lock LEXUS ES300 2005 Repair Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 547 of 969
A78813
No. 1
Number
MarkNo. 2No. 3
No. 4
No. 1 No. 2
No. 3
No. 4 Number Mark
Number Mark
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-171
2263 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(s) If replacing a bearing, replace it with one having the same
number. If the number of the bearing cannot be deter-
mined, select the correct bearing by adding together the
numbers imprinted on the cylinder block and crankshaft,
then refer to the table below for the appropriate bearing
number. The No. 1 and No. 2 journal bearing come in 5
sizes, marked º3º, º4º, º5º, º6º and º7º. The No. 3 and No.
4 journal bearings come in 5 standard bearing sizes,
marked º1º, º2º, º3º, º4º and º5º.
No. 1 and No. 2 journal bearings:
Cylinder
block
+
Crankshaft
=
0 to 56 to 1112 to 1718 to 2324 to 28
Replace-
ment
Bearing
º3ºº4ºº5ºº6ºº7º
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked º5º
No. 3 and No. 4 journal bearings:
Cylinder
block
+
Crankshaft
=
0 to 56 to 1112 to 1718 to 2324 to 28
Replace-
ment
Bearing
º1ºº2ºº3ºº4ºº5º
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked º3º
Page 548 of 969
14-172
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2264 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U) Item
Markmm (in.)
Cylinder block main journal bore diameter (A)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º
º13º
º14º
º15º
º16º66.000 (2.5984)
66.001 (2.5985)
66.002 (2.5985)
66.003 (2.5985)
66.004 (2.5986)
66.005 (2.5986)
66.006 (2.5987)
66.007 (2.5987)
66.008 (2.5987)
66.009 (2.5988)
66.010 (2.5988)
66.011 (2.5989)
66.012 (2.5989)
66.013 (2.5989)
66.014 (2.5990)
66.015 (2.5990)
66.016 (2.5990)
Crankshaft main journal diameter (B)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º61.000 (2.4016)
60.999 (2.4015)
60.998 (2.4015)
60.997 (2.4015)
60.996 (2.4014)
60.995 (2.4014)
60.994 (2.4013)
60.993 (2.4012)
60.992 (2.4012)
60.991 (2.4012)
60.990 (2.4012)
60.989 (2.4011)
60.988 (2.4011)
Standard bearing center wall thicknessº1º
º2º
º3º
º4º
º5º
º6º
º7º2.486 to 2.489 (0.0979 to 0.0980)
2.489 to 2.492 (0.0980 to 0.0981)
2.492 to 2.495 (0.0981 to 0.0982)
2.495 to 2.498 (0.0982 to 0.0983)
2.498 to 2.501 (0.0983 to 0.0985)
2.501 to 2.504 (0.0985 to 0.0986)
2.504 to 2.507 (0.0986 to 0.0987)
Page 549 of 969
A78318
Front Side: Front Side:
Front Side:
Upper Side:Left Side:
80 mm
(3.15 in.)
M1099 mm
(3.90 in.)
M8
27.5 mm
(1.08 in.)28.5mm
(1.12 in.) M6
M6M8 29 mm
(1.14 in.)
Torque: 6.0 NVm (60 kgfVcm, 53 in.Vlbf)
Torque: 7.0 NVm (70 kgfVcm, 62 in.Vlbf)
Torque: 4.0 NVm (40 kgfVcm, 35 in.Vlbf) Torque: 21 NVm (220 kgfVcm, 15 ftVlbf)Torque: 15 NVm (145 kgfVcm, 11 ftVlbf)
52.5 mm
(2.07 in.) Upper Side:
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-173
2265 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
31. INSTALL STUD BOLT
Page 550 of 969
A78319
Front Side:
Upper Side:Right Side:
Lower Side:
Back Side: Back Side: Protrusion Height: 6 mm (0.24 in.)
Protrusion Height: 11 mm (0.43 in.) 4 mm
(0.16 in)
10 mm
(0.39 in.)
22 mm
(0.87 in.)12 mm
(0.47 in.) 12 mm
(0.47 in.)4 mm
(0.16 in)
4 mm
(0.16 in)
12 mm
(0.47 in.)4 mm
(0.16 in)
12 mm
(0.47 in.)
4 mm
(0.16 in)
12 mm
(0.47 in.) Protrusion Height: 6 mm (0.24 in.)
Protrusion Height: 6 mm (0.24 in.)Protrusion Height: 6 mm (0.24 in.) Protrusion Height: 6 mm (0.24 in.) 14-174
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2266 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. INSTALL STRAIGHT PIN
Page 551 of 969
A78816
Upper Side:
Protrusion Height: 10 mm (0.39 in.) Protrusion Height: 4 mm (0.16 in.)16 mm
(0.63 in.)
20 mm
(0.79 in.)11 mm
(0.43 in.)
8 mm
(0.31 in.)
P12418A32958
A78817
80C (176F)
A78376
Front Mark
Front Mark
(Mold Mark)
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-175
2267 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
33. INSTALL RING PIN
34. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not aligned with the
pin hole cutout of the piston.
35. INSTALL W/PIN PISTON SUB-ASSY
(a) Gradually heat the piston up to approximately 80C
(176F).
