Lexus ES: Inspection

INSPECTION

PROCEDURE

1. INSPECT CYLINDER BLOCK FOR WARPAGE

(a) Using a precision straightedge and feeler gauge, check the surface which contacts the cylinder head gasket for warpage. Maximum Warpage: 0.05 mm (0.00197 in.) HINT: If the warpage is more than the maximum, replace the cylinder block sub-assembly.

2. INSPECT CYLINDER BORE

(a) Using a cylinder gauge, measure the cylinder bore diameter at the positions (A) and (B) in the thrust and axial directions.

*a	Thrust Direction
*b	Axial Direction
*c	10 mm (0.394 in.)
*d	Center
	Front of Engine

Reference Diameter (New Parts):

87.500 to 87.513 mm (3.44488 to 3.44539 in.)

Maximum Diameter:

87.63 mm (3.45 in.)

HINT:

If the average diameter of 4 positions is more than the maximum, replace the cylinder block sub-assembly.

3. INSPECT PISTON

(a) Using a gasket scraper, remove any carbon from the piston top.

(b) Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

(c) Using a brush and solvent, thoroughly clean the piston. NOTICE: Do not use a wire brush.

(d) Using a micrometer, measure the piston diameter at a right angle to the piston center line where the distance from the bottom of the piston is as specified. Distance: 10.5 mm (0.413 in.) Reference Piston Diameter (New Parts): 87.472 to 87.502 mm (3.44377 to 3.44495 in.) HINT: If the diameter is less than the minimum, replace the piston and piston pin as a set.

*a Distance

4. INSPECT PISTON OIL CLEARANCE

(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Reference Oil Clearance (New Parts):

-0.002 to 0.041 mm (-0.0000787 to 0.00161 in.)

Maximum Oil Clearance:

0.081 mm (0.00319 in.)

HINT:

If the piston oil clearance is more than the maximum, replace all the pistons with piston pins. If necessary, replace the cylinder block sub-assembly.

5. INSPECT RING GROOVE CLEARANCE

(a) Using a feeler gauge, measure the clearance between a new piston ring set and the wall of the ring groove. Standard Ring Groove Clearance: Item Specified Condition No. 1 compression ring 0.020 to 0.065 mm (0.000787 to 0.00256 in.) No. 2 compression ring 0.020 to 0.055 mm (0.000787 to 0.00217 in.) Oil ring 0.060 to 0.110 mm (0.00236 to 0.00433 in.) HINT: If the groove clearance is not as specified, replace the piston and piston pin as a set.

6. INSPECT PISTON RING END GAP

(a) Insert the piston ring into the cylinder bore.

*a Piston Ring *b 70 mm

(b) Using a piston, push in the piston ring a little beyond the bottom of the ring travel, 70 mm (2.76 in.) from the top of the cylinder block sub-assembly.

(c) Using a feeler gauge, measure the end gap. Standard End Gap: Item Specified Condition No. 1 compression ring 0.21 to 0.24 mm (0.00827 to 0.00945 in.) No. 2 compression ring 0.50 to 0.55 mm (0.0197 to 0.0217 in.) Oil ring 0.10 to 0.30 mm (0.00394 to 0.0118 in.) Maximum End Gap: Item Specified Condition No. 1 compression ring 0.49 mm (0.0193 in.) No. 2 compression ring 0.80 mm (0.0315 in.) Oil ring 0.55 mm (0.0217 in.) HINT: If the end gap is more than the maximum, replace the piston ring set. If the end gap is more than the maximum even with a new piston ring set, replace the cylinder block sub-assembly.

7. INSPECT PISTON PIN OIL CLEARANCE

HINT:

When replacing the piston and piston pin with supply parts, there are a number of piston diameter sizes to choose from, but there is only one size of piston pin diameter.

(a) Confirm each mark on the piston, piston pin and connecting rod.

(b) Using a caliper gauge, measure the inside diameter of the piston pin hole. Standard Piston Pin Hole Inside Diameter: 21.006 to 21.015 mm (0.82701 to 0.82736 in.) Mark Specified Condition A 21.006 to 21.009 mm (0.82701 to 0.82712 in.) B 21.010 to 21.012 mm (0.82716 to 0.82724 in.) C 21.013 to 21.015 mm (0.82728 to 0.82736 in.) HINT: If the diameter is not as specified, replace the piston and piston pin as a set.

(c) Using a micrometer, measure the piston pin diameter. Standard Piston Pin Diameter: 21.004 to 21.013 mm (0.82693 to 0.82728 in.) Mark Specified Condition A 21.004 to 21.007 mm (0.82693 to 0.82705 in.) B 21.008 to 21.010 mm (0.82708 to 0.82716 in.) C 21.011 to 21.013 mm (0.82720 to 0.82728 in.) HINT: If the diameter is not as specified, replace the piston and piston pin as a set. Measurement Position: Measurement Position Piston Pin Position a 5.0 mm (0.197 in.) from side edge b 24.5 mm (0.965 in.) from side edge

(d) Using a caliper gauge, measure the inside diameter of the connecting rod small end bush. Standard Connecting Rod Small End Bush Inside Diameter: 21.012 to 21.021 mm (0.82724 to 0.82760 in.) Mark Specified Condition A 21.012 to 21.015 mm (0.82724 to 0.82736 in.) B 21.016 to 21.018 mm (0.82740 to 0.82748 in.) C 21.019 to 21.021 mm (0.82752 to 0.82760 in.) HINT: If the inside diameter is not as specified, replace the connecting rod sub-assembly.

