engine LEXUS ES300 2005 Owner's Guide

3203F-08
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
C16481
Ventilation
No Ventilation 32-26
- BRAKEBRAKE BOOSTER ASSY
2460 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE BOOSTER ASSY (From July, 2003)
ON-VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Air tightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press the brake pedal several times slowly.
HINT:
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is air tight.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion switch OFF and check that there is no change
in the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Check vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.

320E1-02
- BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32-47
2481 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE ACTUATOR ASSY (W/O VSC)
ON-VEHICLE INSPECTION
1. CONNECT HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operator's manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay ON, check that the pedal does not pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR

3203J-09
32-50
- BRAKEBRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
2484 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
ON-VEHICLE INSPECTION
1. CONNECT HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operator's manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay ON, check that the pedal does not pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR

320OI-03
F42754
Adjustable Pedal
Relay
Engine Room J/B:
F42755
1 2 3
5
32-62
- BRAKEADJUSTABLE PEDAL RELAY(From August, 2002)
2496 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTABLE PEDAL RELAY (From August, 2002)
INSPECTION
1. REMOVE ADJUSTABLE PEDAL RELAY
(a) Remove the adjustable pedal relay from the engine room
J/B.
2. INSPECT ADJUSTABLE PEDAL RELAY
ConditionTester conditionSpecified condition
Constant1 - 2ContinuityConstant3 - 5No continuity
Apply +B between termi-
nals 1 and 23 - 5continuity
3. INSTALL ADJUSTABLE PEDAL RELAY
(a) Install the adjustable pedal relay to the engine room J/B.

C83852F45465
C97690F45054
C83023
30-22
- DRIVE SHAFT / PROPELLER SHAFTFRONT AXLE HUB SUB-ASSY LH (From July, 2003)
2425 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
18. INSTALL FRONT AXLE HUB LH HOLE SNAP RING
(a) Using snap ring pliers, install a new front axle hub LH hole
snap ring.
19. INSTALL FRONT WHEEL BEARING DUST
DEFLECTOR NO.1 LH
(a) Using SST and a hammer, install the bearing dust deflec-
tor No.1 LH.
SST 09316- 60011 (09316- 00011, 09316- 00031),
09608-32010
HINT:
Aligh the hole for the speed sensor in the bearing dust deflector
No.1 LH with the steering knuckle.
20. INSTALL LOWER BALL JOINT ASSY FRONT LH
(a) Install the lower ball joint assy front LH and tighten the nut.
Torque: 123 NVm (1,254 kgfVcm, 90 ftVlbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 60 further.
21. INSTALL FRONT AXLE ASSY LH
(a) Install the front axle assy LH with the 2 bolts and nuts to
the shock absorber assy front LH.
Torque: 210 NVm (2,141 kgfVcm, 155 ftVlbf)
NOTICE:

Only when reusing the bolts and nuts, apply the small
amount of engine oil to the screw part of the nuts.

Do not excessively push out the front axle assy LH.

Be careful not to damage the outboard joint boot.

Be careful not to damage the speed sensor rotor.
22. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (SEE PAGE 30-8)
23. INSTALL TIE ROD ASSY LH (SEE PAGE 30-8)
24. INSTALL FRONT DISC

141C0-02
A82940
Vane Pump
CrankshaftGenerator Measuring Points for Belt Deflection
or Tension
Compressor
- ENGINE MECHANICALENGINE (3MZ-FE)
14-1
2093 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ENGINE (3MZ-FE)
INSPECTION
1. INSPECT ENGINE COOLANT (See page 16-1)
2. INSPECT ENGINE OIL
3. INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20C (68F)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY
5. INSPECT SPARK PLUG (See page 18-3)
6. INSPECT V-RIBBED BELT
(a) Belt deflection:
Pressing force: 98 N (10 kgf, 22 lbf)
New Belt
mm (in.)Used Belt
mm (in.)
V-ribbed Belt
(For fan and generator)9.1 to 10.5
(0.358 to 0.413)11 to 13.5
(0.433 to 0.531)
V-ribbed Belt
(For vane pump)8 to 10
(0.315 to 0.394)11 to 14
(0.433 to 0.551)
(b) Belt tension:
New Belt
N (kg , lb)Used Belt
N (kg , lb)
V-ribbed Belt
(For fan and generator)637 to 735
(65 to 75 , 143 to 165)392 to 588
(40 to 60 , 88 to 132)
V-ribbed Belt
(For vane pump)588 to 686
(60 to 70 , 132 to 154)245 to 392
(25 to 40 , 55 to 88)
NOTICE:

Check the drive belt deflection at the specified point.

