LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 671 of 969
A86562
A86563
16-22
- COOLINGRADIATOR ASSY (3MZ-FE)
2300 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
19. REMOVE RADIATOR ASSY
(a) Disconnect the 2 wire harness connectors.
(b) Remove the radiator from the vehicle.
20. REMOVE RADIATOR SUPPORT CUSHION
(a) Remove the 2 radiator support cushions from the radiator.
21. REMOVE RADIATOR SUPPORT LOWER
(a) Remove the 2 radiator support lowers from the radiator.
22. REMOVE FAN SHROUD SUB-ASSY
(a) Disconnect the temperature detect switch connector.
(b) Remove the 3 bolts, then remove the fan shroud with mo-
tor.
23. REMOVE TEMPERATURE DETECT SWITCH
24. REPLACE RADIATOR ASSY
25. INSTALL FAN SHROUD SUB-ASSY
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
26. INSTALL RADIATOR SUPPORT UPPER
Torque: 14 NVm (142 kgfVcm, 10 ftVlbf)
27. INSTALL HOOD LOCK ASSY
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
28. INSTALL AIR CLEANER INLET NO.1 (See page 19-5)
29. INSTALL AIR CLEANER BRACKET (See page 19-5)
30. INSTALL AIR CLEANER ASSY (See page 19-5)
31. INSTALL AIR CLEANER INLET ASSY (See page 19-5)
32. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
33. ADD ENGINE COOLANT (See page 16-9)
34. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
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 673 of 969
A86590
A86591
A87087
Core PlateCore Plate
A86592
16-24
- COOLINGRADIATOR ASSY (3MZ-FE)
2302 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
7. REMOVE INLET NO.2
(a) Remove the nut and inlet No. 2.
8. REMOVE ATM OIL COOLER
(a) Remove the 2 nuts and 2 washers, then remove the oil
cooler from the radiator tank.
(b) Remove the 2 O-rings from the oil cooler.
9. INSPECT RADIATOR CORE SUB-ASSY
Check the core plate for damage.
HINT:
If the sides of the core plate groove are deformed, it will
be impossible to reassemble the radiator tank. Therefore,
first correct any deformation with pliers or a similar tool.
Water leakage will result if the bottom of the core plate
groove is damaged or dented. Repair or replace if neces-
sary.
NOTICE:
The radiator can only be recaulked 2 times. After being re-
caulked 2 times, the radiator core must be replaced.
10. INSTALL ATM OIL COOLER
(a) Install the 2 new O-rings to the oil cooler.
(b) Install the oil cooler to the radiator tank.
(c) Install the 2 nuts and 2 washers.
Torque: 8.3 N´m (85 kgf´cm, 74 in.´lbf)
11. INSTALL INLET NO.2
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
12. INSTALL INLET NO.1
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
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 676 of 969
- COOLINGRADIATOR ASSY (3MZ-FE)
16-27
2305 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. INSTALL RADIATOR DRAIN COCK PLUG
(a) Install a new O-ring to the drain cock plug.
(b) Install the drain cock plug.
Page 677 of 969
170FZ-02
A66623
C -29 -18 -7 4 16 27 38Recommended Viscosity (SAE)
F -20 0 20 40 60 80 1005W-30
A90353
Oil Pressure
Switch
A90354
Oil Pressure Gauge
- LUBRICATIONLUBRICATION SYSTEM (3MZ-FE)
17-1
2306 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
LUBRICATION SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) Warm up the engine, then stop the engine and wait for 5 minutes.
(b) Check that the engine oil level is between the low and full level marks on the level gage.
If low, check for leakage and add oil up to the full level mark.
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, water intrusion, discoloring
or thinning.
If the quality is visibly poor, replace the oil.
Oil grade:
Use API grade SL ºEnergy-Conservingº, or ILSAC
multigrade engine oil.
SAE 5W-30 is the best choice for good fuel economy,
and good starting in cold weather.
If SAE 5W-30 is not available, SAE 10W-30 may be
used.
However, it should be replaced with SAE 5W-30 at the
next oil replacement.
3. INSPECT OIL PRESSURE
(a) Disconnect the oil pressure switch connector.
(b) Using a deep socket wrench 24 mm, remove the oil pres-
sure switch.
(c) Install the oil pressure gauge.
(d) Warm up the engine.
(e) Inspect the oil pressure.
Oil pressure:
At idle29 kPa (0.3 kgf/cm2, 4.3 psi) or more
At 3,000 rpm245 to 539 kPa (2.5 to 5.5 kgf/cm2, 36 to 78 psi)
Page 678 of 969
A85603
Adhesive 17-2
- LUBRICATIONLUBRICATION SYSTEM (3MZ-FE)
2307 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(g) Using a deep socket wrench 24 mm, install the oil pres-
sure switch.
Torque: 15 NVm (153 kgfVcm, 11 ftVlbf)
NOTICE:
Do not start the engine within 1 hour of installation.
(h) Connect the oil pressure switch connector.
(i) Check for the engine oil leaks.
Page 679 of 969
170HM-01
A84921
64 (653, 47)
64 (653, 47)
Front Fender Apron
Seal RH
Vane Pump V Belt
V Belt No. 1
Generator Bracket No. 2
Engine Mounting Stay No. 2 RH
Engine Moving Control Rod
23 (235, 17)
58 (591, 43)
28 (286, 21)
9.8 (100, 7)
Generator Assy
18 (178, 13)
Engine Under Cover No. 1
Engine Under Cover No. 2
N´m (kgf´cm, ft´lbf)
: Specified torque
Radio Setting Condenser
- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
17-3
2308 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OIL PUMP ASSY (3MZ-FE)
COMPONENTS
Page 680 of 969
A78353
N´m (kgf´cm, ft´lbf)
: Specified torque
8.5 (87, 75 in.Vlbf)
220 (2,250, 162)8.5 (87, 75 in.Vlbf)
28 (286, 21)
27 (280, 20)
Timing Belt Tensioner AssyCrankshaft PulleyTiming Belt No. 1 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH Timing Belt No. 2 Cover
Timing Belt
Engine Wire
Protector
17-4
- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
2309 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)