LEXUS ES300 2005 Repair Manual

A78804
Oil Hole
A78803
SST
EM6535
P00326
A78317
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24. INSTALL CONNECTING ROD SMALL END BUSH
(a) Align the oil holes of a new bush and the connecting rod.
(b) Using SST and a press, press in the bushing.
SST 09222-30010
(c) Using a pin hole grinder, hone the bush to obtain the stan-
dard specified clearance between the bush and piston
pin.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
(d) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, then push it into the con-
necting rod with your thumb.
25. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the new piston ring and wall of the ring groove.
Ring groove clearance:
0.03 to 0.08 mm (0.0012 to 0.0031 in.) for No. 1 ring
0.02 to 0.06 mm (0.0008 to 0.0024 in.) for No. 2 ring
0.03 to 0.11 mm (0.0012 to 0.0043 in.) for oil ring
If the groove clearance is not as specified, replace the piston
ring.

A78805
110 mm
(4.33 in.)
A37355
EM6347A15065
EM6347A15065
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26. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring which it is a little below
the bottom of the ring travel, where is 110 mm (4.33 in.)
from the top of the cylinder block.
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
0.30 to 0.40 mm (0.0118 to 0.0157 in.) for No. 1 ring
0.50 to 0.60 mm (0.0197 to 0.0236 in.) for No. 2 ring
0.15 to 0.40 mm (0.0059 to 0.0157 in.) for oil (side rail)
ring
Maximum end gap:
0.95 mm (0.0374 in.) for No. 1 ring
1.05 mm (0.0413 in.) for No. 2 ring
1.00 mm (0.0394 in.) for oil (side rail) ring

If the end gap is greater than maximum, replace the
piston ring.

If the end gap is greater than maximum, even with
a new piston ring, replace the cylinder block.
27. INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than minimum, replace the bolt.
28. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than minimum, replace the bolt.

P12406
A37157
ZF6928
A78806
No. 1 and No. 4:
Upper
Lower
22.4 mm (0.882 in.)No. 2 and No. 3:
19.0 mm (0.748 in.)
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29. INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, 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.
(b) Using a micrometer, measure the diameter of each main
journal.
Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
If the diameter is not as specified, check the crankshaft oil clear-
ance
(c) Check each main journal 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.
(d) Using a micrometer, measure the diameter of each crank
pin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
If the diameter is not as specified, check the connecting rod oil
clearance.
(e) Check each 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.
30. INSPECT CRANKSHAFT OIL CLEARANCE
HINT:
Crankshaft bearings come in widths of 22.4 mm (0.882 in.) and
19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in
the No. 1 and No. 4 cylinder block journal positions with the
bearing caps. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
(a) Clean each main journal and bearing.

P12599
A78807
Mark
1, 2, 3 or 4
A78808
Plastigage
A10530
A78809Less than 6 mm (0.23 in.) 14-168
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(b) Align the key of the bearing with the keyway of the cylinder
block, then push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
(c) Align the key of the bearing with the keyway of the bearing
cap, then push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
HINT:
A number is marked on each bearing cap to indicate the instal-
lation position.
(d) Place the crankshaft on the cylinder block.
(e) Lay a strip of Plastigage across each journal.
(f) Examine the front marks and numbers, then install the
bearing caps on the cylinder block.
(g) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(h) Temporarily install the 8 bearing cap bolts to the inside
positions.
(i) Install the bearing cap by hand using the inner bolt as a
guide. Stop when the bearing cap is about 6 mm (0.23 in.)
away from contact with the cylinder block.

A10529
A78810
1
3
4
5
6
7
8
2
10
11
13
12
14
15
16
9
A78811
Painted Mark
90
Front90
A78812
1
2
3
4
5
6
7
8
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(j) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure proper fit.
(k) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(l) Using several steps, install and tighten the 16 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 22 NVm (224 kgfVcm, 16 ftVlbf)
(m) Mark the front side of the bearing cap bolts with paint.
(n) Retighten the bearing cap bolts by 90 in the same se-
quence as step (l).
(o) Check that each painted mark is now at a 90 angle to the
front.
NOTICE:
Do not turn the crankshaft.
(p) Using several steps, install and tighten the 8 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 27 NVm (275 kgfVcm, 20 ftVlbf)
HINT:
Use the short bolt for the position marked with the arrow.
(q) Remove the bearing caps.

P12993
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(r) Measure the Plastigage at its widest point.
Standard oil clearance:
0.014 to 0.034 mm (0.0006 to 0.0013 in.) for No. 1 and
No. 2 journals
0.026 to 0.046 mm (0.0010 to 0.0018 in.) for No. 3 and
No. 4 journals
Maximum clearance:
0.05 mm (0.0020 in.) for No. 1 and No. 2 journals
0.06 mm (0.0024 in.) for No. 3 and No. 4 journals

If the oil clearance is greater than maximum, re-
place the bearings.

