the swap info posted was incorrect and only led them to more issues. With some troubleshooting, they were able to get all of the quirks sorted out and have a fully functioning 2016 Gen 4 engine without any CELs or hiccups. The team at Hybrid Pit took their time to ensure the swap was done properly, and not Mickey Moused to rush the car out of their shop.

    Finally, we were ready to take delivery. Right as Roger popped the hood open, I was shocked. To the naked eye, this Gen 4 swap could pass for factory. Sure, if you comb over the engine bay, you’d start noticing a couple differences here and there. Most engine swaps I’ve seen in other platforms have had some sort of wiring mess and other giveaways to notice it right away.

    Here’s the best part... the car passed CA smog the next day! No issues at all. With close to 1000 miles driven since picking up the car, we are very happy with the outcome of the Gen 4 engine swap. MPGs are consistently in the 50s, even with A/C blasting in this warm summer weather. The car also feels a lot quicker, with much more pep than my 2012 Prius. Looks like we’ll be keeping this car for a looooong while! I would definitely recommend this swap to anyone having head gasket issues on their Gen 3 Prius.

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  2. Mavi

    Mavi Active Member

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    Thanks amazing, thanks for the headsup! How's the mileage vs the older engine did it actually improve? Also how much did the labor end of it end up costing? Thanks
     
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  3. ChapmanF

    ChapmanF Senior Member

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    Great story! A rundown of exactly what they did EGR-wise would be welcome.
     
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  4. Mendel Leisk

    Mendel Leisk Senior Member

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    Please, take it to a dealership for something, anything that involves them popping the hood.
     
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  5. jzchen

    jzchen Senior Member

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    Thanks for sharing! Nice!!!

    moto g(7) power ?
     
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  6. xliderider

    xliderider Senior Member

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    Wife and I rode a Gen 4 Uber a while back and were surprised how much acceleration this guy was getting. The Gen 4 sure "felt" much quicker and powerful than our sluggish Gen 3.

    Posted via the PriusChat mobile app.
     
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  7. Grit

    Grit Senior Member

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    Gen 4 - 121 hp @ 5200 rpm
    Gen 3 - 134 hp @ 5200 rpm

    o_O
     
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  8. Mendel Leisk

    Mendel Leisk Senior Member

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    Weird. :confused:
     
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  9. jzchen

    jzchen Senior Member

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    Is this one of those new SAE standard things? Around 2006 the HP of the Toyota Sienna dropped, even though it was the exact same engine as the year prior, just because SAE decided to change it's rating scale. Either that or it's been shifted in favor of more torque?....

    moto g(7) power ?
     
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  10. Mendel Leisk

    Mendel Leisk Senior Member

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    Second that. Any problems, tweaks required?
     
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  11. Grit

    Grit Senior Member

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    I dyno'd both of those gens myself personally at my dyno shop :ROFLMAO:
     
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  12. RMB

    RMB Senior Member

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    From Auto-Brochures.com:

    Gen 3 1.8L engine produces 98hp, 105 lb-ft of torque, electric motor 80hp, 153 lb-ft, with hybrid system net 134hp
    Gen 4 1.8L engine produces 95hp, 105 lb-ft of torque, electric motor 71hp, 120 lb-ft, with hybrid system net 121hp

    Perhaps the IPM/J0V or whatever recall reduced electric motor or hybrid system power output for Gen 3 but didn't release new net power spec, then now comparing to Gen 4 suddenly numbers look odd?
     
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  13. m3pare

    m3pare Senior Member

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    Thank you all for the kind words. As far as pricing goes, please give Hybrid Pit a call for all inquiries here — (855)492-4440. I will let @RightOnTime mention what they have done EGR-wise as I was not there for the entire process.

    Mileage-wise, my sister would see an average of 41-46 MPG with the old engine, depending on A/C usage and city/hwy routes. Now, the car is averaging 50-54 MPG with heavy A/C usage lately. Great improvement across the board!

    I would bring it to the dealership, but I simply do not trust them. I try to do all of the regular maintenance myself — oil/filter changes, coolant/cvt fluid drain & fills, etc. One time, the dealership did not completely tighten a friends oil filter housing, which ended up with the car needing to be towed after leaking many quarts out. Yikes!!

    I too, was surprised by the increased pep of the Gen 4 engine in the Gen 3. Although the output is lower on paper, I suspect it has to be related to the ECU programming. I have driven a friends 2018 Gen 4 and it definitely feels faster than my Gen 3. Wizardry!
     
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  14. ChapmanF

    ChapmanF Senior Member

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    Scales have fallen from my eyes
     
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  15. michaud85

    michaud85 Junior Member

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    Gen 3 vs gen 4 Dyno performance numbers:

    noone has dynod a gen 4 engine running a gen3 ecu. This car is the perfect option to see if maybe he is getting some nice pep, it's completely modified.

    As it sits, this post is helpful for members of this community who are considering taking a car, that needs an engine, to southern cali to spend more than half of what the 10 year old car is worth swapping in a totally random motor from a wreck yard.

    People across the whole earth use PriusChat to save money, distribute new and useful information, and chat with similar minded enthusiasts.

    Mark us all very impressed if this is what it looks like. Please consider sharing what you learned about the EGR with the broader community. This is, afterall, the real meat and potatoes offered here.

    All the other gen4 swap hiccups have been solved on numerous occasions by hobbyists. The solutions have been generously documented here on the forum by the members who discovered them in their driveways. It sounds like alot of their sacrafice and effort was considered to achieve the success we see here.

    It's old outdated technique to hold onto secrets like a master and an apprentice, we have lost many trade skills and secrets throughout history from skilled people who used the same approach.
     
    #15 michaud85, May 18, 2020
    Last edited: May 18, 2020
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  16. Montgomery

    Montgomery Senior Member

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    Very insightful michaud85. I agree. Even if someone here told me how they "did it", I, most likely will still take it to Hybridpit. I live near Hybridpit. I have been saving money to eventually have them do the cleaning of the ECV and install the Oil catch can. I don't have the desire to do it myself and, I don't mind paying someone who has all the right tools, has done it dozens of times and can get it done quickly. Hopefully, we will find out what they were able to accomplish with this Gen4 Gen 3 engine swap. Its important to us all.
     
  17. michaud85

    michaud85 Junior Member

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    These gentleman appear to take pride in what they do and have been notably active members here for some time. They will always have customers who pay them to do excellent work.

    There is nothing wrong with paying people to provide you with a service, even if you are capable of doing it yourself.

    This community is heavily popular based on the open sharing of quality information that can and should be repeatable. It would be nothing without the people who became experts out necessity and curiosity who then took the time to share their findings. Without these generosities this website is reduced to a Prius facebook group.
     
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  18. Montgomery

    Montgomery Senior Member

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    Not disagreeing. In agreement. Duly noted. Complete understand your point.
     
  19. JarrettOriginal

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    Oh man... While my 2010 is doing fine, even though it has some minor oil consumption, I'm glad to know this is a possibility...

    Do you feel comfortable discussing the financials of this?

    +5mpg for posting
     
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