Lexus ES manuals

Lexus ES: Disassembly

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / A25a-fxs (engine Mechanical) / Cylinder Block / Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during cylinder block removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane control system (for HV Model)

Pre-collision system (for HV Model)

Parking support brake system (for HV Model)*

Lighting system (for HV Model)

Memorize steering angle neutral point

Parking assist monitor system (for HV Model)

Panoramic view monitor system (for HV Model)

Initialize power trunk lid system

Power trunk lid system (for HV Model)

Replacement of ECM

Perform Vehicle Identification Number (VIN) registration

MIL illuminates

  • Replacement of engine assembly
  • Gas leak from exhaust system is repaired
  • Replacement of throttle body with motor assembly
  • Cleaning the deposits from the throttle body assembly
  • Replacement of cam timing control motor with EDU assembly
  • Removal and installation of a cam timing control motor with EDU assembly
  • Replacement of camshaft timing gear assembly
  • Removal and installation of a camshaft timing gear assembly
  • Replacement of cylinder head sub-assembly
  • Replacement of camshaft (for intake or exhaust camshaft)
  • Replacement of camshaft timing exhaust gear assembly
  • Replacement of port fuel injector assembly
  • Replacement of direct fuel injector assembly
  • Replacement of fuel pump assembly (for high pressure side)
  • Replacement of engine coolant temperature sensor
  • Replacement of spark plug
  • Replacement of ignition coil assembly
  • Replacement of EGR valve assembly
  • Replacement of knock control sensor
  • Replacement of piston or piston ring

Inspection After Repair
  • Poor idle, etc.
  • Engine start function, etc.

Replacement of inverter with converter assembly

Resolver learning
  • DTCs are stored
  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less
  • Shock or vibration during acceleration

Replacement of hybrid vehicle transaxle assembly
  • Resolver learning
  • Initialize resolver

Front wheel alignment adjustment
  1. Clear zero point calibration data.
  2. Perform yaw rate and acceleration sensor zero point calibration.
  • DTCs are stored
  • ABS warning light illuminates
  • Brake warning light / yellow (minor malfunction) illuminates
  • Slip indicator light illuminates
  • VSC disabled or malfunctions

  • Suspension, tires, etc.*1
  • Replacement of front bumper assembly
  • Measurement of ultrasonic sensor detection angle
  • Ultrasonic sensor detection angle registration
  • Parking support alert system (for HV Model)
  • Parking support brake system (for HV Model)

Suspension, tires, etc.*1

Rear television camera assembly optical axis (Back camera position setting)

Parking assist monitor system (for HV Model)

for Initialization

for Calibration

Replacement of front bumper assembly

Front television camera view adjustment

Panoramic view monitor system (for HV Model)

for Initialization

for Calibration

Suspension, tires, etc.*1
  • Parking assist ECU initialization
  • Adjust steering angle
  • Rear television camera assembly optical axis (Back camera position setting)

Replacement of headlight ECU sub-assembly LH
  • Synchronize the vehicle information
  • Perform headlight ECU sub-assembly LH initialization*2

Lighting system (for HV Model)

Suspension, tires, etc.*1

Perform headlight ECU sub-assembly LH initialization*2
  • *: When performing learning using the Techstream.

    Click here

  • *1: If the vehicle height has changed due to suspension or tire replacement.
  • *2: for LED type turn signal light

NOTICE:

  • After the power switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Audio and Visual System)
  • After the power switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Navigation System)

PROCEDURE

1. REMOVE NO. 1 VENTILATION CASE

NOTICE:

Perform this procedure only when replacement of the No. 1 ventilation case is necessary.

(a) Remove the 4 bolts and No. 1 ventilation case from the cylinder block sub-assembly.

(b) Remove the 3 oil separator gaskets from the No. 1 ventilation case.

2. REMOVE NO. 1 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon socket wrench, remove the No. 1 straight screw plug and gasket from the cylinder block sub-assembly.

3. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.

Standard Thrust Clearance:

0.16 to 0.51 mm (0.00630 to 0.0201 in.)

Maximum Thrust Clearance:

0.512 mm (0.0202 in.)

HINT:

If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.

4. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Note the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.

*a

Alignment Mark

(b) Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts and connecting rod cap.

HINT:

Keep the connecting rod bearing and connecting rod cap together.

(c) Clean the crank pin and connecting rod bearing.

(d) Check the crank pin and connecting rod bearing for pitting and scratches.

