Lexus 3MZ-FE Engine Repair Manual

14-1
ENGINE MECHANICAL
-
ENGINE (3MZ-FE)
ENGINE (3MZ-FE)
141C0-02
INSPECTION
1.
2.
3.
4.
5.
INSPECT ENGINE COOLANT (See page 16-1 )
INSPECT ENGINE OIL
INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20C (68F)
INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY
INSPECT SPARK PLUG (See page 18-3 )
Measuring Points for Belt Deflection
or Tension
6.
(a)
INSPECT V-RIBBED BELT
Belt deflection:
Pressing force: 98 N (10 kgf, 22 lbf)
Generator
Vane Pump
Crankshaft
New Belt
mm (in.)
Used Belt
mm (in.)
V-ribbed Belt
(For fan and generator)
9.1 to 10.5
(0.358 to 0.413)
11 to 13.5
(0.433 to 0.531)
V-ribbed Belt
(For vane pump)
8 to 10
(0.315 to 0.394)
11 to 14
(0.433 to 0.551)
New Belt
N (kg , lb)
Used Belt
N (kg , lb)
V-ribbed Belt
(For fan and generator)
637 to 735
(65 to 75 , 143 to 165)
392 to 588
(40 to 60 , 88 to 132)
V-ribbed Belt
(For vane pump)
588 to 686
(60 to 70 , 132 to 154)
245 to 392
(25 to 40 , 55 to 88)
Compressor
A82940
(b)
Belt tension:
NOTICE:
Check the drive belt deflection at the specified point.
When installing a new belt, set its tension value as
specified.
When inspecting a belt which is used for over 5 minutes, apply the specification of ”Used belt”.
When reinstalling a belt which is used for over 5 minutes, adjust its belt deflection and tension to the intermediate value of each specification in ”Used belt”.
The V- ribbed belt tension and deflection value
should be checked after 2 revolutions of engine
cranking.
When using a belt tension gauge, confirm the accuracy first by using a master gauge.
7.
INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using the hand-held tester or OBD II scan tool:
(1) Connect the hand-held tester or OBD II scan tool
to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester or
OBD II scan tool.
Ignition timing: 8 to 12 BTDC
HINT:
Refer to the hand-held tester or OBD II scan tool operator’s
manual if you need help to select DATA LIST.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2093
14-2
ENGINE MECHANICAL
-
ENGINE (3MZ-FE)
(c)
TC
CG
A85669
When not using the hand-held tester or OBD II scan tool:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)
of the DLC3.
SST 09843-18040
NOTICE:
Make sure of the terminal numbers before connecting
them. Connecting wrong terminals can damage the
engine.
Turn OFF all electrical systems before connecting the
terminals.
Perform this inspection after the cooling fan motor is
turned OFF.
(2) Remove the V-bank cover.
(3)
(4)
Tester Terminal
Engine Wire
A82935
Pull out the engine wire colored by black and red as
shown in the illustration.
Connect the tester terminal of the timing light to the
engine.
NOTICE:
Use a timing light which detects the first signal.
(5) Inspect the ignition timing at idle.
Ignition timing: 8 to 12 BTDC
NOTICE:
When checking the ignition timing, the transmission is in
the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, then check
that the engine speed returns to the idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Inspect the ignition timing at idle.
Ignition timing: 7 to 24 BTDC
(8) Confirm that the ignition timing advances when the
engine speed is increased.
(9) Remove the timing light.
8.
(a)
(b)
INSPECT ENGINE IDLE SPEED
Warm up the engine.
When using the hand-held tester or OBD II scan tool:
(1) Connect the hand-held tester or OBD II scan tool to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester or OBD II scan tool.
Idle speed: 630 to 730 rpm
NOTICE:
When checking the idle speed, the transmission is in the neutral position.
Check the idle speed with the cooling fan OFF.
Switch OFF all accessories and air conditioning before connecting the hand-held tester or OBD
II scan tool.
HINT:
Refer to the hand-held tester or OBD II scan tool operator’s manual for further details.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2094
14-3
ENGINE MECHANICAL
9.
(a)
(b)
(c)
(d)
(e)
-
ENGINE (3MZ-FE)
INSPECT COMPRESSION
Warm up and stop the engine.
Remove the intake air surge tank (see page 11-13 ).
Disconnect the injector connectors.
Remove the ignition coils.
Remove the spark plugs.
(f)
Compression Gauge
P19471
Inspect the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
SST 09992-00500
(2) Fully open the throttle.
(3) While cranking the engine, measure the compression pressure.
Compression pressure:
1.5 MPa (15.3 kgf/cm2, 218 psi)
Minimum pressure:
1.0 MPa (10.2 kgf/cm2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm2, 15 psi)
NOTICE:
Always use a fully-charged battery to obtain engine
speed of 250 rpm or more.
Check the other cylinder’s compression pressure in
the same way.
This measurement must be done as quickly as possible.
(4) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
spark plug hole, then inspect again.
HINT:
If adding oil increases the compression, the piston rings
and/or cylinder bore may be worn or damaged.
If pressure stays low, the valve may be sticking or seated
improperly, or there may be leakage past the gasket.
10. INSPECT CO/HC
HINT:
The ECM properly controls the CO/HC concentration in the emission gas.
(a) Start the engine.
(b) Run the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Check the CO/HC concentration at idle and/or at 2,500 rpm.
HINT:
When doing the 2 mode (with the engine is at idle and at 2,500 rpm) tests, these measuring order are prescribed by the applicable local regulations.
If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.
