T-SB-0169-16

T-SB-0169-16
November 16, 2016
2ZR-FXE Engine Oil Consumption Repair Procedure
Service
Category
Engine/Hybrid System
Section
Engine Mechanical
Market USA
Applicability
YEAR(S)
MODEL(S)
2010, 2012 - 2014
Prius PHV
2012 - 2014
Prius V
2010 - 2014
Prius
ADDITIONAL INFORMATION
Introduction
NOTE
Service Bulletin No. T-SB-0168-16 “2ZR-FXE Engine Oil Consumption Inspection Procedure”
MUST be performed BEFORE continuing with the procedure in this bulletin.
Some 2010 – 2014 model year Prius PHV, Prius V, and Prius vehicles equipped with the
2ZZ-FXE engine may exhibit engine oil consumption. The piston and piston ring assembly have
been changed to reduce the potential for oil consumption. Follow the Repair Procedure in this
bulletin to address this condition.
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE VIN
JTDKN3DU#E0358779
Prius
JTDKN3DU#E1791355
Prius PHV
2ZR-FXE
JTDKN3DP#E3055768
JTDZN3EU#E3339374
Prius V
JTDZN3EU#EJ001475
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
EG1633
R & R Piston and Ring Set
16.6
13101-37120
11
99
APPLICABLE WARRANTY
This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle’s in-service date.
Warranty application is limited to occurrence of the specified condition described in
this bulletin.
Parts Information
PART NUMBER
PART NAME
QTY
13101-37240
Piston
4
13011-37260
Piston Ring Set
1
Gasket Kit
1
PREVIOUS
NEW
13101-37120
13011-37110
04111-37315
04152-37010
04152-YZZA6
Filter, Oil
1
90177-22001
90080-17238
Nut (Front Axle Shaft)
2
90521-33002
90080-52017
Ring, Hole Snap (for Front Drive Shafts)
2
90468-16029
90468-A0003
Pin, Cotter (Lower Ball Joint) for Prius, Prius PHV
2
95381-02525
Pin, Cotter (Lower Ball Joint) for Prius V
2
90468-16017
Pin, Cotter (Tie Rod)
2
PART NAME
QTY
Additional Parts: Only As Needed
PART NUMBER
13201-39185
13201-09A30
Rod Sub-Assy, Connecting
13041-37010-0X
13041-0T010-0X
Bearing, Connecting Rod
13265-22020
Bolt, Connecting Rod
As Needed
90910-02166
90910-A2011
90201-10344
90501-35037
Bolt, Cylinder Head
Washer, Plate, Cylinder Head
90501-A0005
Exhaust Compression Ring
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Required Tools & Equipment
REQUIRED TOOLS & MATERIAL
PART NUMBER
QUANTITY
ILSAC GF-4 Multi-grade SAE 0W-20
–
4.7 liters (5.0 US qts)
FIPG Sealant
00295-00103
As Needed
Super Long Life Coolant (SLLC)
00272-SLLC2
As Needed
Three Bond 1324
–
As Needed
Green Plastigage™
–
As Needed
Cylinder Ridge Reamer
–
1
Torque Wrench
–
1
Piston Ring Compressor
–
1
Piston Heater
–
1
Torque Yield Wrench
–
1
Piston Ring Expander
–
1
Caliper Gauge
–
1
Large Brass Punch
–
1
Engine Stand
–
1
Feeler Gauge
–
1
Precision Straight Edge
–
1
Thread Chaser
–
As Needed
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Gasket Seal Cutter*
09032-00100
1
Cylinder Head Bolt Wrench
09205-16011
1
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Required Tools & Equipment (Continued)
REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
Techstream Lite
PART NUMBER
TS2UNIT
ADE
Techstream Lite (Green Cable)
TSLITEPDLR01
TSLP2DLR01
* Essential SST.
NOTE
Only ONE of the Techstream units listed above is required.
Software version 11.20.019 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
Repair Procedure
NOTE
Removal and replacement of automatic transmission fluid is unnecessary and is NOT covered
under this bulletin.
1. Remove the engine assembly.
Refer to the Technical Information System (TIS), applicable model and model year
Repair Manual:

2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical: Engine
Assembly: Removal”

2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical: Engine
Assembly: Removal”

2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical: Engine
Assembly: Removal”
2. Remove the intake manifold.
Refer to TIS, applicable model and model year Repair Manual:

QTY
2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust:
Intake Manifold: Removal”
© 2016 Toyota Motor Sales, USA
1
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)

2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust:
Intake Manifold: Removal”

2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust:
Intake Manifold: Removal”
3. Disassemble the engine.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Engine Unit: Disassembly”

