engine LEXUS ES300 2005 Manual PDF

A78307
N´m (kgf´cm, ft´lbf)
: Specified torque
 Non-reusable part  Camshaft Setting
Oil Seal Gasket
45 (459, 33)
10 (102, 7)
19 (189, 14)
150 (1,530, 111)
16 (163, 12)
 Cylinder Head
GasketOil Control
Valve Filter Cylinder Head
Cover Rear Cylinder Head
Sub-assy Cylinder Head
Rear Plate Gasket Camshaft Bearing
Cap No. 2
CamshaftCamshaft Timing Gear Assy RH Bank:
Camshaft Bearing
Cap No. 1Camshaft Bearing
Cap No. 2Camshaft Bearing
Cap No. 4
No. 2 CamshaftCamshaft Bearing Cap No. 5
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6 Camshaft Timing Gear Bolt Washer
Camshaft Sub Gear
Camshaft Sub
Gear Wave Washer
Camshaft Sub Gear
Shaft Snap Ring x10
x4
x10
16 (163, 12)
1st: 54 (550, 40)
2st: Turn 90
See page 14-40
x8 14-26
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A78308
 Camshaft Setting
Oil Seal
 Cylinder Head
Gasket No. 2Cylinder Head
Cover Rear
 Cylinder Head
Rear Plate Gasket Camshaft Bearing
Cap No. 2
Camshaft Bearing
Cap No. 1Camshaft Bearing Cap No. 2
Camshaft Bearing
Cap No. 4 Camshaft Bearing
Cap No. 5
Camshaft Bearing
Cap No. 2Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
Camshaft Timing
Gear Bolt WasherCamshaft
Sub Gear
Camshaft Sub
Gear Wave WasherCamshaft Sub
Gear Shaft
Snap Ring
16 (163, 12)
N´m (kgf´cm, ft´lbf)
: Specified torque
 Non-reusable part
LH Bank:
Camshaft Timing Gear Assy
 Gasket
No. 4 Camshaft Sub-assy
No. 3 Camshaft Sub-assy
Oil Control
Valve Filter
x4
150 (1,530, 11)
45 (459, 33)
16 (163, 12)
19 (189, 14)
Engine Hanger No. 2
Cylinder Head LH
20 (199, 14)
1st: 54 (550, 40)
2st: Turn 90
See page 14-4010 (102, 7)
x8 x10 x10
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A78309
N´m (kgf´cm, ft´lbf)
: Specified torque
 Non-reusable part O-ring
 Gasket
8.0 (82, 71 in.Vlbf)
8.0 (82, 71 in.Vlbf)
45 (459, 33)
8.0 (82, 71 in.Vlbf)
8.0 (82, 71 in.Vlbf)
8.0 (82, 71 in.Vlbf)
8.0 (82, 71 in.Vlbf)
30 (306, 22)
43 (439, 32)
20 (199, 14)
8.0 (82, 71 in.Vlbf)
20 (199, 14)
8.0 (82, 71 in.Vlbf)
8.0 (82, 71 in.Vlbf)
20 (199, 14)
Oil Pan Sub-assy No. 2  Gasket Oil Strainer Sub-assy
Oil Pan Drain PlugOil Pan Sub-assy  Oil Pump SealOil Pan Baffle Plate Oil Filter
Sub-assyx6 Water Inlet Housing
Engine Rear Oil Seal Retainer
 Engine Rear
Oil Seal Cylinder Block Sub-assy
20 (199, 14)
Oil Pump Assy
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141J9-02
A60072
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER NO.1
5. REMOVE ENGINE UNDER COVER NO.2
6. REMOVE FRONT FENDER APRON SEAL RH
7. DRAIN ENGINE COOLANT (See page 16-9)
8. DRAIN ENGINE OIL (See page 17-20)
9. DRAIN AUTOMATIC TRANSAXLE FLUID (See page 30-8)
10. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
11. REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5)
12. REMOVE BATTERY
13. REMOVE BATTERY TRAY
14. REMOVE AIR CLEANER INLET ASSY (See page 19-5)
15. REMOVE AIR CLEANER ASSY (See page 19-5)
16. REMOVE AIR CLEANER BRACKET (See page 19-5)
17. REMOVE AIR CLEANER INLET NO.1 (See page 19-5)
18. REMOVE INTAKE AIR RESONATOR SUB-ASSY
(a) Remove the clip and bolt, then remove the intake air resonator.
19. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
20. REMOVE GENERATOR ASSY (See page 19-21)
21. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
22. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
23. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
24. REMOVE GENERATOR BELT ADJUSTING BAR (See page 17-9)
25. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (See page 17-9)
26. SEPARATE TRANSMISSION CONTROL CABLE ASSY (See page 40-44)
27. DISCONNECT UNION TO CHECK VALVE HOSE
28. DISCONNECT FUEL VAPOR FEED HOSE NO.1
29. DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See page 11-1)
30. DISCONNECT HEATER INLET WATER HOSE
31. DISCONNECT HEATER OUTLET WATER HOSE
32. DISCONNECT RADIATOR HOSE INLET
33. DISCONNECT RADIATOR HOSE OUTLET
34. DISCONNECT OIL COOLER INLET HOSE
35. DISCONNECT OIL COOLER OUTLET HOSE
36. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1

