RM3660EC _51 Engine / Hybrid System _080726 8ZR-FXE ENGINE MECHANICAL _0391622 CYLINDER BLOCK A

8ZR-FXE ENGINE MECHANICAL  CYLINDER BLOCK  REPLACEMENT  


PROCEDURE

Hide 1.REPLACE RING PIN

HINT:

It is not necessary to remove the ring pins unless they are being replaced.


a.
A374095C01
0.542,0.427 0.854,0.583 0.313,0.156 10 false *a 0.698,2.99 1.01,3.146 0.313,0.156 10 false *b 1.323,3.563 1.635,3.719 0.313,0.156 10 false *c 2.979,3.281 3.292,3.438 0.313,0.156 10 false *d
*a Top Side
*b Width
*c Height
*d Protrusion Height


Using a plastic hammer, tap in new ring pins to the cylinder block sub-assembly.

Standard Ring Pin:
Item Height Width Protrusion
Ring Pin 14.3 to 14.7 mm (0.563 to 0.579 in.) 12.9 to 13.0 mm (0.508 to 0.512 in.) 7.5 to 8.5 mm (0.295 to 0.335 in.)



Hide 2.REPLACE STUD BOLT

HINT:
·

If a stud bolt is deformed or its threads are damaged, replace it.

·

There are 2 installation types for the No. 1 ventilation case.

·

This procedure is for type A.



a.
A430232C02
0.344,0.167 0.656,0.323 0.313,0.156 10 false *a 2.104,3.51 2.417,3.667 0.313,0.156 10 false *b 2.125,3.958 2.438,4.115 0.313,0.156 10 false *c 2.615,3.688 2.927,3.844 0.313,0.156 10 false *d
*a LH Side
*b 16 mm (0.630 in.)
*c 9 mm (0.354 in.)
*d 27 mm (1.06 in.)


Using an E6 "TORX" socket wrench, install the stud bolts to the cylinder block sub-assembly as shown in the illustration.

Torque:
5.0 N*m (51 kgf*cm, 44 in.*lbf)


Hide 3.REPLACE STRAIGHT PIN

HINT:

It is not necessary to remove the straight pins unless they are being replaced.


a.

Using a plastic hammer, tap in new straight pins to the cylinder block sub-assembly.

A374097C01
0.677,1.802 1.458,1.802 true 2.26,1.115 3.094,2.063 3.094,2.063 1.208,2.063 true 4.396,0.969 3.823,0.969 3.823,0.969 6.458,2.052 true 1.323,4 3.094,4 3.094,4 2.615,4.302 true 1,0.323 1.313,0.479 0.313,0.156 10 false *a 4.313,0.302 4.625,0.458 0.313,0.156 10 false *b 0.927,3.188 1.24,3.344 0.313,0.156 10 false *c 4.427,4.813 4.74,4.969 0.313,0.156 10 false *d 4.927,4.229 5.24,4.385 0.313,0.156 10 false *e 6.771,4.146 7.083,4.302 0.313,0.156 10 false *f 0.552,1.75 0.708,1.948 0.156,0.198 10 false A 3.177,2 3.333,2.198 0.156,0.198 10 false B 3.656,0.917 3.813,1.115 0.156,0.198 10 false C 3.167,3.948 3.323,4.146 0.156,0.198 10 false D
*a Front Side *b Bottom Side
*c Rear Side *d Width
*e Height *f Protrusion Height


Standard Straight Pin:
Item Height Width Protrusion
Pin (A) 36 mm (1.42 in.) 10 mm (0.394 in.) 18.5 to 19.5 mm (0.728 to 0.768 in.)
Pin (B) 12 mm (0.472 in.) 4 mm (0.157 in.) 5.0 to 7.0 mm (0.197 to 0.276 in.)
Pin (C) 22 mm (0.866 in.) 10 mm (0.394 in.) 8.0 to 10.0 mm (0.315 to 0.394 in.)
Pin (D) 18 mm (0.709 in.) 8 mm (0.315 in.) 8.0 to 10.0 mm (0.315 to 0.394 in.)



Hide 13201A 4.REPLACE CONNECTING ROD SMALL END BUSH

a.
A366511N01
0.781,0.698 1.385,0.698 false 0.458,0.615 0.917,0.813 0.458,0.198 10 false SST

Using SST and a press, press out the connecting rod small end bush.

SST
09222-30010  


b.
A366512C01
2.052,1.604 2.563,1.198 2.563,1.198 2.073,0.74 true 2.646,1.135 2.958,1.292 0.313,0.156 10 false *a
*a Oil Hole


Align the oil holes of a new connecting rod small end bush and the connecting rod.


c.
A366511N01
0.781,0.698 1.385,0.698 false 0.458,0.615 0.917,0.813 0.458,0.198 10 false SST

Using SST and a press, press in the connecting rod small end bush.

SST
09222-30010  


d.
A132159

Using a pin hole grinder, hone the connecting rod small end bush to obtain the standard oil clearance between the connecting rod small end bush and piston pin.

Standard Oil Clearance:

0.005 to 0.011 mm (0.000197 to 0.000433 in.)



e.
A132160

Coat the piston pin with engine oil. Push the piston pin into the connecting rod with your thumb to check that the piston pin fits at normal room temperature.