Toyota Prius: Cylinder Block

• Precaution
• Disassembly
• Inspection
• Reassembly

Precaution

PRECAUTION

Disassembly

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
*: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation. *1: Also necessary after performing a tire rotation. *2: It is not necessary to perform this procedure if the tire pressure warning valve and transmitters are installed to the same location.
Replacement of ECM	Update ECU security key	Toyota Prius Vehicle Control History (RoB) are stored
	ECU configuration	-
	Perform Toyota Prius Vehicle Identification Number (VIN) registration	DTC is output
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.
Replacement of inverter with converter assembly	ECU configuration	-
	Resolver learning	DTCs are stored Slight vibration at a Toyota Prius vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration
Replacement of hybrid vehicle transaxle assembly	Resolver learning Initialize resolver	DTCs are stored Slight vibration at a Toyota Prius vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration
Suspension parts	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System
	Parking assist ECU initialization	Panoramic View Monitor System
		Advanced Park
Tires	Initialization*1*2 Tire Position Identification*1*2	Tire Pressure Warning System	Refer to Procedures Necessary When Replacing Parts (for Tire Pressure Warning System) table below
	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System
	Parking assist ECU initialization	Panoramic View Monitor System
		Advanced Park
Replacement of front bumper assembly*	Front television camera view adjustment	Panoramic View Monitor System
		Advanced Park

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.

CAUTION / NOTICE / HINT

COMPONENTS (DESASSEMBLY)

Procedure		Part Name Code
1	NO. 1 VENTILATION CASE	12211		-	-
2	CONNECTING ROD CAP	-		-	-
3	PISTON SUB-ASSEMBLY WITH CONNECTING ROD	-		-	-
4	CONNECTING ROD BEARING	13041	-	-	-
5	PISTON RING SET	13011		-	-
6	PISTON PIN	-		-	-
7	CRANKSHAFT BEARING CAP	-		-	-
8	CRANKSHAFT	13411	-	-	-
9	UPPER CRANKSHAFT THRUST WASHER	11791	-	-	-
10	CRANKSHAFT BEARING	11711	-	-	-
11	CONNECTING ROD SMALL END BUSH	13201A		-	-

*A	Type A	*B	Type B
●	Non-reusable part	-	-

Procedure		Part Name Code
12	NO. 1 OIL NOZZLE SUB-ASSEMBLY	15708		-	-
13	RING PIN	-		-	-
14	STRAIGHT PIN	-		-	-
15	STUD BOLT	-		-	-
16	CLEAN CYLINDER BLOCK	-		-	-

●

Non-reusable part

-

-

PROCEDURE

1. REMOVE NO. 1 VENTILATION CASE

*A

Type A

*B

Type B

(1) Type A:

Remove the 6 bolts and 2 nuts.

(2) Type B:

Remove the 8 bolts.

(3) 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.

2. REMOVE CONNECTING ROD CAP

*a

Paint Mark

-

-

(1) Place a paint mark across each corresponding connecting rod and connecting rod cap.

HINT:

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

(2) Using SST, remove the 8 connecting rod bolts from the connecting rod caps.

SST: 09205-16011

(3) 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.

3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

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

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

4. REMOVE CONNECTING ROD BEARING

5. REMOVE PISTON RING SET

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

(2) 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.

6. REMOVE PISTON PIN

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

(2) Gradually heat each piston to approximately 80 to 90°C (176 to 194°F).

CAUTION:

Be sure to wear protective gloves.

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

7. REMOVE CRANKSHAFT BEARING CAP

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

(2) 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.

8. REMOVE CRANKSHAFT

9. REMOVE UPPER CRANKSHAFT THRUST WASHER

10. REMOVE CRANKSHAFT BEARING

11. REMOVE CONNECTING ROD SMALL END BUSH

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

SST: 09222-30010

12. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(1) 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.