HINT:

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

(e) Lay a strip of Plastigage on the crank pin.

*a

Plastigage

(f) Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod cap to the connecting rod.

*a

Front Mark

(g) Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

(h) Using an E12 "TORX" socket wrench, install and alternately tighten the 2 connecting rod bolts in several steps.

Torque:

38 N·m {387 kgf·cm, 28 ft·lbf}

(i) Mark the front of each connecting rod bolt with paint.

*a

Paint Mark

*b

90°

Front of Engine

(j) Tighten the connecting rod bolts 90° as shown in the illustration.

NOTICE:

Do not turn the crankshaft during the measurement.

(k) Remove the 2 connecting rod bolts and connecting rod cap.

HINT:

Keep the connecting rod bearing and connecting rod cap together.

(l) Measure the Plastigage at its widest point.

Standard Oil Clearance:

0.027 to 0.059 mm (0.00106 to 0.00232 in.)

Maximum Oil Clearance:

0.059 mm (0.00232 in.)

HINT:

  • If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.
  • If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 3 sizes of standard connecting rod bearings, marked "1", "2" or "3" accordingly.

Standard Connecting Rod Big End Inside Diameter:

Mark

Specified Condition

1

51.000 to 51.008 mm (2.00787 to 2.00818 in.)

2

51.009 to 51.016 mm (2.00822 to 2.00850 in.)

3

51.017 to 51.024 mm (2.00854 to 2.00881 in.)

Standard Connecting Rod Bearing Center Wall Thickness:

Mark

Specified Condition

1

1.487 to 1.491 mm (0.0585 to 0.0587 in.)

2

1.492 to 1.495 mm (0.0587 to 0.0589 in.)

3

1.496 to 1.499 mm (0.0589 to 0.0590 in.)

Standard Crank Pin Diameter:

47.992 to 48.000 mm (1.88945 to 1.88976 in.)

NOTICE:

Remove the Plastigage completely after the measurement.

*a

Plastigage

*b

1, 2 or 3 Mark

(m) Perform the inspection above for each cylinder.

5. REMOVE PISTON WITH CONNECTING ROD

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

*a

Ridge Reamer

(b) Remove the 8 connecting rod bolts, 4 connecting rod caps and 4 connecting rod bearings.

(c) Push the 4 pistons, 4 connecting rods and 4 connecting rod bearings out through the top of the cylinder block sub-assembly.

HINT:

  • Keep the connecting rod bearings, connecting rods and connecting rod caps together.
  • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

6. REMOVE CONNECTING ROD BEARING

(a) Remove the 8 connecting rod bearings from the 4 connecting rods and 4 connecting rod caps.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

7. INSPECT CRANKSHAFT THRUST CLEARANCE

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

Standard Thrust Clearance:

0.09 to 0.19 mm (0.00354 to 0.00748 in.)

Maximum Thrust Clearance:

0.25 mm (0.00984 in.)

HINT:

If the thrust clearance is more than the maximum, replace the crankshaft thrust washers as a set. If necessary, replace the crankshaft.

Standard Thrust Washer Thickness:

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

8. REMOVE CRANKSHAFT

(a) Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

(b) Remove the 5 crankshaft bearing caps from the cylinder block sub-assembly.

HINT:

  • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.
  • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(c) Remove the crankshaft from the cylinder block sub-assembly.

HINT:

Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block sub-assembly.

(d) Check each crankshaft journal and crankshaft bearing for pitting and scratches.

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

9. REMOVE CRANKSHAFT THRUST WASHER

(a) Remove the 2 crankshaft thrust washers from the No. 3 journal position of the cylinder block sub-assembly.

10. REMOVE CRANKSHAFT BEARING

(a) Remove the 5 crankshaft bearings and 5 No. 2 crankshaft bearings from the cylinder block sub-assembly and 5 crankshaft bearing caps.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

11. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.

*a

Piston Ring Expander

(b) Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

12. REMOVE PISTON PIN HOLE SNAP RING

(a) Using a screwdriver, pry out the 2 piston pin hole snap rings from the piston.

HINT:

Tape the screwdriver tip before use.

*a

Front Mark Cutout Portion

*b

Protective Tape

13. REMOVE PISTON

(a) Gradually heat each piston to between 80 and 90°C (176 and 194°F).

CAUTION:

Be sure to wear protective gloves.

(b) Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.

HINT:

  • The piston and piston pin are a matched set.
  • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

14. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.

15. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies from the cylinder block sub-assembly.

READ NEXT:

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