A60073
A59893
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
37. DISCONNECT STEERING GEAR OUTLET RETURN
TUBE
38. REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 10-22)
39. SEPARATE ENGINE WIRE
(a) Disconnect the engine wire harness from the ECM and
junction block.
(b) Disconnect the engine wire harness from the engine room
junction block.
(1) Remove the nut, then separate the engine wire har-
ness.
(2) Using a screwdriver, release the engine room junc-
tion block. Separate the engine wire harness by
pulling it upward.
(c) Remove the 2 nuts, then pull out the engine wire harness.
(d) Remove the body ground.
40. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2)
41. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2)
42. REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2)
43. DISCONNECT FRONT STABILIZER LINK ASSY LH (See page 30-8)
44. DISCONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
45. REMOVE FRONT AXLE HUB LH NUT (See page 30-8)
SST 09930-00010
46. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010
HINT:
Perform the same procedure as above on the opposite side.
47. SEPARATE SPEED SENSOR FRONT LH (See page 30-8)
48. SEPARATE SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
49. SEPARATE TIE ROD ASSY LH (See page 30-8)
SST 09628-6201 1
50. SEPARATE TIE ROD ASSY RH
SST 09628-6201 1
HINT:
Perform the same procedure as above on the opposite side.

A59877
A59878
A36439
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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)

A78549
A52890
A78403
RH: LH:
A60501
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
58. REMOVE VANE PUMP ASSY
(a) Remove the 2 nuts, then disconnect the power steering
pressure tube.
(b) Remove the 2 bolts and vane pump.
59. REMOVE FRONT FRAME ASSY
(a) Remove the 2 nuts, then separate the engine mounting
insulator RH and LH.
(b) Remove the bolt, then separate the engine mounting in-
sulator FR.
60. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-8)
SST 09520-01010, 09520-24010 (09520-32040)
61. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30-8)
62. REMOVE STARTER ASSY (See page 19-5)
63. REMOVE ENGINE MOUNTING BRACKET FR (See page 40-9)
64. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9)
65. REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40-9)
66. REMOVE DRIVE SHAFT BEARING BRACKET

A86565
A86566
A86567
3
472
5
6
1
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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.

A86568
A05189
A80061
Oil Pressure
Switch 14-34
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
80. REMOVE MANIFOLD STAY NO.2
(a) Remove the 2 bolts and manifold stay.
81. REMOVE ENGINE MOUNTING BRACKET RH (See page 17-9)
82. REMOVE PUMP BRACKET
(a) Remove the 3 bolts and pump bracket.
83. REMOVE GENERATOR BRACKET NO.1
84. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-9)
85. REMOVE WATER INLET PIPE (See page 16-16)
86. REMOVE WATER INLET (See page 16-16)
87. REMOVE THERMOSTAT
88. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
(a) Using a deep socket wrench 24 mm, remove the oil pres-
sure switch.
89. REMOVE KNOCK SENSOR (See page 10-16)
90. REPLACE PARTIAL ENGINE ASSY
91. INSTALL KNOCK SENSOR (See page 10-16)
92. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080 THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 NVm (153 kgfVcm, 11 ftVlbf)

A86567
3
4
7
25
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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)