13. REMOVE RING PIN

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

14. REMOVE STRAIGHT PIN

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

15. REMOVE STUD BOLT

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

(1) Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the cylinder block sub-assembly.

16. CLEAN CYLINDER BLOCK

NOTICE: If the cylinder is washed at high temperature, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.

Inspection

INSPECTION

PROCEDURE

1. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard Thrust Clearance: Maximum Thrust Clearance Specified Condition Result 0.342 mm 0.0135 in. 0.160 to 0.342 mm 0.00630 to 0.0135 in. mm in.

(b) If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.

2. INSPECT CONNECTING ROD OIL CLEARANCE

HINT:

Using SST, install and alternately tighten the 2 connecting rod bolts in several steps.

Pre-procedure1

(a) Remove the connecting rod cap.

HINT:

Click here

(b) Remove the connecting rod bearing.

HINT:

Click here

(c) Clean the crankshaft crank pin and connecting rod bearing.

(d) Check the crankshaft crank pin and connecting rod bearing for pitting and scratches.

(e) If the crank pin or upper connecting rod bearing is damaged, replace the connecting rod bearings. If necessary, replace the crankshaft.

(f) Lay a strip of Plastigage on the crank pin.

*a Plastigage

(g) Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod bearing cap to the connecting rod.

*a Front Mark

(h) Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

(i) Using SST, install and alternately tighten the 2 connecting rod bolts in several steps. SST: 09205-16011 Torque: 20 N·m {204 kgf·cm, 15 ft·lbf}

(j) Mark the front of each connecting rod bolt with paint.

*a	Paint Mark
*b	90°
	Front of Engine

(k) Tighten the connecting rod bolts 90° as shown in the illustration.

NOTICE:

Do not turn the crankshaft during the measurement.

(l) Remove the 2 connecting rod bolts and connecting rod bearing cap.

Procedure1

(m) Measure the Plastigage at its widest point. Standard Oil Clearance: Maximum Oil Clearance Specified Condition Result 0.070 mm 0.00276 in. 0.014 to 0.038 mm 0.000551 to 0.00150 in. mm in. HINT: If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 3 sizes of standard connecting rod bearings, marked "1", "2", or "3" accordingly. Standard Connecting Rod Large End Bore Diameter: Mark Specified Condition 1 47.000 to 47.008 mm (1.85039 to 1.85070 in.) 2 47.009 to 47.016 mm (1.85074 to 1.85102 in.) 3 47.017 to 47.024 mm (1.85106 to 1.85133 in.) Standard Connecting Rod Bearing Thickness: Mark Specified Condition 1 1.489 to 1.493 mm (0.05862 to 0.05878 in.) 2 1.494 to 1.497 mm (0.05882 to 0.05894 in.) 3 1.498 to 1.501 mm (0.05898 to 0.05909 in.) Standard Crankshaft Pin Diameter: Specified Condition Result 43.992 to 44.000 mm 1.73197 to 1.73228 in. mm in. NOTICE: Completely remove the Plastigage after the measurement.

*a Plastigage *b 1, 2 or 3 Mark

(n) If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.

Post-procedure1

(o) None

3. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard Thrust Clearance: Maximum Thrust Clearance Specified Condition Result 0.18 mm 0.00709 in. 0.04 to 0.14 mm 0.00157 to 0.00551 in. mm in. Standard Thrust Washer Thickness: Specified Condition Result 2.43 to 2.48 mm 0.0957 to 0.0976 in. mm in.

(b) If the thrust clearance is more than the maximum, replace the crankshaft thrust washer set. If necessary, replace the crankshaft.

4. INSPECT CRANKSHAFT OIL CLEARANCE

Pre-procedure1

(a) Check the crankshaft journals and crankshaft bearings for pitting and scratches.

(b) Install the crankshaft bearings.

HINT:

Click here

(c) Install the upper crankshaft thrust washers.

HINT:

Click here

(d) Clean each main journal and crankshaft bearing.

(e) Place the crankshaft on the cylinder block sub-assembly.

