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

8ZR-FXE ENGINE MECHANICAL  CYLINDER BLOCK  DISASSEMBLY  


CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during engine unit removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link

*: The vehicle height changes because of tire replacement.

Replacement of ECM Vehicle Identification Number (VIN) or frame number registration DTC stored (Click here)
ECU configuration - (Click here)
Update ECU security key Vehicle Control History (RoB) are stored (Click here)
Perform Total Short Trip Estimate Registration - (Click here)
Replacement of inverter with converter assembly ECU configuration - (Click here)
Resolver learning
·

DTCs are stored

·

Slight vibration at a vehicle speed of 5 km/h (3 mph) or less

·

Shock or vibration during acceleration


(Click here)
·

Replacement of throttle body assembly

·

Replacement of cylinder head sub-assembly

·

Replacement of camshaft (for intake or exhaust camshaft)

·

Replacement of camshaft timing gear assembly

·

Replacement of piston or piston ring

·

Replacement of fuel injector assembly

·

Replacement of spark plug

·

Replacement of ignition coil assembly

·

Replacement of EGR valve assembly

·

Gas leak from exhaust system is repaired

·

Replacement of knock control sensor


Inspection after repair
·

Poor idle, etc.

·

Engine start function, etc.


(Click here)
Replacement of hybrid vehicle transaxle assembly
·

Resolver learning

·

Initialize resolver


·

DTCs are stored

·

Slight vibration at a vehicle speed of 5 km/h (3 mph) or less


(Click here)
·

Tires

·

Suspension parts


Rear television camera assembly optical axis (Back camera position setting)* Parking Assist Monitor System (Click here)
Parking assist ECU initialization Panoramic View Monitor System (Click here)
Front wheel alignment adjustment
1.

Perform "Reset Memory"

2.

Perform "Calibration"


·

DTCs are stored

·

ABS warning light illuminates

·

Brake system warning light (yellow indicator) illuminates

·

Slip indicator light illuminates

·

Electronically controlled brake system disabled or malfunctions


(Click here)

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven
Effect/Inoperative Function when Necessary Procedure not Performed Necessary Procedure Link
Front Camera System Drive the vehicle straight ahead at 15 km/h (9 mph) or more for 1 second or more. (Click here)


PROCEDURE

Hide 12211 1.REMOVE NO. 1 VENTILATION CASE

HINT:

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

Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.


a.

Type A:

i.
A430233

Remove the 6 bolts and 2 nuts.



b.

Type B:

i.
A374062

Remove the 8 bolts.



c.
A377024C01
1.146,2.885 1.927,3.167 1.927,3.167 2.771,2.688 true 1.854,3.188 2.167,3.344 0.313,0.156 10 false *a
*a Protective Tape


Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.



Hide 2.REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

a.
A374065C01
0.74,0.875 1.292,0.313 true 1.302,0.188 1.615,0.344 0.313,0.156 10 false *a
*a Paint Mark


Place a paint mark across each corresponding connecting rod and connecting rod bearing cap.

HINT:

The paint marks are used to ensure that the same parts are installed in the same combination to their original locations.



b.
A374066N01
0.5,0.927 1.219,0.688 true 0.198,0.875 0.656,1.073 0.458,0.198 10 false SST

Using SST, remove the 8 connecting rod bolts from the connecting rod bearing caps.

SST
09205-16011  


c.
A374067

Using the 2 removed connecting rod bolts, remove the 4 connecting rod caps with connecting rod bearings by wiggling each connecting rod cap left and right.

HINT:

Keep the connecting rod bearing installed to the connecting rod cap.



d.
A157789

Using a ridge reamer, scrape off any carbon on the top of the cylinder.


e.

Push out the 4 pistons with 4 connecting rods and 4 connecting rod bearings through the top of the cylinder block sub-assembly.

HINT:
·

Keep the connecting rod bearings, connecting rods and connecting rod caps together.

·

Arrange the removed parts in such a way that they can be reinstalled to their original locations.




Hide 13041 3.REMOVE CONNECTING ROD BEARING

a.

Remove the 8 connecting rod bearings from the 4 connecting rods and 4 connecting rod caps.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.



Hide 13411 4.REMOVE CRANKSHAFT

a.
A374077N01
3.24,0.573 3.396,0.771 0.156,0.198 10 false 1 3.229,1.667 3.385,1.865 0.156,0.198 10 false 2 0.26,0.583 0.417,0.781 0.156,0.198 10 false 3 0.281,1.646 0.438,1.844 0.156,0.198 10 false 4 2.677,0.531 2.833,0.729 0.156,0.198 10 true 5 2.667,1.667 2.823,1.865 0.156,0.198 10 true 6 0.76,0.469 0.917,0.667 0.156,0.198 10 true 7 0.781,1.677 0.938,1.875 0.156,0.198 10 true 8 1.75,1.823 1.906,2.021 0.156,0.198 10 true 9 1.74,0.344 2.021,0.542 0.281,0.198 10 true 10

Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.


b.
A374078

Using the 2 removed crankshaft bearing cap set bolts, remove the 5 crankshaft bearing caps from the cylinder block sub-assembly by wiggling each crankshaft bearing cap back and forth.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.



c.

Remove the crankshaft from the cylinder block sub-assembly.


Hide 11711 5.REMOVE CRANKSHAFT BEARING

a.
A374080

Remove the 5 upper crankshaft bearings from the cylinder block sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.



b.
A352884

Remove the 5 lower crankshaft bearings from the 5 crankshaft bearing caps.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.



Hide 11791 6.REMOVE UPPER CRANKSHAFT THRUST WASHER

a.
A374079

Remove the 2 upper crankshaft thrust washers from the cylinder block sub-assembly.


Hide 13011 7.REMOVE PISTON RING SET

a.
A374073

Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.


b.

Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.



Hide 13101 8.REMOVE PISTON

a.
A374074

Using a screwdriver, pry out the piston pin hole snap ring from the piston.

NOTICE:
·

Do not remove the piston pin hole snap ring (rear side) unless it is being replaced.

·

Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).




b.
A366230

Gradually heat the piston to approximately 80°C (176°F).

CAUTION:

Be sure to wear protective gloves.



c.
A366231

Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.

HINT:
·

The piston and piston pin are a matched set.

·

Arrange the removed parts in such a way that they can be reinstalled to their original locations.




Hide 15708 9.REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

a.
A374081

Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.