Lexus ES300 (1997 year). Manual - part 478

P00326

EM6347

P12406

P12493

–

ENGINE MECHANICAL

CYLINDER BLOCK

EM–93

830

1997 LEXUS ES300   (RM511U)

(e)

Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.

16.

INSPECT CONNECTING ROD BOLTS

Using vernier calipers, measure the tension portion diameter of
the bolt.

Standard diameter: 7.2 – 7.3 mm (0.284 – 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)

If the diameter is less than minimum, replace the bolt.

17.

INSPECT CRANKSHAFT FOR CIRCLE RUNOUT

(a)

Place the crankshaft on V–blocks.

(b)

Using a dial indicator, measure the circle runout, as
shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 in.)

If the circle runout is greater than maximum, replace the crank-
shaft.

18.

INSPECT MAIN JOURNALS AND CRANK PINS

(a)

Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
60.988 – 61.000 mm (2.4011 – 2.4016 in.)
Crank pin diameter:
52.992 – 53.000 mm (2.0862 – 2.0866 in.)

If the diameter is not as specified, check the oil clearance. (See
disassembly in cylinder block)
If necessary, replace the crankshaft.
(b)

Check each main journal and crank pin for taper and out–
of–round as shown.
Maximum taper and out–of–round:
0.02 mm (0.0008 in.)

If the taper and out–of–round is greater than maximum, replace
the crankshaft.
19.

REPLACE CRANKSHAFT FRONT OIL SEAL
(See page 

LU–13

)

P12589

P12570

SST

P12808

Cut Position

P12810

SST

EM–94

–

ENGINE MECHANICAL

CYLINDER BLOCK

831

1997 LEXUS ES300   (RM511U)

20.

REPLACE CRANKSHAFT REAR OIL SEAL

HINT:
There are 2 methods ((a) and (b)) to replace the oil seal which
are as follows:
(a)

If the rear oil seal retainer is removed from the cylinder
block.
(1)

Using a screwdriver and hammer, tap out the oil
seal.

(2)

Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.

SST

09223–15030,  09950–70010 (09951–07100)

(3)

Apply MP grease to the oil seal lip.

(b)

If the rear oil seal retainer is installed to the cylinder block.
(1)

Using a knife, cut off the oil seal lip.

(2)

Using a screwdriver, pry out the oil seal.

NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.

(3)

Apply MP grease to a new oil seal lip.

(4)

Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.

SST

09223–15030, 09950–70010 (09951–07100)

EM04E–02

P12418

P12417

60

°

C

Z09221

Front Mark
(2 Cavities)

Front Mark
(Mold Mark)

RH Piston

LH Piston

Front Mark
(1 Cavity)

Front Mark
(Mold Mark)

–

ENGINE MECHANICAL

CYLINDER BLOCK

EM–95

832

1997 LEXUS ES300   (RM511U)

REASSEMBLY

HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets, O–rings and oil seals with new parts.

1.

ASSEMBLE PISTON AND CONNECTING ROD

(a)

Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.

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

(b)

Gradually heat the piston to about 60

°

C (140

°

F).

(c)

Coat the piston pin with engine oil.

(d)

Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.

(e)

Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.

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

Z09179

Cord Mark

No.1

No.2

Cord Mark

P12566

RH Piston

Lower Side Rail

No.2
Compression

Front Mark

Expander

Upper Side Rail

No.1
Compression

Lower Side Rail

Upper Side Rail

Front Mark

LH Piston

No.2
Compression

Expander

No.1
Compression

P12402

Z09177

No.1 and No.4

Upper

Lower

22.4 mm

19.0 mm

No.2 and No.3

EM–96

–

ENGINE MECHANICAL

CYLINDER BLOCK

833

1997 LEXUS ES300   (RM511U)

2.

INSTALL PISTON RINGS

(a)

Install the oil ring expander and 2 side rails by hand.

(b)

Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark:
No.1: 1R or T
No.2: 2R or 2T

(c)

Position the piston rings so that the ring ends are as
shown.

NOTICE:
Do not align the ring ends.

3.

INSTALL CONNECTING ROD BEARINGS

(a)

Align the bearing claw with the groove of the connecting
rod or connecting cap.

(b)

Install the bearings in the connecting rod and connecting
rod cap.

4.

INSTALL MAIN BEARINGS

HINT:

Main bearings come in widths of 19.0 mm (0.748 in.) and
22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bear-
ings in the No.1 and No.4 cylinder block journal positions
with the main bearing cap. Install the 19.0 mm (0.748 in.)
bearings in the No.2 and No.3 positions.

Upper bearings have an oil groove and oil holes; lower
bearings do not.