(1) Check the heated oxygen sensor operation (see page 05-126 ).
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2095
14-4
ENGINE MECHANICAL
(2)
Low
High
ENGINE (3MZ-FE)
See the table below for possible causes, then inspect the applicable causes and repair them if
necessary.
CO
Normal
-
HC
High
High
High
Problems
Causes
Rough idle
5. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
6. Incorrect valve clearance
7. Leaks in intake and exhaust valves
8. Leaks in cylinders
Rough idle
(Fluctuating HC reading)
1. Vacuum leaks:
PCV hoses
Intake manifold
Throttle body
Brake booster line
2. Lean mixture causing misfire
Rough idle
(Black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI systems:
Faulty pressure regulator
Defective engine coolant temperature sensor
Defective mass air flow meter
Faulty ECM
Faulty injectors
Faulty throttle body
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2096
14-5
ENGINE MECHANICAL
-
DRIVE BELT (3MZ-FE)
DRIVE BELT (3MZ-FE)
14193-03
REPLACEMENT
1.
2.
REMOVE FRONT WHEEL RH
REMOVE FRONT FENDER APRON SEAL RH
3.
B
C
(a)
(b)
REMOVE V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
Loosen bolts A and B.
Loosen the adjusting bolt C, then remove the V-ribbed
belt.
A
A78698
A
4.
(a)
REMOVE VANE PUMP V BELT
Loosen bolts A and B, then remove the V-ribbed belt.
5.
(a)
(b)
INSTALL VANE PUMP V BELT
Install the V-ribbed belt on each pulley.
Using a bar, adjust the V-ribbed belt tension, then tighten
bolt B.
Torque: 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf)
Tighten bolt A.
Torque: 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf)
B
A78699
A
(c)
B
A78699
6.
B
C
(a)
(b)
(c)
A
A78698
INSTALL V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
Install the V-ribbed belt on each pulley.
Tighten the adjusting bolt C, then adjust the V-ribbed belt
tension.
First tighten bolt A, then tighten bolt B.
Torque:
18 N⋅m (178 kgf⋅cm, 13 ft⋅lbf) for bolt A
58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf) for bolt B
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2097
14-6
ENGINE MECHANICAL
7.
8.
-
DRIVE BELT (3MZ-FE)
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL FRONT WHEEL RH
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2098
14-7
ENGINE MECHANICAL
-
VALVE CLEARANCE (3MZ-FE)
VALVE CLEARANCE (3MZ-FE)
141J7-02
ADJUSTMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE COOLANT (See page 16-9 )
REMOVE FRONT FENDER APRON SEAL RH
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
REMOVE RADIATOR HOSE INLET
REMOVE IGNITION COIL ASSY
11.
(a)
(b)
(b)
(a)
(b)
(a)
(c)
REMOVE CYLINDER HEAD COVER SUB-ASSY
Remove the 2 engine wire harness clamps.
Remove the 3 nuts, then disconnect the engine wire harness.
Remove the 9 bolts and cylinder head cover.
(b)
A78541
12.
(a)
(b)
REMOVE CYLINDER HEAD COVER SUB-ASSY LH
Using an E6 Torx socket wrench, remove the 2 bolts and
disconnect the engine wire harness protector.
Remove the 9 bolts and cylinder head cover.
A36719
13.
(a)
INSPECT VALVE CLEARANCE
Turn the crankshaft pulley, then align the timing notch with
the timing mark ”0” of the timing belt No. 1 cover.
(b) Check that the valve lifters on the intake side of the No.
1 cylinder are not pushed by the cam.
If the valve lifters are pushed, turn the crankshaft by 1 revolution
(360) and align the marks as above.
P18805
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2099
14-8
ENGINE MECHANICAL
VALVE CLEARANCE (3MZ-FE)
(c)
Inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance
measurements. They will be used later to select an
adjusting shim to replace.
(d)
Turn the crankshaft by 2/3 of a revolution (240), then inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance
measurements. They will be used later to select an
adjusting shim to replace.
RH Bank:
3 3
EX
IN
1 1
LH Bank:
-
Front
6 6
IN
EX
2 2
A78666
RH Bank:
5 5
EX
IN
3 3
LH Bank:
Front
2 2
IN
EX
4 4
A78667
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2100
14-9
ENGINE MECHANICAL
VALVE CLEARANCE (3MZ-FE)
(e)
Turn the crankshaft by 2/3 of a revolution (240), then inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance
measurements. They will be used later to select an
adjusting shim to replace.
14.
(a)
(b)
ADJUST VALVE CLEARANCE
Turn the camshaft so that the cam lobe faces upward.
Turn the valve lifter with a screwdriver so that the notches
are perpendicular to the camshaft.
(c)
Using SST (A), press down the valve lifter and place SST
(B) between the camshaft and valve lifter. Remove SST
(A).
SST 09248-55040 (09248-05410, 09248-05420)
RH Bank:
1 1
EX
IN
5 5
LH Bank:
-
Front
4 4
IN
EX
6 6
A78668
Upward
Notch
A78669
Front of No. 1 and No. 2 Cylinders:
SST (A)
HINT:
SST (B)
7
Others:
SST (A)
Apply SST (B) at a slight angle on the side marked with
”9” or ”7” at the position shown in the illustration.
When SST (B) is inserted too deeply, it will get pinched by
the shim. To prevent SST (B) from getting stuck, insert it
gently from the intake side at a slight angle.