(f) Lay a strip of Plastigage across each journal.

*a Plastigage

(g) Confirm the front marks and numbers, and place the 5 crankshaft bearing caps on the cylinder block sub-assembly. HINT: A number is marked on each crankshaft bearing cap to indicate the installation position.

*a Front Mark and Number

(h) Install the crankshaft bearing caps.

NOTICE:

Do not turn the crankshaft.

HINT:

Click here

(i) Remove the crankshaft bearing caps.

HINT:

Click here

Procedure1

(j) Measure the Plastigage at its widest point.

*a	No. 1	*b	No. 2
*c	No. 3	*d	No. 4
*e	No. 5	*f	Plastigage
*g	Cylinder Block Number Mark	*h	Crankshaft Number Mark
*i	Diameter Mark	-	-

Standard Oil Clearance:

Maximum Warpage	Specified Condition	Result
0.05 mm 0.00197 in.	0.014 to 0.038 mm 0.00055 to 0.00150 in.	mm in.

NOTICE:

Completely remove the Plastigage after the measurement.

(k) If replacing a crankshaft bearing, select a new one with the same number.

Crankshaft Bearing:

Cylinder block sub-assembly Crankshaft	Crankshaft bearing to be used
0 to 2	"1"
3 to 5	"2"
6 to 8	"3"
9 to 11	"4"

Standard Cylinder Block Journal Bore Diameter:

Mark	Specified Condition
0	52.000 to 52.002 mm (2.04724 to 2.04732 in.)
1	52.003 to 52.004 mm (2.04736 to 2.04740 in.)
2	52.005 to 52.006 mm (2.04744 to 2.04748 in.)
3	52.007 to 52.009 mm (2.04752 to 2.04759 in.)
4	52.010 to 52.011 mm (2.04763 to 2.04767 in.)
5	52.012 to 52.013 mm (2.04771 to 2.04775 in.)
6	52.014 to 52.016 mm (2.04779 to 2.04787 in.)

Standard Crankshaft Journal Diameter:

Mark	Specified Condition
0	47.999 to 48.000 mm (1.88972 to 1.88976 in.)
1	47.997 to 47.998 mm (1.88964 to 1.88968 in.)
2	47.995 to 47.996 mm (1.88956 to 1.88960 in.)
3	47.993 to 47.994 mm (1.88948 to 1.88952 in.)
4	47.991 to 47.992 mm (1.88941 to 1.88945 in.)
5	47.988 to 47.990 mm (1.88929 to 1.88937 in.)

Standard Bearing Center Wall Thickness:

Mark	Specified Condition
1	1.991 to 1.994 mm (0.07839 to 0.07850 in.)
2	1.995 to 1.997 mm (0.07854 to 0.07862 in.)
3	1.998 to 2.000 mm (0.07866 to 0.07874 in.)
4	2.001 to 2.003 mm (0.07878 to 0.07886 in.)

Post-procedure1

(l) None

5. INSPECT CYLINDER BLOCK FOR WARPAGE

(a) Using a precision straightedge and feeler gauge, check the surfaces which contact the cylinder head gasket for warpage. Maximum Warpage: Specified Condition Result 0.05 mm 0.00197 in. mm in.

(b) If the warpage is more than the maximum, replace the cylinder block sub-assembly.

6. INSPECT CYLINDER BORE

(a) Using a cylinder gauge, measure the cylinder bore diameter at the positions (A) and (B) in the thrust and axial directions.

*a	Thrust Direction
*b	Axial Direction
	Front of Engine

Reference Diameter (New Parts):

Maximum Diameter	Specified Condition	Result
80.63 mm 3.17 in.	80.500 to 80.513 mm 3.16929 to 3.16980 in.	mm in.

Measurement Position:

Measurement Position	Cylinder Bore Position
(A)	10 mm (0.394 in.) from top edge
(B)	50 mm (1.97 in.) from top edge

(b) If the average diameter of 4 positions is more than the maximum, replace the cylinder block sub-assembly.

7. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Push the check valve with a pin to check that it is not stuck.

*a Pin

(b) If the check valve is stuck, replace the No. 1 oil nozzle sub-assembly.

(c) Apply air into (A). Check that air does not leak through (B).

(d) If air leaks, clean or replace the No. 1 oil nozzle sub-assembly.

(e) Push the check valve with a pin while applying air into (A). Check that air passes through (B).

*a Pin

(f) If air does not pass through (B), clean or replace the No. 1 oil nozzle sub-assembly.

8. INSPECT PISTON SUB-ASSEMBLY WITH CONNECTING ROD

(a) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

(b) If abnormal movement is felt, replace the piston and piston pin as a set.

9. INSPECT PISTON

(a) Using a micrometer, measure the piston diameter at a position 9.0 mm (0.354 in.) from the bottom of the piston (refer to the illustration). Reference Piston Diameter (New Parts): Distance Specified Condition Result 9.0 mm 0.354 in. 80.473 to 80.503 mm 3.16822 to 3.16940 in. mm in.

*a 9.0 mm

(b) If the piston diameter is less than the minimum, replace the piston and piston pin as a set.

10. INSPECT PISTON OIL CLEARANCE

(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Reference Oil Clearance (New Parts):

Maximum Oil Clearance	Specified Condition	Result
0.08 mm 0.00315 in.	-0.003 to 0.040 mm -0.000118 to 0.00157 in.	mm in.

(b) If the piston oil clearance is more than the maximum, replace all the pistons with piston pins. If necessary, replace the cylinder block sub-assembly.

11. INSPECT RING GROOVE CLEARANCE

(a) Using a feeler gauge, measure the clearance between a new piston ring set and the wall of the ring groove. Standard Ring Groove Clearance: Item Specified Condition Result No. 1 Compression Ring 0.02 to 0.07 mm 0.000787 to 0.00276 in. mm in. No. 2 Compression Ring 0.02 to 0.06 mm 0.000787 to 0.00236 in. mm in. Oil Ring 0.07 to 0.13 mm 0.00276 to 0.00512 in. mm in.

(b) If the groove clearance is not as specified, replace the piston and piston pin as a set.

12. INSPECT PISTON RING END GAP

Pre-procedure1

(a) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 50 mm (1.97 in.) from the top of the cylinder block sub-assembly.

*a 50 mm

Procedure1

(b) Using a feeler gauge, measure the end gap. Standard End Gap: Item Maximum End Gap Specified Condition Result No. 1 compression ring 0.5 mm 0.0197 in. 0.20 to 0.25 mm 0.00787 to 0.00984 in. mm in. No. 2 compression ring 0.7 mm 0.0276 in. 0.30 to 0.50 mm 0.0118 to 0.0197 in. mm in. Oil ring 0.7 mm 0.0276 in. 0.10 to 0.35 mm 0.00394 to 0.0138 in. mm in.

(c) If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum even with a new piston ring, replace the cylinder block sub-assembly.

Post-procedure1

(d) None

13. INSPECT PISTON PIN OIL CLEARANCE

HINT:

When replacing the piston and piston pin with supply parts, there are a number of piston diameter sizes to choose from, but there is only one size of piston pin diameter.

(a) Using a caliper gauge, measure the piston pin bore diameter. Standard Piston Pin Bore Diameter: 20.006 to 20.015 mm (0.78764 to 0.78799 in.) Item Specified Condition Result Mark A 20.006 to 20.009 mm 0.78764 to 0.78775 in. mm in. Mark B 20.010 to 20.012 mm 0.78779 to 0.78787 in. mm in. Mark C 20.013 to 20.015 mm 0.78791 to 0.78799 in. mm in.

(b) If the diameter is not as specified, replace the piston and piston pin as a set.

