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Inspection [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.
  1. INSPECT CYLINDER BLOCK FOR WARPAGE 
    1. Using a precision straightedge and feeler gauge, check the surfaces that contact the cylinder head gaskets for warpage.
      GTY504394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Feeler Gauge
      *b Precision Straightedge

      Maximum Warpage

      0.05 mm (0.00197 in.)

      If the warpage is greater than the maximum, replace the cylinder block sub-assembly.

    2. Visually check the cylinder for vertical scratches.

      If necessary, replace the cylinder block sub-assembly.

  2. INSPECT CYLINDER BORE 
    1. Using a cylinder gauge, measure the cylinder bore diameter at the positions (A), (B) and (C) in the thrust and axial directions.

      Reference Value (New Parts)

      94.000 to 94.012 mm (3.70078 to 3.70125 in.)

      Maximum Diameter

      94.200 mm (3.70865 in.)

      GTY498413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Axial Direction
      *b Thrust Direction
      *c 10 mm (0.394 in.)
      *d Center
      Front of Engine

      If the diameter is greater than the maximum, replace the cylinder block sub-assembly.

  3. INSPECT PISTON 
    1. Using a micrometer, measure the piston diameter at the position shown in the illustration.
      GTY508478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Distance

      Distance

      14.5 mm (0.571 in.)

      Reference Value (New Parts)

      93.961 to 93.986 mm (3.69924 to 3.70023 in.)

  4. INSPECT PISTON OIL CLEARANCE 
    1. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

      Reference Value (New Parts)

      0.009 to 0.051 mm (0.000354 to 0.00201 in.)

      Maximum Oil Clearance

      0.370 mm (0.0146 in.)

      If the oil clearance is greater than the maximum, replace all the pistons and piston pins. If necessary, replace the cylinder block sub-assembly.

  5. INSPECT RING GROOVE CLEARANCE 
    1. Using a feeler gauge, measure the clearance between a new piston ring set and the wall of the ring groove.
      GTY509686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Feeler Gauge

      Standard Ring Groove Clearance

      Item Specified Condition
      No. 1 Compression Ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
      No. 2 Compression Ring 0.020 to 0.060 mm (0.000787 to 0.00236 in.)
      Oil Ring
      (2-piece Type)      		 0.020 to 0.070 mm (0.000787 to 0.00276 in.)
      Oil Ring
      (3-piece Type)      		 0.06 to 0.11 mm
      (0.00236 to 0.00433 in.)

      If the clearance is not as specified, replace the piston and piston pin as a set.

  6. INSPECT PISTON PIN OIL CLEARANCE 
    1. Check each mark on the piston, piston pin and connecting rod sub-assembly.
      GTY1210512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 1 *b for Bank 2
      *c Piston Pin Hole Inside Diameter Mark *d Front Mark
      *e Connecting Rod Bush Inside Diameter Mark - -
    2. Using a caliper gauge, measure the inside diameter of the piston pin hole.
      GTY148041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Piston Pin Hole Inside Diameter

      Mark Specified Condition
      A 21.998 to 22.001 mm (0.86606 to 0.86618 in.)
      B 22.002 to 22.004 mm (0.86622 to 0.86630 in.)
      C 22.005 to 22.007 mm (0.86634 to 0.86642 in.)
    3. Using a micrometer, measure the piston pin diameter.

      Standard Piston Pin Diameter

      Mark Specified Condition
      A 21.997 to 22.000 mm (0.86602 to 0.86614 in.)
      B 22.001 to 22.003 mm (0.86618 to 0.86626 in.)
      C 22.004 to 22.006 mm (0.86630 to 0.86638 in.)
      GTY521114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 5 mm (0.197 in.)
      *b 28 mm (1.10 in.)
    4. Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement.

      Standard Oil Clearance

      -0.002 to 0.004 mm (-0.00008 to 0.00016 in.)

      Maximum Oil Clearance

      0.015 mm (0.000591 in.)

      If the oil clearance is more than the maximum, replace the piston and piston pin as a set.

    5. Using a caliper gauge, measure the inside diameter of the connecting rod bush.

      Standard Connecting Rod Bush Inside Diameter

      Mark Specified Condition
      A 22.005 to 22.008 mm (0.86634 to 0.86645 in.)
      B 22.009 to 22.011 mm (0.86649 to 0.86657 in.)
      C 22.012 to 22.014 mm (0.86661 to 0.86669 in.)
      GTY517259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Caliper Gauge
    6. Subtract the piston pin diameter measurement from the connecting rod bush inside diameter measurement.