SST (A)
09248-05410
SST (B)
09248-05420
SST (B)
9
A78670
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2101
14-10
ENGINE MECHANICAL
-
VALVE CLEARANCE (3MZ-FE)
(d)
Using a small screwdriver and magnetic finger, remove
the adjusting shim.
(e)
Using a micrometer, measure the thickness of the removed shim.
Calculate the thickness of a new shim so that the valve
clearance comes within the specified value.
SST (B)
Magnetic Finger
A78671
(f)
EM0494
(g)
A
Thickness of new shim
B
Thickness of used shim
C
Measured valve clearance
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.0079 in.))
Exhaust A = B + (C - 0.30 mm (0.0118 in.))
Select a new shim with a thickness which is as close to the
calculated values as possible.
EXAMPLE (Intake):
Measured valve clearance = 0.45 mm (0.0177 in.)
0.45 mm (0.0177 in.) - 0.20 mm (0.0079 in.) = 0.25 mm (0.0098 in.)
(Measured - Specification = Excess clearance)
Used shim measurement = 2.80 mm (0.1102 in.)
0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) = 3.05 mm (0.1201 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 3.05 mm (0.1201 in.)
Select No. 12 shim
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm
(0.1299 in.).
Refer to New Shim Thickness table on the next 2 pages.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2102
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Adjusting Shim Selection Chart (Intake)
Installed Shim Thickness
mm (in.)
Measured Clearance
mm (in.)
ENGINE MECHANICAL
-
Author:
Shim
No.
Thickness
Shim
No.
mm (in.)
Thickness
VALVE CLEARANCE (3MZ-FE)
New Shim Thickness
Date:
HINT: New shims have the thickness in millimeters
imprinted on the face.
14-1 1
V00719
2103
Intake valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and
the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 12
shim.
14-12
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Adjusting Shim Selection Chart (Exhaust)
Installed Shim Thickness
mm (in.)
Measured Clearance
mm (in.)
ENGINE MECHANICAL
-
Author:
Shim
No.
Thickness
Shim
No.
mm (in.)
Thickness
Date:
V00720
2104
Exhaust valve clearance (Cold):
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and
the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 10
shim.
HINT: New shims have the thickness in millimeters
imprinted on the face.
VALVE CLEARANCE (3MZ-FE)
New Shim Thickness
14-13
ENGINE MECHANICAL
SST (A)
(h)
(i)
SST (B)
(j)
-
VALVE CLEARANCE (3MZ-FE)
Place a new adjusting shim on the valve lifter with the imprinted number facing down.
Press down the valve lifter with SST (A), then remove SST
(B).
SST 09248-55040 (09248-05410, 09248-05420)
Recheck the valve clearance.
A78672
15.
(a)
: Seal Packing
Front
A78673
16.
(a)
: Seal Packing
Front
A78674
17.
18.
19.
20.
21.
22.
23.
24.
25.
INSTALL CYLINDER HEAD COVER SUB-ASSY
Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after
applying seal packing.
Do not start the engine within 2 hours after installing.
(b) Install the cylinder head cover with the 9 bolts. Tighten the
bolts uniformly in several steps.
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
(c) Install the engine wire harness with the 3 nuts.
Torque: 8.4 N⋅m (85 kgf⋅cm, 74 in.⋅lbf)
INSTALL CYLINDER HEAD COVER SUB-ASSY LH
Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after
applying seal packing.
Do not start the engine within 2 hours after installing.
(b) Install the cylinder head cover with the 9 bolts. Tighten the
bolts uniformly in several steps.
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
(c) Using an E6 Torx socket wrench, install the engine wire
harness protector with the 2 bolts.
Torque: 8.4 N⋅m (85 kgf⋅cm, 74 in.⋅lbf)
INSTALL IGNITION COIL ASSY
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2105
14-14
ENGINE MECHANICAL
26.
-
VALVE CLEARANCE (3MZ-FE)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2106
14-15
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
PARTIAL ENGINE ASSY (3MZ-FE)
141J8-01
COMPONENTS
x3
7.9 (81, 70 in.⋅lbf)
V-bank Cover Sub-assy
Front Fender Apron Seal RH
x7
Clip
Clip
Radiator Lower Air Deflector
Engine Under Cover No. 1
Engine Under Cover No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
A84923
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2107
14-16
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
9.0 (92, 80 in.⋅lbf)
Air Cleaner Hose No. 1
Mass
Air Flow Meter
Connector
Vacuum Hose
Battery Clamp
Sub-assy
VSV Connector
Air Cleaner Cap
Sub-assy
Battery
5.0 (51, 44 in.⋅lbf)
5.0 (51, 44 in.⋅lbf)
Vacuum Hose
x2
Air Cleaner
Inlet Assy
Battery Tray
Air Cleaner
Filter Element
Sub-assy
x3
5.0 (51, 44 in.⋅lbf)
5.0 (51, 44 in.⋅lbf)
Air Cleaner Inlet
No. 1
Air Cleaner Case
5.0 (51, 44 in.⋅lbf)
x2
7.5 (76, 66 in.⋅lbf)
Air Cleaner Bracket
Clip
Intake Air Resonator
Sub-assy
N·m (kgf·cm, ft·lbf) : Specified torque
A84924
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2108
14-17
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
V Belt No. 1
64 (653, 47)
28 (286, 21)
Generator Bracket No. 2
