Lexus ES300 (2002 year). Manual — part 244

030GZ-01

-

SERVICE SPECIFICATIONS

ENGINE MECHANICAL

03-1 1

112

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

ENGINE MECHANICAL

SERVICE DATA

Battery specific gravity

at 20

C (68

F)

1.25 1.29

New drive belt deflection

Pressing force: 98 N (10 kgf, 22 lbf)

For fan and generator

For vane pump

Used drive belt deflection

Pressing force: 98 N (10 kgf, 22 lbf)

For fan and generator

For vane pump

9.1 - 10.5 mm (0.358 - 0.413 in.)
7.0 - 9.0 mm (0.276 - 0.354 in.)

11.0 - 13.5 mm (0.433 - 0.531 in.)
10.0 - 12.0 mm (0.394 - 0.472 in.)

New drive belt tension

For fan and generator

For vane pump

Used drive belt tension

For fan and generator

For vane pump

617 - 853 N (63 - 87 kgf, 139 - 192 lbf)
647 - 843 N (66 - 86 kgf, 146 - 190 lbf)

294 - 490 N (30 - 50 kgf, 66 - 110 lbf)
323 - 519 N (33 - 53 kgf, 73 - 117 lbf)

Ignition timing

w/ Terminals TC and CG of DLC3 connected

w/ Terminals TC and CG of DLC3 disconnected

8 - 12

BTDC

7 - 24

BTDC

Idle speed

550 - 650 r/min.

Compression pressure

1.47 MPa (15 kgf/cm

2

, 213 psi)

Minimum pressure

0.98 MPa (10 kgf/cm

2

, 142 psi)

Difference between each cylinder

100 kPa (1.0 kgf/cm

2

, 14 psi)

Camshaft circle runout

Maximum

Camshaft cam lobe height

Standard Intake

Exhaust

Minimum Intake

Exhaust

Camshaft Journal diameter

0.06 mm (0.0024 in.)
42.932 - 43.032 mm (1.6902 - 1.6942 in.)
42.764 - 42.864 mm (1.6836 - 1.6876 in.)
42.78 mm (1.6842 in.)
42.61 mm (1.6776 in.)
26.959 - 26.975 mm (1.0614 - 1.0620 in.)

12 pointed head cylinder head set bolt diameter at tension portion

Standard

Minimum

8.95 - 9.05 mm (0.3524 - 0.3563 in.)
8.75 mm (0.3775 in.)

Valve clearance at cold

Intake

Exhaust

0.15 - 0.25 mm (0.006 - 0.010 in.)
0.25 - 0.35 mm (0.010 - 0.014 in.)

Cylinder head warpage

Maximum Cylinder block side

Intake manifold side

Exhaust manifold side

0.05 mm (0.0020 in.)
0.10 mm (0.0039 in.)
0.10 mm (0.0039 in.)

Intake valve overall length

Standard
Minimum

Intake valve stem diameter

Standard

Intake valve margin thickness

Standard
Minimum

95.45 mm (3.7579 in.)
94.95 mm (3.7382 in.)
5.470 - 5.485 mm (0.2154 - 0.2159 in.)
1.0 mm (0.039 in.)
0.5 mm (0.020 in.)

Exhaust valve overall length

Standard
Minimum

Exhaust valve stem diameter

Standard

Exhaust valve margin thickness

Standard
Minimum

95.40 mm (3.7559 in.)
94.90 mm (3.7362 in.)
5.465 - 5.480 mm (0.2152 - 0.2157 in.)
1.0 mm (0.039 in.)
0.5 mm (0.020 in.)

Valve spring free length
Valve spring deviation

Maximum

Valve spring installed tension at 33.8 mm (1.331 in.)