      Standard Oil Clearance

      0.005 to 0.011 mm (0.000197 to 0.000433 in.)

      Maximum Oil Clearance

      0.030 mm (0.00118 in.)

      If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

  7. INSPECT PISTON RING END GAP 
    1. Insert the piston ring into the cylinder bore.
      GTY1082714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring
      *b Approximately 60 mm (2.36 in.)
    2. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 60 mm (2.36 in.) from the top of the cylinder block sub-assembly.
    3. Using a feeler gauge, measure the piston ring end gap.
      GTY503467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Feeler Gauge

      Standard End Gap (2-piece Type)

      Item Specified Condition
      No. 1 Compression Ring 0.23 to 0.28 mm (0.00906 to 0.0110 in.)
      No. 2 Compression Ring 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
      Oil Ring 0.10 to 0.20 mm (0.00394 to 0.00787 in.)

      Standard End Gap (3-piece Type)

      Item Specified Condition
      No. 1 Compression Ring 0.23 to 0.26 mm (0.00906 to 0.0102 in.)
      No. 2 Compression Ring 0.35 to 0.40 mm (0.0138 to 0.0157 in.)
      Oil Ring 0.10 to 0.30 mm (0.00394 to 0.0118 in.)

      Maximum End Gap (2-piece Type)

      Item Specified Condition
      No. 1 Compression Ring 0.40 mm (0.0157 in.)
      No. 2 Compression Ring 0.50 mm (0.0197 in.)
      Oil Ring 0.45 mm (0.0177 in.)

      Maximum End Gap (3-piece Type)

      Item Specified Condition
      No. 1 Compression Ring 0.38 mm (0.0150 in.)
      No. 2 Compression Ring 0.45 mm (0.0177 in.)
      Oil Ring 0.55 mm (0.0217 in.)

      If the end gap is more than the maximum, replace the piston ring set. If the end gap is more than the maximum even with a new piston ring set, replace the cylinder block sub-assembly.

  8. INSPECT CONNECTING ROD SUB-ASSEMBLY 
    1. Using a connecting rod aligner and feeler gauge, check the connecting rod sub-assembly alignment.
      1. Check for misalignment.
        GTY519122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Feeler Gauge

        Maximum Misalignment

        0.05 mm (0.00197 in.) per 100 mm (3.94 in.)

        If the misalignment is greater than the maximum, replace the connecting rod sub-assembly.

      2. Check for twist.
        GTY499577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Feeler Gauge

        Maximum Twist

        0.15 mm (0.00591 in.) per 100 mm (3.94 in.)

        If the twist is greater than the maximum, replace the connecting rod sub-assembly.

  9. INSPECT CONNECTING ROD BOLT 
    1. Using a vernier caliper, measure the diameter of the connecting rod bolt at several points within the area shown in the illustration.

      Standard Diameter

      8.5 to 8.6 mm (0.335 to 0.339 in.)

      Minimum Diameter

      8.3 mm (0.327 in.)

      GTY508702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Area

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

      HINT: 

      • If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage.
      • If there is any thread deformation, replace the connecting rod bolt with a new one.
  10. INSPECT CRANKSHAFT 
    1. Inspect for runout.
      GTY124009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place the crankshaft on V-blocks.
      2. Using a dial indicator, measure the runout at the center journal.

        Maximum Runout

        0.01 mm (0.000394 in.)

        If the runout is more than the maximum, replace the crankshaft.

    2. Inspect the main journals.
      1. Using a micrometer, measure the diameter of each main journal.
        GTY136337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Main Journal Diameter

        66.988 to 67.000 mm (2.63732 to 2.63779 in.)

        If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

      2. Check each main journal for taper and out-of-round as shown in the illustration.

        Maximum Taper and Out-of-round

        0.02 mm (0.000787 in.)

        If the taper or out-of-round is more than the maximum, replace the crankshaft.

    3. Inspect the crank pins.
      1. Using a micrometer, measure the diameter of each crank pin.

        Standard Crank Pin Diameter

        47.982 to 48.000 mm (1.88905 to 1.88976 in.)

        If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

        GTY145646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Check each crank pin for taper and out-of-round as shown in the illustration.

        Maximum Taper and Out-of-round

        0.02 mm (0.000787 in.)

