LEXUS ES300 2005 Repair Manual

A78727
Seal Packing
Seal Width
4 to 5 mm
(0.16 to 0.20 in.) AA
BB
A78825
B C
A
A
A
A86600
A
B
BB
- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
17-15
2320 Author
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45. INSTALL OIL PAN SUB-ASSY NO.2
(a) Remove any old seal packing from the contact surface.
(b) Apply a continuous bead of seal packing (Diameter 4 to
5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Apply seal packing to the inner side of the bolt holes.

Install the oil pan within 3 minutes after applying seal
packing.

Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
46. INSTALL ENGINE MOUNTING BRACKET RH
Torque:
54 NVm (551 kgfVcm,
40 ftVlbf) for bolt A
54 NVm (551 kgfVcm,
40 ftVlbf) for nut B
43 NVm (439 kgfVcm,
32 ftVlbf) for bolt C
47. INSTALL ENGINE MOUNTING INSULATOR RH
Torque:
95 NVm (969 kgfVcm,
70 ftVlbf) for nut A
87 NVm (887 kgfVcm,
64 ftVlbf) for nut B

A60523
A
B
BB
A78827Adjusting Bar Bracket
(a)
(b)
(b)
(a)
(a)
A78828
A
B
C 17-16
- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
2321 Author
: Date
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48. INSTALL ENGINE MOUNTING INSULATOR FR
Torque:
87 NVm (887 kgfVcm,
64 ftVlbf) for bolt A
52 NVm (530 kgfVcm,
38 ftVlbf) for nut B
49. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 NVm (250 kgfVcm,
18 ftVlbf)
50. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
(a) Install the compressor with the 3 bolts.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(b) Install the adjusting bar bracket with the bolt and nut.
Torque:
25 NVm (250 kgfVcm, 18 ftVlbf) for bolt
26 NVm (260 kgfVcm, 19 ftVlbf) for nut
51. INSTALL GENERATOR BELT ADJUSTING BAR
(a) Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
43 NVm (438 kgfVcm, 32 ftVlbf) for nut A
18 NVm (184 kgfVcm, 13 ftVlbf) for bolt B
8.4
NVm (85 kgfVcm, 74 in.Vlbf) for bolt C
52. INSTALL OIL LEVEL GAGE GUIDE (See page 14-133)
53. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9)
54. INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2)
55. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2)

- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
17-17
2322 Author
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56. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2)
57. INSTALL CRANKSHAFT TIMING PULLEY (See page 14-138)
58. INSTALL TIMING BELT IDLER SUB-ASSY NO.1 (See page 16-13)
59. INSTALL TIMING BELT NO.3 COVER (See page 14-93)
60. INSTALL CAMSHAFT TIMING PULLEY (See page 14-93)
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
61. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93)
62. INSPECT TIMING BELT (See page 14-79)
63. INSTALL TIMING BELT (See page 14-79)
SST 09960-10010 (09962-01000, 09963-01000)
64. INSTALL TIMING BELT TENSIONER ASSY (See page 14-79)
65. INSTALL TIMING BELT GUIDE NO.2 (See page 14-79)
66. INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79)
67. INSTALL TIMING BELT NO.2 COVER (See page 14-79)
68. INSTALL TIMING BELT NO.1 COVER (See page 14-79)
69. INSTALL CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021
70. INSTALL GENERATOR BRACKET NO.2 (See page 14-79)
71. INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
72. INSTALL ENGINE MOVING CONTROL ROD (See page 14-79)
73. INSTALL VANE PUMP V BELT (See page 14-5)
74. INSTALL GENERATOR ASSY (See page 19-21)
75. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
76. INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1)
77. INSTALL FRONT WHEEL RH (See page 14-5)
78. ADD ENGINE OIL (See page 17-20)
79. CHECK FOR ENGINE OIL LEAKS
80. CHECK FOR EXHAUST GAS LEAKS
81. SYSTEM INITIALIZATION (See page 19-15)

