light LEXUS ES300 2005 Service Manual

A78719
1
2
3
4
5
67
8
Front
A78730
90
Front
Painted Mark
A78718
Front
- ENGINE MECHANICALCYLINDER HEAD GASKET NO.2 (3MZ-FE)
14-135
2227 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
43. INSTALL CYLINDER HEAD LH
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil to the threads of the cylin-
der head bolts.
(b) Install the plate washer to the cylinder head bolt.
(c) Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 54 NVm (550 kgfVcm, 40 ftVlbf)
(d) Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90in the same se-
quence as step (c).
(f) Check that each painted mark is now at a 90 angle to the
front.
(g) Using a socket hexagon wrench 8, install the hexagon
bolt.
Torque: 19 NVm (189 kgfVcm, 14 ftVlbf)
(h) Install the wire harness clamp bracket with the bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(i) Connect the ground cable with the bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
44. INSTALL NO.4 CAMSHAFT SUB-ASSY (See page 14-107)
45. INSTALL NO.3 CAMSHAFT SUB-ASSY (See page 14-107)
46. INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7)
47. INSTALL IGNITION COIL ASSY (See page 14-7)
48. INSTALL WATER INLET PIPE (See page 16-16)

A78779
Width
A78780
45
1.0 to 1.4 mm
(0.039 to 0.055 in.)30
A78781
45 60
1.0 to 1.4 mm
(0.039 to 0.055 in.)
EM6368
14-148
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
2240 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
NOTICE:
Do not rotate the valve.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360 around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360 around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the width between 1.0 and 1.4 mm
(0.039 to 0.055 in.).
18. REPAIR VALVE SEATS
NOTICE:
Releasing the seat cutter pressure gradually helps to make
smoother valve seat faces.
(a) If the seating is too high on the valve face, use the 30 and
45 cutters to correct the seat.
(b) If the seating is too low on the valve face, use the 60 and
45 cutters to correct the seat.
(c) Lap the valve and valve seat by hand with an abrasive
compound.
(d) Recheck the valve seating position.
19. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)

A78787
RH Cylinder:
49 mm
(1.93 in.)
M8
A78788
LH Cylinder:
49 mm
(1.93 in.)
M8
A78789
Intake: Exhaust:
Light Brown
Gray
A78790
SST 14-152
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
2244 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
28. INSTALL STUD BOLT
(a) Install the stud bolts on the intake side.
Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf)
29. INSTALL STUD BOLT
(a) Install the stud bolts on the exhaust side.
Torque: 15 NVm (153 kgfVcm, 11 ftVlbf)
30. INSTALL VALVE STEM OIL O SEAL OR RING
(a) Apply a light coat of engine oil to the valve stem.
NOTICE:
Installing the oil seals for intake and exhaust to the oppo-
site valve guide bush may cause an improper installation.
HINT:
The intake valve oil seal is light brown and the exhaust valve oil
seal is gray.
(b) Using SST, push in a new oil seal.
SST 09201-41020
NOTICE:
Failure to use SST will cause the seal to be damaged or im-
properly seated.

P12668
A78770
SST
A05246
A52900
A78772
SST
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
14-153
2245 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
31. INSTALL INTAKE VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the origi-
nal locations.
(b) Using SST, compress the spring and place the 2 retainer
locks around the valve stem.
SST 09202-70020 (09202-00010)
(c) Using a plastic-faced hammer and discarded valve (the
tip is wrapped with tape), lightly tap the installed valve to
fit into place.
NOTICE:
Be careful not to damage the installed valve stem tip.
32. INSTALL EXHAUST VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the origi-
nal locations.
(b) Using SST, compress the spring and place the 2 retainer
locks around the valve stem.
SST 09202-70020 (09202-00010)

A05246
A78791Seal Packing
A78792
: Semicircular Plug
RH Cylinder:
LH Cylinder:Front 14-154
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
2246 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Using a plastic-faced hammer and discarded valve (the
tip is wrapped with tape), lightly tap the installed valve to
fit into place.
NOTICE:
Be careful not to damage the installed valve stem tip.
33. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil to the valve lifter.
NOTICE:
Install the same parts in the same combination to the original locations.
(b) Install the valve lifter.
(c) Check that the valve lifter is rotated smoothly by hand.
34. INSTALL SEMICIRCULAR PLUG
(a) Remove any old seal packing material.
(b) Apply seal packing to the plug grooves.
Seal packing: Part No. 08826-00080 or equivalent
(c) Install the 2 plugs to the cylinder heads.
NOTICE:

Install the plugs so that they are flush with the top of
the cylinder head.

Install the plugs within 3 minutes after applying seal
packing.

Do not expose the seal packing to engine oil within 2
hours after installing.

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.

P12415
P12799
A78798
3
4
5
6
7
8
2
1
A787991
3
4
5
6
7
8
2
10
11
13
12
1415
16
9
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-161
2253 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using a plastic-faced hammer and brass bar, lightly tap
out the piston pin, then remove the connecting rod.
HINT:

The piston and piston pin are a matched set.

Store the pistons, piston pins, rings, connecting rods and
bearings in the correct order so that they can be returned
to the original locations when reassembling.
13. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
HINT:
The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to
0.0780 in.).
14. REMOVE CRANKSHAFT
(a) Using several steps, loosen and remove the 8 bearing
cap bolts and 8 seal washers uniformly in the sequence
shown in the illustration.
(b) Using several steps, loosen and remove the 16 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion.

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.

A10529
A78810
1
3
4
5
6
7
8
2
10
11
13
12
14
15
16
9
A78811
Painted Mark
90
Front90
A78812
1
2
3
4
5
6
7
8
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-169
2261 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(j) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure proper fit.
(k) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(l) Using several steps, install and tighten the 16 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 22 NVm (224 kgfVcm, 16 ftVlbf)
(m) Mark the front side of the bearing cap bolts with paint.
(n) Retighten the bearing cap bolts by 90 in the same se-
quence as step (l).
(o) Check that each painted mark is now at a 90 angle to the
front.
NOTICE:
Do not turn the crankshaft.
(p) Using several steps, install and tighten the 8 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 27 NVm (275 kgfVcm, 20 ftVlbf)
HINT:
Use the short bolt for the position marked with the arrow.
(q) Remove the bearing caps.

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.