Lexus ES300 (1997 year). Manual — part 469

P25421

Exhaust

8

6

5

4

3

2

1

9

10

7

P12874

Intake

Align

P12961

Intake

P12959

Intake

6

5

4

3

2

1

9

10

7

8

P12872

Intake

Service Bolt

–

ENGINE MECHANICAL

CYLINDER HEAD

EM–57

794

1997 LEXUS ES300 (RM511U)

(8)

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

(9)

Install and uniformly tighten the 10 bearing cap
bolts, in several passes, in the sequence shown.

Torque: 1 6 N·m (160 kgf·cm, 12 ft·lbf)

(b)

Install the intake camshaft.
(1)

Apply new engine oil to the thrust portion and jour-
nal of the camshaft.

(2)

Align the timing marks (1 dot mark) of the camshaft
drive and driven gears.

(3)

Place the intake camshaft on the cylinder head.

(4)

Install the 5 bearing caps in their proper locations.

(5)

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

(6)

Install and uniformly tighten the 10 bearing cap
bolts, in several passes, in the sequence shown.

Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)

(7)

Remove the service bolt.

7.

CHECK AND ADJUST VALVE CLEARANCE
(See page

EM–4

)

Turn the camshaft and position the cam lobe upward, and
check and adjust the valve clearance.

P13274

Seal Packing

P12813

Front

Semi–Circular Plug

P12812

: Seal Packing

Front

RH Side

LH Side

EM–58

–

ENGINE MECHANICAL

CYLINDER HEAD

795

1997 LEXUS ES300 (RM511U)

8.

INSTALL SEMI–CIRCULAR PLUGS

(a)

Remove any old packing (FIPG) material.

(b)

Apply seal packing to the semi–circular plug grooves.
Seal packing: Part No. 08826–00080 or equivalent

(c)

Install the 4 semi–circular plugs to the cylinder heads.

9.

INSTALL CYLINDER HEAD COVERS

(a)

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

(b)

Install the gasket to the cylinder head cover.

(c)

Install the cylinder head cover with the 8 bolts. Uniformly
tighten the bolts in several passes. Install the 2 cylinder
head covers.
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)

P18771

Manifold
Stay

P18773

P12710

New O–Ring

P18750

Manifold
Stay

S04789

Ground

Strap

Inlet Pipe

Rear
Plate

–

ENGINE MECHANICAL

CYLINDER HEAD

EM–59

796

1997 LEXUS ES300 (RM511U)

10.

INSTALL RH EXHAUST MANIFOLD

(a)

Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

(b)

Install the exhaust manifold stay with the bolt and nut. Al-
ternately tighten the bolt and nut.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

(c)

Connect the oxygen sensor (bank 1 sensor 1) connector.

11.

INSTALL NO.1 EGR PIPE

Install 2 new gaskets and the EGR pipe with the 4 nuts.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

12.

INSTALL PS PUMP BRACKET
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)

13.

INSTALL OIL DIPSTICK AND GUIDE

(a)

Install a new O–ring to the dipstick guide.

(b)

Apply soapy water to the O–ring.

(c)

Push in the dipstick guide end into the guide hole of the
No.1 oil pan.

(d)

Install the dipstick guide with the bolt.
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)

(e)

Install the dipstick.

14.

INSTALL CAMSHAFT POSITION SENSOR

15.

INSTALL LH EXHAUST MANIFOLD

(a)

Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

(b)

Install the exhaust manifold stay with the bolt and nut. Al-
ternately tighten the bolt and nut.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

(c)

Connect the oxygen sensor (bank 1 sensor 1) connector.

16.

INSTALL WATER INLET PIPE

(a)

Install a new O–ring to the water inlet pipe.

(b)

Apply soapy water to the O–ring.

(c)

Connect the water inlet pipe to the water inlet.

(d)

Install the bolt holding the water inlet pipe to the cylinder
head.
Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf)

17.

INSTALL CYLINDER HEAD REAR PLATE
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)

18.

INSTALL ENGINE WIRE PROTECTOR

P12981

L = 133 mm (5.24 in.)

L = 180 mm (7.09 in.)

L = 72 mm (2.83 in.)

L = 335 mm (13.19 in.)

L = 180 mm

(7.09 in.)

L = Length

Join

Line

Join

Line

Z14262

New Gasket

EM–60

–

ENGINE MECHANICAL

CYLINDER HEAD

797

1997 LEXUS ES300 (RM511U)

19.

INSTALL NO.3 TIMING BELT COVER

(a)

Check that the timing belt cover gaskets have no cracks
or peeling, etc.

If the gaskets have cracks or peeling etc., replace them using
these steps:

Using a screwdriver and gasket scraper, remove all
the old gasket material.

Thoroughly clean all components to remove all the
loose material.

Remove the backing paper from a new gasket and
install the gasket evenly to the part of the timing belt
cover shaded black in the illustration.

NOTICE:
When joining 2 gaskets, do not leave a gap between them.
Cut off any excess gasket.

After installing the gasket, press down on it so that
the adhesive firmly sticks to the timing belt cover.

(b)

Install the timing belt cover with the 6 bolts.
Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf)

(c)

Install the 3 engine wire clamps to the timing belt cover.

20.

INSTALL NO.2 IDLER PULLEY
(See page

EM–20

)

21.

INSTALL CAMSHAFT TIMING PULLEYS
(See page

EM–20

)

22.

INSTALL TIMING BELT
(See page

EM–20

)

23.

INSTALL SPARK PLUGS

24.

INSTALL IGNITION COILS

25.

INSTALL PS PUMP DRIVE BELT

26.

INSTALL GENERATOR DRIVE BELT

27.

INSTALL WATER OUTLET

(a)

Install 2 new gaskets.

(b)

Connect the water outlet to the bypass hose.

(c)

Install the water outlet with the 2 bolts, 2 nuts and 2 plate
washers. Alternately tighten the bolts and nuts.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)

NOTICE:
Do not scratch the seal surface of the water outlet with the
stud bolt.
(d)

Connect these connectors, (strap) and hoses:

ECT sender gauge connector

ECT sensor connector

Ground strap (connector)

Radiator hose

Engine coolant reservoir hose