23 (235, 17)
58 (591, 43)
Radio Setting
Condenser
Engine Moving
Control Rod
9.8 (100, 7)
8.4 (85, 74 in.⋅lbf)
64 (653, 47)
43 (438, 32)
18 (178, 13)
Engine Mounting
Stay No. 2 RH
18 (184, 13)
Generator Assy
Generator Belt Adjusting Bar
Fuel Vapor
Feed Hose No. 1
Heater Inlet
Water Hose
Union to Check
Valve Hose
Oil Reservoir to Pump Hose No. 1
Fuel Pipe
Sub-assy No. 1
Radiator Hose Inlet
Radiator Hose Outlet
Heater Outlet
Water Hose
Steering Gear Outlet
Return Tube
Fuel Pipe Clamp No. 1
Transmission Control
Cable Assy
Oil Cooler Inlet Hose
Fan Belt Adjusting
Bar Bracket
25 (250, 18)
Oil Cooler Outlet Hose
25 (250, 18)
Compressor and
Magnetic Clutch
15 (153, 11)
25 (250, 18)
N·m (kgf·cm, ft·lbf) : Specified torque
A84925
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2109
14-18
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
Steering Intermediate Shaft Assy
35 (360, 26)
Front Stabilizer Link
Assy LH
35 (360, 26)
Tie Rod Assy LH
74 (755, 55)
49 (500, 36)
Cotter Pin
Speed Sensor Front LH
8.0 (82, 71 in.⋅lbf)
Front Suspension Arm
Sub-assy Lower No. 1 LH
294 (2,998, 217)
Front Axle Hub LH Nut
75 (765, 55)
75 (765, 55)
56 (571, 41)
Exhaust Pipe
Gasket
62 (633, 46)
Exhaust Pipe Assy Front
Exhaust Pipe
Gasket
Exhaust Pipe Gasket
Exhaust Pipe No. 1
Support Bracket Rear
62 (633, 46)
Exhaust Pipe No. 1
Support Bracket Front
33 (337, 24)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
33 (337, 24)
A84926
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2110
14-19
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
Vane Pump V Belt
7.8 (80, 69 in.⋅lbf)
43 (439, 32)
43 (439, 32)
Vane Pump Assy
95 (969, 70)
87 (887, 64)
95 (969, 70)
Front Frame Assy
Front Suspension Member
Brace Rear RH
Frame Side Rail Plate
Sub-assy RH
Front Suspension Member
Brace Rear LH
Frame Side Rail Plate
Sub-assy LH
32 (326, 24)
32 (326, 24)
85 (867, 63)
85 (867, 63)
N·m (kgf·cm, ft·lbf) : Specified torque
A84927
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2111
14-20
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
Front Drive Shaft Assy RH
Drive Shaft Bearing
Bracket Hole Snap Ring
64 (650, 47)
46 (469, 34)
Drive Plate & Torque
Converter Setting Bolt
32 (330, 24)
Drive Shaft Bearing Bracket
41 (420, 30)
x5
7.8 (80, 69 in.⋅lbf)
64 (653, 47)
37 (379, 27)
Flywheel Housing Under Cover
Exhaust Pipe Support Bracket No. 1
21 (214, 15)
Automatic Transaxle
Assy
64 (653, 47)
Engine Mounting
Bracket FR
Front Drive Shaft LH Hole
Snap Ring
Front Drive
Shaft Assy LH
Starter Assy
9.8 (100, 7)
37 (380, 26)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A84928
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2112
14-21
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
8.0 (82, 71 in.⋅lbf)
Emission Control Valve Set
20 (199, 14)
20 (199, 14)
Emission Control
Valve Bracket
20 (199, 14)
28 (286, 21)
Surge Tank
Stay No. 2
Intake Air Surge Tank
Surge Tank Stay No. 1
Engine Hanger No. 1
28 (286, 21)
15 (153, 11)
Air Surge Tank to
Intake Manifold Gasket
8.4 (86, 74 in.⋅lbf)
15 (153, 11)
15 (153, 11)
15 (153, 11)
x4
x2
x5
15 (153, 11)
Intake Manifold
Intake Manifold to
Head Gasket No. 1
Water Outlet
8.0 (80, 71 in.⋅lbf)
Intake Manifold to
Head Gasket No. 2
Ignition Coil Assy
83 (846, 61)
x8
Drive Plate
Spacer Rear
Drive Plate
Spacer Front
Drive Plate & Ring Gear
Sub-assy
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86169
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2113
14-22
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
8.5 (87, 75 in.⋅lbf)
x3
Exhaust Manifold
Heat Insulator No. 1
Exhaust Manifold Sub-assy RH
x6
Exhaust Manifold to
Head Gasket
49 (500, 36)
Knock Sensor
20 (199, 14)
8.0 (82, 71 in.⋅lbf)
O-ring
x3
Water Inlet
32 (326, 24)
20 (199, 14)
O-ring
x3
Thermostat
Pump Bracket
8.5 (87, 75 in.⋅lbf)
Water Inlet Pipe
15 (153, 11)
Engine Oil Pressure
Switch Assy
Exhaust Manifold to
Head LH Gasket
54 (551, 40)
Exhaust Manifold
Heat Insulator
No. 2
Engine Mounting Bracket RH
49 (500, 36)
Manifold Stay No. 2
58 (591, 43)
x6
49 (500, 36)
Generator Bracket No. 1
8.5 (87, 75 in.⋅lbf)
49 (500, 36)
25 (250, 18)
Compressor Mounting Bracket No. 1
Exhaust Manifold
Converter Sub-assy
No. 2
Manifold Converter
Insulator No. 3
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86170
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2114
14-23
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
Oil Filler Cap Sub-assy
Spark Plug
25 (250, 18)
8.0 (80, 71 in.⋅lbf)
x9
Cylinder Head
Cover Sub-assy
Ventilation Valve
Sub-assy
Cylinder Head
Cover Gasket
VVT Sensor
8.0 (80, 71 in.⋅lbf)
Oil Filler
Cap Gasket
x9
Cylinder Head
Cover
Sub-assy LH
Spark Plug
Tube Gasket
8.0 (82, 71 in.⋅lbf)
Cylinder Head Cover
Gasket No. 2
O-ring
Spark Plug
Tube Gasket LH
8.0 (82, 71 in.⋅lbf)
Camshaft Timing
Oil Control Valve Assy
O-ring
Oil Level Gage Guide
Oil Level Gage
Sub-assy
O-ring
N·m (kgf·cm, ft·lbf) : Specified torque
8.0 (82, 71 in.⋅lbf)
Non-reusable part
A78304
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2115