When installing a new belt, set its tension value as
specified.

When inspecting a belt which is used for over 5 min-
utes, apply the specification of ºUsed beltº.

When reinstalling a belt which is used for over 5 min-
utes, adjust its belt deflection and tension to the inter-
mediate value of each specification in ºUsed beltº.

The V- ribbed belt tension and deflection value
should be checked after 2 revolutions of engine
cranking.

When using a belt tension gauge, confirm the accura-
cy first by using a master gauge.
7. INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using the hand-held tester or OBD II scan tool:
(1) Connect the hand-held tester or OBD II scan tool
to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester or
OBD II scan tool.
Ignition timing: 8 to 12 BTDC
HINT:
Refer to the hand-held tester or OBD II scan tool operator's
manual if you need help to select DATA LIST.

A85669
TC
CG
A82935
Tester TerminalEngine Wire 14-2
- ENGINE MECHANICALENGINE (3MZ-FE)
2094 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) When not using the hand-held tester or OBD II scan tool:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)
of the DLC3.
SST 09843-18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connecting wrong terminals can damage the
engine.

Turn OFF all electrical systems before connecting the
terminals.

Perform this inspection after the cooling fan motor is
turned OFF.
(2) Remove the V-bank cover.
(3) Pull out the engine wire colored by black and red as
shown in the illustration.
(4) Connect the tester terminal of the timing light to the
engine.
NOTICE:
Use a timing light which detects the first signal.
(5) Inspect the ignition timing at idle.
Ignition timing: 8 to 12 BTDC
NOTICE:
When checking the ignition timing, the transmission is in
the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, then check
that the engine speed returns to the idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Inspect the ignition timing at idle.
Ignition timing: 7 to 24 BTDC
(8) Confirm that the ignition timing advances when the
engine speed is increased.
(9) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the hand-held tester or OBD II scan tool:
(1) Connect the hand-held tester or OBD II scan tool to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester or OBD II scan tool.
Idle speed: 630 to 730 rpm
NOTICE:

When checking the idle speed, the transmission is in the neutral position.

Check the idle speed with the cooling fan OFF.

Switch OFF all accessories and air conditioning before connecting the hand-held tester or OBD
II scan tool.
HINT:
Refer to the hand-held tester or OBD II scan tool operator's manual for further details.

P19471
Compression Gauge
- ENGINE MECHANICALENGINE (3MZ-FE)
14-3
2095 Author
: Date
:
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

14193-03
A78698
B
AC
A78699
A
B
A78699
A
B
A78698
B
AC
- ENGINE MECHANICALDRIVE BELT (3MZ-FE)
14-5
2097 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
DRIVE BELT (3MZ-FE)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Loosen bolts A and B.
(b) Loosen the adjusting bolt C, then remove the V-ribbed
belt.
4. REMOVE VANE PUMP V BELT
(a) Loosen bolts A and B, then remove the V-ribbed belt.
5. INSTALL VANE PUMP V BELT
(a) Install the V-ribbed belt on each pulley.
(b) Using a bar, adjust the V-ribbed belt tension, then tighten
bolt B.
Torque: 43 NVm (439 kgfVcm, 32 ftVlbf)
(c) Tighten bolt A.
Torque: 43 NVm (439 kgfVcm, 32 ftVlbf)
6. INSTALL V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Install the V-ribbed belt on each pulley.
(b) Tighten the adjusting bolt C, then adjust the V-ribbed belt
tension.
(c) First tighten bolt A, then tighten bolt B.
Torque:
18 NVm (178 kgfVcm, 13 ftVlbf) for bolt A
58 NVm (591 kgfVcm, 43 ftVlbf) for bolt B