check engine LEXUS ES300 2005 Owner's Guide
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Camshaft
Sub Gear
Camshaft Gear
Bolt Washer Wave Washer
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72. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign object is on the mesh part of the fil-
ter.
(b) Assemble the valve filter and plug.
(c) Install the plug with a new gasket.
Torque: 45 NVm (459 kgfVcm, 33 ftVlbf)
73. INSTALL CYLINDER HEAD COVER REAR
(a) Install the rear cover and a new gasket.
Torque: 10 NVm (102 kgfVcm, 7 ftVlbf)
74. INSTALL CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear bolt washer and camshaft sub
gear.
HINT:
Attach the pins on the gears to the gear bolt washer ends.
(c) Install the wave washer.
(d) Using snap ring pliers, install the snap ring.
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81. INSTALL WATER PUMP ASSY
(a) Install a new gasket and the water pump with the 3 bolts
and 3 nuts.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
82. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to a new O-ring, then install it to the level gage guide.
(b) Install the level gage guide.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
83. INSTALL OIL FILTER SUB-ASSY
(a) Using a socket hexagon wrench 12, install the oil filter
union.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
(b) Check and clean the oil filter installation surface.
(c) Apply clean engine oil to the gasket of a new oil filter.
(d) Lightly screw the oil filter into place, then tighten it until the
gasket contacts the seat.
(e) Using SST, tighten it by an additional 3/4 turn.
SST 09228-07501
84. INSTALL TIMING BELT IDLER BRACKET
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
85. INSTALL TIMING BELT NO.3 COVER
(a) Visually check for cracks and breaks on the gasket of the
timing belt cover.
HINT:
If there is a trace of water intrusion when checking visually, re-
pair the gasket with seal packing when the crack length is within
2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack
length is 3 to 4 cm (1.18 to 1.57 in.) or longer.
Page 443 of 969
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(b) Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 NVm (1,275 kgfVcm, 92 ftVlbf)
(c) Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 NVm (1,275 kgfVcm, 92 ftVlbf)
87. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 NVm (438 kgfVcm, 32 ftVlbf)
88. INSTALL TIMING BELT IDLER SUB-ASSY NO.1
(a) Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot
bolt.
Torque: 34 NVm (347 kgfVcm, 25 ftVlbf)
89. INSTALL TIMING BELT
(a) Remove any oil or water on the pulleys, then keep them
clean.
NOTICE:
If there is a trace of water and/or oil on the timing belt,
repair the leakage and install a new timing belt.
Only wipe the pulleys; do not use any cleaning agent.
(b) Check the idler pulleys.
(1) Check that the idler pulley turns smoothly.
(2) Visually check the seal portion of the idler pulley for
oil leakage.
(c) Check the water pump.
(1) Turn the pulley, then check that water pump bearing
moves smoothly and does not make a noise.
(2) Visually check the drain hole for coolant leakage.
(d) Temporarily install the crankshaft pulley bolt and washer
to the crankshaft.
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90. INSTALL TIMING BELT TENSIONER ASSY
(a) Set the timing belt tensioner upright on the press.
(b) Slowly press in the push rod.
NOTICE:
Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205
lbf) to the rod.
(c) Align the holes of the push rod and housing, then pass a
1.5 mm hexagon wrench through the holes to keep the
setting position of the push rod.
(d) Release the press.
(e) Temporarily install the tensioner with the 2 bolts. Alter-
nately tighten the 2 bolts.
Torque: 27 NVm (280 kgfVcm, 20 ftVlbf)
NOTICE:
Be sure to tighten the bolts uniformly. Installing the ten-
sioner at an angle may cause failure of its proper operation.
(f) Remove the 1.5 mm hexagon wrench from the tensioner.
(g) Turn the crankshaft 2 revolutions slowly, then align the
timing mark of the crankshaft timing pulley with the oil
pump body.
NOTICE:
Always turn the crankshaft clockwise.
(h) Check that the timing marks of the RH and LH timing pul-
leys are aligned with the timing marks of the timing belt
No. 3 cover as shown in the illustration.
If the marks are not aligned, remove the timing belt and reinstall
it.
(i) Remove the crankshaft pulley bolt.
91. INSTALL TIMING BELT GUIDE NO.2
(a) Install the timing belt guide with the cup side facing the en-
gine front.
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92. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
93. INSTALL TIMING BELT NO.2 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
94. INSTALL TIMING BELT NO.1 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
95. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft, then slide the pulley into place.
(b) Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 NVm (2,250 kgfVcm, 162 ftVlbf)
96. INSTALL VVT SENSOR
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
97. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
98. INSTALL ENGINE HANGER NO.2
Torque: 20 NVm (199 kgfVcm, 14 ftVlbf)
99. 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 1 revolution
(360) and align the marks as above.
Page 452 of 969
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SST (B)
SST (A)
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: Seal Packing
Front
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(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.
101. INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) Install the gasket to the cylinder head cover.
(b) 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.
