2006 Prius Engine Replacement

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by KitsuneVoss, Jun 24, 2025 at 11:22 AM.

  1. KitsuneVoss

    KitsuneVoss Member

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    Starting this as a new thread. This is going to try to be as "Step by Step" as possible. Also so I can look back if I need to.
    Everything "small" is being put in ziplock backs and being labeled with a sharpie.
    Day One:
    1. Start with removing battery plug and disconnect the aux battery (10 mm on the wall of the car)
    Battery Plug.jpg
    2. Moved the lock of the hatchback so that it will not lock
    Hatchback.jpg
    3. Disconnect bolts holding hood and line for windshield wipers (12 mm)
    Note that when I tried to replace the hood before I put a plumbing fixture in to make it easy to remove

    Hood-2.jpg Hood-1.jpg Hood_Off.jpg
    4. Remove wiper arms (14 mm)
    The double one you need to wiggle around a little to get it off.
    Prying does not really work. Wiggle it
    Wiper-1.jpg
    5. Remove plastic cover on windshield wiper "tray." Came off easy.
    6. Disconnect the wiring harness to the wiper motor assembly and remove bolts holding motor in (10 mm)
    Remove plastic clip from wiper motor "tray"
    Wiper motor should come out easy
    Wiper_Motor_Connector-1.jpg
    7. Remove bolts holding relay box on tray (10 mm), remove clips holding relay box to tray, and then tray on (10 mm). Should come off easy once bolts are removed.
    Compartment-1.jpg

    Waiting on the electrical system to drain completely so covered engine compartment with plastic so that no water, or at least little water, gets in the engine compartment. Going to try to do just a little a day.
     
  2. Tombukt2

    Tombukt2 Senior Member

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    This is cool I want to see engine n trans split whilst in car . Haven't had to do this gen2 yet on a keeper in my junker w trans in position in car and engine hanging from boom and front mount removed pass side. I still couldn't get enuff room to slide engine to pas side to let go of trans output shaft. Sucked . So on this junk car I undid trans. But in my keeper I'm always hoping not to drop trans. But I've not looked at any vids or anything but looking at it quickly I saw trouble . Maybe undoing trans mount at driver side w jack under and tilting trans output side towards over pass fender at angle not there's enough room for that angle . I just hate to disconnect suspension . But if I have 2
     
  3. KitsuneVoss

    KitsuneVoss Member

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    The insulation is falling off the underside of metal wiper tray where it is over the engine.
    I worry about fragments falling in the spark plug openings when I am working there.
    I think I can use my 2009 tray but what is the next best option?
    Remove the insulation completely?
     
  4. ColoradoCrow

    ColoradoCrow Senior Member

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    I removed mine completely after it fell apart. I would think it would quiet engine noise a bit... But I havent had one on our white Prius for 4 years now.
     
  5. Tombukt2

    Tombukt2 Senior Member

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  6. KitsuneVoss

    KitsuneVoss Member

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    Day Two:
    1. Removed air box. Two 10 mm screws on engine. When I last removed the air box, the hose clamps were not worth trying to reuse so replaced with new ones. If you are reusing the old ones, may need a lot of PB Blaster first. Wire harness holding the MAF sensor. Used a pick to get it loose. Spraying down the bolts / screws to the MAF sensor in hopes of replacing the screws.
    Airbox-01.jpg MAF Sensor connector.jpg
    2. Disconnected fuel injector and coil connectors.
    3. Disconnect wire harness in front of brake fluid reservoir. I don't think it connects to it but the position
    Wire Harness-01.jpg
    4. Unbolted, slid out intake manifold
    Five bolts, all 12 mm. Sprayed them down heavily with PB Blaster. The outer ones however will need a deep socket to remove. Of note, the two hoses that go into the manifold just use butterfly type clips. The bolt on the driver's side was crazy to get to and why it took so long. Could have likely just removed the two hoses and gotten to it far easier. Also like 100 degrees outside. Ended up prying a bit with a large screwdriver to get the intake manifold off. Some wires still are attaching the intake but have not removed yet. I removed a clip holding the wire to the driver's side of a bracket on the intake manifold and then that bracket to get to the driver's side of the intake manifold. 10 mm holding bracket and royal pain to get to. What you do that is pry outward on the other side of where the hose / wire bundle is. Removed wire harness on passenger side of manifold. Carefully used need nose pliers to unlock.
    Fourth image is really blurry
    Manifold 01.jpg Manifold 02.jpg Manifold 03.jpg Manifold 04.jpg
    Stopped at that point. Covered engine with plastic and put away my tools.

    A few questions
    1. Using a video. Not trying to overwhelm myself by watching the whole thing. Will I be removing the fuel rail at some point? Will I want to use these fuel injectors. Not had any problems with the old ones from the 2009 but these are just rebuild. I am planning to replace the spark plugs of the replacement engine when I get there.
    2. I assume that I want a new intake manifold gasket but just checking?
    3. May actually be crazy but can I put the engine hoist in the back of the ranger instead of on plywood?
    Thinking then once the engine is out, could just drive forward with it.
     
    #6 KitsuneVoss, Jun 25, 2025 at 10:38 AM
    Last edited: Jun 25, 2025 at 11:01 AM
  7. Tombukt2

    Tombukt2 Senior Member

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    Yer hoist should pick up engine enuff to push car back . Or this hoist I'm using swivels 280 or so degrees once engines up I swing it from front of car to beside it by pushing on the beam. .
     
  8. Tombukt2

    Tombukt2 Senior Member

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    You need secure the cherry picker to truck bed you gonna be at angle . I usually use short chain .