check engine LEXUS ES300 2005 Workshop Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 513 of 969
- ENGINE MECHANICALCYLINDER HEAD GASKET NO.2 (3MZ-FE)
14-137
2229 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
85. CHECK FOR EXHAUST GAS LEAKS
86. INSPECT IGNITION TIMING (See page 14-1)
SST 09843-18040
87. INSPECT ENGINE IDLE SPEED (See page 14-1)
88. INSPECT COMPRESSION (See page 14-1)
SST 09992-00500
89. INSPECT CO/HC (See page 14-1)
90. SYSTEM INITIALIZATION (See page 19-15)
Page 514 of 969
141JK-01
A78764SST
A78765
Cut Position 14-138
- ENGINE MECHANICALOIL PUMP SEAL (3MZ-FE)
2230 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OIL PUMP SEAL (3MZ-FE)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
4. REMOVE VANE PUMP V BELT (See page 14-5)
5. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
6. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
7. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
8. REMOVE CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
9. REMOVE TIMING BELT NO.1 COVER
10. REMOVE TIMING BELT NO.2 COVER (See page 14-79)
11. REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79)
12. REMOVE TIMING BELT GUIDE NO.2
13. REMOVE TIMING BELT (See page 14-79)
14. REMOVE CRANKSHAFT TIMING PULLEY
(a) Remove the bolt and timing belt plate.
(b) Install the pulley bolt to the crankshaft.
(c) Using SST, remove the crankshaft timing pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05011)
NOTICE:
Do not scratch the sensor part of the crankshaft tim-
ing pulley.
Before using SST, apply lubricating oil to the threads
and tip of the center bolt 150.
15. REMOVE OIL PUMP SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out
the oil seal.
NOTICE:
After removing, check the crankshaft for damage. If dam-
aged, smooth the surface with 400-grit sandpaper.
Page 515 of 969
A78766
SST
A78746
Inward
Sensor
- ENGINE MECHANICALOIL PUMP SEAL (3MZ-FE)
14-139
2231 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
16. INSTALL OIL PUMP SEAL
(a) Apply multi-purpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST and a hammer, tap in the new oil seal until its
surface is flush with the oil pump edge.
SST 09223-00010
NOTICE:
Be careful not to tap the oil seal at an angle.
Wipe off extra grease on the crankshaft.
17. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft, then slide the pulley into place.
NOTICE:
Do not scratch the sensor area of the crankshaft timing
pulley.
(b) Install the timing belt plate with the bolt.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
18. INSPECT TIMING BELT (See page 14-79)
19. INSTALL TIMING BELT (See page 14-79)
SST 09960-10010 (09962-01000, 09963-01000)
20. INSTALL TIMING BELT TENSIONER ASSY (See page 14-79)
21. INSTALL TIMING BELT GUIDE NO.2 (See page 14-79)
22. INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79)
23. INSTALL TIMING BELT NO.2 COVER (See page 14-79)
24. INSTALL TIMING BELT NO.1 COVER (See page 14-79)
25. INSTALL CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021
26. INSTALL GENERATOR BRACKET NO.2 (See page 14-79)
27. INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
28. INSTALL ENGINE MOVING CONTROL ROD (See page 14-79)
29. INSTALL VANE PUMP V BELT (See page 14-5)
30. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
31. INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1)
32. INSTALL FRONT WHEEL RH (See page 14-5)
33. CHECK FOR ENGINE OIL LEAKS
Page 516 of 969
141JL-02
A78767
SST
A78768
Cut Position
Cut Position
A78769
SST
A78767
SST 14-140
- ENGINE MECHANICALENGINE REAR OIL SEAL (3MZ-FE)
2232 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ENGINE REAR OIL SEAL (3MZ-FE)
REPLACEMENT
1. REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40-9)
2. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
(b) Remove the 8 bolts, rear spacer, drive plate and front
spacer.
3. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out
the oil seal.
NOTICE:
After removing, check the crankshaft for damage. If dam-
aged, smooth the surface with 400-grit sandpaper.
4. INSTALL ENGINE REAR OIL SEAL
(a) Apply multi-purpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign materials.
(b) Using SST and a hammer, tap in the oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
Be careful not to tap the oil seal at an angle.
Wipe off extra grease on the crankshaft.
5. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
(b) Clean the 8 bolts and 8 bolt holes.
(c) Apply adhesive to 2 or 3 threads of the 8 bolts.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent
(d) Install the front spacer, drive plate and rear spacer on the
crankshaft.
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 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 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.
Page 534 of 969
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.
Page 539 of 969
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)
14-163
2255 Author: Date:
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.
Page 541 of 969
A78804
Oil Hole
A78803
SST
EM6535
P00326
A78317
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-165
2257 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
24. INSTALL CONNECTING ROD SMALL END BUSH
(a) Align the oil holes of a new bush and the connecting rod.
(b) Using SST and a press, press in the bushing.
SST 09222-30010
(c) Using a pin hole grinder, hone the bush to obtain the stan-
dard specified clearance between the bush and piston
pin.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
(d) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, then push it into the con-
necting rod with your thumb.
25. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the new piston ring and wall of the ring groove.
Ring groove clearance:
0.03 to 0.08 mm (0.0012 to 0.0031 in.) for No. 1 ring
0.02 to 0.06 mm (0.0008 to 0.0024 in.) for No. 2 ring
0.03 to 0.11 mm (0.0012 to 0.0043 in.) for oil ring
If the groove clearance is not as specified, replace the piston
ring.