Lexus GS300/400 (2000 year). Service manual - part 148

P04467

P02436

P04469

P04599

Plastigage

P02426

–

ENGINE MECHANICAL (2JZ–GE)

CYLINDER BLOCK

EM–77

1431

15.

CHECK CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rods back and forth.

Standard thrust clearance:
0.250 – 0.402 mm (0.0098 – 0.0158 in.)
Maximum thrust clearance:
 0.50 mm (0.0197 in.)

If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.

Connecting rod thickness:
25.898 – 25.950 mm (1.0196 – 1.0217 in.)

16.

REMOVE CONNECTING ROD CAPS AND CHECK
OIL CLEARANCE

(a)

Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.

(b)

Remove the connecting rod cap bolts.

(c)

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

HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d)

Clean the crank pin and bearings.

(e)

Check the crank pin and bearing for pitting and scratches.

If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.

(f)

Lay a strip of Plastigage across the crank pin.

(g)

Install the connecting rod cap with the 2 bolts.
(See page 

EM–91

)

Torque:
1st     30 N·m (300 kgf·cm, 22 ft·lbf)
2nd    Turn extra 90

°

NOTICE:
Do not turn the crankshaft.
(h)

Remove the 2 bolts, connecting rod cap and lower bear-
ing. (See procedure (b) and (c) above)

P04470

Z02391

Mark
1, 2, 3 , 4 or 5

Mark
1, 2 or 3

Mark
0, 1 or 2

No.1

No.2

No.3 No.4

No.5

No.6

Number mark

1

2

2

2

3

3

1

Connecting rod cap

Crankshaft

Use bearing

EXAMPLE:  Connecting rod cap ”3” + Crankshaft ”1”
= Total number 4 (Use bearing ”4”)

1

2

3

0

1

2

0

1

2

0

3

4

4

5

EM–78

–

ENGINE MECHANICAL (2JZ–GE)

CYLINDER BLOCK

1432

(i)

Measure the Plastigage at its widest point.
Standard oil clearance:

STD

0.023 – 0.041 mm (0.0009 – 0.0016 in.)

U/S 0.25

0.028 – 0.066 mm (0.0011 – 0.0026 in.)

Maximum oil clearance:

STD

0.07 mm (0.0027 in.)

U/S 0.25

0.08 mm (0.0031 in.)

If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.

HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the connecting rod cap and crankshaft, then select-
ing the bearing with the same number as the total. There are 5
sizes of standard bearings, marked ”1”, ”2”, ”3”, ”4” and ”5” ac-
cordingly.

Reference
       Connecting rod big end inside diameter:

Mark ”1”

55.025 – 55.031 mm (2.1663 – 2.1666 in.)

Mark ”2”

55.031 – 55.037 mm (2.1666 – 2.1668 in.)

Mark ”3”

55.037 – 55.043 mm (2.1668 – 2.1670 in.)

       Crankshaft crank pin diameter:

Mark ”0”

51.994 – 52.000 mm (2.0470 – 2.0472 in.)

Mark ”1”

51.988 – 51.994 mm (2.0468 – 2.0470 in.)

Mark ”2”

51.982 – 51.988 mm (2.0465 – 2.0468 in.)

       Standard sized bearing center wall thickness:

Mark ”1”

1.498 – 1.501 mm (0.0590 – 0.0591 in.)

Mark ”2”

1.501 – 1.504 mm (0.0591 – 0.0592 in.)

Mark ”3”

1.504 – 1.507 mm (0.0592 – 0.0593 in.)

Mark ”4”

1.507 – 1.510 mm (0.0593 – 0.0594 in.)

Mark ”5”

1.510 – 1.513 mm (0.0594 – 0.0596 in.)

(j)

Completely remove the Plastigage.

A02684

Z07401

4

12

8

14 10

6

2

3

7

11

13

9

5

1

P04472

P04471

–

ENGINE MECHANICAL (2JZ–GE)

CYLINDER BLOCK

EM–79

1433

17.

REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES

(a)

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

(b)

Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.

Keep the bearings, connecting rod and cap togeth-
er.

Arrange the piston and connecting rod assemblies
in correct order.

18.

CHECK CRANKSHAFT THRUST CLEARANCE

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

Standard thrust clearance:
0.020 – 0.220 mm (0.0008 – 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)

If the thrust clearance is greater than maximum, replace the
thrust washers as a set.

Thrust washer thickness:
1.940 – 1.990 mm (0.0764 – 0.0783 in.)

19.

REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE

(a)

Uniformly loosen and remove the 14 main bearing cap
bolts, in several passes, in the sequence shown.

(b)

Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the main bearing
caps, lower bearings and lower thrust washers (No.4
main bearing cap only).

HINT:

Keep the lower bearing and main bearing cap together.

Arrange the main bearing caps and lower thrust washers
in correct order.

(c)

Lift out the crankshaft.

HINT:
Keep the upper bearing and upper thrust washers together with
the cylinder block.
(d)

Clean each main journal and bearing.

(e)

Check each main journal and bearing for pitting and
scratches.

If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f)

Place the crankshaft on the cylinder block.

P04792

Plastigage

P04468

A02784

Mark
0, 1, 2, 3, 4,
5, 6 or 7

1, 2, 3, 4 or 5

Mark
0, 1, 2, 3, 4,
5, 6 or 7

No.1

No.5

No.6

No.2

No.3

No.4

No.7

No.1

No.2

Mark

No.3

No.4

No.5

No.6

No.7

(A)

(B)

Cylinder block (A)

Crankshaft (B) =

+

Total number

” ” : Number mark

Use bearing

0–2

3–5

6–8

9–11 12–14

”2”

”3”

”1”

”5”

”4”

EXAMPLE:  Cylinder block ”3” (A)

+ Crankshaft ”4” (B)

= Total number 7 (Use bearing ”3”)

EM–80

–

ENGINE MECHANICAL (2JZ–GE)

CYLINDER BLOCK

1434

(g)

Lay a strip of Plastigage across each journal.

(h)

Install the main bearing caps. (See page 

EM–91

)

Torque:
1st     45 N·m (450 kgf·cm, 33 ft·lbf)
2nd    Turn extra 90

°

NOTICE:
Do not turn the crankshaft.
(i)

Remove the main bearing caps.
(See procedures (a) and (b) above)

(j)

Measure the Plastigage at its widest point.
Standard clearance:

STD

0.026 – 0.040 mm (0.0010 – 0.0016 in.)

U/S 0.25

0.025 – 0.061 mm (0.0010 – 0.0024 in.)

Maximum clearance:

STD

0.06 mm (0.0024 in.)

U/S 0.25

0.08 mm (0.0031 in.)

If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.

HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then refer to the
table below for the appropriate bearing number. There are 5
sizes of standard bearings, marked ”1”, ”2”, ”3”, ”4” and ”5” ac-
cordingly.