length LEXUS ES300 2005 Owner's Guide
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 476 of 969
A78748
Seal Packing
Gasket
A78749
E
F
Joining
Line D
G
Gasket Joining Portion:
Seal Packing E
Joining
Line
A78750
FrontFront
Belt
GuideBelt
Guide
14-100
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
2192 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) If the timing belt cover gasket is needed to repair, follow
the procedure below.
(1) Repair the cracks and breaks by applying seal
packing to the damaged area.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high
as the gasket.
(c) If the timing belt cover gasket is needed to replace, follow
the procedure below.
(1) Using a screwdriver and gasket scraper, remove
the remaining gasket.
NOTICE:
Be careful not to damage the timing belt cover.
(2) Remove the backing paper from a new gasket, then
affix the gasket along the groove of the timing belt
cover as shown in the illustration.
NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uni-
form.
HINT:
GasketDEFG
Length335 mm
(13.19 in.)180 mm
(7.09 in.)133 mm
(5.24 in.)72 mm
(2.83 in.)
(3) If there is a gap between the ends of the gasket, ap-
ply seal packing to close the gap.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high
as the gasket.
(d) Install the timing belt cover with the 6 bolts.
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
35. INSTALL CAMSHAFT TIMING PULLEY
(a) Pay attention to the orientation of the belt guide. Install
the camshaft timing pulley with the belt guide properly ori-
ented, then tighten the bolt temporarily.
HINT:
Align the belt guide of the RH timing pulley so it faces the
front of the engine as illustrated.
Align the belt guide of the LH timing pulley so it faces the
rear of the engine as illustrated.
Page 477 of 969
A78763
150 mm
(5.91 in.)SST RH:
A78762
SSTLH:
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
14-101
2193 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using SST, tighten the RH pulley bolt.
SST 09960- 10010 (09962- 01000, 09963- 01000),
09249-63010
Torque: 125 NVm (1,275 kgfVcm, 92 ftVlbf)
NOTICE:
The torque indicated above is used without SST on the ex-
tension tool. If you are using the extension tool, find the
reading of the torque wrench by the formula (see page
01-5).
Extended length:
SST (09249-63010) 150mm (5.91 in.)
(c) Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 NVm (1275 kgfVcm, 92 ftVlbf)
36. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 NVm (438 kgfVcm, 32 ftVlbf)
37. INSPECT TIMING BELT (See page 14-79)
38. INSTALL TIMING BELT (See page 14-79)
SST 09960-10010 (09962-01000, 09963-01000)
39. INSTALL TIMING BELT TENSIONER ASSY (See page 14-79)
40. INSTALL TIMING BELT GUIDE NO.2 (See page 14-79)
41. INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79)
42. INSTALL TIMING BELT NO.2 COVER (See page 14-79)
43. INSTALL TIMING BELT NO.1 COVER (See page 14-79)
44. INSTALL CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021
45. INSTALL GENERATOR BRACKET NO.2 (See page 14-79)
46. INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
47. INSTALL ENGINE MOVING CONTROL ROD (See page 14-79)
48. INSPECT VALVE CLEARANCE (See page 14-7)
49. ADJUST VALVE CLEARANCE (See page 14-7)
SST 09248-55040 (09248-05410, 09248-05420)
50. INSTALL VANE PUMP V BELT (See page 14-5)
51. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
52. INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1)
53. INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-7)
54. INSTALL IGNITION COIL ASSY (See page 14-7)
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 520 of 969
A78773
Cylinder Block Surface:
Exhaust Manifold Surface: Intake Manifold Surface:
A05227
EM2534
Overall Length
Z00052
14-144
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
2236 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the warpage on the surfaces which contacts the cyl-
inder block and manifolds.
Maximum warpage:
0.05 mm (0.0020 in.) for cylinder block surface
0.10 mm (0.0039 in.) for intake manifold surface
0.10 mm (0.0039 in.) for exhaust manifold surface
If the warpage is greater than maximum, replace the cylinder
head.
10. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
11. INSPECT INTAKE VALVE
(a) Inspect the valve overall length.
Standard overall length: 95.45 mm (3.7579 in.)
Minimum overall length: 94.95 mm (3.7382 in.)
If the overall length is less than minimum, replace the valve.
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Page 521 of 969
A78774
Margin
Thickness
EM2534
Overall Length
Z00052
A78774
Margin
Thickness
EM0801
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
14-145
2237 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Inspect the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.
12. INSPECT EXHAUST VALVE
(a) Inspect the valve overall length.
Standard overall length: 95.40 mm (3.7559 in.)
Minimum overall length: 94.90 mm (3.7362 in.)
If the overall length is less than minimum, replace the valve.
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.465 to 5.480 mm (0.2152 to 0.2157 in.)
(c) Inspect the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.
13. INSPECT INNER COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the
spring.
Free length: 45.50 mm (1.7913 in.)
If the free length is not as specified, replace the spring.
Page 522 of 969
A78775
Deviation
EM0281
P12754
A05234
14-146
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
2238 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using a steel square, measure the deviation of the spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the spring.
(c) Using a spring tester, measure the tension of the spring
when the spring is the specified installed length.
Installed tension:
186 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf)
at 33.8 mm (1.331 in.)
If the installed tension is not as specified, replace the spring.
14. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
valve guide bush.
Bush inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the
valve guide bush inside diameter measurement.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0024 in.) for intake
0.030 to 0.065 mm (0.0012 to 0.0026 in.) for exhaust
Maximum oil clearance:
0.08 mm (0.0031 in.) for intake
0.10 mm (0.0039 in.) for exhaust
If the clearance is greater than maximum, replace the valve and
valve guide bush.
15. REMOVE VALVE GUIDE BUSH
(a) Heat the cylinder head up to 80 to 100 C
(176 to 212 F).
