Lexus ES300 (1997 year). Manual — part 474

Z18551

No.1 Piston Ring

Oil Ring (Expander)

Piston

Snap Ring

Connecting Rod

Connecting Rod Bearing

Connecting Rod Cap

Oil Ring (Side Rail)

Piston Pin

No.2 Piston Ring

Snap Ring

Connecting Rod Bushing

Crankshaft

Rear Oil Seal

Seal Washer

Rear Oil Seal
Retainer

Cylinder Block

Upper Main Bearing

Upper Crankshaft
Thrust Washer

Crankshaft

Lower Crankshaft
Thrust Washer

Lower Main Bearing

Main Bearing Cap

Seal Washer

Non–reusable part

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

27 (275, 20)

8 (80, 69 in.·lbf)

x 6

See Page

EM–95

1st 24.5 (250, 18)
2nd Turn 90

°

See Page

EM–95

1st 22 (225, 16)
2nd Turn 90

°

–

ENGINE MECHANICAL

CYLINDER BLOCK

EM–77

814

1997 LEXUS ES300 (RM511U)

EM04C–02

S04921

P12946

P18761

P12389

SST

EM–78

–

ENGINE MECHANICAL

CYLINDER BLOCK

815

1997 LEXUS ES300 (RM511U)

DISASSEMBLY

1.

INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY

2.

REMOVE TIMING BELT AND PULLEYS
(See page

EM–14

)

3.

REMOVE CYLINDER HEAD
(See page

EM–30

)

4.

REMOVE GENERATOR, ADJUSTING BAR AND
BRACKET ASSEMBLY

(a)

Disconnect the 2 wire clamps from the wire brackets.

(b)

Remove the 3 nuts, the generator, adjusting bar and
bracket assembly.

5.

REMOVE OIL PRESSURE SWITCH
(See page

LU–1

)

6.

REMOVE A/C COMPRESSOR HOUSING BRACKET

Remove the 3 bolts and compressor housing bracket.

7.

REMOVE NO.2 IDLER PULLEY BRACKET

Remove the 2 bolts and idler pulley bracket.

8.

REMOVE KNOCK SENSORS

(a)

Disconnect the 2 knock sensor connectors.

(b)

Using SST, remove the 2 knock sensors.
SST

09816–30010

P18762

P18763

Water
Seal
Plate

Oil Filter
Union

12 mm
Hexagon
Wrench

Coolant
Drain
Union

P12410

P12508

–

ENGINE MECHANICAL

CYLINDER BLOCK

EM–79

816

1997 LEXUS ES300 (RM511U)

9.

REMOVE WATER INLET HOUSING

(a)

Remove the engine wire band.

(b)

Disconnect the engine wire clamp from the bracket.

(c)

Remove the 8 bolts, 2 nuts and water inlet housing.

10.

REMOVE WATER PUMP
(See page

CO–6

)

11.

REMOVE NO.2 OIL PAN
(See page

LU–9

)

12.

REMOVE OIL STRAINER
(See page

LU–9

)

13.

REMOVE NO.1 OIL PAN
(See page

LU–9

)

14.

REMOVE OIL PUMP
(See page

LU–9

)

15.

REMOVE OIL FILTER
(See page

LU–3

)

16.

REMOVE OIL FILTER UNION

Using a 12 mm hexagon wrench, remove the oil filter union.
17.

REMOVE WATER SEAL PLATE

Remove the 2 nuts and seal plate.
18.

REMOVE ENGINE COOLANT DRAIN UNION

19.

REMOVE EGR COOLER

Remove the 3 bolts, 2 nuts, EGR cooler and gasket.

20.

REMOVE REAR OIL SEAL RETAINER

(a)

Remove the 6 bolts.

(b)

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

P12695

P13329

P12707

P12696

P12728

Plasticgage

EM–80

–

ENGINE MECHANICAL

CYLINDER BLOCK

817

1997 LEXUS ES300 (RM511U)

21.

CHECK CONNECTING ROD THRUST CLEARANCE

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

Standard thrust clearance:
0.15 – 0.30 mm (0.0059 – 0.0118 in.)
Maximum thrust clearance: 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:
20.80 – 20.85 mm (0.8189 – 0.8209 in.)

22.

REMOVE CONNECTING ROD CAPS AND CHECK
OIL CLEARANCE

(a)

Check the matchmarks on the connecting rod and cap are
aligned 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.

(f)

Lay a strip of Plasticgage across the crank pin.