(b) Coat the piston pin with engine oil.
(c) Align the front marks of the piston and connecting rod,
then push in the piston pin with your thumb until the pin
contacts the snap ring.
Page 552 of 969
P12418A32958
A78320
No. 1:
No. 2:2A
A86598
Lower Side
Rail
No. 2
Compression Expander No. 1
Compression
Front Mark
Upper Side
Rail
P12402
A78806
No. 1 and No. 4:
Upper
Lower
22.4 mm (0.882 in.)No. 2 and No. 3:
19.0 mm (0.748 in.) 14-176
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2268 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
36. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
HINT:
Be sure that the end of gap of the snap ring is not aligned with
the pin hole cutout of the piston.
37. INSTALL PISTON RING SET
(a) Install the expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings.
HINT:
The No. 2 compression ring is installed with the code mark º2Aº
facing upward as shown in the illustration.
(c) Position the piston rings so that the ring ends are ar-
ranged as shown in the illustration.
NOTICE:
Do not align the ring ends.
38. INSTALL CONNECTING ROD BEARING
(a) Align the key of the bearing with the keyway of the con-
necting rod or cap.
NOTICE:
Clean the backside of the bearing and bearing surface of
the connecting rod. The surface should be free of dust and
oils.
39. INSTALL CRANKSHAFT BEARING
HINT:
Crankshaft bearings come in widths of 22.4 mm (0.882 in.) and
19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in
the No. 1 and No. 4 cylinder block journal positions with the
main bearing caps. Install the 19.0 mm (0.748 in.) bearings in
the No. 2 and No. 3 positions.
(a) Clean each main journal and the bearing.
Page 553 of 969
P12599
A78807
Mark
1, 2, 3 or 4
P12600
A05264
A10530
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-177
2269 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Align the key of the bearing with the keyway of the cylinder
block, then push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
(c) Align the key of the bearing with the keyway of the bearing
cap, then push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
HINT:
A number is marked on each bearing cap to indicate the instal-
lation position.
40. INSTALL CRANKSHAFT THRUST WASHER SET
(a) Install the 2 thrust washers under the No. 2 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
(b) Install the 2 thrust washers on the No. 2 bearing cap with
the grooves facing outward.
41. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, then install the
crankshaft on the cylinder block.
(b) Examine the front marks and numbers, then install the
bearing caps on the cylinder block.
(c) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
Page 554 of 969
A78809Less than 6 mm (0.23 in.)
A10529
A78810
1
3
4
5
6
7
8
2
10
11
13
12
14
15
16
9
A78811
Painted Mark
90
Front90
A78812
1
2
3
4
5
6
7
8 14-178
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2270 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Temporarily install the 8 bearing cap bolts to the inside
positions.
(e) Install the bearing cap by hand using the inner bolt as a
guide. Stop when the bearing cap is about 6 mm (0.23 in.)
away from contact with the cylinder block.
(f) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure proper fit.
(g) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(h) Using several steps, install and tighten the 16 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 22 NVm (224 kgfVcm, 16 ftVlbf)
(i) Mark the front side of the bearing cap bolts with paint.
(j) Retighten the bearing cap bolts by 90 in the same se-
quence as step (h).
(k) Check that each painted mark is now at a 90 angle to the
front.
(l) Check that the crankshaft turns smoothly.
(m) Using several steps, install and tighten the 8 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 27 NVm (275 kgfVcm, 20 ftVlbf)
HINT:
Use the short bolt for the position marked with the arrow.
Page 555 of 969
A78322
Front Mark (Cavity)
Front
A78794
Protrusion Front
P12697
A78795
90
Front90Painted Mark
A78822
Front Side:
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-179
2271 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
42. INSTALL PISTON SUB-ASSY W/CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and sur-
faces of the connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the numbered pis-
ton and connecting rod assemblies correctly into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.
(d) Check that the protrusion of the cap is facing the correct
direction.
(e) Apply a light coat of engine oil to the threads of the cap
bolts.
(f) Tighten the cap bolts in several steps by the specified
torque.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(g) Mark the front side of each cap bolt with paint.
(h) Retighten the cap bolts by 90 as shown in the illustration.
(i) Check that the crankshaft turns smoothly.
43. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.1 PLUG
(a) Using a socket hexagon wrench 10, install a new gasket
and the screw plug.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
Page 556 of 969
A78823
Left Side:
A78824
Back Side :
A62377
Seal Width
3 to 5 mm (0.12 to 0.20 in.)
BA
B A 14-180
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2272 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
44. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.2 PLUG
(a) Using a socket hexagon wrench 10, install a new gasket
and the screw plug.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
45. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.3 PLUG
(a) Using a socket hexagon wrench 10, install a new gasket
and the screw plug.
Torque: 50 NVm (510 kgfVcm, 37 ftVlbf)
46. INSTALL WATER SEAL PLATE
(a) Remove any old seal packing from the contact surface.
(b) Apply a continuous bead of seal packing (Diameter 3 to
5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the seal plate within 3 minutes after applying
seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the seal plate with the 2 nuts.
Torque: 18 NVm (184 kgfVcm, 13 ftVlbf)
47. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSY
(a) Apply adhesive to 2 or 3 threads of the drain cock end.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent