service 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 470 of 969
A05077
Clamp
Clamp
Clamp
A78706Align
A78707
Main GearSub Gear
Service Bolt
A78708
101
2
3
4
5
6
7
89 14-94
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
2186 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. REMOVE TIMING BELT NO.3 COVER
(a) Disconnect the 3 engine wire harness clamps from the
timing belt No. 3 cover.
(b) Remove the 6 bolts and timing belt cover.
26. 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 472 of 969
A78715
SST
A52353
P12595
A78732
Camshaft
Sub Gear
Camshaft Gear
Bolt Washer Wave Washer
A52353
14-96
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
2188 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.
30. INSTALL CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear bolt washer and camshaft sub
gear.
HINT:
Attach the pins on the gears to the gear bolt washer ends.
(c) Install the wave washer.
(d) Using snap ring pliers, install the snap ring.
Page 473 of 969
A78733
SST
A78734
Align
A05738
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
14-97
2189 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.
31. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Align the alignment pin with the alignment pin groove,
then install the VVT-i on 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 nut 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.
32. 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 475 of 969
A78739
Align
A05204
A78740
101
23
4
5
6
7
8
9
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
14-99
2191 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
33. 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.
34. INSTALL TIMING BELT NO.3 COVER
(a) Visually check for cracks and breaks on the gasket of the
timing belt cover.
HINT:
If there is a trace of water intrusion when checking visually, re-
pair the gasket with seal packing when the crack length is within
2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack
length is 3 to 4 cm (1.18 to 1.57 in.) or longer.
Page 484 of 969
A78711Main GearSub Gear
Service Bolt
A78712
10
12
3
4
5
67
89
A78713
10
1
2
3
4
5
6
7
89 14-108
- ENGINE MECHANICALCAMSHAFT (LH BANK) (3MZ-FE)
2200 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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 No. 3 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.
24. REMOVE NO.4 CAMSHAFT SUB-ASSY
(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. 4 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. 4 camshaft.
25. REMOVE CAMSHAFT TIMING GEAR ASSY (See page 14-93)
26. REMOVE CAMSHAFT SUB GEAR NO.3 (See page 14-93)
SST 09960-10010 (09962-01000, 09963-00500)
27. INSTALL CAMSHAFT SUB GEAR NO.3 (See page 14-93)
SST 09960-10010 (09962-01000, 09963-00500)
28. INSTALL CAMSHAFT TIMING GEAR ASSY (See page 14-93)
Page 486 of 969
A78743
10
1
23
4
5
6
7
8
9
A78744
Align
A05214
A78745
10
1
2
3
45
6
7
8
9 14-1 10
- ENGINE MECHANICALCAMSHAFT (LH BANK) (3MZ-FE)
2202 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(i) Using several steps, install and tighten the 10 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 16 NVm (163 kgfVcm, 12 ftVlbf)
30. 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 to 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, install and tighten the 10 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 16 NVm (163 kgfVcm, 12 ftVlbf)
(g) Remove the service bolt.
31. INSTALL TIMING BELT NO.3 COVER (See page 14-93)
32. INSTALL CAMSHAFT TIMING PULLEY (See page 14-93)
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
33. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93)
Page 587 of 969
A86347DLC3
Hand-held Tester
A62390
FP
+B
- FUELFUEL SYSTEM (3MZ-FE)
11-7
2035 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand-held tester.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON and the hand-held tes-
ter ON.
NOTICE:
Do not start the engine.
(3) Select the ACTIVE TEST mode on the hand-held
tester.
(4) If you need help to select the ACTIVE TEST mode
on the hand-held tester, refer to the hand-held tes-
ter operator's manual.
(b) When not using the hand-held tester.
(1) Remove the circuit opening relay.
(2) Using a service wire, connect terminals FP and +B
of the engine room relay block.
NOTICE:
Pay due attention to the terminal connecting position to
avoid a malfunction.
(3) Turn the ignition switch ON, and check that the fuel
pump operates.
NOTICE:
Do not start the engine.
(c) Check that there are no fuel leaks after doing mainte-
nance anywhere on the fuel system.
Page 598 of 969
110XW-02
A79485 A79485 Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
5.9 (60, 52 in.Vlbf)
x8Fuel Pump Tube Sub-assy
Tube Joint Clip Fuel Tank Bent Tube Set Plate
Fuel Suction
w/ Pump & Gauge Tube Assy
Fuel Suction Tube Set Gasket Vapor Pressure Sensor Connector Fuel Pump ConnectorRear Floor Service Hole Cover Rear Seat Cushion Assy
11-18- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
2046 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (3MZ-FE)
COMPONENTS
Page 600 of 969
110XX-02
A79487
(b)
(c)
A91017
Nylon Tube Fuel Tube Joint
O-ring
Tube Joint Clip Fuel Suction Plate
A79488
Tube Joint Clip
A79489
(b)
(b)
(b)(b)(b)
(b)
(b)
(b) 11-20
- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
2048 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Removal & Installation and Disassembly & Reassembly
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3. REMOVE REAR SEAT CUSHION ASSY (See page 72-39)
4. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Remove the rear floor service hole cover.
(b) Disconnect the vapor pressure sensor connector.
(c) Disconnect the fuel pump connector.
5. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY
(a) Remove the tube joint clip, then pull out the fuel pump
tube.
NOTICE:
Check around the connector for dirt or mud before
this operation. Remove the dirt if necessary.
Be careful of mud because the fuel tube joint has an
O-ring which seals the pipe and connector that can
be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the con-
nector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull
the connector to release. Pull the connector carefully.
(b) Remove the 8 bolts, then remove the fuel tank vent tube
set plate.
Page 604 of 969
A79489Mark
A81595
Tube Joint ClipCollar
A79487
New Butyl Tape
11-24- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
2052 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
24. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY
(a) Install a new gasket to the fuel suction tube w/ pump &
gauge.
(b) Install the fuel suction tube w/ pump & gauge to the fuel
tank.
NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gauge.
(c) Align the mark of the fuel tank vent tube set plate with the
fuel suction tube w/ pump & gauge.
(d) Install the fuel tank bent tube set plate with the 8 bolts.
Torque: 5.9 NVm (60 kgfVcm, 52 in.Vlbf)
(e) Install the fuel pump tube with the tube joint clip.
NOTICE:
Check the connected part for scratch or foreign ob-
jects.
Check that the fuel tube joint is inserted securely.
Check that the tube joint clip is on the collar of the fuel
tube joint.
After installing the tube joint clip, check that the fuel
tube joint has not been pulled off.
25. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
26. CHECK FOR FUEL LEAKS (See page 11-5)
27. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the fuel pump connector.
(b) Connect the vapor pressure sensor connector.
(c) Using new butyl tape, install the rear floor service hole
cover.
28. INSTALL REAR SEAT CUSHION ASSY
29. SYSTEM INITIALIZATION (See page 19-15)