If necessary, replace the crankshaft.
NOTICE:
Completely remove the Plastigage.

A78813
No. 1
Number
MarkNo. 2No. 3
No. 4
No. 1 No. 2
No. 3
No. 4 Number Mark
Number Mark
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(s) If replacing a bearing, replace it with one having the same
number. If the number of the bearing cannot be deter-
mined, select the correct bearing by adding together the
numbers imprinted on the cylinder block and crankshaft,
then refer to the table below for the appropriate bearing
number. The No. 1 and No. 2 journal bearing come in 5
sizes, marked º3º, º4º, º5º, º6º and º7º. The No. 3 and No.
4 journal bearings come in 5 standard bearing sizes,
marked º1º, º2º, º3º, º4º and º5º.
No. 1 and No. 2 journal bearings:
Cylinder
block
+
Crankshaft
=
0 to 56 to 1112 to 1718 to 2324 to 28
Replace-
ment
Bearing
º3ºº4ºº5ºº6ºº7º
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked º5º
No. 3 and No. 4 journal bearings:
Cylinder
block
+
Crankshaft
=
0 to 56 to 1112 to 1718 to 2324 to 28
Replace-
ment
Bearing
º1ºº2ºº3ºº4ºº5º
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked º3º

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2005 LEXUS ES330 REPAIR MANUAL (RM1124U) Item
Markmm (in.)
Cylinder block main journal bore diameter (A)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º
º13º
º14º
º15º
º16º66.000 (2.5984)
66.001 (2.5985)
66.002 (2.5985)
66.003 (2.5985)
66.004 (2.5986)
66.005 (2.5986)
66.006 (2.5987)
66.007 (2.5987)
66.008 (2.5987)
66.009 (2.5988)
66.010 (2.5988)
66.011 (2.5989)
66.012 (2.5989)
66.013 (2.5989)
66.014 (2.5990)
66.015 (2.5990)
66.016 (2.5990)
Crankshaft main journal diameter (B)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º61.000 (2.4016)
60.999 (2.4015)
60.998 (2.4015)
60.997 (2.4015)
60.996 (2.4014)
60.995 (2.4014)
60.994 (2.4013)
60.993 (2.4012)
60.992 (2.4012)
60.991 (2.4012)
60.990 (2.4012)
60.989 (2.4011)
60.988 (2.4011)
Standard bearing center wall thicknessº1º
º2º
º3º
º4º
º5º
º6º
º7º2.486 to 2.489 (0.0979 to 0.0980)
2.489 to 2.492 (0.0980 to 0.0981)
2.492 to 2.495 (0.0981 to 0.0982)
2.495 to 2.498 (0.0982 to 0.0983)
2.498 to 2.501 (0.0983 to 0.0985)
2.501 to 2.504 (0.0985 to 0.0986)
2.504 to 2.507 (0.0986 to 0.0987)

A78318
Front Side: Front Side:
Front Side:
Upper Side:Left Side:
80 mm
(3.15 in.)
M1099 mm
(3.90 in.)
M8
27.5 mm
(1.08 in.)28.5mm
(1.12 in.) M6
M6M8 29 mm
(1.14 in.)
Torque: 6.0 NVm (60 kgfVcm, 53 in.Vlbf)
Torque: 7.0 NVm (70 kgfVcm, 62 in.Vlbf)
Torque: 4.0 NVm (40 kgfVcm, 35 in.Vlbf) Torque: 21 NVm (220 kgfVcm, 15 ftVlbf)Torque: 15 NVm (145 kgfVcm, 11 ftVlbf)
52.5 mm
(2.07 in.) Upper Side:
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
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31. INSTALL STUD BOLT

A78319
Front Side:
Upper Side:Right Side:
Lower Side:
Back Side: Back Side: Protrusion Height: 6 mm (0.24 in.)
Protrusion Height: 11 mm (0.43 in.) 4 mm
(0.16 in)
10 mm
(0.39 in.)
22 mm
(0.87 in.)12 mm
(0.47 in.) 12 mm
(0.47 in.)4 mm
(0.16 in)
4 mm
(0.16 in)
12 mm
(0.47 in.)4 mm
(0.16 in)
12 mm
(0.47 in.)
4 mm
(0.16 in)
12 mm
(0.47 in.) Protrusion Height: 6 mm (0.24 in.)
Protrusion Height: 6 mm (0.24 in.)Protrusion Height: 6 mm (0.24 in.) Protrusion Height: 6 mm (0.24 in.) 14-174
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32. INSTALL STRAIGHT PIN