Lexus ES: Replacement
REPLACEMENT
PROCEDURE
1. REPLACE STRAIGHT PIN
NOTICE:
If a straight pin is deformed, replace it.
(a) Using a plastic hammer, tap in new straight pins to the cylinder block sub-assembly.
| *a | Front Side | *b | Rear Side |
| *c | Top Side | *d | Bottom Side |
| *e | RH Side | *f | 23 mm (0.906 in.) |
| *g | 6 mm (0.236 in.) | *h | 11 mm (0.433 in.) |
| *i | 9 mm (0.354 in.) | - | - |
Standard Protrusion Height:
| Item | Specified Condition |
|---|---|
| Pin (A) | 23 mm (0.906 in.) |
| Pin (B) | 6 mm (0.236 in.) |
| Pin (C) | 11 mm (0.433 in.) |
| Pin (D) | 9 mm (0.354 in.) |
2. REPLACE STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
(a) Using E8 and E10 "TORX" socket wrenches, install the stud bolts to the cylinder block sub-assembly.
| *A | w/ Stud Bolt | - | - |
| *a | Front Side | *b | LH Side |
| *c | 24 mm (0.9449 in.) | *d | 12 mm (0.4724 in.) |
| *e | 52 mm (2.05 in.) | *f | 23 mm (0.906 in.) |
| *g | 15 mm (0.591 in.) | *h | 40 mm (1.57 in.) |
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
3. REPLACE CONNECTING ROD SMALL END BUSH
| (a) Using SST and a press, press out the connecting rod small end bush. SST: 09222-30010 |
|
| (b) Align the oil hole of a new connecting rod small end bush with the oil hole of the connecting rod. |
|
| (c) Using SST and a press, push in the connecting rod small end bush. SST: 09222-30010 |
|
| (d) Using a pin hole grinder, hone the connecting rod small end bush to obtain the standard oil clearance between the connecting rod small end bush and piston pin. Standard Oil Clearance: 0.005 to 0.011 mm (0.000197 to 0.000433 in.) |
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(e) Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
HINT:
Check that the piston pin fits at a normal room temperature.
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Reassembly
REASSEMBLY PROCEDURE 1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY (a) Using a 5 mm hexagon socket wrench, install the 3 No. 1 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 3 bol
Precaution
PRECAUTION HINT:
Any digits beyond the 1/100 mm (1/1000 in.) place for standard, minimum and maximum values should be used as a reference only.
When both standard and maximum or minimum values ar
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