suspension LEXUS ES300 2005 User Guide

141J7-02
A78541
(b)
(b)
(b)(a)
(a)
A36719
P18805
- ENGINE MECHANICALVALVE CLEARANCE (3MZ-FE)
14-7
2099 Author
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:
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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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)

A84926
N´m (kgf´cm, ft´lbf)
: Specified torque
49 (500, 36)
74 (755, 55)
75 (765, 55)
Steering Intermediate Shaft Assy
Front Suspension Arm
Sub-assy Lower No. 1 LH
Front Axle Hub LH Nut
Tie Rod Assy LH
Speed Sensor Front LH
 Cotter Pin
294 (2,998, 217)
62 (633, 46)
Exhaust Pipe Assy Front
Exhaust Pipe No. 1
Support Bracket Front
8.0 (82, 71 in.Vlbf)
75 (765, 55)
 Exhaust Pipe Gasket
 Non-reusable part33 (337, 24)
35 (360, 26)
Front Stabilizer Link
Assy LH
35 (360, 26)

56 (571, 41)
 Exhaust Pipe
Gasket
33 (337, 24)
Exhaust Pipe No. 1
Support Bracket Rear

 Exhaust Pipe
Gasket
62 (633, 46)
14-18
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2110 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A84927N´m (kgf´cm, ft´lbf)
: Specified torque
7.8 (80, 69 in.Vlbf)
43 (439, 32)
87 (887, 64)
Vane Pump V Belt
Vane Pump Assy
Front Frame Assy
Frame Side Rail Plate
Sub-assy RH
Frame Side Rail Plate
Sub-assy LHFront Suspension Member
Brace Rear RH
Front Suspension Member
Brace Rear LH
43 (439, 32)
95 (969, 70)
85 (867, 63)
32 (326, 24)
95 (969, 70)
85 (867, 63)
32 (326, 24)
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-19
2111 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A59877
A59878
A36439
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2123 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
51. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-8)
52. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
53. SEPARATE FRONT AXLE ASSY LH (See page 30-8)
54. SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
55. SEPARATE STEERING INTERMEDIATE SHAFT ASSY (See page 51-21)
56. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b) Remove the 4 bolts and 2 nuts, then remove the frame
side rail plate RH and LH.
(c) Remove the 4 bolts and 2 nuts, then remove the front sus-
pension member brace rear RH and LH.
(d) Carefully remove the engine assembly from the vehicle.
(e) Install the engine hanger No. 2 in the correct direction as
shown in the illustration.
Torque: 20 NVm (199 kgfVcm, 14 ftVlbf)
HINT:
Engine hanger No. 212282-20020
Bolt91621-60822
(f) Attach the engine sling and hang the engine assembly
with the chain block.
57. REMOVE VANE PUMP V BELT (See page 14-5)

A59877
BNut
A
BNut
A
A59878
Nut
D
CNut
D
C
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
122. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with the transaxle on the engine
lifter.
(b) Install the engine assembly to the vehicle.
(c) Install the frame side rail plate RH and LH with the 4 bolts
and 2 nuts.
Torque:
85 NVm (867 kgfVcm, 63 ftVlbf) for bolt A
32 NVm (326 kgfVcm, 24 ftVlbf) for bolt B and nut
(d) Install the front suspension member brace rear RH and
LH with the 4 bolts and 2 nuts.
Torque:
85 NVm (867 kgfVcm, 63 ftVlbf) for bolt C
32 NVm (326 kgfVcm, 24 ftVlbf) for bolt D and nut
123. CONNECT STEERING INTERMEDIATE SHAFT ASSY (See page 51-21)
124. INSTALL FRONT AXLE ASSY LH (See page 30-8)
125. INSTALL FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
126. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-8)
127. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
128. INSTALL TIE ROD ASSY LH (See page 30-8)
129. INSTALL TIE ROD ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
130. INSTALL SPEED SENSOR FRONT LH (See page 30-8)
131. INSTALL SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
132. INSTALL FRONT AXLE HUB LH NUT (See page 30-8)
133. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
134. INSTALL FRONT STABILIZER LINK ASSY LH (See page 30-8)
135. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
136. INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2)
137. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2)
138. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2)
139. CONNECT FUEL PIPE SUB-ASSY NO.1 (See page 11-1)

141JC-01
A86358N´m (kgf´cm, ft´lbf) : Specified torque
7.9 (81, 70 in.Vlbf)x3
V-bank Cover Sub-assy
Mass Air Flow
Meter Connector Fuel Vapor Feed Hose
Assy
Vacuum Hose
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
5.0 (51, 44 in.Vlbf)
W/O TEMS:
Front Suspension Upper Brace Center
80 (816, 59)
Spacer
x2
Vacuum Hose
80 (816, 59)x2
Spacer
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CAMSHAFT (RH BANK) (3MZ-FE)
COMPONENTS

141JD-01
A78761
RH:
SST
A78762
SSTLH:
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
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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.

14-102
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
2194 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
55. INSTALL INTAKE AIR SURGE TANK (See page 11-13)
56. INSTALL EMISSION CONTROL VALVE SET (See page 11-13)
57. INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
58. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
59. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
60. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
61. INSTALL FRONT WHEEL RH (See page 14-5)
62. ADD ENGINE COOLANT (See page 16-9)
63. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
64. SYSTEM INITIALIZATION (See page 19-15)

141JG-01
A86358N´m (kgf´cm, ft´lbf) : Specified torque
7.9 (81, 70 in.Vlbf)x3
V-bank Cover Sub-assy
Mass Air Flow
Meter Connector Fuel Vapor Feed Hose
Assy
Vacuum Hose
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
5.0 (51, 44 in.Vlbf)
W/O TEMS:
Front Suspension Upper Brace Center
80 (816, 59)
Spacer
x2
Vacuum Hose
80 (816, 59)x2
Spacer
14-1 12
- ENGINE MECHANICALCYLINDER HEAD GASKET (3MZ-FE)
2204 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CYLINDER HEAD GASKET (3MZ-FE)
COMPONENTS