ignition LEXUS ES300 2005 User Guide

P19471
Compression Gauge
- ENGINE MECHANICALENGINE (3MZ-FE)
14-3
2095 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the intake air surge tank (see page 11-13).
(c) Disconnect the injector connectors.
(d) Remove the ignition coils.
(e) Remove the spark plugs.
(f) Inspect the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
SST 09992-00500
(2) Fully open the throttle.
(3) While cranking the engine, measure the compres-
sion pressure.
Compression pressure:
1.5 MPa (15.3 kgf/cm
2, 218 psi)
Minimum pressure:
1.0 MPa (10.2 kgf/cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 15 psi)
NOTICE:

Always use a fully-charged battery to obtain engine
speed of 250 rpm or more.

Check the other cylinder's compression pressure in
the same way.

This measurement must be done as quickly as pos-
sible.
(4) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
spark plug hole, then inspect again.
HINT:

If adding oil increases the compression, the piston rings
and/or cylinder bore may be worn or damaged.

If pressure stays low, the valve may be sticking or seated
improperly, or there may be leakage past the gasket.
10. INSPECT CO/HC
HINT:
The ECM properly controls the CO/HC concentration in the emission gas.
(a) Start the engine.
(b) Run the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Check the CO/HC concentration at idle and/or at 2,500 rpm.
HINT:
When doing the 2 mode (with the engine is at idle and at 2,500 rpm) tests, these measuring order are pre-
scribed by the applicable local regulations.
If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.
(1) Check the heated oxygen sensor operation (see page 05-126).

14-4
- ENGINE MECHANICALENGINE (3MZ-FE)
2096 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(2) See the table below for possible causes, then inspect the applicable causes and repair them if
necessary.
COHCProblemsCauses
NormalHighRough idle
5. Faulty ignitions:

Incorrect timing

Fouled, shorted or improperly gapped plugs
6. Incorrect valve clearance
7. Leaks in intake and exhaust valves
8. Leaks in cylinders
LowHighRough idle
(Fluctuating HC reading)
1. Vacuum leaks:

PCV hoses

Intake manifold

Throttle body

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI systems:

Faulty pressure regulator

Defective engine coolant temperature sensor

Defective mass air flow meter

Faulty ECM

Faulty injectors

Faulty throttle body

141J7-02
A78541
(b)
(b)
(b)(a)
(a)
A36719
P18805
- ENGINE MECHANICALVALVE CLEARANCE (3MZ-FE)
14-7
2099 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
VALVE CLEARANCE (3MZ-FE)
ADJUSTMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT (See page 16-9)
3. REMOVE FRONT FENDER APRON SEAL RH
4. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
5. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
6. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
7. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
8. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
9. REMOVE RADIATOR HOSE INLET
10. REMOVE IGNITION COIL ASSY
11. REMOVE CYLINDER HEAD COVER SUB-ASSY
(a) Remove the 2 engine wire harness clamps.
(b) Remove the 3 nuts, then disconnect the engine wire har-
ness.
(c) Remove the 9 bolts and cylinder head cover.
12. REMOVE CYLINDER HEAD COVER SUB-ASSY LH
(a) Using an E6 Torx) socket wrench, remove the 2 bolts and
disconnect the engine wire harness protector.
(b) Remove the 9 bolts and cylinder head cover.
13. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft pulley, then align the timing notch with
the timing mark º0º of the timing belt No. 1 cover.
(b) Check that the valve lifters on the intake side of the No.
1 cylinder are not pushed by the cam.
If the valve lifters are pushed, turn the crankshaft by 1 revolution
(360) and align the marks as above.

A78672
SST (B)
SST (A)
A78673
: Seal Packing
Front
A78674
: Seal Packing
Front
- ENGINE MECHANICALVALVE CLEARANCE (3MZ-FE)
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2105 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(h) Place a new adjusting shim on the valve lifter with the im-
printed number facing down.
(i) Press down the valve lifter with SST (A), then remove SST
(B).
SST 09248-55040 (09248-05410, 09248-05420)
(j) Recheck the valve clearance.
15. INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.