(c) 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)
102. INSTALL CYLINDER HEAD COVER SUB-ASSY LH
(a) Install the gasket to the cylinder head cover.
(b) 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.
(c) 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)
103. INSTALL SPARK PLUG
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
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(3) Check that the timing marks of the camshaft timing
pulleys and the timing belt No. 3 cover are aligned.
If not, turn the crankshaft by 1 revolution (360).
(4) Remove the crankshaft pulley bolt.
(b) If reusing the timing belt, check that there are 3 installa-
tion marks on the timing belt as shown in the illustration.
(1) If the installation marks have disappeared, put new
installation marks on the timing belt before remov-
ing.
(c) Set the No. 1 cylinder to approximately 60 BTDC/com-
pression.
(1) Turn the crankshaft counterclockwise by approxi-
mately 60.
NOTICE:
If the timing belt is disengaged, having the crankshaft
pulley set at the wrong angle can cause contact of the pis-
ton head with the valve head when removing the camshaft
timing pulley and camshaft, which causes damage. So al-
ways set the crankshaft pulley at the correct angle.
(d) Remove the timing belt tensioner.
NOTICE:
Do not reinstall the tensioner with its plunger extended.
(e) Remove the timing belt in this order.
1stNo. 1 idler pulley
2ndRH camshaft timing pulley
3rdNo. 2 idler pulley
4thLH camshaft timing pulley
5thWater pump pulley
6thCrankshaft timing pulley
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14. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow contact of the timing belt with oil, water
or steam.
Do not use the timing belt tension when installing or
removing the mounting bolt of the camshaft timing
pulley.
Check the belt for any defects as shown in the illustrations.
Also, check these points below.
(a) If the belt tears in a short time:
Check if the belt is installed properly.
Check if the timing cover gasket is damaged and if
it is installed properly.
(b) If the belt teeth are cracked or damaged, check if either
camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check if there are nicks on the side of the idler pulley lock
and water pump.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and alignment of each pulley.
(e) If there is noticeable wear on the belt teeth:
Check the timing cover for damage.
Check that the gasket has been installed correctly.
Check for foreign objects on the pulley teeth.
If there is any doubt about the belt condition, replace the timing
belt.
15. INSTALL TIMING BELT
(a) Remove any oil or water on the pulleys, then keep them
clean.
NOTICE:
If there is a trace of water and/or oil on the timing belt,
repair the leakage and install a new timing belt.
Only wipe the pulleys; do not use any cleaning agent.
(b) Check the idler pulleys.
(1) Check that the idler pulley turns smoothly.
(2) Visually check the seal portion of the idler pulley for
oil leakage.
(c) Check the water pump.
(1) Turn the pulley, then check that water pump bearing
moves smoothly and does not make a noise.
(2) Visually check the drain hole for coolant leakage.
(d) Temporarily install the crankshaft pulley bolt and washer
to the crankshaft.
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16. INSTALL TIMING BELT TENSIONER ASSY
(a) Set the timing belt tensioner upright on the press.
(b) Slowly press in the push rod.
NOTICE:
Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205
lbf) to the rod.
(c) Align the holes of the push rod and housing, then pass a
1.5 mm hexagon wrench through the holes to keep the
setting position of the push rod.
(d) Release the press.
(e) Temporarily install the tensioner with the 2 bolts. Alter-
nately tighten the 2 bolts.
Torque: 27 NVm (280 kgfVcm, 20 ftVlbf)
NOTICE:
Be sure to tighten the bolts uniformly. Installing the ten-
sioner at an angle may cause failure of its proper operation.
(f) Remove the 1.5 mm hexagon wrench from the tensioner.
(g) Turn the crankshaft 2 revolutions slowly, then align the
timing mark of the crankshaft timing pulley with the oil
pump body.
NOTICE:
Always turn the crankshaft clockwise.
(h) Check that the timing marks of the RH and LH timing pul-
leys are aligned with the timing marks of the timing belt
No. 3 cover as shown in the illustration.
If the marks are not aligned, remove the timing belt and reinstall
it.
(i) Remove the crankshaft pulley bolt.
17. INSTALL TIMING BELT GUIDE NO.2
(a) Install the timing belt guide with the cup side facing the en-
gine front.
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18. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH with the 2 bolts
and nut.
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
19. INSTALL TIMING BELT NO.2 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
20. INSTALL TIMING BELT NO.1 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
(c) Install the 2 engine wire protector clamps to the timing belt No. 3 cover.
21. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft, then slide the pulley into place.
(b) Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 NVm (2250 kgfVcm, 162 ftVlbf)
22. INSTALL GENERATOR BRACKET NO.2
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
23. INSTALL ENGINE MOUNTING STAY NO.2 RH
(a) Install the engine mounting stay No. 2 and engine mount-
ing bracket No. 2 with the bolt.
Torque: 64 NVm (653 kgfVcm, 47 ftVlbf)