14-24
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
Timing Belt
8.5 (87, 75 in.⋅lbf)
Timing Belt No. 2 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH
28 (286, 21)
Timing Belt No. 1 Cover
8.5 (87, 75 in.⋅lbf)
220 (2,250, 162)
Crankshaft Pulley
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
A78305
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2116
14-25
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
28 (286, 21)
Collar
8.5 (87, 75 in.⋅lbf)
Timing Belt
Idler Bracket
Bushing
x6
Camshaft Timing Pulley
43 (438, 32)
125 (1,275, 92)
Timing Belt Idler
Sub-assy No. 2
Water Pump Assy
Water Pump Gasket
8.0 (82, 71 in.⋅lbf)
8.0 (82, 71 in.⋅lbf)
Timing Belt Idler Sub-assy No. 1
34 (347, 25)
Crankshaft Timing Pulley
Crankshaft
Position Sensor
8.0 (82, 71 in.⋅lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
8.0 (80, 71 in.⋅lbf)
Timing Belt Plate
A78306
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2117
14-26
ENGINE MECHANICAL
RH Bank:
-
PARTIAL ENGINE ASSY (3MZ-FE)
Camshaft Bearing
Cap No. 4
Camshaft Timing Gear Bolt Washer
Camshaft Sub Gear
Camshaft Sub
Gear Wave Washer
Camshaft Bearing
Cap No. 2
16 (163, 12)
x10
Camshaft Sub Gear
Shaft Snap Ring
Camshaft Bearing
Cap No. 1
Camshaft Bearing Cap No. 5
Camshaft Bearing Cap No. 2
No. 2 Camshaft
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
x10
16 (163, 12)
150 (1,530, 111)
Camshaft Bearing
Cap No. 2
Camshaft Timing Gear Assy
Camshaft
Cylinder Head
Rear Plate Gasket
19 (189, 14)
See page 14-40
1st: 54 (550, 40)
2st: Turn 90
x8
10 (102, 7)
x4
Cylinder Head
Sub-assy
Cylinder Head
Cover Rear
45 (459, 33)
Gasket
Oil Control
Valve Filter
Camshaft Setting
Oil Seal
Cylinder Head
Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78307
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2118
14-27
ENGINE MECHANICAL
16 (163, 12)
PARTIAL ENGINE ASSY (3MZ-FE)
Camshaft Bearing Cap No. 2
Camshaft Bearing
Cap No. 5
LH Bank:
-
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
Camshaft Timing Gear Assy
x10
150 (1,530, 11)
Camshaft Bearing
Cap No. 2
Camshaft Sub
Camshaft Bearing
Gear Shaft
Cap No. 4
Camshaft Snap Ring
Sub Gear
No. 3 Camshaft Sub-assy
Camshaft Bearing
Cap No. 2
16 (163, 12)
x10
Camshaft Bearing
Cap No. 1
Camshaft Sub
Gear Wave Washer
No. 4 Camshaft Sub-assy
Camshaft Timing
Gear Bolt Washer
See page 14-40
1st: 54 (550, 40)
2st: Turn 90
Oil Control
Valve Filter
Gasket
45 (459, 33)
10 (102, 7)
x4
x8
19 (189, 14)
Cylinder Head LH
Cylinder Head
Cover Rear
Camshaft Setting
Oil Seal
Cylinder Head
Rear Plate Gasket
Engine Hanger No. 2
Cylinder Head
Gasket No. 2
20 (199, 14)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78308
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2119
14-28
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
8.0 (82, 71 in.⋅lbf)
Water Inlet Housing
Engine Rear Oil Seal Retainer
Engine Rear
Oil Seal
Cylinder Block Sub-assy
Oil Pump Assy
20 (199, 14)
43 (439, 32)
x6
8.0 (82, 71 in.⋅lbf)
30 (306, 22)
O-ring
8.0 (82, 71 in.⋅lbf)
8.0 (82, 71 in.⋅lbf)
Oil Filter
Sub-assy
Oil Pan Baffle Plate
Oil Pump Seal
20 (199, 14)
8.0 (82, 71 in.⋅lbf)
Oil Pan Sub-assy
20 (199, 14)
8.0 (82, 71 in.⋅lbf)
20 (199, 14)
Gasket
Oil Strainer Sub-assy
8.0 (82, 71 in.⋅lbf)
8.0 (82, 71 in.⋅lbf)
Gasket
Oil Pan Sub-assy No. 2
45 (459, 33)
Oil Pan Drain Plug
8.0 (82, 71 in.⋅lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78309
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2120
14-29
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
141J9-02
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
(a)
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
DISCONNECT BATTERY NEGATIVE TERMINAL
REMOVE FRONT WHEELS
REMOVE ENGINE UNDER COVER NO.1
REMOVE ENGINE UNDER COVER NO.2
REMOVE FRONT FENDER APRON SEAL RH
DRAIN ENGINE COOLANT (See page 16-9 )
DRAIN ENGINE OIL (See page 17-20 )
DRAIN AUTOMATIC TRANSAXLE FLUID (See page 30-8 )
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
REMOVE BATTERY
REMOVE BATTERY TRAY
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
REMOVE AIR CLEANER ASSY (See page 19-5 )
REMOVE AIR CLEANER BRACKET (See page 19-5 )
REMOVE AIR CLEANER INLET NO.1 (See page 19-5 )
REMOVE INTAKE AIR RESONATOR SUB-ASSY
Remove the clip and bolt, then remove the intake air resonator.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
REMOVE GENERATOR ASSY (See page 19-21 )
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
REMOVE GENERATOR BELT ADJUSTING BAR (See page 17-9 )
SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (See page 17-9 )
SEPARATE TRANSMISSION CONTROL CABLE ASSY (See page 40-44 )
DISCONNECT UNION TO CHECK VALVE HOSE
DISCONNECT FUEL VAPOR FEED HOSE NO.1
DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See page 11-1 )
DISCONNECT HEATER INLET WATER HOSE
DISCONNECT HEATER OUTLET WATER HOSE
DISCONNECT RADIATOR HOSE INLET
DISCONNECT RADIATOR HOSE OUTLET
DISCONNECT OIL COOLER INLET HOSE
DISCONNECT OIL COOLER OUTLET HOSE
36.
DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1
A60072
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2121
14-30
ENGINE MECHANICAL
37.
-
PARTIAL ENGINE ASSY (3MZ-FE)
DISCONNECT STEERING GEAR OUTLET RETURN
TUBE
A60073
38.
REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 10-22 )
39. SEPARATE ENGINE WIRE
(a) Disconnect the engine wire harness from the ECM and
junction block.
(b)
A59893
(c)
(d)
Disconnect the engine wire harness from the engine room
junction block.
(1) Remove the nut, then separate the engine wire harness.
(2) Using a screwdriver, release the engine room junction block. Separate the engine wire harness by
pulling it upward.
Remove the 2 nuts, then pull out the engine wire harness.
Remove the body ground.
40. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
41. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
42. REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2 )
43. DISCONNECT FRONT STABILIZER LINK ASSY LH (See page 30-8 )
44. DISCONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
45. REMOVE FRONT AXLE HUB LH NUT (See page 30-8 )
SST 09930-00010
46. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010
HINT:
Perform the same procedure as above on the opposite side.
47. SEPARATE SPEED SENSOR FRONT LH (See page 30-8 )
48. SEPARATE SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
49. SEPARATE TIE ROD ASSY LH (See page 30-8 )
SST 09628-6201 1
50. SEPARATE TIE ROD ASSY RH
SST 09628-6201 1
HINT:
Perform the same procedure as above on the opposite side.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2122
14-31
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
51. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-8 )
52. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
53. SEPARATE FRONT AXLE ASSY LH (See page 30-8 )
54. SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
55. SEPARATE STEERING INTERMEDIATE SHAFT ASSY (See page 51-21 )
56. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b)
Remove the 4 bolts and 2 nuts, then remove the frame
side rail plate RH and LH.
(c)
Remove the 4 bolts and 2 nuts, then remove the front suspension member brace rear RH and LH.
Carefully remove the engine assembly from the vehicle.
A59877
(d)
A59878
(e)
Install the engine hanger No. 2 in the correct direction as
shown in the illustration.
Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf)
HINT:
(f)
Engine hanger No. 2
12282-20020
Bolt
91621-60822
Attach the engine sling and hang the engine assembly
with the chain block.
A36439
57.
REMOVE VANE PUMP V BELT (See page 14-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2123
14-32
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
58.
(a)
REMOVE VANE PUMP ASSY
Remove the 2 nuts, then disconnect the power steering
pressure tube.
(b)
Remove the 2 bolts and vane pump.
59.
(a)
REMOVE FRONT FRAME ASSY
Remove the 2 nuts, then separate the engine mounting
insulator RH and LH.
(b)
Remove the bolt, then separate the engine mounting insulator FR.
A78549
A52890
RH:
LH:
A78403
A60501
60.
61.
62.
63.
64.
65.
66.
REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-8 )
SST 09520-01010, 09520-24010 (09520-32040)
REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30-8 )
REMOVE STARTER ASSY (See page 19-5 )
REMOVE ENGINE MOUNTING BRACKET FR (See page 40-9 )
REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9 )
REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40-9 )
REMOVE DRIVE SHAFT BEARING BRACKET
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2124
14-33
ENGINE MECHANICAL
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
-
PARTIAL ENGINE ASSY (3MZ-FE)
REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-140 )
SST 09213-54015 (91651-60855), 09330-00021
INSTALL ENGINE STAND
REMOVE ENGINE HANGER NO.2
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
REMOVE INTAKE MANIFOLD (See page 10-16 )
REMOVE WATER OUTLET (See page 10-16 )
REMOVE IGNITION COIL ASSY
REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-120 )
REMOVE EXHAUST MANIFOLD SUB-ASSY RH (See page 14-120 )
77.
(a)
REMOVE MANIFOLD CONVERTER INSULATOR NO.3
Remove the bolt and nut, then remove the insulator.
78.
REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.2
Remove the 2 bolts and insulator.
A86565
(a)
A86566
4
7
79.
