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HOMESERVICE MANUALSLEXUS2004IS 300 BASE, AUTOMATICREPAIR AND DIAGNOSISENGINE PERFORMANCEFUEL DELIVERYENGINE MECHANICALCYLINDER BLOCKDISASSEMBLY
2004 Lexus IS 300 Base, Automatic

Cylinder Block: Disassembly

2004 Lexus IS 300 Base, AutomaticSECTION Disassembly
  1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 
  2. REMOVE GENERATOR 

    Remove the bolt, nut, pipe bracket and generator.

  3. REMOVE TIMING BELT AND PULLEYS (See  REMOVAL   ) 
  4. REMOVE NO.2 WATER BYPASS PIPE WITH HOSE 

    Remove the bolt, 2 nuts, water bypass pipe and gasket.

  5. REMOVE WATER PUMP 

    Remove the 6 bolts, water pump and O-ring.

  6. REMOVE CYLINDER HEAD (See  REMOVAL   ) 
  7. REMOVE OIL PRESSURE SWITCH (See  OIL AND FILTER  ) AND KNOCK SENSORS (See  KNOCK SENSOR  ) 
  8. REMOVE OIL FILTER AND BRACKET ASSEMBLY 
    1. Remove the union bolt and oil filter bracket.
    2. Remove the gasket from the union bolt.
    3. Remove the O-ring from the oil filter bracket.
  9. REMOVE NO. 1 OIL PIPE 

    Remove the union bolt, oil pipe and 2 gaskets.

  10. REMOVE FUEL INLET PIPE 

    Remove the 2 bolts and fuel inlet pipe.

  11. REMOVE LH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY 

    Remove the 4 bolts and mounting bracket.

  12. REMOVE RH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY 

    Remove the 4 bolts and mounting bracket.

  13. REMOVE OIL PUMP (See  REMOVAL  ) 
  14. REMOVE REAR OIL SEAL RETAINER 
    1. Remove the 6 bolts of the retainer.
    2. Remove the oil seal retainer by prying the area between the oil seal retainer and main bearing cap with a screwdriver.
    Fig 1: Removing Rear Oil Seal Retainer
    G00889419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CHECK CONNECTING ROD THRUST CLEARANCE 

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

    1. Standard thrust clearance: 0.250 - 0.402 mm (0.0098 - 0.0158 in.) 
    2. 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 crankshaft.

    Fig 2: Checking Connecting Rod Thrust Clearance
    G00889420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connecting rod thickness: 25.898 - 25.950 mm (1.0196 - 1.0217 in.) 
  16. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE 
    1. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
    2. Remove the connecting rod cap bolts.
      Fig 3: Removing Connecting Rod Cap Bolts
      G00889421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
      Fig 4: Removing Connecting Rod Cap
      G00889422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Keep the lower bearing inserted with the connecting rod cap.

    4. Clean the crank pin and bearings.
    5. 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.

    6. Lay a strip of Plastigage across the crank pin.
      Fig 5: Laying Strip Of Plastigage Across Crank Pin
      G00889423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the connecting rod cap with the 2 bolts (See REASSEMBLY  ).
      Fig 6: Installing Connecting Rod Cap
      G00889424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.