Page 523 of 969
A78776
SST
P12956
A78777
Intake:
34.5 mm
(1.358 in.)40.5 mm
(1.594 in.) Exhaust:
A78778
SST
Z09124
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
14-147
2239 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using SST and a hammer, tap out the valve guide bush.
SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
16. INSTALL VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bush bore diameter
of the cylinder head.
Diameter: 10.295 to 10.313 mm (0.4053 to 0.4060 in.)
If the bush bore diameter of the cylinder head is greater than
10.313 mm (0.4060 in.), machine the bush bore to the dimen-
sion of 10.345 to 10.363 mm (0.4073 to 0.4080 in.).
HINT:
Bush diameter:
STD10.333 to 10.344 mm (0.4068 to 0.4072 in.)
O/S10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Bush length:
Intake34.5 mm (1.358 in.)
Exhaust40.5 mm (1.594 in.)
(b) Heat the cylinder head up to 80 to 100 C (176 to 212 F).
(c) Using SST and a hammer, tap in a new valve guide bush
to the specified protrusion height.
SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
Protrusion height:
11.1 to 11.5 mm (0.437 to 0.453 in.) for intake
8.9 to 9.3 mm (0.350 to 0.366 in.) for exhaust
(d) Using a sharp 5.5 mm reamer, ream the valve guide bush
to obtain the standard specified clearance between the
valve guide bush and valve stem.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0024 in.) for intake
0.030 to 0.065 mm (0.0012 to 0.0026 in.) for exhaust
Page 708 of 969
2605T-05
C91608
B Front:A
C91609
C Rear:
D
SA3213
A
DB
Front
C
F40165
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
26-5
2368 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT WHEEL ALIGNMENT (From July, 2003)
ADJUSTMENT
1. INSPECT TIRE (See page 26-5)
2. MEASURE VEHICLE HEIGHT
Vehicle height:
FrontA - B: 120 mm (4.72 in.)
RearD - C: 52 mm (2.05 in.)
Measuring points:
A: Ground clearance of front wheel center
B: Ground clearance of lower suspension arm No. 2 set bolt
center
C: Ground clearance of strut rod set bolt center
D: Ground clearance of rear wheel center
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specified value.
HINT:
Bounce the vehicle at the corners up and down to stabilize the
suspension and inspect the vehicle height.
3. INSPECT TOE-IN
Toe-in:
Toe-in
(total)A + B: 0° ± 12' (0° ± 0.2°)
C - D: 0 ± 2 mm (0 ± 0.08 in.)
If the toe-in is not within the specified value, adjust it at the rack
ends.
4. ADJUST TOE-IN
(a) Remove the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to
adjust the toe-in.
HINT:
Try to adjust the toe-in to the center of the specified value.
(d) Make sure that the lengths of the right and left rack ends
are the same.
(e) Torque the tie rod end lock nuts.
Torque: 74 N´m (755 kgf´cm, 55 ft´lbf)
(f) Place the boots on the seats and install the clips.
HINT:
Make sure that the boots are not twisted.
(g) Perform VSC system calibration. (See page 05-471)
Page 709 of 969
SA0028
AB
FrontA B
A: Inside
B: Outside
Z03382
Alignment
TesterGauge
C93871
26-6
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
2369 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully left and right, and measure
the turning angle.
Wheel turning angle:
Inside wheel36°39' ± 2° (36.65° ± 2°)
Outside wheel: Reference32°11' (32.18°)
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.
6. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
(a) Put the front wheel on the center of the alignment tester.
(b) Set the camber - caster - kingpin gauge at the center of
the axle hub or drive shaft.
Camber, caster and steering axis inclination:
Camber
Left-right error-0°43' ± 45' (-0.72° ± 0.75°)
45' (0.75°) or less
Caster
Left-right error2°46' ± 45' (2.77° ± 0.75°)
45' (0.75°) or less
Steering axis inclination11°27' (11.45°)
If the caster and steering axis inclination are not within the spec-
ification, after the camber has been correctly adjusted, recheck
the suspension parts for damage and/or worn out parts.
7. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheel.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
HINT:
When removing nuts, stop the bolt from rotating and loosen the
nut.
(c) Clean the installation surfaces of the shock absorber and
the steering knuckle.
(d) Temporarily install the 2 nuts.
Page 734 of 969
N00372
HeightThickness
Length
R10282
Feeler Gauge
F41490
F41491F41622
Compressed Air
R08702
Vernier Calipers
51-12
- POWER STEERINGVANE PUMP ASSY
2587 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
26. INSPECT VANE PUMP ROTOR AND VANE PUMP
PLATES
(a) Using a micrometer, measure the height, thickness and
length of the vane pump plates.
Minimum height: 8.6 mm (0.339 in.)
Minimum thickness: 1.397 mm (0.05500 in.)
Minimum length: 14.991 mm (0.59020 in.)
(b) Using a feeler gauge, measure the clearance between
the vane pump rotor groove and vane pump plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the vane pump assy.
27. INSPECT FLOW CONTROL VALVE
(a) Coat the flow control valve with power steering fluid and
check that it falls smoothly into the flow control valve hole
by its own weight.
(b) Check the flow control valve for leakage. Close one of the
holes and apply compressed air of 392 - 490 kPa (4 - 5
kgf/cm
2, 57 - 71 psi) into the opposite side hole, and con-
firm that air does not come out from the end holes.
If necessary, replace the vane pump assy.
28. INSPECT FLOW CONTROL VALVE COMPRESSION
SPRING
(a) Using vernier calipers, measure the free length of the flow
control valve compression spring.
Minimum free length: 32.24 mm (1.2693 in.)
If it is not within the specification, replace the vane pump assy.