Do not start the engine within 2 hours after installing.
(b) Install the cylinder head cover with the 9 bolts. Tighten the
bolts uniformly in several steps.
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
(c) Install the engine wire harness with the 3 nuts.
Torque: 8.4 NVm (85 kgfVcm, 74 in.Vlbf)
16. INSTALL CYLINDER HEAD COVER SUB-ASSY LH
(a) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.

Do not start the engine within 2 hours after installing.
(b) Install the cylinder head cover with the 9 bolts. Tighten the
bolts uniformly in several steps.
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
(c) Using an E6 Torx) socket wrench, install the engine wire
harness protector with the 2 bolts.
Torque: 8.4 NVm (85 kgfVcm, 74 in.Vlbf)
17. INSTALL IGNITION COIL ASSY
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
18. INSTALL INTAKE AIR SURGE TANK (See page 11-13)
19. INSTALL EMISSION CONTROL VALVE SET (See page 11-13)
20. INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
21. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
22. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
23. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
24. ADD ENGINE COOLANT (See page 16-9)
25. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)

A86169
: Specified torque
 Non-reusable part Air Surge Tank to
Intake Manifold Gasket
8.0 (80, 71 in.Vlbf)
83 (846, 61)
15 (153, 11)
15 (153, 11)
8.4 (86, 74 in.Vlbf)15 (153, 11)
15 (153, 11)
28 (286, 21)
20 (199, 14)
28 (286, 21)
8.0 (82, 71 in.Vlbf)
20 (199, 14)
20 (199, 14)
Emission Control Valve Set
Emission Control
Valve Bracket
Engine Hanger No. 1Surge Tank Stay No. 1Surge Tank
Stay No. 2
Intake Air Surge Tank
Intake Manifold
 Intake Manifold to
Head Gasket No. 1
 Intake Manifold to
Head Gasket No. 2 Water Outlet
Ignition Coil Assy
Drive Plate
Spacer Front
Drive Plate & Ring Gear
Sub-assyDrive Plate
Spacer Rear
x8
N´m (kgf´cm, ft´lbf)
15 (153, 11)x2
x5 x4
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2113 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A86565
A86566
A86567
3
472
5
6
1
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-33
2125 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
67. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-140)
SST 09213-54015 (91651-60855), 09330-00021
68. INSTALL ENGINE STAND
69. REMOVE ENGINE HANGER NO.2
70. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
71. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
72. REMOVE INTAKE MANIFOLD (See page 10-16)
73. REMOVE WATER OUTLET (See page 10-16)
74. REMOVE IGNITION COIL ASSY
75. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-120)
76. REMOVE EXHAUST MANIFOLD SUB-ASSY RH (See page 14-120)
77. REMOVE MANIFOLD CONVERTER INSULATOR NO.3
(a) Remove the bolt and nut, then remove the insulator.
78. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.2
(a) Remove the 2 bolts and insulator.
79. REMOVE EXHAUST MANIFOLD CONVERTER
SUB-ASSY NO.2
(a) Using several steps, loosen and remove the 7 nuts in the
sequence shown in the illustration.
(b) Remove the exhaust manifold converter No. 2 and gasket
from the cylinder head LH.