(c) Using a micrometer, measure the piston pin diameter. Standard Piston Pin Diameter: 20.004 to 20.013 mm (0.78756 to 0.78791 in.) Item Specified Condition Result Mark A 20.004 to 20.007 mm 0.78756 to 0.78768 in. mm in. Mark B 20.008 to 20.010 mm 0.78772 to 0.78779 in. mm in. Mark C 20.011 to 20.013 mm 0.78783 to 0.78791 in. mm in. Measurement Position: Measurement Position Piston Pin Position a 5 mm (0.197 in.) from side edge b 25 mm (0.984 in.) from side edge

(d) If the diameter is not as specified, replace the piston and piston pin as a set.

(e) Using a caliper gauge, measure the connecting rod small end bush bore diameter. Standard Connecting Rod Small End Bush Bore Diameter: 20.012 to 20.021 mm (0.78787 to 0.78823 in.) Item Specified Condition Result Mark A 20.012 to 20.015 mm 0.78787 to 0.78799 in. mm in. Mark B 20.016 to 20.018 mm 0.78803 to 0.78811 in. mm in. Mark C 20.019 to 20.021 mm 0.78815 to 0.78823 in. mm in.

(f) If the diameter is not as specified, replace the connecting rod small end bush.

(g) Subtract the piston pin diameter measurement from the piston pin bore diameter measurement. Standard Oil Clearance: Maximum Oil Clearance Specified Condition Result 0.010 mm 0.000394 in. -0.001 to 0.005 mm -0.0000394 to 0.000197 in. mm in.

*a Upper Side *b Lower Side *c Front Mark *d Piston Pin Bore Diameter Mark *e Connecting Rod Small End Bush Bore Diameter Mark

(h) If the oil clearance is more than the maximum, replace the piston and piston pin as a set.

(i) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

Standard Oil Clearance:

Maximum Oil Clearance	Specified Condition	Result
0.014 mm 0.000551 in.	0.005 to 0.011 mm 0.000197 to 0.000433 in.	mm in.

(j) If the oil clearance is more than the maximum, replace the connecting rod small end bush. If necessary, replace the piston and piston pin as a set.

14. INSPECT CONNECTING ROD BOLT

(a) Using a vernier caliper, measure the diameter of the connecting rod bolt at several points within the area shown in the illustration. Standard Diameter: Minimum Diameter Specified Condition Result 6.4 mm 0.252 in. 6.6 to 6.7 mm 0.260 to 0.264 in. mm in. NOTICE: Diameter measurements should be done at several points. If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage. If there is any thread deformation, replace the connecting rod bolt with a new one.

*a Measurement Area

(b) If the diameter is less than the minimum, replace the connecting rod bolt.

15. INSPECT CRANKSHAFT

(a) Inspect the runout.

(1) Using a dial indicator and V-blocks, measure the runout as shown in the illustration. Maximum Runout: Specified Condition Result 0.03 mm 0.00118 in. mm in.

(2) If the runout is more than the maximum, replace the crankshaft.

(b) Inspect the main journals.

(1) Using a micrometer, measure the diameter of each main journal. Standard Diameter: 47.988 to 48.000 mm (1.88929 to 1.88976 in.) Standard Diameter (Reference): Mark Specified Condition 0 47.999 to 48.000 mm (1.88972 to 1.88976 in.) 1 47.997 to 47.998 mm (1.88964 to 1.88968 in.) 2 47.995 to 47.996 mm (1.88956 to 1.88960 in.) 3 47.993 to 47.994 mm (1.88948 to 1.88952 in.) 4 47.991 to 47.992 mm (1.88941 to 1.88945 in.) 5 47.988 to 47.990 mm (1.88929 to 1.88937 in.)

(2) If the diameter is not as specified, check the crankshaft oil clearance.

(3) Check each main journal for taper and out-of-round as shown in the illustration.

Maximum Taper and Out-of-Round:

Specified Condition	Result
0.004 mm 0.000157 in.	mm in.

(4) If the taper or out-of-round is more than the maximum, replace the crankshaft.

