LEXUS ES300 2005 Repair Manual

- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
35. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
(a) Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)
36. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
(a) Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)

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)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CYLINDER BLOCK ASSY (3MZ-FE)
COMPONENTS

A78312N´m (kgf´cm, ft´lbf)
: Specified torque
27 (275, 20)
27 (275, 20)1st: 22 (224, 16)
2st: Turn 90
See page (14-158)
Cylinder Block Sub-assy
Upper Crankshaft Thrust WasherCrankshaft Bearing
Crankshaft Bearing
Lower Crankshaft Thrust Washer
Crankshaft Bearing CapCrankshaft
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

1419M-03
P12695
A78793
Plastigage
A78794
Protrusion Front 14-158
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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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.

P12697
A78795
90
Front90Painted Mark
P12698
A79803
Number Mark
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(h) Tighten the cap bolts in several steps by the specified
torque.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(i) Mark the front side of each cap bolt with paint.
(j) Retighten the cap bolts by 90 as shown in the illustration.
NOTICE:
Do not turn the crankshaft.
(k) Remove the cap bolts, cap and lower bearing.
(l) Measure the Plastigage at its widest point.
Standard oil clearance:
0.038 to 0.066 mm (0.0015 to 0.0026 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
NOTICE:
Completely remove the Plastigage.

If the oil clearance is greater than maximum, re-
place the bearing.

If necessary, grind or replace the crankshaft.
HINT:
If replacing the bearing, replace it with one having the same
number as marked on the connecting rod. There are 4 sizes of
standard bearings, marked º1 º, º2º, º3º and º4º accordingly.
Reference:
Standard bearing center wall thickness:
Markmm (in.)
º1º1.484 to 1.487 (0.0584 to 0.0585)
º2º1.487 to 1.490 (0.0585 to 0.0587)
º3º1.490 to 1.493 (0.0587 to 0.0588)
º4º1.493 to 1.496 (0.0588 to 0.0589)

A05258
A78315
P12403
A78797
80C (176F) 14-160
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2252 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
8. REMOVE PISTON SUB-ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push out the piston and connecting rod assembly from
the top of the cylinder block.
HINT:

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order so they can be returned to the original loca-
tions when reassembling.
9. REMOVE CONNECTING ROD BEARING
10. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and expander by hand.
11. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
12. REMOVE W/PIN PISTON SUB-ASSY
(a) Gradually heat the piston up to approximately 80C
(176F).

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)
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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.

P12603
A78800
Joint Surface
Z09222
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- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Using a screwdriver, pry out the bearing caps. Remove
the 4 bearing caps and 4 lower bearings.
NOTICE:

Carefully pry out the main bearing cap by alternately
lifting each end of the bearing cap little by little.

Be careful not to damage the joint surface of the cylin-
der block and bearing cap.
15. REMOVE CRANKSHAFT THRUST WASHER SET
16. REMOVE CRANKSHAFT BEARING
17. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the warpage on the surface which contacts the cylin-
der head gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than maximum, replace the cylinder
block.

A88633
Thrust Direction
Axial Direction Front
10 mm (0.39 in.)
A
B
A78316
13.0 mm
(0.512 in.)
Z00064
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
18. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A and B in the thrust and axial directions.
Standard diameter:
92.000 to 92.012 mm (3.6220 to 3.6225 in.)
Maximum diameter: 92.132 mm (3.6272 in.)
If the average diameter of 4 positions is greater than maximum,
replace the cylinder block.
19. INSPECT W/PIN PISTON SUB-ASSY
(a) Using a micrometer, measure the diameter of the piston.
Align the micrometer so it is 13.0 mm (0.512 in.) from the
bottom of the piston and at a right angle (90) to the piston
pin holes as illustrated.
Piston diameter:
91.953 to 91.967 mm (3.6202 to 3.6207 in.)
20. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)

If the oil clearance is greater than maximum, replace all the 6 pistons.

If necessary, replace the cylinder block.
21. INSPECT CONNECTING ROD SUB-ASSY
(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Inspect for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If misalignment is greater than maximum, replace the connect-
ing rod assembly.

Z00065
EM6525
EM0227
A78803
SST 14-164
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(2) Inspect for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than maximum, replace the connecting rod
assembly.
22. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
bush.
Bush inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the
bush inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)

If the oil clearance is greater than maximum, re-
place the bush.

If necessary, replace the piston and piston pin to-
gether.
23. REMOVE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bush.
SST 09222-30010