RM3660EC _51 Engine / Hybrid System _080739 NR Series ENGINE MECHANICAL _0391938 CYLINDER BLOCK A

NR Series 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 cylinder block 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
Replacement of ECM	Perform Vehicle Identification Number (VIN) or frame number registration	DTC is stored	(201906,999999,_51,_080777,_0393969,RM100000001I1RD,)
	1. Reset memory 2. Deceleration sensor zero point calibration 3. CVT oil pressure calibration	· Large shift shock · Deterioration of fuel efficiency	(201906,999999,_52,_080728,_0392261,RM100000001HP98,)
	Code registration (Immobiliser system)	Engine start	See Service Bulletin for the registration method
Replacement of piston ring	Clear Heavy Knock History	-	(201906,999999,_51,_080777,_0393969,RM100000001I1RE,)
· Replacement of throttle body with motor assembly · Replacement of engine assembly · Replacement of cylinder head sub-assembly · Replacement of camshaft (for intake or exhaust camshaft) · Replacement of camshaft timing gear assembly · Replacement of camshaft timing exhaust gear assembly · Replacement of piston or piston ring · Replacement of mass air flow meter sub-assembly · Replacement of fuel injector assembly · Replacement of fuel pump (for high pressure side) · Replacement of engine coolant temperature sensor · Replacement of spark plug · Replacement of ignition coil assembly · Gas leaks from exhaust system · Replacement of knock control sensor · Replacement of fuel delivery pipe (fuel pressure sensor)	Inspection After Repair	· Poor idle, etc. · Engine start function, etc.	(201906,999999,_51,_080777,_0393969,RM100000001I1RE,)
Replacement of starter assembly	Clear the number of starter operations	Stop and Start System	(201906,999999,_51,_080774,_0393362,RM100000001HXHH,)
Replacement of battery	Integrated current value initialization	Stop and Start System	(201906,999999,_51,_080774,_0393362,RM100000001HXHH,)
Replacement of continuously variable transaxle assembly	Air bleed the oil pump with motor assembly	Stop and Start System	(201906,999999,_51,_080774,_0393362,RM100000001HXHH,)
Replacement of continuously variable transaxle assembly	1. Reset memory 2. Deceleration sensor zero point calibration 3. CVT oil pressure calibration	· Large shift shock · Deterioration of fuel efficiency	(201906,999999,_52,_080728,_0392261,RM100000001HP98,)
Replacement of CVT fluid	Air bleed the oil pump with motor assembly	Stop and Start System	(201906,999999,_51,_080774,_0393362,RM100000001HXHH,)
Replacement of CVT fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly	(201906,999999,_52,_080728,_0392261,RM100000001HP98,)
Tires	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System	(202304,999999,_56,_080754,_0596561,RM100000002AX0C,)
Suspension parts	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System	(202304,999999,_56,_080754,_0596561,RM100000002AX0C,)
Front wheel alignment adjustment	· Perform "Reset Memory" · Perform acceleration sensor zero point calibration and store system information memorization	· VSC is disabled or malfunctions · DTCs are stored · Slip indicator light illuminates · ABS warning light illuminates	(202304,999999,_54,_080770,_0599814,RM100000002BA8F,)

HINT:

When the cable is disconnected / reconnected to the 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
Stop and Start System	Idle the engine for approximately 5 to 60 minutes or drive the vehicle until stop and start control is permitted	(201906,999999,_51,_080774,_0393362,RM100000001HXHC,)
Pre-collision System	Perform steering sensor zero point calibration	(202304,999999,_95,_139716,_0601175,RM100000002BFOE,)
Lane Tracing Assist System	Perform steering sensor zero point calibration	(202304,999999,_95,_139716,_0601175,RM100000002BFOE,)

PROCEDURE

Hide Display 12211A 1.REMOVE NO. 1 VENTILATION CASE

Remove the 8 bolts.

0.875,2.74 1.708,3.177 1.708,3.177 2.521,2.771 true 1.625,3.24 1.938,3.396 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.

Remove the 2 oil separator gaskets from the case separator.

Remove the 2 bolts and case separator from the No. 1 ventilation case.

Hide Display 2.REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

0.76,0.677 1.417,0.302 true 1.469,0.219 1.781,0.375 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.

1.25,0.979 1.688,0.979 false 0.969,0.917 1.427,1.115 0.458,0.198 10 false SST

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

SST: 09205-16011

Using the 2 removed connecting rod bolts, remove the 4 connecting rod bearing caps with lower connecting rod bearings by wiggling each connecting rod cap back and forth.

HINT:: Keep the lower connecting rod bearing installed to the connecting rod cap.

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

HINT:: ·

Keep the connecting rod bearing, connecting rod and connecting rod bearing cap together.

·

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

Hide Display 13041 3.REMOVE CONNECTING ROD BEARING

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

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

Hide Display 13411 4.REMOVE CRANKSHAFT

2.792,0.344 2.948,0.542 0.156,0.198 10 true 1 2.802,1.823 2.958,2.021 0.156,0.198 10 true 2 0.75,0.365 0.906,0.563 0.156,0.198 10 true 3 0.729,1.823 0.885,2.021 0.156,0.198 10 true 4 2.281,0.354 2.438,0.552 0.156,0.198 10 true 5 1.25,0.354 1.406,0.552 0.156,0.198 10 true 7 2.281,1.813 2.438,2.01 0.156,0.198 10 true 6 1.75,1.823 1.906,2.021 0.156,0.198 10 true 9 1.25,1.813 1.406,2.01 0.156,0.198 10 true 8 1.771,0.354 2.167,0.542 0.396,0.188 10 true 10

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

Using the 2 removed crankshaft bearing cap set bolts, remove the 5 No. 1 crankshaft bearing caps from the cylinder block sub-assembly by wigging 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.

Remove the crankshaft from the cylinder block sub-assembly.

Hide Display 11711 5.REMOVE CRANKSHAFT BEARING

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.

Remove the 5 lower crankshaft bearings from the 5 No. 1 crankshaft bearing caps.

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

Hide Display 11791 6.REMOVE UPPER CRANKSHAFT THRUST WASHER

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

Hide Display 13011 7.REMOVE PISTON RING SET

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

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

NOTICE:: ·

Because it is difficult to tell the difference between the top and bottom sides visually, when the parts will be reassembled, mark the top surfaces of the upper side rail and lower side rail with paint marks ahead of time to prevent incorrect assembly.

·

If it is impossible to tell the difference between the top and bottom sides, it must not be used again.

Hide Display 13101 8.REMOVE PISTON SUB-ASSEMBLY WITH PIN

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).

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

CAUTION:: Be sure to wear protective gloves.

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

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.

Hide Display 13516B 10.REMOVE OIL JET

Remove the oil jet from the cylinder block sub-assembly.