(c) Inspect the crank pins.

(1) Using a micrometer, measure the diameter of each crank pin. Standard Diameter: Specified Condition Result 43.992 to 44.000 mm 1.73197 to 1.73228 in. mm in.

(2) If the diameter is not as specified, check the connecting rod oil clearance.

(3) Inspect each crank pin for taper and out-of-round.

Maximum Taper and Out-of-Round:

Specified Condition	Result
0.004 mm 0.000157 in.	mm in.

(4) If the taper or out-of-round is more than the maximum, replace the crankshaft.

16. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using a vernier caliper, measure the length of the crankshaft bearing cap set bolt from the seat to the end. Standard Length: Maximum Length Specified Condition Result 86.7 mm 3.41 in. 84.3 to 85.7 mm 3.32 to 3.37 in. mm in. NOTICE: If the length is greater than the maximum, replace the crankshaft bearing cap set bolt with a new one. Failure to do so may lead to engine damage. If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.

*a Measurement Length *b Measurement Area *c 55 mm (2.17 in.)

(b) Using a vernier caliper, measure the minimum diameter of the threads at several points within the area shown in the illustration.

Standard Diameter:

Measurement Point (Distance from the Seat)	Minimum Diameter	Specified Condition	Result
55 mm 2.17 in.	9.1 mm 0.358 in.	9.77 to 9.96 mm 0.385 to 0.392 in.	mm in.

Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

Perform "Inspection After Repair" after replacing the piston or piston ring.

Click here

CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)

Procedure		Part Name Code
1	STUD BOLT	-		-	-
2	STRAIGHT PIN	-		-	-
3	RING PIN	-		-	-
4	NO. 1 OIL NOZZLE SUB-ASSEMBLY	15708		-	-

N*m (kgf*cm, ft.*lbf): Specified torque

●

Non-reusable part

Procedure		Part Name Code
5	CONNECTING ROD SMALL END BUSH	13201A		-	-
6	PISTON PIN	-		-	-
7	PISTON RING SET	13011		-	-
8	CRANKSHAFT BEARING	11711		-	-
9	UPPER CRANKSHAFT THRUST WASHER	11791		-	-
10	CRANKSHAFT	13411		-	-
11	CRANKSHAFT BEARING CAP	-		-	-
12	CONNECTING ROD BEARING	13041		-	-
13	PISTON SUB-ASSEMBLY WITH CONNECTING ROD	-		-	-
14	CONNECTING ROD CAP	-		-	-
15	NO. 1 VENTILATION CASE	12211		-	-

*A	Type A	*B	Type B
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
●	Non-reusable part	-	-
*T1	1st: 40 (408, 30) 2nd: Turn 90°	*T2	1st: 20 (204, 15) 2nd: Turn 90°

PROCEDURE

1. INSTALL STUD BOLT

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

*a	LH Side	*b	16 mm (0.630 in.)
*c	9 mm (0.354 in.)	*d	27 mm (1.06 in.)

(1) Using an E6 "TORX" socket wrench, install the 2 stud bolts to the cylinder block sub-assembly as shown in the illustration.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

2. INSTALL STRAIGHT PIN

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

*a	Front Side	*b	Bottom Side
*c	Rear Side	*d	Width
*e	Height	*f	Protrusion Height

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

Standard Straight Pin:

Item	Height	Width	Protrusion Height
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)	18 mm (0.709 in.)	8 mm (0.315 in.)	8.0 to 10.0 mm (0.315 to 0.394 in.)
Pin (D)	22 mm (0.866 in.)	10 mm (0.394 in.)	11.0 to 13.0 mm (0.433 to 0.512 in.)

3. INSTALL RING PIN

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

*a	Upper Side	*b	Width
*c	Height	*d	Protrusion Height

(1) Using a plastic hammer, tap 2 new ring pins into the cylinder block sub-assembly.

Standard Ring Pin

Item	Height	Width	Protrusion Height
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.)

4. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(1) Using a 5 mm socket hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

5. INSTALL CONNECTING ROD SMALL END BUSH

*a

Oil Hole

-

-

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

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

SST: 09222-30010

(3) 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.)

(4) 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.

6. INSTALL PISTON PIN

HINT:

Perform this procedure only when replacement of the piston pin hole snap ring (rear side) is necessary.

*a

Front Mark

*b

Cutout

(1) Using a screwdriver, install a new piston pin hole snap ring (rear side) at one end of the piston pin hole.

(2) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

CAUTION:

Be sure to wear protective gloves.

(3) Align the front marks of the piston and connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the snap ring.

HINT:

The piston and piston pin are a matched set.

(4) Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.

NOTICE:

Make sure that the end gap of the snap ring is not aligned with the cutout of the piston pin hole.

(5) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

HINT:

Perform "Inspection After Repair" after replacing the piston.

Click here

7. INSTALL PISTON RING SET

*1	Upper Side Rail	*2	Oil Ring Expander
*3	Lower Side Rail	-	-
*a	Press around the circumference	*b	Ring End
*c	Correct	*d	Incorrect (Ends of the oil ring expander are overlapping)

(1) Install the oil ring expander, upper side rail and lower side rail to the piston by hand.

NOTICE:

When installing the upper side rail and lower side rail, the ends of the oil ring expander may overlap. If it occurs, the upper side rail or lower side rail may move out of its groove.

(2) Check that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.

*1	No. 1 Compression Ring and Oil Ring Expander	*2	No. 2 Compression Ring
*3	Upper Side Rail	*4	Lower Side Rail
*a	No. 1 Compression Ring	*b	No. 2 Compression Ring
*c	Code Mark	*d	Paint Mark
*e	Code Mark (No mark)	*f	Code Mark (2T)
*g	Front of Engine	-	-
	Upward	-	-

(1) Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring so that the paint marks are positioned as shown in the illustration.

(2) Position the piston ring set so that the ring ends are as shown in the illustration.

HINT:

Perform "Inspection After Repair" after replacing the piston ring.

Click here

8. INSTALL CRANKSHAFT BEARING

*a

Scale

*b

Vernier Caliper

(1) Install the 4 upper crankshaft bearings (except the No. 3 journal).

1. Install the 4 upper crankshaft bearings to the cylinder block sub-assembly.

NOTICE:

Do not apply engine oil to the 4 upper crankshaft bearings or the contact surfaces.

HINT:

Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.

2. Using a scale, measure the distance between the cylinder block sub-assembly edge and the crankshaft bearing edge.

Dimension (A):

0.5 to 1.0 mm (0.0197 to 0.0394 in.)

(2) Install the crankshaft bearing (for No. 3 journal).

1. Install the crankshaft bearing to the cylinder block sub-assembly.

NOTICE:

Do not apply engine oil to the upper crankshaft bearing or the contact surface.

HINT:

Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the upper crankshaft bearing. The amount visible on each side of the holes should be equal.

2. Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and the crankshaft bearing edge.

Difference between (B) and (C):

0.5 mm (0.0197 in.) or less

(3) Install the crankshaft bearing.

1. Install the crankshaft bearing to the cylinder block sub-assembly.

HINT:

Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.

2. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the crankshaft bearing edge.

Difference between (D) and (E):

0.5 mm (0.0197 in.) or less

NOTICE:

Do not apply engine oil to the crankshaft bearings or the contact surfaces.

9. INSTALL UPPER CRANKSHAFT THRUST WASHER

*a

Oil Grooves

-

-

(1) Install the 2 upper crankshaft thrust washers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

(2) Apply engine oil to the upper crankshaft thrust washers.

10. INSTALL CRANKSHAFT

(1) Apply engine oil to the upper crankshaft bearings and install the crankshaft to the cylinder block sub-assembly.

