lock LEXUS ES300 2005 Repair Manual

1419J-03
A78310
Non-reusable part
N´m (kgf´cm, ft´lbf)
: Specified torque Valve Lifter
Valve Spring Retainer Lock
Valve Spring Retainer
Inner Compression Spring

Exhaust Valve Guide Bush
Valve Stem Oil O Seal or Ring
Valve Spring Seat

Intake Valve Guide Bush
Exhaust Valve Intake Valve
Valve Adjusting Shim
RH Cylinder:
W/ Head Straight Screw
Plug No. 1
LH Cylinder:
W/ Head Straight Screw
Plug No. 2

Gasket
Semicircular Plug
44 (449, 32)
14-142
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
2234 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CYLINDER HEAD ASSY (3MZ-FE)
COMPONENTS

1419K-03
A78770
SST
A78772
SST
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
14-143
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
(a) Using a straight hexagon wrench 14, remove the 2 screw plugs.
2. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
(a) Using a straight hexagon wrench 14, remove the 2 screw plugs.
3. REMOVE VALVE LIFTER
HINT:
Store the lifters in the correct order so that they can be returned to the original locations when reassembling.
4. REMOVE INTAKE VALVE
(a) Using SST, compress the spring, then remove the 2 re-
tainer locks, retainer, spring and valve.
SST 09202-70020 (09202-00010)
HINT:
Store the valves, springs, seats and retainers in the correct or-
der so that they can be returned to the original locations when
reassembling.
5. REMOVE EXHAUST VALVE
(a) Using SST, compress the spring, then remove the 2 re-
tainer locks, retainer, spring and valve.
SST 09202-70020 (09202-00010)
HINT:
Store the valves, springs, seats and retainers in the correct or-
der so that they can be returned to the original locations when
reassembling.
6. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Using needle-nose pliers, remove the oil seal.
7. REMOVE VALVE SPRING SEAT
8. REMOVE SEMICIRCULAR PLUG

A78773
Cylinder Block Surface:
Exhaust Manifold Surface: Intake Manifold Surface:
A05227
EM2534
Overall Length
Z00052
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the warpage on the surfaces which contacts the cyl-
inder block and manifolds.
Maximum warpage:
0.05 mm (0.0020 in.) for cylinder block surface
0.10 mm (0.0039 in.) for intake manifold surface
0.10 mm (0.0039 in.) for exhaust manifold surface
If the warpage is greater than maximum, replace the cylinder
head.
10. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
11. INSPECT INTAKE VALVE
(a) Inspect the valve overall length.
Standard overall length: 95.45 mm (3.7579 in.)
Minimum overall length: 94.95 mm (3.7382 in.)
If the overall length is less than minimum, replace the valve.
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.470 to 5.485 mm (0.2154 to 0.2159 in.)

A78784
Protrusion Height
Mark
A78785
Wooden
BlockPress
Protrusion
Height
A78786
Wooden
Block
Flush
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
26. INSTALL SPARK PLUG TUBE
(a) Using paint, mark the standard height from the edge.
Standard protrusion height:
42.4 to 43.4 mm (1.669 to 1.709 in.)
HINT:
Use either end of the spark plug tube.
(b) Apply adhesive to the end of the spark plug tube which will
be pressed into the cylinder head.
Adhesive: Part No. 08833-00070 THREE BOND 1324
or equivalent
NOTICE:

Install the spark plug tube within 3 minutes after ap-
plying adhesive.

Do not deform the spark plug tube.

Do not expose the spark plug tube to coolant within
1 hour after installing.
(c) Using a press and wooden block, install the spark plug
tube to the required protrusion height.
NOTICE:
Be careful not to drip the adhesive.
27. INSTALL PCV PIPE (RH CYLINDER)
(a) Using a wooden block and hammer, tap in 2 new PCV
pipes until their top edges are flush with the cylinder head
edge.
NOTICE:
Be careful not to damage the cylinder head edge.

