LEXUS ES300 2005 Repair Manual

V00720
Adjusting Shim Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and
the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 10
shim.New Shim Thickness mm (in.)
ThicknessThickness Shim
No. Shim
No.
HINT: New shims have the thickness in millimeters
imprinted on the face.
Installed Shim Thickness
Measured Clearance
mm (in.)mm (in.)
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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A78672
SST (B)
SST (A)
A78673
: Seal Packing
Front
A78674
: Seal Packing
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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)

141JA-01
A84916
64 (653, 47)
64 (653, 47)
Front Fender Apron
Seal RH
Vane Pump V Belt
V Belt No. 1
Generator Bracket No. 2
Engine Mounting Stay No. 2 RHEngine Moving Control Rod
N´m (kgf´cm, ft´lbf)
: Specified torque
23 (235, 17)
58 (591, 43)
28 (286, 21)
Radio Setting Condenser
- ENGINE MECHANICALTIMING BELT (3MZ-FE)
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TIMING BELT (3MZ-FE)
COMPONENTS

A78353
N´m (kgf´cm, ft´lbf)
: Specified torque
8.5 (87, 75 in.Vlbf)
220 (2,250, 162)8.5 (87, 75 in.Vlbf)
28 (286, 21)
27 (280, 20)
Timing Belt Tensioner AssyCrankshaft PulleyTiming Belt No. 1 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH Timing Belt No. 2 Cover
Timing Belt
Engine Wire
Protector
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141JB-01
A78546
A52344
P18816
A78755
SST
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REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
4. REMOVE VANE PUMP V BELT (See page 14-5)
5. REMOVE ENGINE MOVING CONTROL ROD
(a) Remove the reserve tank cap.
(b) Remove the 4 bolts, engine moving control rod and brack-
et.
6. REMOVE ENGINE MOUNTING STAY NO.2 RH
(a) Remove the bolt, engine mounting stay No. 2 and engine
mounting bracket No. 2.
7. REMOVE GENERATOR BRACKET NO.2
(a) Remove the nut and generator bracket.
8. REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021

A78756
SST
A78759
Clamp
Clamp
P18814
A78326
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(b) Using SST and the pulley bolt, remove the pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05031)
NOTICE:
Before using SST, apply lubricating oil to the threads and
tip of the center bolt 150.
9. REMOVE TIMING BELT NO.1 COVER
10. REMOVE TIMING BELT NO.2 COVER
(a) Disconnect the 2 engine wire protector clamps from the
timing belt No. 3 cover.
(b) Remove the 5 bolts and timing belt cover.
11. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the 2 bolts, nut and engine mounting bracket
RH.
12. REMOVE TIMING BELT GUIDE NO.2
13. REMOVE TIMING BELT
(a) Set the No. 1 cylinder to the TDC/compression.
(1) Temporarily install the crankshaft pulley bolt and
washer to the crankshaft.
(2) Turn the crankshaft clockwise, then align the timing
mark of the crankshaft timing pulley with the oil
pump body.

A05052
A52840
A78327
Turn
Approximately 60
A78702
(5)
(6) (1)(4) (2)(3)
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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.

A82349
Turn
Approximately 60
A78751
SST
A05062
A52840
A78702(1) (2)
(3) (4)
(5)
(6)
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(e) Turn the crankshaft counterclockwise by approximately
60.
NOTICE:
To prevent contact of the piston head with the valve head,
set the crankshaft pulley at the 60 BTDC/compression
position.
(f) Using SST, turn the timing pulleys, then align the timing
marks of the timing pulleys with the timing belt No. 3 cover.
SST 09960-10010 (09962-01000, 09963-01000)
(g) Turn the crankshaft, then align the timing mark of the
crankshaft timing pulley with the oil pump body.
(h) Align the front mark on the timing belt so it faces forward.
(i) Align the installation mark on the timing belt with the tim-
ing mark of the crankshaft timing pulley.
(j) Align the installation marks on the timing belt with the tim-
ing marks of the camshaft timing pulleys.
(k) Install the timing belt in this order.
1stCrankshaft timing pulley
2ndWater pump pulley
3rdLH camshaft timing pulley
4thNo. 2 idler pulley
5thRH camshaft timing pulley
6thNo. 1 idler pulley

A36238
A78326
Turn
A05052
A36239
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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.