11. INSTALL CRANKSHAFT BEARING CAP

*a	Front Mark and Number	*b	Less than 5 mm
	Front of Engine	-	-

(1) Apply engine oil to the lower crankshaft bearings.

(2) Confirm the front marks and numbers, and place the 5 crankshaft bearing caps on the cylinder block sub-assembly.

(3) Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.

(4) Temporarily install the 10 crankshaft bearing cap set bolts.

(5) Push on the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and cylinder block sub-assembly is less than 5 mm (0.197 in.).

*a	Paint Mark	-	-
	Front of Engine	-	-

(1) Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.

(2) Install the crankshaft bearing cap set bolts.

NOTICE:

The crankshaft bearing cap set bolts are tightened in 2 progressive steps.

(3) Step 1

1. Install and uniformly tighten the 10 crankshaft bearing cap set bolts in the sequence shown in the illustration.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

HINT:

If a crankshaft bearing cap set bolt cannot be tightened to the specified torque, replace it.

(4) Step 2

1. Mark the front of the crankshaft bearing cap set bolts with paint.

2. Tighten the crankshaft bearing cap set bolts by 90° in the order shown in step 1.

(5) Check that the paint marks are now at a 90° angle.

(6) Check that the crankshaft turns smoothly.

(7) Check the crankshaft thrust clearance.

Click here

12. INSTALL CONNECTING ROD BEARING

*a

Vernier Caliper

-

-

(1) Install the 8 connecting rod bearings to the 4 connecting rods and 4 connecting rod caps.

(2) Using a vernier caliper, measure the distance between the edges of the connecting rod and connecting rod bearing, and the connecting rod cap and the connecting rod bearing.

Difference between (A) and (B):

0.7 mm (0.0276 in.) or less

NOTICE:

Do not apply engine oil to the connecting rod bearings or the contact surfaces.

13. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

*1	No. 1 Compression Ring and Oil Ring Expander	*2	No. 2 Compression Ring
*3	Upper Side Rail	*4	Lower Side Rail
*a	Front of Engine	-	-

(1) Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.

(2) Position the piston ring set so that the ring ends are as shown in the illustration.

*a	Press around the circumference	*b	Ring End
*c	Correct	*d	Incorrect (Ends of the oil ring expander are overlapping)
*e	Front Mark	-	-

(1) Confirm that the ends of the oil ring expander are not overlapping and that the upper side rail and lower side rail are securely installed into the groove.

(2) Using a piston ring compressor, push the correctly numbered piston with connecting rod into the cylinder with the front marks of each piston sub-assembly with connecting rod facing the front of the engine.

14. INSTALL CONNECTING ROD CAP

*a	Front Mark	*b	Paint Mark
	Front of Engine	-	-

(1) Check that the front mark of the connecting rod cap is facing in the correct direction.

(2) Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.

(3) Install the 8 connecting rod bolts.

NOTICE:

The connecting rod bolts are tightened in 2 progressive steps.

(4) Step 1

1. Using SST, alternately tighten the connecting rod bolts in several steps.

SST: 09205-16011

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(5) Step 2

1. Mark the front of the connecting rod bolts with paint.

2. Further tighten the connecting rod bolts 90° as shown in the illustration.

(6) Check that the paint marks are now at a 90° angle.

(7) Check that the crankshaft turns smoothly.

(1) Check the connecting rod thrust clearance.

Click here

15. INSTALL NO. 1 VENTILATION CASE

*A	Type A	*B	Type B
*a	Seal Packing	*b	2.0 to 3.0 mm
*c	5.0 mm	-	-

(1) Apply seal packing in a continuous line as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Application Specification:

Seal Packing Diameter	Distance from Inside Edge of Cover to Center of Seal Packing
2.0 to 3.0 mm (0.0787 to 0.118 in.)	5.0 mm (0.197 in.)

(2) Type A:

Install the No. 1 ventilation case with the 6 bolts and 2 nuts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(3) Type B:

Install the No. 1 ventilation case with the 8 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}