LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
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 524 of 969
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.)
Page 525 of 969
P12685
A33264
A05238
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
14-149
2241 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
20. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.009 to 31.025 mm (1.2208 to 1.2215 in.)
(b) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, re-
place the valve lifter.
If necessary, replace the cylinder head.
21. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshaft timing gear.
(b) Install the camshafts to the cylinder head.
NOTICE:
Install the camshafts with the valves and sub gear re-
moved.
Install the camshafts with their timing marks
matched.
(c) Set the dial indicator to the teeth of the intake camshaft
at a right angle (90).
(d) Measure the backlash of the camshaft timing gear at least
4 positions.
Standard backlash:
0.020 to 0.200 mm (0.0008 to 0.0079 in.)
Maximum backlash: 0.30 mm (0.0118 in.)
22. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.040 to 0.090 mm (0.0016 to 0.0035 in.)
Maximum thrust clearance: 0.12 mm (0.0047 in.)
If the thrust clearance is greater than maximum, re-
place the camshaft.
If necessary, replace the bearing caps and cylinder
head together.
23. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Clean the camshafts.
(c) Place the camshafts on the cylinder head.
Page 526 of 969
A05239
A05240
A78782
RH Cylinder:
10 mm (0.39 in.)
8 mm (0.31 in.)
A78783
LH Cylinder:
10 mm (0.39 in.)
8 mm (0.31 in.) 14-150
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
2242 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(e) Install the bearing caps.
Torque: 16 NVm (163 kgfVcm, 12 ftVlbf)
NOTICE:
Do not turn the camshaft.
(f) Remove the bearing caps.
(g) Measure the Plastigage at its widest point.
Standard oil clearance:
Intake #4, #5 journals
0.025 to 0.057 mm (0.0010 to 0.0022 in.)
Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum oil clearance 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, re-
place the camshaft.
If necessary, replace the bearing caps and cylinder
head together.
NOTICE:
Completely remove the Plastigage.
24. INSTALL RING W/HEAD PIN (RH CYLINDER)
(a) Using a plastic-faced hammer, tap in a new ring pin to the
specified protrusion height.
Protrusion height: 3 mm (0.12 in.)
25. INSTALL RING PIN (LH CYLINDER)
(a) Using a plastic-faced hammer, tap in a new ring pin to the
specified protrusion height.
Protrusion height: 3 mm (0.12 in.)
Page 527 of 969
A78784
Protrusion Height
Mark
A78785
Wooden
BlockPress
Protrusion
Height
A78786
Wooden
Block
Flush
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
14-151
2243 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
26. INSTALL SPARK PLUG TUBE
(a) Using paint, mark the standard height from the edge.
Standard protrusion height:
42.4 to 43.4 mm (1.669 to 1.709 in.)
HINT:
Use either end of the spark plug tube.
(b) Apply adhesive to the end of the spark plug tube which will
be pressed into the cylinder head.
Adhesive: Part No. 08833-00070 THREE BOND 1324
or equivalent
NOTICE:
Install the spark plug tube within 3 minutes after ap-
plying adhesive.
Do not deform the spark plug tube.
Do not expose the spark plug tube to coolant within
1 hour after installing.
(c) Using a press and wooden block, install the spark plug
tube to the required protrusion height.
NOTICE:
Be careful not to drip the adhesive.
27. INSTALL PCV PIPE (RH CYLINDER)
(a) Using a wooden block and hammer, tap in 2 new PCV
pipes until their top edges are flush with the cylinder head
edge.
NOTICE:
Be careful not to damage the cylinder head edge.
Page 528 of 969
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.
Page 529 of 969
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)
Page 530 of 969
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.