45.50 mm (1.7913 in.)
2.0 mm (0.079 in.)
186 - 206 N (19.0 - 21.0 kgf, 41.9 - 46.3 lbf)

03-12

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SERVICE SPECIFICATIONS

ENGINE MECHANICAL

113

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

Bushing inside diameter
Valve guide bushing oil clearance

Standard Intake

Exhaust

Maximum Intake

Exhaust

Cylinder head valve guide bushing bore diameter

STD

O/S 0.05

Bushing diameter

STD

O/S 0.05

Bushing length

Intake

Exhaust

Bushing protrusion height

Intake

Exhaust

5.510 - 5.530 mm (0.2169 - 0.2177 in.)
0.025 - 0.060 mm (0.0010 - 0.0024 in.)
0.030 - 0.065 mm (0.0012 - 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
10.295 - 10.313 mm (0.4053 - 0.4060 in.)
10.345 - 10.363 mm (0.4073 - 0.4080 in.)
10.333 - 10.344 mm (0.4068 - 0.4072 in.)
10.383 - 10.394 mm (0.4088 - 0.4092 in.)
34.5 mm (1.358 in.)
40.5 mm (1.594 in.)
11.1 - 11.5 mm (0.437 - 0.453 in.)
8.9 - 9.3 mm (0.350 - 0.366 in.)

Lifter diameter
Lifter bore diameter
Oil clearance

Standard

Maximum

30.966 - 30.976 mm (1.2191 - 1.2195 in.)
31.000 - 31. 018 mm (1.2205 - 1.2212 in.)
0.024 - 0.050 mm (0.0009 - 0.0021 in.)
0.07 mm (0.0028 in.)

Camshaft gear backlash

Standard

Maximum

Camshaft thrust clearance

Standard

Maximum

Camshaft oil clearance

Standard Intake #4, #5 journals

Other journals

Maximum

0.020 - 0.200 mm (0.0008 - 0.0079 in.)
0.30 mm (0.0118 in.)
0.040 - 0.090 mm (0.0016 - 0.0035 in.)
0.12 mm (0.0047 in.)
0.025 - 0.057 mm (0.0010 - 0.0022 in.)
0.025 - 0.062 mm (0.0010 - 0.0024 in.)
0.10 mm (0.0039 in.)

Connecting rod thrust clearance

Standard

Maximum

Connecting rod oil clearance

Standard

Maximum

0.15 - 0.30 mm (0.0059 - 0.0118 in.)
0.35 mm (0.0138 in.)
0.038 - 0.066 mm (0.0015 - 0.0026 in.)
0.08 mm (0.0031 in.)

Crankshaft thrust clearance

Standard

Maximum

0.04 - 0.24 mm (0.0016 - 0.0094 in.)
0.30 mm (0.0118 in.)

Cylinder block warpage

Maximum

0.05 mm (0.0020 in.)

Cylinder bore diameter

Standard

Maximum

87.500 - 87.512 mm (3.4449 - 3.4453 in.)
87.52 mm (3.4457 in.)

Piston diameter
Oil clearance

Standard

Maximum

87.406 - 87.416 mm (3.4412 - 3.4416 in.)
0.084 - 0.106 mm (0.0033 - 0.0042 in.)
0.13 mm (0.0051 in.)

Connecting rod out-of alignment

Maximum

Connecting rod twist

Maximum

0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

Connecting rod bushing inside diameter
Piston pin diameter
Oil clearance

Standard

Maximum

22.005 - 22.014 mm (0.8663 - 0.8667 in.)
21.997 - 22.006 mm (0.8660 - 0.8664 in.)
0.005 - 0.011 mm (0.0002 - 0.0004 in.)
0.05 mm (0.0020 in.)

Piston ring groove clearance

No.1
No.2

Oil

0.02 - 0.07 mm (0.0008 - 0.0028 in.)
0.02 - 0.06 mm (0.0008 - 0.0024 in.)
0.03 - 0.11 mm (0.0011 - 0.0043 in.)

Piston ring end gap

Standard No.1

No.2

Oil (Side rail)

Maximum No. 1

No.2

Oil (Side rail)

0.25 - 0.35 mm (0.0098 - 0.0138 in.)
0.35 - 0.45 mm (0.0138 - 0.0177 in.)
0.15 - 0.40 mm (0.0059 - 0.0157 in.)
0.95 mm (0.0374 in.)
1.05 mm (0.0413 in.)
1.00 mm (0.0394 in.)

Connecting rod bolt diameter

Standard
Minimum

7.2 - 7.3 mm (0.283 - 0.287 in.)
7.0 mm (0.276 in.)

Crankshaft bearing cap set bolt diameter

Standard
Minimum

7.5 - 7.6 mm (0.295 - 0.299 in.)
7.2 mm (0.283 in.)