2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Engine Unit: Disassembly”

2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Engine Unit: Disassembly”
4. Remove the cylinder head.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Cylinder Head Gasket: Removal”

2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Cylinder Head Gasket: Removal”

2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Cylinder Head Gasket: Removal”
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
5. Remove the pistons from the connecting rods.
A. Remove the piston sub-assemblies with
connecting rod.
(1) Using a ridge reamer, remove ALL
the carbon from the top of the cylinder.
Figure 1.
(2) Check that the matchmarks on the
connecting rod and cap are aligned to
ensure correct reassembly.
Figure 2.
HINT
The matchmarks on the connecting
rods and caps are provided for
ensuring correct reassembly.
1
© 2016 Toyota Motor Sales, USA
Matchmark
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
(3) Using SST 09205-16011, uniformly
loosen the 2 bolts.
Figure 3.
1
SST
(4) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and
lower bearing by moving the connecting rod cap right and left.
HINT
Keep the lower bearing inserted in the connecting rod cap.
(5) Inspect the connecting rod oil clearance.
a. Clean the crank pin and bearing.
b. Check the crank pin and bearing for pitting and scratches.
c. Lay a strip of Plastigage™ on
the crank pin.
Figure 4.
1
© 2016 Toyota Motor Sales, USA
Plastigage™
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
d. Check that the front mark of the
connecting rod cap is
facing forward.
Figure 5.
1
e. Install and alternately tighten the
bolts of the connecting rod cap in
several steps.
Front Mark
Figure 6.
Torque: 20 N*m (204 kgf*cm, 15 ft*lbf)
SST: 09205-16011
NOTE
The connecting cap bolts should be
tightened in 2 progressive steps.
1
© 2016 Toyota Motor Sales, USA
SST
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
f.
Mark the front of the connecting
rod cap bolts with paint.
Figure 7.
Retighten the cap bolts by 90˚
as shown.
1
Paint Mark
2
90˚
3
Engine Front
g. Remove the 2 bolts and connecting rod cap.
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
h. Measure the Plastigage™ at its widest point.
Standard Oil Clearance: 0.014 to 0.038 mm (0.000551 to 0.00150 in.)
Maximum Oil Clearance: 0.070 mm (0.00276 in.)
If the oil clearance is greater than the maximum, replace the connecting rod bearings. If
necessary, inspect the crankshaft.
NOTE
Completely remove the Plastigage™ after the measurement.
NOTICE
If replacing a bearing, replace it with one that has the same number as its respective
connecting rod cap. Each bearing’s standard thickness is indicated by a 1, 2, or 3
mark on its surface.
Standard Connecting Rod Large End
Bore Diameter:
MARK
SPECIFIED CONDITION
1
47.000 to 47.008 mm (1.85039 to 1.85071 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.)
Figure 8.
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:
MARK
SPECIFIED CONDITION
1
2
43.992 to 44.000 mm
(1.7320 to 1.7323 in.)
3
© 2016 Toyota Motor Sales, USA
1
Plastigage™
2
1, 2, or 3 Mark
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
(6) Push the piston, connecting rod assembly, and upper bearing through the top of the
cylinder block.
HINT
Keep the bearing, connecting rod, and cap together.
Arrange the piston and connecting rod assemblies in the correct order.
(7) Repeat for the other 3 piston/connecting rod assemblies.
B. Remove the connecting rod bearings.
HINT
Arrange the removed parts in the correct order.
C. Inspect the cylinder bore for abnormal damage.
Visually check the cylinder bore for the presence of crosshatch.
 If the cylinder bore has visible crosshatch, the cylinder block is OK to re-use.
 Confirm that ONLY light vertical marks are present, if any.
NOTE
It is normal for an in-service block to have light markings present from carbon and
should NOT be interpreted as excessive cylinder wall scratches.
ONLY replace the short block if multiple, severe scratches are present.
Do NOT hone the cylinder walls.
D. Using a screwdriver, pry out the 2 piston
pin snap rings.
Figure 9.
HINT
If necessary, sublet the following
specialized and precision operations
to a local engine machining shop.
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
E. Remove the piston.
(1) Gradually heat the piston to
approximately 176˚ to 194˚F
(80˚ to 90˚C).
Figure 10.
HINT
If necessary, sublet the following
specialized and precision operations
to a local engine machining shop.
(2) Using a plastic hammer and brass
bar, lightly tap out the piston pin and
remove the connecting rod.
Figure 11.
NOTICE
The piston, pin and connecting rod
are a matched set.
Arrange the piston, pins, rings, and
connecting rods, and bearings in
the correct order.
Refer to TIS, applicable model and model year Repair Manual:
 2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Cylinder Block: Disassembly”
 2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Cylinder Block: Disassembly”
 2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Cylinder Block: Disassembly”
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
6. Inspect the connecting rod and bearings to determine if parts are suitable for re-use.
HINT
If necessary, sublet the following specialized and precision operations to a local engine
machining shop.
A. Using a caliper gauge, measure the
connecting rod small end bore diameter.
Figure 12.
Standard Connecting Rod Small End
Bore Diameter: 20.012 to 20.021 mm
(0.78787 to 0.78823 in.)
Ensure the connecting rod small end
bore diameter measurement is within
specification for the piston
bore diameter.
Replace the connecting rod.
B. Inspect the connecting rod bolt.
Figure 13.
Using vernier calipers, measure the
tension portion diameter of the bolt.
Standard diameter:
6.6 to 6.7 mm (0.260 to 0.264 in.)
Minimum diameter:
6.4 mm (0.252 in.)
If the diameter is less than the minimum,
replace the connecting rod bolt.
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
7. Using a screwdriver, install a NEW snap
ring at one end of the piston pin hole.
Figure 14.
HINT
Make sure that the end gap of the snap
ring is NOT aligned with the pin hole
cutout portion of the piston.
1
Service Hole
8. Gradually heat the piston to approximately 80° to 90°C (176° to 194°F).
9. 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 pin comes into
contact with the snap ring.
Figure 15.
HINT
The piston and pin are a matched set.
1
Front Mark
10. Using a screwdriver, install a NEW snap ring on the other end of the piston pin hole.
HINT
Make sure that the end gap of the snap ring is NOT aligned with the pin hole cutout portion
of the piston.
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
11. Check the fitting condition between the
piston and piston pin by trying to move the
piston back and forth on the piston pin.
Figure 16.
12. Install the NEW Piston Rings Set.
Figure 17.
NOTE
3 piece oil control ring installation
procedure is NOT included in the Repair
Manual. Follow the steps below to install
the piston rings and refer to the Repair
Manual for ALL other reassembly steps.
1
Upper Oil Ring Side Rail
2
Oil Ring Expander
3
Lower Oil Ring Side Rail
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
A. Install the oil ring expander and 2 oil ring side rails by hand.
NOTE
When installing the oil expander ring, do NOT overlap the ends.
Figure 18.
1
Push Oil Ring Expander Surface Into Piston
With Thumb
4
NG Condition
2
Normal Condition
5
Do NOT Overlap
3
Align End of Ring
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
B. Using a piston ring expander, install the
No. 1 compression ring and
No. 2 compression ring with the code
mark positioned as shown.
Figure 19.
NOTE
Install the No. 2 compression ring with
the code mark facing upward.
A
Code Mark
1
No. 1 Compression Ring
2
No. 2 Compression Ring
3
Upward
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
C. Position the piston rings so that the ends
are as shown.
Figure 20.
A
TMC Made
B
TMMK Made
1
No. 1 Compression Ring
2
No. 2 Compression Ring
3
Oil Ring Expander
4
Upper Side Rail – Oil Control Ring
5
Lower Side Rail – Oil Control Ring
6
Front Mark
7
Front Side
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
13. Reassemble the cylinder block.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical: Cylinder
Block: Reassembly”