        If the taper or out-of-round is more than the maximum, replace the crankshaft.

  11. INSPECT CRANKSHAFT OIL CLEARANCE 
    1. Check the journal and crankshaft bearing for pitting and scratches.

      HINT: 

      If the journal or crankshaft bearing is damaged, replace the crankshaft bearing.

    2. Install the crankshaft bearing.

      See step  4

    3. Place the crankshaft on the cylinder block sub-assembly.
    4. Lay a strip of Plastigage across each journal.
      GTY517062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    5. Confirm the front marks and numbers, and install the crankshaft bearing caps to the cylinder block sub-assembly.

      See step  6

      NOTE:
      • Do not apply engine oil to the crankshaft bearings or journal.
      • Do not turn the crankshaft.

      HINT: 

      A number is marked on each crankshaft bearing cap to indicate the installation position.

    6. Remove the crankshaft bearing caps.

      See step  6

    7. Measure the Plastigage at its widest point.

      Standard Oil Clearance

      Item Specified Condition
      No. 1, No. 5 Journal 0.017 to 0.030 mm (0.000669 to 0.00118 in.)
      Other Journals 0.024 to 0.037 mm (0.000945 to 0.00146 in.)

      Maximum Oil Clearance

      Item Specified Condition
      No. 1, No. 5 Journal 0.050 mm (0.00197 in.)
      Other Journals 0.060 mm (0.00236 in.)

      If the oil clearance is greater than the maximum, replace the crankshaft bearings. If necessary, replace the crankshaft.

    8. If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block sub-assembly and crankshaft. Refer to the table below for the appropriate bearing number. There are 6 sizes of standard bearings. For No. 1 and No. 5 journals, use bearings marked 4, 5, 6, 7, 8 or 9. For other journals, use bearings marked 3, 4, 5, 6, 7 or 8.

      HINT: 

      EXAMPLE: Cylinder block sub-assembly "07" + Crankshaft "06" = Total number 13 (Use upper bearing "6" and lower bearing "7")

      GTY682239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cylinder Block Main Journal Diameter Number Mark *b Crankshaft Main Journal Diameter Number Mark
      *c No. 1 Journal Bearing *d No. 2 Journal Bearing
      *e No. 3 Journal Bearing *f No. 4 Journal Bearing
      *g No. 5 Journal Bearing *h No. 1 and No. 5 Journal Bearing
      *i No. 2, No. 3 and No. 4 Journal Bearing *j Bearing Number
      *k 22.5 mm (0.886 in.) *l 21 mm (0.827 in.)

      Standard Crankshaft Main Journal Diameter

      Item Specified Condition
      Mark 00 66.999 to 67.000 mm (2.63775 to 2.63779 in.)
      Mark 01 66.998 to 66.999 mm (2.63771 to 2.63775 in.)
      Mark 02 66.997 to 66.998 mm (2.63767 to 2.63771 in.)
      Mark 03 66.996 to 66.997 mm (2.63763 to 2.63767 in.)
      Mark 04 66.995 to 66.996 mm (2.63759 to 2.63763 in.)
      Mark 05 66.994 to 66.995 mm (2.63755 to 2.63759 in.)
      Mark 06 66.993 to 66.994 mm (2.63751 to 2.63755 in.)
      Mark 07 66.992 to 66.993 mm (2.63748 to 2.63751 in.)
      Mark 08 66.991 to 66.992 mm (2.63744 to 2.63748 in.)
      Mark 09 66.990 to 66.991 mm (2.63740 to 2.63744 in.)
      Mark 10 66.989 to 66.990 mm (2.63736 to 2.63740 in.)
      Mark 11 66.988 to 66.989 mm (2.63732 to 2.63736 in.)

      Standard Bearing Center Wall Thickness for No. 1 and No. 5 Journals

      Cylinder Block Number Mark + Crankshaft Number Mark Upper Bearing
      Number Mark Specified Condition
      00 to 02 4 2.501 to 2.504 mm (0.0985 to 0.0986 in.)
      03 to 05 5 2.504 to 2.507 mm (0.0986 to 0.0987 in.)
      06 to 08 5 2.504 to 2.507 mm (0.0986 to 0.0987 in.)
      09 to 11 6 2.507 to 2.510 mm (0.0987 to 0.0988 in.)
      12 to 14 6 2.507 to 2.510 mm (0.0987 to 0.0988 in.)
      15 to 17 7 2.510 to 2.513 mm (0.0988 to 0.0989 in.)
      18 to 20 7 2.510 to 2.513 mm (0.0988 to 0.0989 in.)
      21 to 23 8 2.513 to 2.516 mm (0.0989 to 0.0991 in.)
      24 to 26 8 2.513 to 2.516 mm (0.0989 to 0.0991 in.)
      27 to 28 9 2.516 to 2.519 mm (0.0991 to 0.0992 in.)

