Lexus ES300 (1997 year). Manual — part 479

P12599

P20070

Mark
1, 2, 3 or 4

P12600

P12495

P20071

–

ENGINE MECHANICAL

CYLINDER BLOCK

EM–97

834

1997 LEXUS ES300 (RM511U)

(a)

Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.

NOTICE:
Install the bearing with the oil hole in the cylinder block.

(b)

Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 lower bearings.

HINT:
A number is marked on each main bearing cap to indicate the
installation position.

5.

INSTALL UPPER THRUST WASHERS

Install the 2 thrust washers under the No.2 journal position of
the cylinder block with the oil grooves facing outward.

6.

PLACE CRANKSHAFT ON CYLINDER BLOCK

7.

PLACE MAIN BEARING CAPS AND LOWER THRUST
WASHERS ON CYLINDER BLOCK

(a)

Install the 2 thrust washers on the No.2 bearing cap with
the grooves facing outward.

P20072

S06287

Less than 6 mm

P20074

P12753

8

7

6

1

5

2

3

4

9

10

13

14

15

16

11

12

4

7

P25741

Painted Mark

Front

90

°

90

°

EM–98

–

ENGINE MECHANICAL

CYLINDER BLOCK

835

1997 LEXUS ES300 (RM511U)

(b)

Temporarily place the 4 main bearing caps level and let
them in their proper locations.

(c)

Apply a light coat of engine oil on the threads and under
the main bearing cap bolts for the 12 pointed head.

(d)

Temporarily install the 8 main bearing cap bolts to the in-
side positions.

(e)

Insert the main bearing cap with your hand until the clear-
ance between the main bearing cap and the cylinder
block will become less than 6 mm (0.23 in.) by making the
2 internal main bearing cap bolts as a guide.

(f)

Using a plastic–faced hammer, lightly tap the bearing cap
to ensure a proper fit.

8.

INSTALL 12 POINTED HEAD MAIN BEARING CAP
BOLTS

HINT:

The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any of the main bearing cap bolts is broken or deformed,
replace it.

(a)

Apply a light coat of engine oil on the threads and under
the main bearing cap bolts.

(b)

Install and uniformly tighten the 16 main bearing cap bolts
in several passes, in the sequence shown.
Torque: 22 N·m (225 kgf·cm, 16 ft·lbf)

If any of the main bearing cap bolts does not meet the torque
specification, replace the main bearing cap bolt.

(c)

Mark the front of the main bearing cap bolts with paint.

(d)

Retighten the main bearing cap bolts by 90

°

in the numer-

ical order shown.

(e)

Check that the painted mark is now at a 90

°

angle to the

front.

P12586

8

7

6

1

5

2

3

4

Z09219

Front Mark
(2 Cavities)

RH Piston

LH Piston

Front Mark
(1 Cavity)

Front

Front

P12699

P12801

Front

Protrusion

–

ENGINE MECHANICAL

CYLINDER BLOCK

EM–99

836

1997 LEXUS ES300 (RM511U)

9.

INSTALL HEXAGON HEAD MAIN BEARING CAP
BOLTS

(a)

Install a new seal washer to the main bearing cap bolt.

(b)

Install and uniformly tighten the 8 main bearing cap bolts
in several passes, in the sequence shown.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)

(c)

Check that the crankshaft turns smoothly.

10.

CHECK CRANKSHAFT THRUST CLEARANCE
(See page

EM–78

)

11.

INSTALL PISTON AND CONNECTING ROD
ASSEMBLES

Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
HINT:
The shape of the piston varies for the RH and LH banks. The
RH piston is marked with ”R”, the LH piston with ”L”.

12.

PLACE CONNECTING ROD CAP ON CONNECTING
ROD

(a)

Match the numbered connecting rod cap with the con-
necting rod.

(b)

Align the pin dowels of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod.

(c)

Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.

13.

INSTALL CONNECTING ROD CAP BOLTS

HINT:

The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any of the connecting rod cap bolts is broken or de-
formed, replace it.

P12697

P25743

Painted Mark

Front

90

°

90

°

P12911

Seal Width
2 – 3 mm

A

B

A

B

EM–100

–

ENGINE MECHANICAL

CYLINDER BLOCK

837

1997 LEXUS ES300 (RM511U)

(a)

Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.

(b)

Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque: 24.5 N·m (250 kgf·cm, 18 ft·lbf)

If any of the connecting rod cap bolts does not meet the torque
specification, replace the connecting rod cap bolts.

(c)

Mark the front of the connecting cap bolts with paint.

(d)

Retighten the cap bolts by 90

°

as shown.

(e)

Check that the painted mark is now at a 90

°

angle to the

front.

(f)

Check that the crankshaft turns smoothly.

14.

CHECK CONNECTING ROD THRUST
CLEARANCE (See page

EM–78

)

15.

INSTALL REAR OIL SEAL RETAINER

(a)

Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.

Using a razor blade and gasket scraper, remove all
the oil packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non–residue solvent, clean both sealing
surfaces.

(b)

Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826–00080 or equivalent

Install a nozzle that has been cut to a 2 – 3 mm (0.08
– 0.12 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.

(c)

Install the oil seal retainer with the 6 bolts Uniformly tight-
en the bolt in several passes, in the sequence shown.
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)

16.

INSTALL EGR COOLER

Install a new gasket and the EGR cooler with the 3 bolts and 2
nuts.

Torque: 9 N·m (90 kgf·cm, 78 in.·lbf)