key LEXUS ES300 2005 User Guide
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 515 of 969
A78766
SST
A78746
Inward
Sensor
- ENGINE MECHANICALOIL PUMP SEAL (3MZ-FE)
14-139
2231 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
16. INSTALL OIL PUMP SEAL
(a) Apply multi-purpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST and a hammer, tap in the new oil seal until its
surface is flush with the oil pump edge.
SST 09223-00010
NOTICE:
Be careful not to tap the oil seal at an angle.
Wipe off extra grease on the crankshaft.
17. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft, then slide the pulley into place.
NOTICE:
Do not scratch the sensor area of the crankshaft timing
pulley.
(b) Install the timing belt plate with the bolt.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
18. INSPECT TIMING BELT (See page 14-79)
19. INSTALL TIMING BELT (See page 14-79)
SST 09960-10010 (09962-01000, 09963-01000)
20. INSTALL TIMING BELT TENSIONER ASSY (See page 14-79)
21. INSTALL TIMING BELT GUIDE NO.2 (See page 14-79)
22. INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79)
23. INSTALL TIMING BELT NO.2 COVER (See page 14-79)
24. INSTALL TIMING BELT NO.1 COVER (See page 14-79)
25. INSTALL CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021
26. INSTALL GENERATOR BRACKET NO.2 (See page 14-79)
27. INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
28. INSTALL ENGINE MOVING CONTROL ROD (See page 14-79)
29. INSTALL VANE PUMP V BELT (See page 14-5)
30. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
31. INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1)
32. INSTALL FRONT WHEEL RH (See page 14-5)
33. CHECK FOR ENGINE OIL LEAKS
Page 544 of 969
P12599
A78807
Mark
1, 2, 3 or 4
A78808
Plastigage
A10530
A78809Less than 6 mm (0.23 in.) 14-168
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2260 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.
(d) Place the crankshaft on the cylinder block.
(e) Lay a strip of Plastigage across each journal.
(f) Examine the front marks and numbers, then install the
bearing caps on the cylinder block.
(g) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(h) Temporarily install the 8 bearing cap bolts to the inside
positions.
(i) 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.
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 649 of 969
A86216
Keyway
KeyPlastic-faced
Hammer
- EXHAUSTEXHAUST PIPE ASSY (3MZ-FE)
15-5
2278 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. INSTALL TAIL PIPE BAFFLE
(a) Align the keyway of the tail pipe baffle with the key on the
exhaust pipe tail.
(b) Using a plastic-faced hammer, tap the tail pipe baffle to
install.
15. INSTALL EXHAUST PIPE ASSY TAIL
(a) Install a new gasket and the exhaust pipe tail to the 3 exhaust pipe supports.
(b) Tighten the 2 new nuts.
Torque: 56 NVm (574 kgfVcm, 41 ftVlbf)
16. INSTALL HEATED OXYGEN SENSOR (See page 12-24)
SST 09224-00010
17. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
18. CHECK FOR EXHAUST GAS LEAKS
19. INSTALL FLOOR PANEL BRACE REAR
Torque: 20 NVm (199 kgfVcm, 14 ftVlbf)
20. SYSTEM INITIALIZATION (See page 19-15)
Page 689 of 969
A36784
A78725
Seal Packing
Seal Width
2 to 3 mm
(0.08 to 0.12 in.) A
A
BB
C
C
A36785
- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
17-13
2318 Author: Date:
41. INSTALL OIL PUMP ASSY
(a) Remove any old seal packing material from the contact
surface.
(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 794 of 969
A58810
Length
A81178
A73991
keyway
Key
A79727
Rubber
Cutout
A79728Key Keyway
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-13
2345 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Inspect the length.
(1) Using vernier calipers, measure the snap ring
length.
Maximum length: 5.0 mm (0.197 in.)
If the length is greater than maximum, replace it with a new snap
ring.
13. INSTALL STARTER COMMUTATOR END FRAME
COVER
(a) Install the starter commutator end frame cover to the
starter commutator end frame.
14. INSTALL STARTER ARMATURE PLATE
(a) Insert the starter armature plate to the starter field frame.
(b) Align the keyway of the starter plate with the key inside the
starter yoke, then install the starter plate.
15. INSTALL STARTER COMMUTATOR END FRAME
ASSY
(a) Align the rubber with the cutout of the starter field frame.
(b) Install the starter commutator end frame to the starter field
frame.
16. INSTALL STARTER FIELD FRAME ASSY
(a) Align the key of the starter field frame with the keyway of
the starter drive housing.
Page 816 of 969
C92308
NVm (kgfVcm, ftVlbf) : Specified torque
35 (360, 26)
Non-reusable partUn-lock Waring
Switch AssyTransponder Key Amplifier
Ignition Switch Lock
Cylinder Assy
Steering Column Upper
w/ Switch Bracket Assy
Steering Column Assy
Ignition or Starter
Switch Assy
Steering Sliding
Yoke Sub-assySteering Column
Clamp Upper
Tapered-Head Bolt
- STEERING COLUMNSTEERING COLUMN ASSY
50-7
2568 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 818 of 969
C90687
C90688Matchmarks
- STEERING COLUMNSTEERING COLUMN ASSY
50-9
2570 Author: Date:
15. REMOVE TURN SIGNAL SWITCH ASSY
(a) Disconnect the 3 connectors.
(b) Disconnect the airbag connector.
(c) Remove the 3 screws and turn signal switch assy.
16. REMOVE INSTRUMENT PANEL FINISH PLATE(See page 71-1 1)
17. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Place the ignition switch lock cylinder assy at the key ACC
position.
(b) Remove the cable cap claw from the key interlock and pull
out the floor shift parking lock cable assy.
18. DISCONNECT STEERING SLIDING YOKE SUB-ASSY
(a) Place the matchmarks on the steering sliding yoke sub-
assy and intermediate shaft sub-assy.
(b) Remove the bolt and disconnect the steering sliding yoke
sub-assy .
19. REMOVE STEERING COLUMN HOLE COVER SUB-ASSY NO.2
(a) Remove the hose clamp.
(b) Remove the steering column hole cover sub-assy No.2.
20. REMOVE STEERING COLUMN ASSY
(a) Disconnect the connectors and wire harness clamps.
(b) Disconnect the driver side junction block.
Page 819 of 969
C90690
C90689
Matchmarks
C90844H41505
Matchmarks
C90692
50-10
- STEERING COLUMNSTEERING COLUMN ASSY
2571 Author: Date:
(c) Remove the 2 nuts, bolt and steering column assy from
the instrument panel reinforcement assy.
21. REMOVE STEERING INTERMEDIATE SHAFT
SUB-ASSY
(a) Place the matchmarks on the steering intermediate shaft
sub-assy and steering gear assy.
(b) Remove the bolt and steering intermediate shaft sub-
assy.
22. REMOVE STEERING SLIDING YOKE SUB-ASSY
(a) Place the matchmarks on the steering sliding yoke sub-
assy and steering main shaft assy.
(b) Remove the bolt and steering yoke sub-assy.
23. REMOVE TRANSPONDER KEY AMPLIFIER
(a) Widen the claw hung on the upper bracket by approx. 1.0
mm (0.039 in.) using a screwdriver.
(b) Pull the transponder key amplifier toward the rear of the
vehicle with the claw open.
NOTICE:
Take care not to use excessive force to prevent the case
from being damage.