170F4-03
A33002
A33003
A33004
A33005
17-18
- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
2323 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE OIL PUMP RELIEF VALVE
(a) Remove the plug, spring and relief valve.
2. INSPECT OIL PUMP RELIEF VALVE
(a) Apply a light coat of engine oil to the relief valve.
(b) Check that the relief valve falls smoothly into the valve
hole by its own weight.
3. INSPECT OIL PUMP ASSY
(a) Remove the oil pump cover.
(1) Remove the 10 screws and oil pump cover.
(b) Remove the oil pump rotor set.
NOTICE:
Do not change the combination or turn over the 2 removed
rotors.
(c) Inspect the oil pump rotor set.
(1) Apply a light coat of engine oil to the oil pump rotor
set, then place them into the oil pump body. Check
that the rotors revolve smoothly.
(d) Inspect the tip clearance.
(1) Using a feeler gauge, measure the clearance be-
tween the drive and driven rotor tips.
Standard tip clearance:
0.06 to 0.18 mm (0.0024 to 0.0071 in.)
Maximum tip clearance: 0.35 mm (0.0138 in.)
(e) Inspect the body clearance.
(1) Using a feeler gauge, measure the clearance be-
tween the driven rotor and body.
Standard body clearance:
0.250 to 0.325 mm (0.0098 to 0.0128 in.)
Maximum body clearance: 0.30 mm (0.0118 in.)
(f) Inspect the side clearance.
(1) Using a feeler gauge and precision straight edge,
measure the clearance between the rotors and pre-
cision straight edge.
Standard side clearance:
0.03 to 0.09 mm (0.0012 to 0.0035 in.)
Maximum side clearance: 0.15 mm (0.0059 in.)

A78905
Marks
- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
17-19
2324 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(g) Install the oil pump rotor set.
(1) Apply a light coat of engine oil to the oil pump gear
set, then place it into the pump body with the marks
facing the pump body cover side.
(h) Install the oil pump cover.
(1) Install the 10 screws and oil pump cover.
Torque: 10 NVm (105 kgfVcm, 8 ftVlbf)
4. INSTALL OIL PUMP RELIEF VALVE
(a) Apply a light coat of engine oil to the relief valve, then insert the relief valve and spring into the pump
body hole.
(b) Install the oil pump relief valve plug.
Torque: 49 NVm (500 kgfVcm,
36 ftVlbf)

170F5-03
A78720
SST
P12582
Additional
3/4 TurnSST
17-20
- LUBRICATIONOIL FILTER SUB-ASSY (3MZ-FE)
2325 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OIL FILTER SUB-ASSY (3MZ-FE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with engine oil will cause removal of natural oils from the skin,
leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.

Precautions should be taken when replacing engine oil to minimize the risk of your skin making
contact with used engine oil. Wear protective clothing and gloves. Wash your skin thoroughly
with soap and water, or use water-less hand cleaner to remove any used engine oil. Do not use
gasoline, thinners, or solvents.

For environmental protection used oil and used oil filter must be disposed of at designated dis-
posal sites.
1. REMOVE ENGINE UNDER COVER NO.1
2. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, then drain the oil into a container.
(c) Clean and install the oil drain plug with a new gasket.
Torque: 45 NVm (459 kgfVcm,
33 ftVlbf)
3. REMOVE OIL FILTER SUB-ASSY
(a) Using SST, remove the oil filter.
SST 09228-07501
4. INSTALL OIL FILTER SUB-ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, then tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228-07501
5. ADD ENGINE OIL
(a) Fill with fresh engine oil.
Capacity:
Drain and refill with oil filter change4.7 liters (5.0 US qts, 4.1 lmp. qts)
Drain and refill without oil filter change4.5 liters (4.8 US qts, 4.0 lmp. qts)
Dry fill5.5 liters (5.8 US qts, 4.8 lmp. qts)
6. CHECK FOR ENGINE OIL LEAKS

1809A-01
- IGNITIONIGNITION SYSTEM (3MZ-FE)
18-1
2326 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
IGNITION SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in this section mean temperature of the coils themselves. ºColdº is from -10C
(14F) to 50C (122F) and ºHotº is from 50C (122F) to 100C (212F).
1. INSPECT IGNITION COIL AND SPARK TEST
(a) Check the DTCs.
NOTICE:
If a DTC is present, perform troubleshooting in accordance with a procedure for that DTC.
(b) Check that a spark occurs.
(1) Remove the 6 ignition coils (see page 18-7).
(2) Using a spark plug wrench 16 mm, remove the 6 spark plugs.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(3) Install the spark plugs to each ignition coil, then connect the ignition coil connectors.
(4) Disconnect the 6 fuel injector connectors.
(5) Ground the spark plugs.
(6) Check that the spark plug occurs at each spark plug while the engine is being cranked.
NOTICE:

Be sure to ground the spark plugs when checking.

Replace the ignition coil if physical impact is felt.

Do not crank the engine for more than 2 seconds.
If a spark does not occur, perform the following test.
1 SPARK TEST
NG
2 CHECK CONNECTION OF IGNITION COIL CONNECTOR
NG CONNECT SECURELY
OK
3 REPLACE IT WITH NORMAL IGNITION COIL AND PERFORM SPARK TEST AGAIN
OK REPLACE IGNITION COIL ASSY
(See page 18-7)
NG
4 CHECK POWER SUPPLY TO IGNITION COIL
(a) Turn the ignition switch ON.
(b) Check that there is battery voltage at the ignition coil positive (+) terminal.
NG CHECK WIRE HARNESS (BETWEEN IGNITION
(START) SWITCH ASSY AND IGNITION COIL
ASSY)
OK

18-2
- IGNITIONIGNITION SYSTEM (3MZ-FE)
2327 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
5 INSPECT VVT SENSOR (See page 18-3)
NG REPLACE VVT SENSOR (See page 18-5)
OK
6 INSPECT CRANKSHAFT POSITION SENSOR (See page 18-3)
NG REPLACE CRANKSHAFT POSITION SENSOR
(See page 18-6)
OK
7 INSPECT IGT SIGNAL FROM ECM (See page 05-34)
NG REPLACE ECM (See page 10-22)
OK
REPAIR WIRE HARNESS (BETWEEN IGNI-
TION COIL ASSY AND IGNITION (START)
SWITCH ASSY)

1809B-01
IG0147
Ohmmeter
Ground
B01301
IG0316
B02101
1.0 to 1.1 mm
(0.039 to 0.043 in.)Spark Plug Gauge
- IGNITIONIGNITION SYSTEM (3MZ-FE)
18-3
2328 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INSPECTION
1. INSPECT SPARK PLUG
NOTICE:

Do not use a wire brush to clean the spark plug.

Do not try to adjust the electrode gap of a used spark
plug.
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the insulation and body ground.
Resistance: 10 MW or more
If the resistance is not as specified, check the electrode gap.
(b) Alternative inspection method.
(1) Quickly accelerate the engine speed to 4,000 rpm
5 times.
(2) Remove the spark plug.
(3) Visually check the spark plug.
(4) If the electrode is dry...OK.
(5) If the electrode is wet...Proceed to step (c).
(6) Reinstall the spark plug.
(c) Check the appearance.
(1) Check the thread and insulator of the spark plug for
damage.
If damaged, replace the spark plug.
Recommended spark plug:
SupplierType
DENSOSK20R11
NGKIFR6A11
(d) Inspect the electrode gap.
(1) Using a spark plug gauge, measure the electrode
gap.
Maximum electrode gap of used spark plug:
1.3 mm (0.051 in.)
If the electrode gap is greater than maximum, replace the spark
plug.
Electrode gap of new spark plug:
1.0 to 1.1 mm (0.039 to 0.043 in.)

B62019
A84690
Ohmmeter
A84688
Ohmmeter 18-4
- IGNITIONIGNITION SYSTEM (3MZ-FE)
2329 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Clean the spark plugs.
If the electrode has traces of wet carbon, clean the electrode
with a spark plug cleaner, then dry it.
Air pressure: Blow 588 kPa (6 kgf/cm
2, 85 psi)
Duration: 20 seconds or shorter
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
2. INSPECT VVT SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
Tester ConnectionSpecified Condition
1 (G+) - 2 (G-)835 to 1,400 W at cold
1 (G+) - 2 (G-)1,060 to 1,645 W at hot
NOTICE:
ºColdº and ºHotº mean temperature of the coils them-
selves. ºColdº is from -10C (14F) to 50C (122F) and
ºHotº is from 50C (122F) to 100C (212F).
If the resistance is not as specified, replace the VVT sensor.
3. INSPECT CRANKSHAFT POSITION SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
Tester ConnectionSpecified Condition
1 (NE+) - 2 (NE-)1,630 to 2,740 W at cold
1 (NE+) - 2 (NE-)2,065 to 3,225 W at hot
NOTICE:
ºColdº and ºHotº mean temperature of the coils them-
selves. ºColdº is from -10C (14F) to 50C (122F) and
ºHotº is from 50C (122F) to 100C (212F).
If the resistance is not as specified, replace the crankshaft posi-
tion sensor.