service 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 69 of 969
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
03-5
21 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U) Direct clutch & O/D clutch
Pack clearance0.61 - 0.83 mm (0.02401 - 0.03268 in.)
Return spring free length25.91 mm (1.0201 in.)
Flange thickness Mark
0
1
2
3
4
5
6
2.5 mm (0.098 in.)
2.6 mm (0.102 in.)
2.7 mm (0.106 in.)
2.8 mm (0.110 in.)
2.9 mm (0.114 in.)
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
2nd brake
Pack clearance0.62 - 0.91 mm (0.0244 - 0.0358 in.)
Return spring free length16.61 mm (0.6539 in.)
Flange thickness Mark
1
2
3
4
5
6
73.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
3.5 mm (0.138 in.)
3.6 mm (0.142 in.)
U/D clutch
Pack clearance1.51 - 1.71 mm (0.0594 - 0.0673 in.)
U/D clutch drum bushing inside diameter STD
Max.37.06 - 37.08 mm (1.4591 - 1.4598 in.)
37.13 mm (1.4618 in.)
Return spring free length17.14 mm (0.6752 in.)
Flange thickness Mark
1
2
3
4
5
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
U/D brake
Pack clearance1.81 - 2.20 mm (0.0713 - 0.0866 in.)
Return spring free length14.04 mm (0.5528 in.)
Flange thickness Mark
1
2
3
3.0 mm (0.118 in.)
3.2 mm (0.126 in.)
3.4 mm (0.134 in.)
1st & reverse brake
Pack clearance1.16 - 1.35 mm (0.0457 - 0.0531in.)
Return spring free length15.53 mm (0.6114 in.)
Flange thickness Mark
1
2
3
4
5
6
7
8
1.8 mm (0.071 in.)
1.9 mm (0.075 in.)
2.0 mm (0.079 in.)
2.1 mm (0.083 in.)
2.2 mm (0.087 in.)
2.3 mm (0.091 in.)
2.4 mm (0.094 in.)
2.5 mm (0.098 in.)
Page 70 of 969
03-6
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
22 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U) U/D planetary gear
Preload (at 60 rpm)0.50 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
Front planetary gear
Turning torque (at 60 rpm) New Bearing
Used Bearing0.51 - 1.02 NVm (5.1 - 10.0 kgfVcm, 4.4 - 8.7 in.Vlbf)
0.26 - 0.51 NVm (2.7 - 5.2 kgfVcm, 2.3 - 4.5 in.Vlbf)
Input shaft
End play0.262 - 1.249 mm (0.0103 - 0.0492 in.)
Transaxle rear cover
Bearing press fit depth20.55 - 21.25 mm (0.8091 - 0.8366 in.)
Transmission valve body
Valve body installation bolt length A
B
C41 mm (1.614 in.)
57 mm (2.244 in.)
25 mm (0.984 in.)
Accumulator
SpringFree length/Outer diameterColor
B3Inner
Outer62.00 (2.4409) / 15.50 (0.610)
74.23 (2.9224) / 16.50 (0.649)Purple
Purple
C260.96 (2.3999) / 14.10 (0.555)Yellow
C372.20 (2.8425) / 19.0 (0.748)Colorless
Front differential(U151E)
Backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness Mark
-
-
-
1.625 mm (0.0640 in.)
1.725 mm (0.0679 in.)
1.825 mm (0.0719 in.)
Praload (at 60 rpm) New bearing
Used bearing0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
Flange thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
Front differential (U151F)
Side gear backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Page 71 of 969
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
03-7
23 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U) Thrust washer thickness
= Clearance - 0.162 - 0.265 mm (0.0064 - 0.0104 in.)
Mark
A
B
C
D
E
F
G
H
J
K
0.95 mm (0.0373 in.)
1.00 mm (0.0393 in.)
1.05 mm (0.0413 in.)
1.10 mm (0.0433 in.)
1.15 mm (0.0453 in.)
1.20 mm (0.0472 in.)
1.25 mm (0.0492 in.)
1.30 mm (0.0512 in.)
1.35 mm (0.0532 in.)
1.40 mm (0.0552 in.)
Pinion's backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness Mark
MA
MB
MC
MD
ME
MF
MG
MH
MJ
MK
ML
MM
MN
0.80 mm (0.0313 in.)
0.85 mm (0.0333 in.)
0.90 mm (0.0353 in.)
0.95 mm (0.0373 in.)
1.00 mm (0.0393 in.)
1.05 mm (0.0413 in.)
1.10 mm (0.0433 in.)
1.15 mm (0.0453 in.)
1.20 mm (0.0472 in.)
1.25 mm (0.0492 in.)
1.30 mm (0.0512 in.)
1.35 mm (0.0532 in.)
1.40 mm (0.0552 in.)
Praload (at 60 rpm) New bearing
Used bearing0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
Flange thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
Oil seal press in depth5.5 - 6.5 mm (0.217 - 0.256 in.)