2
(a)
(b)
6
3
REMOVE EXHAUST MANIFOLD CONVERTER
SUB-ASSY NO.2
Using several steps, loosen and remove the 7 nuts in the
sequence shown in the illustration.
Remove the exhaust manifold converter No. 2 and gasket
from the cylinder head LH.
5
1
A86567
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2125
14-34
ENGINE MECHANICAL
80.
(a)
-
PARTIAL ENGINE ASSY (3MZ-FE)
REMOVE MANIFOLD STAY NO.2
Remove the 2 bolts and manifold stay.
A86568
81.
REMOVE ENGINE MOUNTING BRACKET RH (See page 17-9 )
82.
(a)
REMOVE PUMP BRACKET
Remove the 3 bolts and pump bracket.
A05189
83.
84.
85.
86.
87.
REMOVE
REMOVE
REMOVE
REMOVE
REMOVE
GENERATOR BRACKET NO.1
COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-9 )
WATER INLET PIPE (See page 16-16 )
WATER INLET (See page 16-16 )
THERMOSTAT
88. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
(a) Using a deep socket wrench 24 mm, remove the oil pressure switch.
Oil Pressure
Switch
A80061
89.
90.
91.
92.
(a)
(b)
REMOVE KNOCK SENSOR (See page 10-16 )
REPLACE PARTIAL ENGINE ASSY
INSTALL KNOCK SENSOR (See page 10-16 )
INSTALL ENGINE OIL PRESSURE SWITCH ASSY
Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080 THREE BOND 1344,
LOCTITE 242 or equivalent
Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2126
14-35
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
93.
94.
95.
96.
97.
INSTALL THERMOSTAT (See page 16-16 )
INSTALL WATER INLET (See page 16-16 )
INSTALL WATER INLET PIPE (See page 16-16 )
INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-9 )
INSTALL GENERATOR BRACKET NO.1
Torque: 58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf)
98. INSTALL PUMP BRACKET
Torque: 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf)
99. INSTALL ENGINE MOUNTING BRACKET RH (See page 17-9 )
100. INSTALL MANIFOLD STAY NO.2
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
4
1
2
5
101. INSTALL EXHAUST MANIFOLD CONVERTER
SUB-ASSY NO.2
(a) Install a new gasket and the exhaust manifold converter
No. 2 with the 7 nuts. Using several steps, tighten the nuts
uniformly in the sequence shown in the illustration.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(b) Retighten nuts 1 and 2 as shown in the illustration.
6
3
7
A86567
102. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf)
103. INSTALL MANIFOLD CONVERTER INSULATOR NO.3
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf)
104. INSTALL EXHAUST MANIFOLD SUB-ASSY RH (See page 14-120 )
105. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-120 )
106. INSTALL IGNITION COIL ASSY (See page 14-7 )
107. INSTALL WATER OUTLET (See page 10-16 )
108. INSTALL INTAKE MANIFOLD (See page 10-16 )
109. INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
110. INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
111. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-140 )
SST 09213-54015 (91651-60855), 09330-00021
112. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 N⋅m (650 kgf⋅cm, 47 in.⋅lbf)
113. INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40-9 )
114. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9 )
115. INSTALL ENGINE MOUNTING BRACKET FR (See page 40-9 )
116. INSTALL STARTER ASSY (See page 19-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2127
14-36
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
117. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-8 )
118. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30-8 )
RH:
119. INSTALL FRONT FRAME ASSY
(a) Install the engine mounting insulator RH and LH with the
2 nuts.
Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf)
LH:
A78403
(b)
Install the engine mounting insulator FR with the bolt.
Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf)
A60501
120. INSTALL VANE PUMP ASSY
(a) Temporarily tighten the bolt.
(b) Install the adjusting strut to the engine mounting bracket
RH with the bolt.
Torque: 43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf)
A52890
(c)
Connect the power steering pressure tube with the 2 nuts.
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf)
A78549
121. INSTALL VANE PUMP V BELT (See page 14-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2128
14-37
ENGINE MECHANICAL
Nut
B
Nut
B
A
A
A59877
D
C
Nut
C
PARTIAL ENGINE ASSY (3MZ-FE)
122. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with the transaxle on the engine
lifter.
(b) Install the engine assembly to the vehicle.
(c) Install the frame side rail plate RH and LH with the 4 bolts
and 2 nuts.
Torque:
85 N⋅m (867 kgf⋅cm, 63 ft⋅lbf) for bolt A
32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt B and nut
(d)
Nut
-
Install the front suspension member brace rear RH and
LH with the 4 bolts and 2 nuts.
Torque:
85 N⋅m (867 kgf⋅cm, 63 ft⋅lbf) for bolt C
32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt D and nut
D
A59878
123. CONNECT STEERING INTERMEDIATE SHAFT ASSY (See page 51-21 )
124. INSTALL FRONT AXLE ASSY LH (See page 30-8 )
125. INSTALL FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
126. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-8 )
127. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
128. INSTALL TIE ROD ASSY LH (See page 30-8 )
129. INSTALL TIE ROD ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
130. INSTALL SPEED SENSOR FRONT LH (See page 30-8 )
131. INSTALL SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
132. INSTALL FRONT AXLE HUB LH NUT (See page 30-8 )
133. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
134. INSTALL FRONT STABILIZER LINK ASSY LH (See page 30-8 )
135. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
136. INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 )
137. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
138. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
139. CONNECT FUEL PIPE SUB-ASSY NO.1 (See page 11-1 )
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ENGINE MECHANICAL
140.
141.
142.
143.
144.
