Disassembly [11/2021 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus IS 500, 2023 Lexus IS 500, and 2022 Lexus IS 500. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the connecting rod thrust clearance while moving the connecting rod sub-assembly back and forth.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Thrust Clearance

0.15 to 0.55 mm (0.00591 to 0.0217 in.)

Maximum Thrust Clearance

0.70 mm (0.0276 in.)

If the connecting rod thrust clearance is more than the maximum, replace the connecting rod sub-assembly. If necessary, replace the crankshaft.

INSPECT CONNECTING ROD OIL CLEARANCE

Note the alignment marks on the connecting rod sub-assembly and connecting rod cap so that they can be reinstalled to their original locations.

Remove the 2 connecting rod bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using the 2 removed connecting rod bolts, remove the connecting rod cap and connecting rod bearing by wiggling the connecting rod cap right and left.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Keep the connecting rod bearing installed to the connecting rod cap.

Clean the crank pin and connecting rod bearing.
NOTE:
Check the crank pin and connecting rod bearing for pitting and scratches.

Lay a strip of Plastigage on the crank pin.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check that the front mark of the connecting rod cap is facing the front of the engine.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Front Mark
	Front of Engine

Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
Install the connecting rod bolts.
NOTE:
Do not turn the crankshaft during the procedure.

HINT:

The connecting rod bolts are tightened in 2 progressive steps.
Step 1:
1. Install and alternately tighten the connecting rod bolts of each connecting rod cap in several steps.
  Torque: 40 N.m (408 kgf/cm, 30 ft.lbf)
  
  Fig 1: Tightening Bolts Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Step 2:

Mark the front side of each connecting rod bolt with paint.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Paint Mark
*b	90°
	Front of Engine

Tighten the connecting rod bolts another 90° as shown in the illustration.

Check that the paint marks are now at a 90° angle to the front of engine.
NOTE:
Do not turn the crankshaft during the procedure.
Remove the 2 connecting rod bolts and connecting rod cap.

Measure the Plastigage at its widest point.

Standard Oil Clearance

0.037 to 0.062 mm (0.00146 to 0.00244 in.)

Maximum Oil Clearance

0.080 mm (0.00315 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Plastigage	*b	Number Mark
*c	No. 1	*d	No. 2
*e	No. 3	*f	No. 4

If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

HINT:

If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 6 sizes of standard connecting rod bearings, marked 2, 3, 4, 5, 6 or 7 accordingly.
Select the correct connecting rod bearing by adding together the number marks imprinted on the connecting rod big end and crankshaft pin.
Connecting rod "1" + Crankshaft pin "2" = 3 (Use bearing "3")

Standard Connecting Rod Bearing Center Wall Thickness

Mark	Specified Condition
2	1.483 to 1.486 mm (0.05839 to 0.05850 in.)
3	1.486 to 1.489 mm (0.05850 to 0.05862 in.)
4	1.489 to 1.492 mm (0.05862 to 0.05874 in.)
5	1.492 to 1.495 mm (0.05874 to 0.05886 in.)
6	1.495 to 1.498 mm (0.05886 to 0.05898 in.)
7	1.498 to 1.501 mm (0.05898 to 0.05909 in.)

Standard Connecting Rod Big End Diameter

Mark	Specified Condition
1	51.000 to 51.006 mm (2.00787 to 2.00811 in.)
2	51.006 to 51.012 mm (2.00811 to 2.00834 in.)
3	51.012 to 51.018 mm (2.00834 to 2.00858 in.)
4	51.018 to 51.024 mm (2.00858 to 2.00881 in.)

Standard Crankshaft Pin Diameter

Mark	Specified Condition
1	47.994 to 48.000 mm (1.88952 to 1.88976 in.)
2	47.988 to 47.994 mm (1.88929 to 1.88952 in.)
3	47.982 to 47.988 mm (1.88905 to 1.88929 in.)

Completely remove the Plastigage.
Perform the inspection for each cylinder.

REMOVE PISTON WITH CONNECTING ROD SUB-ASSEMBLY

Using a ridge reamer, remove all the carbon from the top of the cylinder.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Push the piston, connecting rod sub-assembly and connecting rod bearing through the top of the cylinder block sub-assembly.
HINT:
- Keep each connecting rod bearing, connecting rod sub-assembly and connecting rod cap together.
- Arrange the removed parts in such a way that they can be reinstalled to their original locations.

REMOVE CONNECTING ROD BEARING
1. Remove the connecting rod bearings from the connecting rod sub-assembly and connecting rod cap.
  HINT:
  
  Arrange the removed parts in such a way that they can be reinstalled to their original locations.

INSPECT CRANKSHAFT THRUST CLEARANCE

Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard Thrust Clearance

0.020 to 0.220 mm (0.000787 to 0.00866 in.)

Maximum Thrust Clearance

0.30 mm (0.0118 in.)

If the crankshaft thrust clearance is more than the maximum, replace crankshaft thrust washer set. If necessary, replace the crankshaft.

Standard Crankshaft Thrust Washer Thickness

2.44 to 2.49 mm (0.0961 to 0.0980 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE CRANKSHAFT

Uniformly loosen and remove the 10 bolts and 10 seal washers in several steps in the order shown in the illustration.

Fig 2: Crankshaft Bearing Cap Side Bolts Loosening Sequence (1 Of 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Uniformly loosen and remove the 20 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

Fig 3: Crankshaft Bearing Cap Side Bolts Loosening Sequence (2 Of 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a screwdriver, pry out the crankshaft bearing caps. Remove the 5 crankshaft bearing caps and 5 lower crankshaft bearings.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Cylinder Block Sub-assembly
*2	Crankshaft Bearing Cap
*a	Protective Tape
*b	Contact Surface

NOTE:

Pry up the crankshaft bearing caps gradually and evenly in turns.
Be careful not to damage the contact surfaces between the cylinder block sub-assembly and crankshaft bearing caps.

HINT:

Tape the screwdriver tip before use.

Remove the crankshaft.

REMOVE CRANKSHAFT THRUST WASHER SET

Remove the crankshaft thrust washer set from the No. 2 journal position of the cylinder block sub-assembly.

REMOVE CRANKSHAFT BEARING
1. Remove the 5 upper crankshaft bearings from the cylinder block sub-assembly.
  HINT:
  
  Arrange the removed parts in such a way that they can be reinstalled to their original locations.
2. Remove the 5 lower crankshaft bearings from the 5 crankshaft bearing caps.

REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies.

REMOVE PISTON RING SET

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.

for 2-piece Type:
1. Using a piston ring expander, remove the oil ring.
2. Remove the oil ring expander by hand.
for 3-piece Type:
1. Remove the oil ring expander, upper side rail and lower side rail by hand.

REMOVE PISTON

Remove the connecting rod sub-assembly from the piston.

Using a screwdriver, pry out the piston pin hole snap ring from the piston.
Gradually heat the piston to approximately 80°C (176°F).
WARNING:
Be sure to wear protective gloves.

Using a brass bar and a plastic hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly.

HINT:

The piston and piston pin are a matched set.
Arrange the removed parts in such a way that they can be installed to their original locations.

Clean the piston.

Using a gasket scraper, remove any carbon from the piston top.

Using a groove cleaning tool or broken ring, clean the piston ring grooves.

Using solvent and a brush, thoroughly clean the piston.

NOTE:

Do not use a wire brush.