drain LEXUS ES300 2005 Owner's Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 432 of 969
A78727
Seal Packing
Seal Width
4 to 5 mm
(0.16 to 0.20 in.) AA
BB
A78728
Seal PackingSeal Width 3 to 5 mm
(0.12 to 0.20 in.)
A78314
10
1
2
3
4
5
6
78
9 14-56
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2148 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Apply a continuous bead of seal packing (Diameter 4 to
5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pan within 3 minutes after applying seal
packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
66. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 45 NVm (459 kgfVcm, 33 ftVlbf)
67. INSTALL WATER INLET HOUSING
(a) Remove any old packing material from the contact sur-
face.
(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 water inlet housing within 3 minutes after
applying seal packing.
Do not expose the seal packing to coolant within 2
hours after installing.
(c) Install the water inlet housing with the 8 bolts and 2 nuts.
Using several steps, tighten the bolts and nuts uniformly
in the sequence shown in the illustration.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
Page 443 of 969
A78703
SST
A78704
SST
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-67
2159 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 NVm (1,275 kgfVcm, 92 ftVlbf)
(c) Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 NVm (1,275 kgfVcm, 92 ftVlbf)
87. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 NVm (438 kgfVcm, 32 ftVlbf)
88. INSTALL TIMING BELT IDLER SUB-ASSY NO.1
(a) Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot
bolt.
Torque: 34 NVm (347 kgfVcm, 25 ftVlbf)
89. INSTALL TIMING BELT
(a) Remove any oil or water on the pulleys, then keep them
clean.
NOTICE:
If there is a trace of water and/or oil on the timing belt,
repair the leakage and install a new timing belt.
Only wipe the pulleys; do not use any cleaning agent.
(b) Check the idler pulleys.
(1) Check that the idler pulley turns smoothly.
(2) Visually check the seal portion of the idler pulley for
oil leakage.
(c) Check the water pump.
(1) Turn the pulley, then check that water pump bearing
moves smoothly and does not make a noise.
(2) Visually check the drain hole for coolant leakage.
(d) Temporarily install the crankshaft pulley bolt and washer
to the crankshaft.
Page 458 of 969
EM3336
14-82
- ENGINE MECHANICALTIMING BELT (3MZ-FE)
2174 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. 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.
(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.
15. INSTALL TIMING BELT
(a) Remove any oil or water on the pulleys, then keep them
clean.
NOTICE:
If there is a trace of water and/or oil on the timing belt,
repair the leakage and install a new timing belt.
Only wipe the pulleys; do not use any cleaning agent.
(b) Check the idler pulleys.
(1) Check that the idler pulley turns smoothly.
(2) Visually check the seal portion of the idler pulley for
oil leakage.
(c) Check the water pump.
(1) Turn the pulley, then check that water pump bearing
moves smoothly and does not make a noise.
(2) Visually check the drain hole for coolant leakage.
(d) Temporarily install the crankshaft pulley bolt and washer
to the crankshaft.
Page 469 of 969
141JD-01
A78761
RH:
SST
A78762
SSTLH:
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
14-93
2185 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT (See page 16-9)
3. REMOVE FRONT WHEEL RH
4. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
5. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
6. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
7. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
8. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
9. REMOVE IGNITION COIL ASSY
10. REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-7)
11. REMOVE FRONT FENDER APRON SEAL RH
12. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
13. REMOVE VANE PUMP V BELT (See page 14-5)
14. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
15. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
16. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
17. REMOVE CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
18. REMOVE TIMING BELT NO.1 COVER
19. REMOVE TIMING BELT NO.2 COVER (See page 14-79)
20. REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79)
21. REMOVE TIMING BELT GUIDE NO.2
22. REMOVE TIMING BELT (See page 14-79)
23. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
24. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the bolt and RH timing pulley.
SST 09960- 10010 (09962- 01000, 09963- 01000),
09249-63010
(b) Using SST, remove the bolt and LH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
HINT:
Arrange the camshaft timing pulleys (RH and LH sides) so that
they can be returned to the original locations when reassem-
bling.