2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical: Cylinder
Block: Reassembly”

2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical: Cylinder
Block: Reassembly”
14. Install the cylinder head.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Cylinder Head Gasket: Installation”

2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Cylinder Head Gasket: Installation”

2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Cylinder Head Gasket: Installation”
15. Reassemble the engine.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Engine Unit – “2ZR-FXE Engine Mechanical:
Engine Unit: Reassembly”

2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Engine Unit – “2ZR-FXE Engine Mechanical:
Engine Unit: Reassembly”

2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Engine Unit – “2ZR-FXE Engine Mechanical:
Engine Unit: Reassembly”
© 2016 Toyota Motor Sales, USA
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2ZR-FXE Engine Oil Consumption Repair Procedure
Repair Procedure (Continued)
16. Install the intake manifold.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust:
Intake Manifold: Installation”

2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust:
Intake Manifold: Installation”

2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust:
Intake Manifold: Installation”
17. Install the engine assembly.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 / 2013 / 2014 Prius:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Engine Assembly: Installation”

2010 / 2012 / 2013 / 2014 Prius PHV:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Engine Assembly: Installation”

2012 / 2013 / 2014 Prius V:
Engine/Hybrid System – Engine Mechanical – “2ZR-FXE Engine Mechanical:
Engine Assembly: Installation”
18. Perform Health Check using Techstream and test drive the vehicle to confirm
normal operation.
© 2016 Toyota Motor Sales, USA