lock LEXUS ES300 2005 Owners Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 427 of 969
A62375
A05245
A05243
EM3336
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-51
2143 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
51. REMOVE OIL PUMP SEAL
(a) Using a screwdriver, pry out the oil seal.
52. REMOVE SPARK PLUG TUBE GASKET
(a) Bend up the tab on the ventilation baffle plate which pre-
vents the gasket from slipping out.
NOTICE:
Be careful not to damage the baffle plate of the cylinder
head cover.
(b) Using a screwdriver and hammer, tap out the gasket.
(c) Using needle-nose pliers, pry out the gasket.
NOTICE:
Be careful not to damage the cylinder head cover.
53. 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.
Page 428 of 969
EM1628
A51428
A51429
A78721
Tension Portion 14-52
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2144 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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.
54. INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the runout is greater than maximum, replace the camshaft.
(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
43.132 to 43.232 mm (1.6981 to 1.7020 in.) for intake
43.010 to 43.110 mm (1.6933 to 1.6972 in.) for exhaust
Minimum cam lobe height:
42.98 mm (1.6921 in.) for intake
42.86 mm (1.6874 in.) for exhaust
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 to 26.975 mm (1.0614 to 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
55. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard outside diameter:
8.95 to 9.05 mm (0.3524 to 0.3563 in.)
Minimum outside diameter: 8.75 mm (0.3445 in.)
If the diameter is less than minimum, replace the bolt.
Page 430 of 969
A36784
A78725
Seal Packing
Seal Width
2 to 3 mm
(0.08 to 0.12 in.) A
A
BB
C
C
A36785
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- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2146 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
60. INSTALL OIL PUMP ASSY
(a) Remove any old packing material from the contact sur-
face.
(b) Apply a light coat of engine oil to a new O-ring, then place
it on the cylinder block.
(c) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pump within 3 minutes after applying
seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(d) Align the key of the oil pump drive gear with the keyway
located on the crankshaft, then slide the oil pump into
place.
Page 433 of 969
A78324
Front
A78717
1
2
3
4
5
67
8
Front
A78730
90
Front
Painted Mark
A78716
Front
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-57
2149 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
68. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
with the R mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in or-
der not to damage the gasket at the bottom part of the
head.
69. INSTALL CYLINDER HEAD SUB-ASSY
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil to the threads of the cylin-
der head bolts.
(b) Install the plate washers to the cylinder head bolts.
(c) Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 54 NVm (550 kgfVcm, 40 ftVlbf)
(d) Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90in the same se-
quence as step (c).
(f) Check that each painted mark is now at a 90 angle to the
front.
(g) Using a socket hexagon wrench 8, install the hexagon
bolt.
Torque: 19 NVm (189 kgfVcm, 14 ftVlbf)
Page 434 of 969
A79822
Front
A78719
1
2
3
4
5
67
8
Front
A78730
90
Front
Painted Mark
A78718
Front 14-58
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2150 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
70. INSTALL CYLINDER HEAD GASKET NO.2
(a) Place a new cylinder head gasket on the cylinder block
with the L mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in or-
der not to damage the gasket at the bottom part of the
head.
71. INSTALL CYLINDER HEAD LH
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil to the threads of the cylin-
der head bolts.
(b) Install the plate washers to the cylinder head bolts.
(c) Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 54 NVm (550 kgfVcm, 40 ftVlbf)
(d) Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90 in the same se-
quence as step (c).
(f) Check that each painted mark is now at a 90 angle to the
front.
(g) Using a socket hexagon wrench 8, install the hexagon
bolt.
Torque: 19 NVm (189 kgfVcm, 14 ftVlbf)
Page 436 of 969
A78733
SST
A78734
Align
A05738
14-60
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2152 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Using SST, align the holes of the camshaft main gear and
sub gear by turning the camshaft sub gear counterclock-
wise, then temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(f) Align the gear teeth of the main gear and sub gear, then
tighten the service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
NOTICE:
Be careful not to damage the camshaft journals.
HINT:
When installing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
75. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Align the alignment pin with the alignment pin groove,
then install the VVT-i into the camshaft.
NOTICE:
Install it with the lock pin engaged and locked at the most
retard angle position.
(b) Apply engine oil to the nut, mounting surface of the VVT-i
and screw threads.
NOTICE:
Be sure to apply the oil, otherwise the specified
torque cannot be obtained.
New nuts must be used when replacing the VVT-i
unit.
(c) Using a 46 mm socket wrench, install and tighten a lock
nut by turning it counterclockwise.
Torque: 150 NVm (1,530 kgfVcm, 111 ftVlbf)
NOTICE:
The lock nut has LH threads.
Never use any tools other than the socket wrench.
Other tools will deform the cam angle rotor.
76. INSTALL NO.2 CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
Page 444 of 969
A82349
Approximately 60
Turn
A78751
SST
A05062
A52840
A78702(1) (2)
(3) (4)
(5)
(6) 14-68
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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 crankshaft pulley, then align the tim-
ing marks of the timing pulley 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
Page 445 of 969
A36238
A78326
Turn
A05052
A36239
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-69
2161 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.
Page 456 of 969
A78756
SST
A78759
Clamp
Clamp
P18814
A78326
Turn 14-80
- ENGINE MECHANICALTIMING BELT (3MZ-FE)
2172 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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.
Page 457 of 969
A05052
A52840
A78327
Turn
Approximately 60
A78702
(5)
(6) (1)(4) (2)(3)
- ENGINE MECHANICALTIMING BELT (3MZ-FE)
14-81
2173 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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