Lexus ES: Reassembly

(a) Using a 5 mm hexagon wrench, install the 4 No. 2 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(a) Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Align the cutout of the piston and front mark of the connecting rod, insert the connecting rod into the piston, and then push in the piston pin with your thumb until the piston pin comes into contact with the piston pin hole snap ring.

NOTICE:

Do not change the combination of the pistons and piston pins.

(e) Using a screwdriver, install a new piston pin hole snap ring to the piston pin hole on the front side of the piston.

NOTICE:

Be sure that the end gap of the piston pin hole snap ring is not aligned with the cutout of the piston.

HINT:

Tape the screwdriver tip before use.

(f) Check the fitting condition between the piston and piston pin.

(1) Move the connecting rod back and forth on the piston pin. Check the fitting condition.

HINT:

If abnormal movement is felt, replace the piston and piston pin as a set.

(2) Rotate the piston back and forth on the piston pin. Check the fitting condition.

HINT:

If abnormal movement is felt, replace the piston and piston pin as a set.

(a) Install the oil ring expander by hand.

*1

Upper Side Rail

*2

Lower Side Rail

*a

Paint (Orange)

*b

Paint (Light Blue)

Upper Side

*a

Press around the circumference

*b

Ring End

*c

Correct

*d

Incorrect (Ends of the oil ring expander are overlapping)

*1

No. 1 Compression Ring

*2

No. 2 Compression Ring

*a

Code Mark

*b

Paint Mark

Upward

No. 1 Compression Ring

1N

Orange

No. 2 Compression Ring

2N

Pink

*1

No. 1 Compression Ring

*2

No. 2 Compression Ring

*3

Oil Ring Expander

*4

Upper Side Rail

*5

Lower Side Rail

*a

Front Mark

Front of Engine

(b) Install the 5 crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.

NOTICE:

Do not apply engine oil to the crankshaft bearings or the contact surfaces.

(c) Using a vernier caliper, measure the distance between the cylinder block sub-assembly edge and the crankshaft bearing edge.

Difference between (A) and (B):

0 to 0.7 mm (0 to 0.0276 in.)

(d) Install the 5 No. 2 crankshaft bearings to the 5 crankshaft bearing caps as shown in the illustration.

NOTICE:

Do not apply engine oil to the No. 2 crankshaft bearings or the contact surfaces.

HINT:

The color of the No. 1, No. 3 and No. 5 journal bearings are different from that of the No. 2 and No. 4 journal bearings. Be sure to check the color before installation.

(b) Install the 2 crankshaft thrust washers to the No. 3 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

(b) Confirm the front marks and numbers, and install the 5 crankshaft bearing caps to the cylinder block sub-assembly with the front marks positioned as shown in the illustration.

(1) Uniformly install and tighten the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

Torque:

61 N·m {622 kgf·cm, 45 ft·lbf}

HINT:

If a crankshaft bearing cap set bolt cannot be tightened to the specified torque, replace it.

*a

Paint Mark

*b

90°

Front of Engine

(a) Clean the connecting rod bearing contact surfaces of the connecting rod and connecting rod cap, and both surfaces of the 2 connecting rod bearings.

*1

No. 1 Compression Ring

*2

No. 2 Compression Ring

*3

Oil Ring Expander

*4

Upper Side Rail

*5

Lower Side Rail

*a

Front Mark

Front of Engine

*a

Press around the circumference

*b

Ring End

*c

Correct

*d

Incorrect (Ends of the oil ring expander are overlapping)

(d) Using a piston ring compressor, push the correctly numbered piston with connecting rod into the cylinder with the front marks of each piston with connecting rod facing the front of the engine.

(e) Check that the front mark of the connecting rod cap is facing the correct direction.

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

Torque:

38 N·m {387 kgf·cm, 28 ft·lbf}

*a

Paint Mark

*b

90°

Front of Engine

(a) Using a 10 mm hexagon socket wrench, install the cylinder block with head straight screw plug and a new gasket to the cylinder block sub-assembly.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

(a) Install 3 new oil separator gaskets to the No. 1 ventilation case.

(b) Install the No. 1 ventilation case to the cylinder block sub-assembly with the 4 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}