light 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 554 of 969
A78809Less than 6 mm (0.23 in.)
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 14-178
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2270 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Temporarily install the 8 bearing cap bolts to the inside
positions.
(e) 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.
(f) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure proper fit.
(g) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(h) 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)
(i) Mark the front side of the bearing cap bolts with paint.
(j) Retighten the bearing cap bolts by 90 in the same se-
quence as step (h).
(k) Check that each painted mark is now at a 90 angle to the
front.
(l) Check that the crankshaft turns smoothly.
(m) 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.
Page 555 of 969
A78322
Front Mark (Cavity)
Front
A78794
Protrusion Front
P12697
A78795
90
Front90Painted Mark
A78822
Front Side:
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-179
2271 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
42. INSTALL PISTON SUB-ASSY W/CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and sur-
faces of the connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the numbered pis-
ton and connecting rod assemblies correctly into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.
(d) Check that the protrusion of the cap is facing the correct
direction.
(e) Apply a light coat of engine oil to the threads of the cap
bolts.
(f) Tighten the cap bolts in several steps by the specified
torque.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(g) Mark the front side of each cap bolt with paint.
(h) Retighten the cap bolts by 90 as shown in the illustration.
(i) Check that the crankshaft turns smoothly.
43. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.1 PLUG
(a) Using a socket hexagon wrench 10, install a new gasket
and the screw plug.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
Page 558 of 969
100IZ-01
A86347DLC3
Hand-held Tester
A86347DLC3
Hand-held Tester
- ENGINE CONTROL SYSTEMSFI SYSTEM (3MZ-FE)
10-1
2006 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
SFI SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Check the operation.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Start the engine and allow it to warm up.
(4) Connect the hand-held tester, then select VVT from
the ACTIVE TEST menu.
(5) Check the engine speed when the OCV is operated
with the hand-held tester.
Standard:
Tester OperationSpecified Condition
OCV is OFFNormal engine speed
OCV is ONRough idle or engine stall
If the operation is not as specified, inspect the camshaft timing
oil control valve (see page 10-2).
2. INSPECT THROTTLE BODY ASSY
(a) Check the operation (throttle control motor).
(1) Turn the ignition switch ON.
(2) When turning the accelerator pedal position sensor
lever, check the running sound of the motor. Also,
check that there is no friction sound.
If the operation is not as specified, inspect the throttle body (see
page 10-2).
(b) Check the operation (throttle position sensor).
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Check that the check engine warning light does not
light up.
(4) Check that the throttle valve opening percentage
(THROTTLE POS) of CURRENT DATA showns the
standard value.
Standard throttle valve opening percentage:
60 % or more
NOTICE:
When checking the standard throttle valve opening per-
centage, the transmission is in the neutral position.
3. INSPECT ACCELERATOR PEDAL POSITION SENSOR
(a) Inspect the voltage.
(1) After turning the ignition switch ON, check CURRENT DATA, then verify that the throttle position
sensor voltage is within the standard value.
Standard voltage: 0.6 to 1.0 V
If the voltage is not as specified, inspect the accelerator pedal (see page 10-2).
Page 563 of 969
100J1-01
A86244
(a)
(b)
RH Bank:
A86306
(a)
(b)
LH Bank: 10-6
- ENGINE CONTROL SYSTEMCAMSHAFT TIMING OIL CONTROL VALVE
ASSY (3MZ-FE)
2011 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CAMSHAFT TIMING OIL CONTROL VALVE ASSY (3MZ-FE)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Disconnect the 2 camshaft timing oil control valve con-
nectors.
(b) Remove the 2 bolts, then remove the 2 camshaft timing
oil control valves.
HINT:
The camshaft timing oil control valve is installed with the bolt.
4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Apply a light coat of engine oil to the O-ring on each camshaft timing oil control valve.
(b) Install the 2 camshaft timing oil control valves with the 2 bolts.
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
NOTICE:
Be careful not to twist the O-ring.
(c) Connect the 2 camshaft timing oil control valve connectors.
5. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
6. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
7. CHECK FOR ENGINE OIL LEAKS
8. SYSTEM INITIALIZATION (See page 19-15)
Page 595 of 969
A86303
(b)
(b)
(b)
(b)
A86304
(c)
(d)(c)
(c)
(c)(d)
(d)
(d)
(d)
(d)
A81137
A79762
New O-ring
New Grommet
A81139
Turn
Push
- FUELFUEL INJECTOR ASSY (3MZ-FE)
11-15
2043 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Remove the 4 bolts, then remove the 2 fuel delivery pipes
together with the 6 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when removing the
fuel delivery pipe.
(c) Remove the 4 delivery pipe No. 1 spacers from the intake
manifold.
(d) Remove the 6 insulators from the intake manifold.
(e) Pull out the fuel injector from the fuel delivery pipe.
11. INSTALL FUEL INJECTOR ASSY
(a) Install new grommets to each fuel injector.
(b) Apply a light coat of spindle oil or gasoline to new O-rings,
then install them to each fuel injector.
(c) Apply a light coat of spindle oil or gasoline to the place
where the fuel delivery pipe contacts the O-ring.
(d) Push the fuel injector while twisting it back and forth to
install it in the fuel delivery pipe.
NOTICE:
Be careful not to twist the O-ring.
After installing the fuel injectors, check that they turn
smoothly. If not, replace O-ring with a new O-ring.