Page 72 of 969
0305L-1 1
03-8
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
24 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TORQUE SPECIFICATION
Part TightenedNVmkgfVcmftVlbf
Differential gear lube apply tube x Transaxle housing9.810087 in.Vlbf
Front planetary gear lock nut210-3502141-3569155-258
Brake apply tube clamp x Transaxle case5.45548 in.Vlbf
Transaxle case No. 1 plug x Transaxle rear cover7.47565 in.Vlbf
Transaxle rear cover x Transaxle case Bolt A
Other bolt19
25190
25014
18
Pawl shaft clamp x Transaxle case9.810087 in.Vlbf
Oil pump assy x Transaxle case2222616
Transaxle housing x Transaxle case Bolt A
Bolt B
Bolt C
Bolt D25
33
29
22255
337
295
22618
24
21
16
Automatic transmission case plug x Transaxle housing7.47565 in.Vlbf
Automatic transmission case plug x Transaxle case7.47565 in.Vlbf
Parking lock pawl bracket x Transaxle case2020515
Manual detent spring x Transaxle case Bolt A
Bolt B20
12205
12015
9
Transmission wire x Transaxle housing5.45548 in.Vlbf
Transmission valve body x Transaxle case1111 08
ATF temperature sensor clamp x Transmission valve body6.66758 inVlbf
Valve body oil strainer assy x Transmission valve body1111 08
Automatic transaxle oil pan sub-assy x Transaxle case7.88069 in.Vlbf
Drain plug x Automatic transaxle oil pan sub-assy4950036
Speed sensor x Transaxle case1111 58
Oil cooler tube union x Transaxle case Union
Elbow27
27276
27620
20
Park/neutral start switch x nut6.97061 in.Vlbf
Park/neutral start switch x Bolt5.45548 in.Vlbf
Park/neutral start switch x Control shaft lever131309
Speedometer driven hole cover sub-assy x Transaxle case6.97061
Oil pump body x Stator shaft assy9.810087 in.Vlbf
Line pressure control solenoid assy x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve SL1x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve SL2x Transmission valve body assy10.811 08
Shift solenoid valve SL3x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve S4x Transmission valve body assy10.811 08
Shift solenoid valve DSL x Transmission valve body assy10.811 08
Front differential case x Front differential ring gear95.197070
Page 419 of 969
A78535
A78706Align
A78707
Main GearSub Gear
Service Bolt
A78708
101
2
3
4
5
6
7
89
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-43
2135 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
26. REMOVE WATER PUMP ASSY
(a) Remove the 3 bolts and 3 nuts, then remove the water
pump and gasket.
27. REMOVE CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being removed. 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) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
(c) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 5 bearing caps and camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
Page 420 of 969
A78709
10
1
2
3
4
5
67
8
9
A78710Align
A78711Main GearSub Gear
Service Bolt 14-44
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2136 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
28. REMOVE NO.2 CAMSHAFT
(a) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 5 bearing caps and No. 2 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 2 camshaft.
29. REMOVE NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being removed. 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) Align the timing marks (1 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
Page 423 of 969
A78715
SST
A52353
A05275
A78716
Front
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-47
2139 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using SST, turn the sub gear counterclockwise, then re-
move the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, camshaft sub gear and cam-
shaft gear bolt washer.
HINT:
Arrange the camshaft sub gears and gear bolt washers (RH and
LH sides) so that they can be returned to the original locations
when reassembling.
34. REMOVE ENGINE HANGER NO.2
35. REMOVE CYLINDER HEAD COVER REAR
36. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the plug, gasket and valve filter.
37. REMOVE CYLINDER HEAD SUB-ASSY
(a) Using a socket hexagon wrench 8, remove the hexagon
bolt.
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 438 of 969
A78739
Align
A05204
A78740
101
23
4
5
6
7
8
9 14-62
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2154 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
77. INSTALL 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.
(b) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears.
(c) Place the camshaft on the cylinder head.
(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(f) Using several steps, tighten the 10 bearing cap bolts uni-
formly in the sequence shown in the illustration.
Torque: 16 NVm (163 kgfVcm, 12 ftVlbf)
(g) Remove the service bolt.
78. INSTALL NO.4 CAMSHAFT SUB-ASSY
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 440 of 969
A78744
Align
A05214
A78745
10
1
2
3
45
6
7
8
9
A78746
Inward
Sensor 14-64
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2156 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
79. INSTALL NO.3 CAMSHAFT SUB-ASSY
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.
(b) Align the timing marks (1 dot marks) of the camshaft drive
and driven gears.
(c) Place the camshaft on the cylinder head.
(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(f) Using several steps, tighten the 10 bearing cap bolts uni-
formly in the sequence shown in the illustration.
Torque: 16 NVm (163 kgfVcm, 12 ftVlbf)
(g) Remove the service bolt.
80. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the timing pulley with the key located
on the crankshaft, then slide the timing 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)