Page 483 of 969
141JF-01
A78710Align
- ENGINE MECHANICALCAMSHAFT (LH BANK) (3MZ-FE)
14-107
2199 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT (See page 16-9)
3. REMOVE FRONT WHEEL RH
4. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
5. REMOVE RADIATOR HOSE INLET
6. REMOVE IGNITION COIL ASSY
7. REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7)
8. REMOVE FRONT FENDER APRON SEAL RH
9. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
10. REMOVE VANE PUMP V BELT (See page 14-5)
11. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
12. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
13. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
14. REMOVE CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
15. REMOVE TIMING BELT NO.1 COVER
16. REMOVE TIMING BELT NO.2 COVER (See page 14-79)
17. REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79)
18. REMOVE TIMING BELT GUIDE NO.2
19. REMOVE TIMING BELT (See page 14-79)
20. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
21. REMOVE CAMSHAFT TIMING PULLEY (See page 14-93)
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
22. REMOVE TIMING BELT NO.3 COVER (See page 14-93)
23. 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.
Page 496 of 969
141JH-01
A86571
14-120
- ENGINE MECHANICALCYLINDER HEAD GASKET (3MZ-FE)
2212 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. DRAIN ENGINE COOLANT (See page 16-9)
4. DRAIN ENGINE OIL (See page 17-20)
5. REMOVE FRONT WHEEL RH
6. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
7. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
8. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
9. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
10. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
11. REMOVE INTAKE MANIFOLD (See page 10-16)
12. REMOVE WATER OUTLET (See page 10-16)
13. REMOVE FRONT FENDER APRON SEAL RH
14. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
15. REMOVE VANE PUMP V BELT (See page 14-5)
16. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
17. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
18. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
19. REMOVE CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
20. REMOVE TIMING BELT NO.1 COVER
21. REMOVE TIMING BELT NO.2 COVER (See page 14-79)
22. REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79)
23. REMOVE TIMING BELT GUIDE NO.2
24. REMOVE TIMING BELT (See page 14-79)
25. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
26. REMOVE CAMSHAFT TIMING PULLEY (See page 14-93)
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
27. REMOVE TIMING BELT NO.3 COVER (See page 14-93)
28. SEPARATE VANE PUMP ASSY
29. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2)
30. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2)
31. REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2)
32. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the 3 bolts and exhaust manifold heat insulator.
Page 509 of 969
141JJ-01
A86574
- ENGINE MECHANICALCYLINDER HEAD GASKET NO.2 (3MZ-FE)
14-133
2225 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. DRAIN ENGINE COOLANT (See page 16-9)
4. DRAIN ENGINE OIL (See page 17-20)
5. REMOVE FRONT WHEEL RH
6. REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5)
7. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
8. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
9. REMOVE AIR CLEANER INLET ASSY (See page 19-5)
10. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
11. REMOVE AIR CLEANER CASE (See page 19-5)
12. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
13. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
14. REMOVE INTAKE MANIFOLD (See page 10-16)
15. REMOVE WATER OUTLET (See page 10-16)
16. REMOVE FRONT FENDER APRON SEAL RH
17. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
18. REMOVE VANE PUMP V BELT (See page 14-5)
19. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
20. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
21. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
22. REMOVE CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
23. REMOVE TIMING BELT NO.1 COVER
24. REMOVE TIMING BELT NO.2 COVER (See page 14-79)
25. REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79)
26. REMOVE TIMING BELT GUIDE NO.2
27. REMOVE TIMING BELT (See page 14-79)
28. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
29. REMOVE CAMSHAFT TIMING PULLEY (See page 14-93)
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
30. REMOVE TIMING BELT NO.3 COVER (See page 14-93)
31. REMOVE MANIFOLD STAY NO.2 (See page 14-29)
32. SEPARATE EXHAUST PIPE ASSY FRONT (See page 15-2)
33. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt which secures the oil level gage guide
from the cylinder head LH.
(b) Pull out the oil level gage guide and oil level gage together
from the cylinder block.
(c) Remove the O-ring from the oil level gage guide.
Page 532 of 969
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
14-156
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2248 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CYLINDER BLOCK ASSY (3MZ-FE)
COMPONENTS
Page 534 of 969
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.
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