P12668
A78770
SST
A05246
A52900
A78772
SST
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
31. INSTALL INTAKE VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the origi-
nal locations.
(b) Using SST, compress the spring and place the 2 retainer
locks around the valve stem.
SST 09202-70020 (09202-00010)
(c) Using a plastic-faced hammer and discarded valve (the
tip is wrapped with tape), lightly tap the installed valve to
fit into place.
NOTICE:
Be careful not to damage the installed valve stem tip.
32. INSTALL EXHAUST VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the origi-
nal locations.
(b) Using SST, compress the spring and place the 2 retainer
locks around the valve stem.
SST 09202-70020 (09202-00010)

1419L-03
A78311
1st: 25 (250, 18)
2st: Turn 90
See page (14-158)
N´m (kgf´cm, ft´lbf)
: Specified torque
 Non-reusable partPiston Pin Hole
Snap Ring
 Piston Pin Hole Snap Ring
Connecting Rod Small
End Bush
 Gasket
 Gasket  Gasket
50 (510, 37)
39 (398, 29)
18 (184, 13)
30 (306, 22)
30 (306, 22)
39 (398, 29)
Piston Ring (No. 1 Compression Ring)
Piston Ring (No. 2 Compression Ring)
Piston Ring (Side Rail)Piston Ring (Expander)
Connecting Rod Sub-assy
Connecting Rod Bearing
Connecting Rod Cap
Cylinder Block Sub-assy
Cylinder Block w/ Head
Straight Screw No. 3 Plug
Cylinder Block Water Drain Cock
Sub-assy Cylinder Block w/ Head
Straight Screw No. 2 Plug Cylinder Block w/ Head
Straight Screw No. 1 Plug Cylinder Block Water
Drain Cock Sub-assy
Water Seal Plate


Piston PinPiston
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CYLINDER BLOCK ASSY (3MZ-FE)
COMPONENTS

A78312N´m (kgf´cm, ft´lbf)
: Specified torque
27 (275, 20)
27 (275, 20)1st: 22 (224, 16)
2st: Turn 90
See page (14-158)
Cylinder Block Sub-assy
Upper Crankshaft Thrust WasherCrankshaft Bearing
Crankshaft Bearing
Lower Crankshaft Thrust Washer
Crankshaft Bearing CapCrankshaft
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

1419M-03
P12695
A78793
Plastigage
A78794
Protrusion Front 14-158
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2250 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
2. REMOVE WATER SEAL PLATE
3. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
(a) Using a socket hexagon wrench 10, remove the screw plug.
4. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
(a) Using a socket hexagon wrench 10, remove the screw plug.
5. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
(a) Using a socket hexagon wrench 10, remove the screw plug.
6. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)

If the thrust clearance is greater than maximum, re-
place the connecting rod.

If necessary, replace the crankshaft.
7. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the matchmarks on the connecting rod and
cap are aligned to ensure correct reassembly.
(b) Remove the cap bolts.
(c) Clean the crank pin, bearing and connecting rod.
(d) Check the crank pin and bearing for pitting and scratches.
(e) Lay a strip of Plastigage across the crank pin.
(f) Check that the protrusion of the cap is facing the correct
direction.
(g) Apply a light coat of engine oil to the threads of the cap
bolts.

P12697
A78795
90
Front90Painted Mark
P12698
A79803
Number Mark
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(h) Tighten the cap bolts in several steps by the specified
torque.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(i) Mark the front side of each cap bolt with paint.
(j) Retighten the cap bolts by 90 as shown in the illustration.
NOTICE:
Do not turn the crankshaft.
(k) Remove the cap bolts, cap and lower bearing.
(l) Measure the Plastigage at its widest point.
Standard oil clearance:
0.038 to 0.066 mm (0.0015 to 0.0026 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
NOTICE:
Completely remove the Plastigage.

If the oil clearance is greater than maximum, re-
place the bearing.

If necessary, grind or replace the crankshaft.
HINT:
If replacing the bearing, replace it with one having the same
number as marked on the connecting rod. There are 4 sizes of
standard bearings, marked º1 º, º2º, º3º and º4º accordingly.
Reference:
Standard bearing center wall thickness:
Markmm (in.)
º1º1.484 to 1.487 (0.0584 to 0.0585)
º2º1.487 to 1.490 (0.0585 to 0.0587)
º3º1.490 to 1.493 (0.0587 to 0.0588)
º4º1.493 to 1.496 (0.0588 to 0.0589)

A05258
A78315
P12403
A78797
80C (176F) 14-160
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2252 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
8. REMOVE PISTON SUB-ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push out the piston and connecting rod assembly from
the top of the cylinder block.
HINT:

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order so they can be returned to the original loca-
tions when reassembling.
9. REMOVE CONNECTING ROD BEARING
10. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and expander by hand.
11. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
12. REMOVE W/PIN PISTON SUB-ASSY
(a) Gradually heat the piston up to approximately 80C
(176F).