LEXUS LS430 2003 Factory Repair Manual

Fig. 482: Installing Piston And Connecting Rod
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b. Place the connecting rod cap on the connecting rod.
1. Match the numbered connecting rod cap with the connecting rod.
2. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and
install the connecting rod cap.
Fig. 483: Placing Connecting Rod Cap

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3. Check that the outside mark of the connectin
g rod cap is facing in correct direction.

Fig. 484: Identifying Outside Mark Of Connecting Rod Cap
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c. Install the connecting rod cap bolts.
HINT:
The connecting rod cap bolts are tightened in 2 progressive steps (see steps (2) and (4)).
If any one of the connecting rod cap bolts is broken or deformed, replace it.
1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap
bolts.
2. Install and alternately tighten the 2 connecting rod cap bolts in several passes.
Fig. 485: Tightening Connecting Rod Cap Bolts

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Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
If an
y one of the connecting rod cap bolts does not meet the torque specification, replace the

connecting rod cap bolts.
3. Mark the front of the connecting cap bolt with paint.
4. Retighten the cap bolts 90° as shown in the illustration.
5. Check that the painted mark is now at a 90° angle to the front.
d. Check that the crankshaft turns smoothly.
e. Check the connecting rod thrust clearance (see step 2).
27.INSTALL WATER SEAL PLATE
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces
of the seal plate and cylinder block.
Fig. 486: Identifying Painted Mark

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Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces and sealing groove.
Thoroughly clean all components to remove all loose material.
Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the seal plate as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

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0b001300110013001b00030057005200030013001100140015[ in.) opening.
Parts must be assembled within 5 minutes of application. Otherwise the material must be
removed and reapplied.
Immediately remove the nozzle from the tube and reinstall the cap.
c. Install the seal plate with the 2 nuts. Alternately tighten the nuts in several passes.
Torque: 14 N.m (143 kgf.cm, 10 ft.lbf)
Fig. 487: Applying Seal Packing

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28.INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a. Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826-00100 or equivalent

Fig. 488: Applying Seal Packing
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b. Install the RH and LH drain unions.
Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
HINT:
After appl
ying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

Fig. 489: Installing RH And LH Drain Unions
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Fig. 1: Exploded View Of Exhaust Pipe Assy Components And Replacements (USA And Canada)

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Fig. 2: Exploded View Of Exhaust Pipe Assy Components And Replacements (Korea)

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1.REMOVE FRONT FLOOR BRACE CENTER
a. Remove the 4 bolts and floor brace.
2.Bank 1, 2 sensor 2:
REMOVE HEATED OXYGEN SENSOR
a. Remove the 2 sensors.
3.REMOVE EXHAUST PIPE ASSY FRONT
a. Loosen the clamp.
b. Remove the 4 bolts, 4 nuts, pipe and 2 gaskets.
4.REMOVE EXHAUST PIPE ASSY CENTER
a. Loosen the 2 clamps.
b. Remove the pipe.
5.REMOVE EXHAUST PIPE ASSY TAIL (LH)
a. Remove the pipe from the 3 rings.
6.REMOVE EXHAUST PIPE ASSY TAIL (RH)
a. Remove the pipe from the 3 rings.
7.INSTALL EXHAUST PIPE ASSY FRONT
a. Install the 2 new gaskets to the pipe.
b. Install the pipe to the TWC with the 4 bolts and 4 nuts.
Torque: 44 N.m (450 kgf.cm, 32 ft.lbf)
8.Bank 1, 2 sensor 2:
INSTALL HEATED OXYGEN SENSOR
a. Install the 2 sensors.
Torque: 44 N.m (450 kgf.cm, 32 ft.lbf)
HINT:
Before installing the sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
After installing the sensor, check that the sensor wire is not twisted. If it is twisted, remove the
sensor and reinstall it.
9.INSTALL EXHAUST PIPE ASSY CENTER
a. Install the pipe.
b. Tighten the clamp.
Standard dimension (A): 13 to 15 mm (0.51 to 0.59 in.)