2010-2014 Toyota Prius 2ZR-FXE Engine Oil Consumption Repair Procedure T-SB-0169-16


Please see T-SB-0169-16

2010, 2012 - 2014 Prius PHV
2012 - 2014 Prius V
2010 - 2014 Prius

* 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.

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

Repair Procedure:
1. Remove the engine assembly

2. Remove the intake manifold.

3. Disassemble the engine.

4. Remove the cylinder head.

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.
(2) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(3) Using SST 09205-16011, uniformly loosen the 2 bolts.
(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.
(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.
d. Check that the front mark of the connecting rod cap is facing forward.
e. Install and alternately tighten the bolts of the connecting rod cap in several steps.
f. Mark the front of the connecting rod cap bolts with paint. Retighten the cap bolts by 90˚ as shown
g. Remove the 2 bolts and connecting rod cap
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.

(6) Push the piston, connecting rod assembly, and upper bearing through the top of the cylinder block.

(7) Repeat for the other 3 piston/connecting rod assemblies.

B. Remove the connecting rod bearings

C. Inspect the cylinder bore for abnormal damage. Visually check the cylinder bore for the presence of crosshatc
If the cylinder bore has visible crosshatch, the cylinder block is OK to re-us
Confirm that ONLY light vertical marks are present, if any.

D. Using a screwdriver, pry out the 2 piston pin snap rings.

E. Remove the piston.
(1) Gradually heat the piston to approximately 176˚ to 194˚F (80˚ to 90˚C).
(2) Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

6. Inspect the connecting rod and bearings to determine if parts are suitable for re-use.
A. Using a caliper gauge, measure the connecting rod small end bore diameter. 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. 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.

7. Using a screwdriver, install a NEW snap ring at one end of the piston pin 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.

10. Using a screwdriver, install a NEW snap ring on the other end of the piston pin hole.

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

12. Install the NEW Piston Rings Set.
A. Install the oil ring expander and 2 oil ring side rails by hand.
B. Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring with the code mark positioned as shown.
C. Position the piston rings so that the ends are as shown.

13. Reassemble the cylinder block

14. Install the cylinder head

15. Reassemble the engine.

16. Install the intake manifold.

17. Install the engine assembly

18. Perform Health Check using Techstream and test drive the vehicle to confirm normal operation