2012 Toyota Prius excessive piston skirt wear?

Would be a time saver for sure, no idea about the quality.

You COULD fix the original block but it would have to be welded up and then milled flat, then presumably all cylinders would need to be bored at least 10 thou over(or whatever it takes to get them back to spec) new oversized pistons/rings bearings gaskets etc. problem with that approach is you need a quality machine shop and time.
 
Hard to tell from that picture whether it is erosion or a crack, but it sure does have the appearance of a crack. Do you have a heat gun? If so, try cleaning the surface, then heating it evenly. See if a crack appears. Sometimes this method will cause the crack to seep contaminates and show.

It is also hard to tell just how deep the erosion is. You could take a file, and draw it across the block a few times, to see just how low that section is. Use care not to get filings inside oil passages or other areas.

The thing is, I don't believe Prius engines are known to crack here.
 
Doesn’t appear to have a crack.

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That's one heck of a blowout. Maybe it could be re-surfaced if it's not too deep. Sometimes pictures make things look worse than they are. It is always a sinking feeling when a simple head gasket job turns into a major overhaul.

Of course, if you choose to rework the block surface, it is sometimes possible to not overhaul it. Takes some care to pull that off, but if parts are in acceptable condition for re-use, it may work.

A rebuilt short block has probably also been resurfaced.
 
Never really experienced it myself, but I've heard of piston skirts collapsing due to severe overheating which is a possibility for that engine. I think you made the right choice. A rebuilt engine seems to be the proper path.
 
+1
At least you'd be certain you are getting something with a warranty that'll last.

Also, I'm not sure as to what would cause this issue.
My initial guess was extended OCI's, but I'm not a licensed mechanic.
I thought it was common knowledge
But generation 3 Prius 2010-2015+ (V was made as g3 longer) all have defective motors that fail randomly in this way sometime after 100,000 miles.

Lots of blown head gaskets and all the symptoms described.

Toyota used a redesigned ring in 2014+ g3 but there is evidence it’s just a bandaid.

Tons of information on this on priuschat.

Most folks who run g3 big miles
change oil often, go up a grade oil, use a catch can and clean the egr system as maintenance


Worth noting the Gen iv motor will swap into a g3 with some work, if labor is free it saves money and may be a better long term investment.


As for your motor if your labor is free and you already have the work and materials in it just slap a double head gasket on, go down a plug heat level (cooler plugs) on the defective cylinders and try to drive it.

You may get 20,000-30000 miles giving you time to get the best possible motor which might be a 2016+ Prius motor as another full 2010-2015 g3 motor will just repeat this process sometime randomly after 100,000 miles
 
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This spot on the engine block itself where the head gasket was blown out between the two cylinders, is a little concerning to me.
Try some 2,000 grit wet paper to take it down flush and slap it back together and send it?
He and his wife don’t have the kind of money to have the block all machined or to replace the entire engine for that matter. I’m trying to do my best to save him as much as possible on the repair but we will for sure be putting new timing chain, tensioner, and guides on it during reassembly. But the oil milkshake that we drained out of it is definitely a bit concerning.

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Block is done. Head should also be resurfaced as well.

Your best route at this point is a junkyard motor. Those are a pig in a poke but Toyota new isn’t going tk be viable economically particularly if money is short.

Good luck with it - I know you are helping a friend but don’t want to see you throw away time and money.
 
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