Page 603 of 969
A65038
New O-ring
A65040
O-ring
A86272
Cover
Tube Joint Clip
- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)11-23
2051 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
15. INSTALL FUEL PRESSURE REGULATOR ASSY
(a) Apply a light coat of spindle oil or gasoline to a new O-
ring, then install it to the fuel pressure regulator.
(b) Push in the fuel pressure regulator to the fuel tank fuel fil-
ter.
16. INSTALL FUEL PUMP FILTER
(a) Install the fuel pump filter with a new clip.
17. INSTALL FUEL PUMP
(a) Apply a light coat of gasoline or spindle oil to the O-ring
on the fuel pump.
(b) Push in the fuel pump to the fuel tank fuel filter.
18. INSTALL FUEL PUMP HARNESS
19. INSTALL FUEL SUCTION PLATE SUB-ASSY
20. INSTALL FUEL SENDER GAUGE ASSY
21. INSTALL FUEL PUMP CUSHION RUBBER
22. INSTALL FUEL SUCTION SUPPORT NO.2
23. INSTALL VAPOR PRESSURE SENSOR ASSY
(a) Install the vapor pressure sensor with the tube joint clip.
NOTICE:
Check the connected part for scratch or foreign ob-
jects.
Check that the vapor pressure sensor is inserted se-
curely.
Check that the tube joint clip is on the collar of the va-
por pressure sensor.
After installing the tube joint clip, check that the vapor
pressure sensor has not been pulled off.
(b) Install the cover.
Page 672 of 969
160QL-01
A87082
Dimension ºBº
Overhaul HandleStopper Bolt SSTPart ºAº
Claw
A86587Stopper Bolt
Core Plate
SST
Radiator Tank
A86588
Ta p
A86589
- COOLINGRADIATOR ASSY (3MZ-FE)
16-23
2301 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE RADIATOR DRAIN COCK PLUG
(a) Remove the drain cock plug.
(b) Remove the O-ring from the drain cock plug.
2. ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01030)
(a) Install the claw to the overhaul handle by inserting it in the
hole in part ºAº as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that
dimension ºBº is as shown in the illustration.
Dimension ºBº: 0.2 to 0.3 mm (0.008 to 0.012 in)
NOTICE:
If the stopper bolt is not adjusted, the claw may be dam-
aged.
3. UNCAULK CORE PLATE
(a) Using SST to release the core plate, grip the handle until
stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)
4. REMOVE RADIATOR TANK UPPER
(a) Lightly tap the bracket of the radiator tank (or radiator tank
pipe) with a soft-faced hammer, then remove the radiator
tank.
(b) Remove the O-ring.
5. REMOVE RADIATOR TANK LOWER
HINT:
Perform the same procedures as the radiator tank upper.
6. REMOVE INLET NO.1
(a) Remove the bolt.
(b) Remove the nut and inlet No. 1.
Page 674 of 969
A87088
Normal
O-ringX Twisted
X Twisted
A86593
Ta pCORRECT
WRONG Radiator Tank
Core
Plate
A87090
Dimension ºBº
Stopper Bolt
Overhaul Handle Punch AssemblyPart ºAº
SST
- COOLINGRADIATOR ASSY (3MZ-FE)
16-25
2303 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. INSTALL RADIATOR TANK UPPER
(a) After checking that there are no foreign objects in the core
plate groove, install a new O-ring without twisting it.
HINT:
When cleaning the core plate groove, lightly rub it with sandpa-
per without scratching it.
(b) Install the radiator tank without damaging the O-ring.
(c) Tap the core plate with a soft-faced hammer so that there
is no gap between the core plate and radiator tank.
14. INSTALL RADIATOR TANK LOWER
HINT:
Perform the same procedures as the radiator tank upper.
15. ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01020)
(a) Install the punch assembly to the overhaul handle by in-
serting it in the hole in part ºAº as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that
dimension ºBº is as shown in the illustration.
Dimension ºBº: 8.4 mm (0.341 in.)
Page 675 of 969
A86594
5
SST
Stopper
Bolt
Radiator
Tank
Core
Plate 1
6482 7 3
A86595
Rib
Bracket
A86596
A86597
H 16-26
- COOLINGRADIATOR ASSY (3MZ-FE)
2304 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
16. CAULK CORE PLATE
(a) Lightly press SST against the core plate in the order
shown in the illustration. After repeating this a few times,
fully caulk the core plate by gripping the handle until
stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01020)
HINT:
Do not tap the areas protruding around the pipes, brack-
ets or tank ribs.
The points shown in the illustration and oil cooler near
here cannot be tapped with the SST. Use pliers or a simi-
lar tool and be careful not to damage the core plate.
(b) Check the core plate height (H) after completing the
caulking.
Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.)
If the height is not as specified, adjust the stopper bolt of the
handle again, then caulk again.
Page 689 of 969
A36784
A78725
Seal Packing
Seal Width
2 to 3 mm
(0.08 to 0.12 in.) A
A
BB
C
C
A36785
- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
17-13
2318 Author: Date:
41. INSTALL OIL PUMP ASSY
(a) Remove any old seal packing material from the contact
surface.
(b) Apply a light coat of engine oil to a new O-ring, then place
it on the cylinder block.
(c) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pump within 3 minutes after applying
seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(d) Align the key of the oil pump drive gear with the keyway
located on the crankshaft, then slide the oil pump into
place.