-

SERVICE SPECIFICATIONS

ENGINE MECHANICAL

03-13

114

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

Crankshaft circle runout

Maximum

Main journal diameter
Main journal taper and out-of-round

Maximum

Crank pin diameter
Crank pin taper and out-of-round

Maximum

0.06 mm (0.0024 in.)
60.988 - 61.000 mm (2.4011 - 2.4016 in.)
0.02 mm (0.0008 in.)
52.992 - 53.000 mm (2.0863 - 2.0866 in.)
0.02 mm (0.0008 in.)

Crankshaft oil clearance

Standard No. 1 and No. 4 journals

No. 2 and No. 3 journals

Maximum No. 1 and No. 4 journals

No. 2 and No. 3 journals

0.014 - 0.034 mm (0.0006 - 0.0013 in.)
0.026 - 0.046 mm (0.0010 - 0.0018 in.)
0.05 mm (0.0020 in.)
0.06 mm (0.0024 in.)

030H0-01

03-14

-

SERVICE SPECIFICATIONS

ENGINE MECHANICAL

115

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

TORQUE SPECIFICATION

Part Tightened

N

⋅

m

kgf

⋅

cm

ft

⋅

lbf

Engine hanger No. 2 x Cylinder head

20

199

14

Knock control sensor x Cylinder block

39

398

29

Oil pressure switch assy x Cylinder block

15

152

11

Compressor mounting bracket No.1 x Cylinder block

25

255

18

Generator bracket No.1 x Cylinder block

58

591

43

Pump bracket x Cylinder head

32

326

24

Drive shaft bearing bracket x Cylinder block

64

653

47

Exhaust manifold LH x Cylinder head

49

500

36

Exhaust manifold RH x Cylinder head

49

500

36

Ignition coil assy x Cylinder head cover

8.0

82

71 in.

⋅

lbf

Surge tank stay No.1 x Cylinder head

20

199

14

Surge tank stay No.1 x Intake air surge tank

20

199

14

Engine hanger No. 1 x Cylinder head

20

199

14

Engine hanger No. 1 x Intake air surge tank

20

199

14

Manifold stay No. 2 x Exhaust manifold LH

34

347

25

Manifold stay No. 2 x Automatic transaxle assy

34

347

25

Engine mounting insulator RH x Engine mounting bracket

95

969

70

Engine mounting insulator LH x Automatic transaxle assy

95

969

70

Engine mounting insulator FR x Automatic transaxle assy

87

887

64

Vane pump assy x Pump bracket

43

439

32

Vane pump assy x Engine mounting bracket

43

439

32

Frame side rail plate sub-assembly x Front frame assy
(See page

14-20

)

Bolt A

85

867

63

(See age

14 20

)

Bolt A
Bolt B

Nut

85
32
32

867
326
326

63
24
24

Front suspension member brace rear x Front frame assy
(See page

14-20

)

Bolt C

85

867

63

(See age

14 20

)

Bolt C
Bolt D

Nut

85
32
32

867
326
326

63
24
24

Compressor and magnetic clutch x Compressor mounting bracket No.1
(See page

14 20

)

Bolt

25

250

18

(See page

14-20

)

Bolt

Nut

25
26

250
260

18
19

Generator belt adjusting bar x Cylinder block
(See page

14-20

)

Nut A

Bolt B

Bolt C

43
18

8.0

438
184

82

32
13

71 in.

⋅

lbf

Generator bracket No. 2 x Transverse engine engine mounting bracket

28

286

21

Intermediate shaft sub-assy

35

357

26

Drive plate & ring gear x Torque converter

41

418

30

Flywheel housing under cover x Automatic transaxle assy

7.8

80

69 in.

⋅

lbf

Front suspension arm x Lower ball joint

127

1,295

94

Tie rod end x Steering knuckle

49

500

36

Front axle hub nut x Front drive shaft

294

2,998

217

Front stabilizer link assy x Front suspension

74

755

55

V-bank cover x Cylinder head cover

7.9

81

70 in.

⋅

lbf

Engine mounting stay No. 2 RH x Transverse engine engine mounting
bracket

64

653

47

Engine moving control rod (See page

14-20

)

Bolt A

64

653

47

Engine moving control rod (See age

14 20

)

Bolt A
Bolt B

64
23

653
235

47
17

Front wheel

103

1,050

76

Camshaft sub-gear x Main gear

5.4

55

48 in.

⋅

lbf

Engine rear oil seal retainer x Cylinder block

8.0

82

71 in.

⋅

lbf