      Standard Bearing Center Wall Thickness for No. 1 and No. 5 Journals

      Cylinder Block Number Mark + Crankshaft Number Mark Lower Bearing
      Number Mark Specified Condition
      00 to 02 5 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      03 to 05 5 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      06 to 08 6 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      09 to 11 6 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      12 to 14 7 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
      15 to 17 7 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
      18 to 20 8 2.497 to 2.500 mm (0.0983 to 0.0984 in.)
      21 to 23 8 2.497 to 2.500 mm (0.0983 to 0.0984 in.)
      24 to 26 9 2.500 to 2.503 mm (0.0984 to 0.0985 in.)
      27 to 28 9 2.500 to 2.503 mm (0.0984 to 0.0985 in.)

      Standard Bearing Center Wall Thickness for Other Journals

      Cylinder Block Number Mark + Crankshaft Number Mark Upper Bearing
      Number Mark Specified Condition
      00 to 02 3 2.482 to 2.485 mm (0.0977 to 0.0978 in.)
      03 to 05 4 2.485 to 2.488 mm (0.0978 to 0.0980 in.)
      06 to 08 4 2.485 to 2.488 mm (0.0978 to 0.0980 in.)
      09 to 11 5 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      12 to 14 5 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      15 to 17 6 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      18 to 20 6 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      21 to 23 7 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
      24 to 26 7 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
      27 to 28 8 2.497 to 2.500 mm (0.0983 to 0.0984 in.)

      Standard Bearing Center Wall Thickness for Other Journals

      Cylinder Block Number Mark + Crankshaft Number Mark Lower Bearing
      Number Mark Specified Condition
      00 to 02 4 2.501 to 2.504 mm (0.0985 to 0.0986 in.)
      03 to 05 4 2.501 to 2.504 mm (0.0985 to 0.0986 in.)
      06 to 08 5 2.504 to 2.507 mm (0.0986 to 0.0987 in.)
      09 to 11 5 2.504 to 2.507 mm (0.0986 to 0.0987 in.)
      12 to 14 6 2.507 to 2.510 mm (0.0987 to 0.0988 in.)
      15 to 17 6 2.507 to 2.510 mm (0.0987 to 0.0988 in.)
      18 to 20 7 2.510 to 2.513 mm (0.0988 to 0.0989 in.)
      21 to 23 7 2.510 to 2.513 mm (0.0988 to 0.0989 in.)
      24 to 26 8 2.513 to 2.516 mm (0.0989 to 0.0991 in.)
      27 to 28 8 2.513 to 2.516 mm (0.0989 to 0.0991 in.)
    9. Completely remove the Plastigage.
  12. INSPECT CRANKSHAFT BEARING CAP SET BOLT 
    1. Using a vernier caliper, measure the diameter of the threads at the measurement point.

      Standard Diameter

      for Inside Position 

      10.8 to 11.0 mm (0.425 to 0.433 in.)

      for Outside Position 

      9.8 to 10.0 mm (0.386 to 0.394 in.)

      Minimum Diameter

      for Inside Position 

      10.7 mm (0.421 in.)

      for Outside Position 

      9.7 mm (0.382 in.)

      Measurement Point (Distance from the Seat)

      47 mm (1.85 in.)

      GTY495465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Inside Position
      *b for Outside Position

      If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt. Failure to do so may lead to engine damage.

      If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.

  13. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Push the check valve with a pin to check that it is not stuck.
      GTY105077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the check valve is stuck, replace the No. 1 oil nozzle sub-assembly.

    2. While covering (A), blow air into (B). Check that air does not leak through (C).

      If air leaks, clean or replace the No. 1 oil nozzle sub-assembly.

      GTY519434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push the check valve while covering (A), and blow air into (B). Check that air passes through (C).

      If air does not pass through, clean or replace the No. 1 oil nozzle sub-assembly.

      GTY1082717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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