Lexus LS400 (2000 year). Manual — part 101

EM0A0–02

P21860

Pull

O–Ring

P20615

RH Side

A01878

LH Side

Cover

Wire Protector

Bracket

Ground Cable

Bracket

P20616

Coolant Drain Union

Water Seal Plate

EM–90

–

ENGINE MECHANICAL

CYLINDER BLOCK

1272

DISASSEMBLY

1.

INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY

2.

REMOVE TIMING BELT AND PULLEYS
(See page

EM–15

)

3.

REMOVE CYLINDER HEAD (See page

EM–34

)

4.

REMOVE RH ENGINE MOUNTING BRACKET

5.

REMOVE LH ENGINE MOUNTING BRACKET

6.

REMOVE WATER BYPASS PIPE

(a)

Disconnect the engine wire clamp from the bracket on the
water bypass pipe.

(b)

Remove the bolt.

(c)

Pull out the water bypass pipe from the water pump.

(d)

Remove the O–ring from the water bypass pipe.

7.

REMOVE STARTER (See page

ST–5

)

8.

REMOVE KNOCK SENSORS (See page

SF–85

)

9.

REMOVE ENGINE WIRE

(a)

Disconnect the crankshaft position sensor connector.

(b)

Remove the 2 bolts, and disconnect the engine wire from
the RH side of the cylinder block.

(c)

Remove the 2 bolts and engine wire cover from the LH
side of the cylinder block.

(d)

Remove the 4 bolts and engine wire.

10.

REMOVE WATER PUMP (See page

CO–8

)

11.

REMOVE NO.2 OIL PAN (See page

LU–9

)

12.

REMOVE OIL PAN BAFFLE PLATE
(See page

LU–9

)

13.

REMOVE NO.1 OIL PAN (See page

LU–9

)

14.

REMOVE OIL STRAINER (See page

LU–9

)

15.

REMOVE OIL PUMP (See page

LU–9

)

16.

REMOVE WATER SEAL PLATE

Remove the 2 bolts and seal plate.
17.

REMOVE ENGINE COOLANT DRAIN UNIONS

Remove the RH and LH drain unions.

A01899

Pry

A02220

A01900

A02221

–

ENGINE MECHANICAL

CYLINDER BLOCK

EM–91

1273

18.

REMOVE REAR OIL SEAL RETAINER

(a)

Remove the 7 bolts.

(b)

Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.

(c)

Remove the O–ring.

19.

CHECK CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back an forth.

Thrust clearance:

Standard

0.160 – 0.290 mm (0.0063 – 0.0138 in.)

Maximum

0.35 mm (0.0138 in.)

If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.

Connecting rod thickness:
22.880 – 22.920 mm (0.9008 – 0.9024 in.)

20.

REMOVE CONNECTING ROD CAPS AND CHECK
OIL CLEARANCE

(a)

Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.

(b)

Remove the 2 connecting rod cap bolts.

(c)

Using the 2 removed connecting rod cap bolts, remove
the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.

HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d)

Clean the crank pin and bearing.

(e)

Check the crank pin and bearing for pitting and scratches.

If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.

A02222

Plastigage

A02114

A02223

Z14349

Num ber
Mark

Num ber
Mark

Num ber
Mark

No.1

No.2

No.3

No.4

Connecting rod cap

Crankshaft

Use bearing

Number mark

1

2

3

4

7

6

1

2

1

1

2

1

3

2

2

3

1

2

3

3

2

4

1

3

3

4

4

2

3

5

EXAMPLE:
Connecting rod cap ”3” + Crankshaft ”1”
= Total number 4 (Use bearing ”4”)

EM–92

–

ENGINE MECHANICAL

CYLINDER BLOCK

1274

(f)

Lay a strip of Plastigage across the crank pin.

(g)

Install the connecting rod cap with the 2 bolts.
(See page

EM–110

)

NOTICE:
Do not turn the crankshaft.
(h)

Remove the 2 bolts, connecting rod cap and lower bear-
ing. (See procedure (b) and (c) above)

(i)

Measure the Plastigage at its widest point.
Oil clearance:

Standard

0.027 – 0.053 mm (0.0011 – 0.0021 in.)

Maximum

0.065 mm (0.0026 in.)

If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.

HINT:
If using a standard bearing, replace it with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the connecting rod cap and crankshaft, then select-
ing the bearing with the same number as the total. There are 6
sizes of standard bearings, marked ”2”, ”3”, ”4”, ”5”, ”6” and ”7”.

EM6412

Ridge
Mark

P20722

–

ENGINE MECHANICAL

CYLINDER BLOCK

EM–93

1275

Reference
Connecting rod big end inside diameter:

Mark ”1”

55.000 – 55.006 mm (2.1654 – 2.1656 in.)

Mark ”2”

55.006 – 55.012 mm (2.1656 – 2.1658 in.)

Mark ”3”

55.012 – 55.018 mm (2.1658 – 2.1661 in.)

Mark ”4”

55.018 – 55.024 mm (2.1661 – 2.1663 in.)

Crankshaft crank pin diameter:

Mark ”1”

51.994 – 52.000 mm (2.0470 – 2.0472 in.)

Mark ”2”

51.988 – 51.994 mm (2.0468 – 2.0470 in.)

Mark ”3”

51.982 – 51.988 mm (2.0465 – 2.0468 in.)

Standard sized bearing center wall thickness:

Mark ”2”

1.484 – 1.487 mm (0.0584 – 0.0585 in.)

Mark ”3”

1.487 – 1.490 mm (0.0585 – 0.0587 in.)

Mark ”4”

1.490 – 1.493 mm (0.0587 – 0.0588 in.)

Mark ”5”

1.493 – 1.496 mm (0.0588 – 0.0589 in.)

Mark ”6”

1.496 – 1.499 mm (0.0589 – 0.0590 in.)

Mark ”7”

1.499 – 1.502 mm (0.0590 – 0.0591 in.)

(j)

Completely remove the Plastigage.

21.

REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES

(a)

Using a ridge reamer, remove all the carbon from the top
of the cylinder.

(b)

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

HINT:

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in cor-
rect order.

22.

CHECK CRANKSHAFT THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.

Thrust clearance:

Standard

0.020 – 0.220 mm (0.0008 – 0.0087 in.)

Maximum

0.30 mm (0.0118 in.)

If the thrust clearance is greater than maximum, replace the
thrust washers as a set.

Thrust washer thickness:
2.440 – 2.490 mm (0.0961 – 0.0980 in.)