(e) Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement.

Standard Oil Clearance:

-0.001 to 0.005 mm (-0.0000394 to 0.000197 in.)

Maximum Oil Clearance:

0.015 mm (0.000591 in.)

HINT:

If the oil clearance is more than the maximum, replace the piston and piston pin as a set.

(f) Subtract the piston pin diameter measurement from the connecting rod small end bush inside diameter measurement.

Standard Oil Clearance:

0.005 to 0.011 mm (0.000197 to 0.000433 in.)

Maximum Oil Clearance:

0.021 mm (0.000827 in.)

HINT:

If the oil clearance is more than the maximum, replace the connecting rod sub-assembly. If necessary, replace the connecting rod sub-assembly and piston pin as a set.

8. INSPECT CONNECTING ROD

(a) Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.

(1) Check for misalignment.

Maximum Misalignment:

0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

If the misalignment is more than the maximum, replace the connecting rod.

(2) Check for twist. Maximum Twist: 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is more than the maximum, replace the connecting rod.

9. INSPECT CRANKSHAFT

(a) Inspect for runout.

(1) Clean the crank journal.

(2) Place the crankshaft on V-blocks.

(3) Using a dial indicator and V-blocks, measure the runout as shown in the illustration. Maximum Runout: 0.03 mm (0.00118 in.) HINT: If the runout is more than the maximum, replace the crankshaft.

(b) Inspect the main journals.

(1) Using a micrometer, measure the diameter of each main journal.

Standard Main Journal Diameter:

55.988 to 56.000 mm (2.20425 to 2.20472 in.)

HINT:

If the diameter is not as specified, check the crankshaft oil clearance. If necessary, replace the crankshaft.

(2) Check each main journal for taper and out-of-round as shown in the illustration. Maximum Taper and Out-of-round: 0.003 mm (0.000118 in.) HINT: If the taper or out-of-round is more than the maximum, replace the crankshaft.

(c) Inspect the crank pins.

(1) Using a micrometer, measure the diameter of each crank pin.

Standard Crank Pin Diameter:

47.992 to 48.000 mm (1.88945 to 1.88976 in.)

HINT:

If the diameter is not as specified, check the connecting rod oil clearance. If necessary, replace the crankshaft.

(2) Inspect each crank pin for taper and out-of-round as shown in the illustration. Maximum Taper and Out-of-round: 0.003 mm (0.000118 in.) HINT: If the taper or out-of-round is more than the maximum, replace the crankshaft.

10. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Install the crankshaft bearings.

Click here

(b) Install the crankshaft thrust washers.

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(c) Place the crankshaft on the cylinder block sub-assembly.

(d) Lay a strip of Plastigage across each journal.

*a Plastigage

(e) Install the crankshaft bearing caps.

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NOTICE:

Do not turn the crankshaft.

(f) Remove the crankshaft bearing caps.

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(g) Measure the Plastigage at its widest point.

Standard Oil Clearance:

for No. 3 journal

0.020 to 0.043 mm (0.000787 to 0.00169 in.)

except No. 3 journal

0.014 to 0.037 mm (0.000551 to 0.00146 in.)

Maximum Oil Clearance:

for No. 3 journal

0.044 mm (0.00173 in.)

except No. 3 journal

0.048 mm (0.00189 in.)

NOTICE:

Remove the Plastigage completely after the measurement.

If the oil clearance is more than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.

HINT:

If replacing a crankshaft bearing, select a new one with the same number. If the number of the crankshaft bearing cannot be determined, calculate the correct crankshaft bearing number by adding together the numbers imprinted on the cylinder block sub-assembly and crankshaft. Then refer to the following table for the appropriate crankshaft bearing number. There are 4 sizes of standard bearings, marked "1", "2", "3", "4" or "5" accordingly.

(h) Perform the inspection for each journal.

11. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using a vernier caliper, measure the outer diameter at position A shown in the illustration.

*a	Measurement Area B
*b	5.0 mm (0.197 in.)
*c	10 mm (0.394 in.)
	Measurement Location A

Standard Diameter:

10.73 to 10.97 mm (0.422 to 0.432 in.)

(b) Using a vernier caliper, measure the outer diameter within range B shown in the illustration at several locations.

(c) Calculate the difference between the measurement at position A and position B.

Minimum Diameter:

The outer diameter difference is 0.3 mm (0.0118 in.)

12. INSPECT CONNECTING ROD BOLT

(a) Using a vernier caliper, measure the outer diameter at position A shown in the illustration.

*a	Measurement Area B
*b	5.0 mm (0.197 in.)
*c	10 mm (0.394 in.)
	Measurement Location A

Standard Diameter:

8.36 to 8.5 mm (0.329 to 0.335 in.)

(b) Using a vernier caliper, measure the outer diameter within range B shown in the illustration at several locations.

(c) Calculate the difference between the measurement at position A and position B.

Minimum Diameter:

The outer diameter difference is 0.05 mm (0.00197 in.)

13. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Blow air into the (A) side, and check that air passes through (B) easily. HINT: If the result is not as specified, replace the No. 1 oil nozzle sub-assembly.

*a Air

14. INSPECT NO. 2 OIL NOZZLE SUB-ASSEMBLY

(a) Blow air into the (A) side, and check that air passes through (B) easily. HINT: If the result is not as specified, replace the No. 2 oil nozzle sub-assembly.

*a Air

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