A86567
3
4
7
25
61
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-35
2127 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
93. INSTALL THERMOSTAT (See page 16-16)
94. INSTALL WATER INLET (See page 16-16)
95. INSTALL WATER INLET PIPE (See page 16-16)
96. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-9)
97. INSTALL GENERATOR BRACKET NO.1
Torque: 58 NVm (591 kgfVcm, 43 ftVlbf)
98. INSTALL PUMP BRACKET
Torque: 32 NVm (326 kgfVcm, 24 ftVlbf)
99. INSTALL ENGINE MOUNTING BRACKET RH (See page 17-9)
100. INSTALL MANIFOLD STAY NO.2
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
101. I N S TA L L E XHAUST MANIFOLD CONVERTER
SUB-ASSY NO.2
(a) Install a new gasket and the exhaust manifold converter
No. 2 with the 7 nuts. Using several steps, tighten the nuts
uniformly in the sequence shown in the illustration.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
(b) Retighten nuts 1 and 2 as shown in the illustration.
102. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
103. INSTALL MANIFOLD CONVERTER INSULATOR NO.3
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
104. INSTALL EXHAUST MANIFOLD SUB-ASSY RH (See page 14-120)
105. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-120)
106. INSTALL IGNITION COIL ASSY (See page 14-7)
107. INSTALL WATER OUTLET (See page 10-16)
108. INSTALL INTAKE MANIFOLD (See page 10-16)
109. INSTALL INTAKE AIR SURGE TANK (See page 11-13)
110. INSTALL EMISSION CONTROL VALVE SET (See page 11-13)
111. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-140)
SST 09213-54015 (91651-60855), 09330-00021
112. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 NVm (650 kgfVcm, 47 in.Vlbf)
113. INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40-9)
114. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9)
115. INSTALL ENGINE MOUNTING BRACKET FR (See page 40-9)
116. INSTALL STARTER ASSY (See page 19-5)

- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
157. ADD AUTOMATIC TRANSAXLE FLUID
158. ADD ENGINE OIL (See page 17-20)
159. ADD COOLANT (See page 16-9)
160. ADD POWER STEERING FLUID
161. BLEED POWER STEERING FLUID
162. INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40-1)
163. CHECK FOR ENGINE OIL LEAKS
164. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
165. CHECK POWER STEERING FLUID LEAKAGE
166. INSPECT FOR FUEL LEAKS
167. CHECK FOR EXHAUST GAS LEAKS
168. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-5)
169. INSPECT STEERING WHEEL CENTER POINT
170. INSPECT IGNITION TIMING (See page 14-1)
SST 09843-18040
171. INSPECT ENGINE IDLE SPEED (See page 14-1)
172. INSPECT CO/HC (See page 14-1)
173. CHECK ABS SPEED SENSOR SIGNAL (See page 05-420, 05-471)
174. SYSTEM INITIALIZATION (See page 19-15)

A78385
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
Camshaft Timing Gear Assy
150 (1,530, 111)
Camshaft Bearing Cap No. 5
16 (163, 12)
x10
Camshaft
N´m (kgf´cm, ft´lbf)
: Specified torque

Non-reusable partCamshaft Setting
Oil Seal
8.0 (80, 71 in.Vlbf)
8.4 (85, 74 in.Vlbf)
8.0 (80, 71 in.Vlbf)
16 (163, 12)
Ignition Coil AssyEngine Wire
Engine Wire
Cylinder Head
Cover GasketCylinder Head Cover Sub-assy
Camshaft Bearing
Cap No. 2
x10Camshaft Bearing
Cap No. 4Camshaft Timing Gear
Bolt Washer
Camshaft Sub Gear
Camshaft Sub Gear
Wave Washer
Camshaft Sub Gear
Shaft Snap Ring


Camshaft Bearing Cap No. 2
No. 2 Camshaft
Camshaft Bearing
Cap No. 1
x9 14-92
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
2184 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

141JD-01
A78761
RH:
SST
A78762
SSTLH:
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
14-93
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT (See page 16-9)
3. REMOVE FRONT WHEEL RH
4. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
5. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
6. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
7. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
8. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
9. REMOVE IGNITION COIL ASSY
10. REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-7)
11. REMOVE FRONT FENDER APRON SEAL RH
12. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
13. REMOVE VANE PUMP V BELT (See page 14-5)
14. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
15. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
16. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
17. REMOVE CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
18. REMOVE TIMING BELT NO.1 COVER
19. REMOVE TIMING BELT NO.2 COVER (See page 14-79)
20. REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79)
21. REMOVE TIMING BELT GUIDE NO.2
22. REMOVE TIMING BELT (See page 14-79)
23. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
24. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the bolt and RH timing pulley.
SST 09960- 10010 (09962- 01000, 09963- 01000),
09249-63010
(b) Using SST, remove the bolt and LH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
HINT:
Arrange the camshaft timing pulleys (RH and LH sides) so that
they can be returned to the original locations when reassem-
bling.