145.
146.
147.
148.
149.
150.
151.
152.
153.
-
PARTIAL ENGINE ASSY (3MZ-FE)
CONNECT TRANSMISSION CONTROL CABLE ASSY (See page 40-44 )
INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See page 17-9 )
INSTALL GENERATOR BELT ADJUSTING BAR (See page 17-9 )
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
INSTALL GENERATOR ASSY (See page 19-21 )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL INTAKE AIR RESONATOR SUB-ASSY
Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)
INSTALL AIR CLEANER INLET NO.1 (See page 19-5 )
INSTALL AIR CLEANER BRACKET (See page 19-5 )
INSTALL AIR CLEANER ASSY (See page 19-5 )
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
154. CHECK CONNECTION OF VACUUM HOSE
Vacuum Hose Routing Diagram:
From Canister
Actuator
VSV for EVAP
Vacuum Surge
Tank
Vacuum Tank
VSV for ACIS
Actuator
VSV
Cap
Engine Mounting
Insulator FR
VSV for Active Control
Engine Mount
A86570
155. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
156. INSTALL FRONT WHEELS (See page 14-5 )
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ENGINE MECHANICAL
157.
158.
159.
160.
161.
162.
163.
164.
165.
166.
167.
168.
169.
170.
171.
172.
173.
174.
-
PARTIAL ENGINE ASSY (3MZ-FE)
ADD AUTOMATIC TRANSAXLE FLUID
ADD ENGINE OIL (See page 17-20 )
ADD COOLANT (See page 16-9 )
ADD POWER STEERING FLUID
BLEED POWER STEERING FLUID
INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40-1 )
CHECK FOR ENGINE OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
CHECK POWER STEERING FLUID LEAKAGE
INSPECT FOR FUEL LEAKS
CHECK FOR EXHAUST GAS LEAKS
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-5 )
INSPECT STEERING WHEEL CENTER POINT
INSPECT IGNITION TIMING (See page 14-1 )
SST 09843-18040
INSPECT ENGINE IDLE SPEED (See page 14-1 )
INSPECT CO/HC (See page 14-1 )
CHECK ABS SPEED SENSOR SIGNAL (See page 05-420 , 05-471 )
SYSTEM INITIALIZATION (See page 19-15 )
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
141CR-02
OVERHAUL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
(a)
(b)
11.
12.
REMOVE SPARK PLUG
REMOVE OIL FILLER CAP SUB-ASSY
REMOVE OIL FILLER CAP GASKET
REMOVE CYLINDER HEAD COVER SUB-ASSY LH
REMOVE CYLINDER HEAD COVER GASKET NO.2
REMOVE CYLINDER HEAD COVER SUB-ASSY
REMOVE CYLINDER HEAD COVER GASKET
REMOVE VENTILATION VALVE SUB-ASSY
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
REMOVE VVT SENSOR
Remove both the camshaft oil control valves.
Remove the O-ring from each camshaft oil control valve.
REMOVE OIL LEVEL GAGE SUB-ASSY
REMOVE OIL LEVEL GAGE GUIDE
13.
(a)
REMOVE CRANKSHAFT PULLEY
Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
SST
A78700
(b)
Using SST and the pulley bolt, remove the pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05031)
NOTICE:
Before using SST, apply lubricating oil to the threads and
tip of the center bolt 150.
SST
A78701
14.
15.
16.
17.
REMOVE TIMING BELT NO.1 COVER
REMOVE TIMING BELT NO.2 COVER
REMOVE ENGINE MOUNTING BRACKET RH
REMOVE TIMING BELT GUIDE NO.2
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ENGINE MECHANICAL
18.
(a)
-
PARTIAL ENGINE ASSY (3MZ-FE)
REMOVE TIMING BELT
Set the No. 1 cylinder to the TDC/compression.
(1) Temporarily install the crankshaft pulley bolt and
washer to the crankshaft.
(2) Turn the crankshaft clockwise, then align the timing
mark of the crankshaft timing pulley with the oil
pump body.
Turn
A78326
(3)
Check that the timing marks of the camshaft timing
pulleys and the timing belt No. 3 cover are aligned.
If not, turn the crankshaft by 1 revolution (360).
(4) Remove the crankshaft pulley bolt.
A05052
(b)
If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.
(1) If the installation marks have disappeared, put new
installation marks on the timing belt before removing.
A52840
(c)
Approximately 60
Turn
A78327
Set the No. 1 cylinder to approximately 60 BTDC/compression.
(1) Turn the crankshaft counterclockwise by approximately 60.
NOTICE:
If the timing belt is disengaged, having the crankshaft
pulley set at the wrong angle can cause contact of the piston head with the valve head when removing the camshaft
timing pulley and camshaft, which causes damage. So always set the crankshaft pulley at the correct angle.
(d) Remove the timing belt tensioner.
NOTICE:
Do not reinstall the tensioner with its plunger extended.
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ENGINE MECHANICAL
(e)
(3)
(5)
(2)
(4)
(1)
-
PARTIAL ENGINE ASSY (3MZ-FE)
Remove the timing belt in this order.
1st
No. 1 idler pulley
2nd
RH camshaft timing pulley
3rd
No. 2 idler pulley
4th
LH camshaft timing pulley
5th
Water pump pulley
6th
Crankshaft timing pulley
(6)
A78702
19.
(a)
20.
21.
REMOVE TIMING BELT IDLER SUB-ASSY NO.1
Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
REMOVE CRANKSHAFT POSITION SENSOR
22.
(a)
REMOVE CAMSHAFT TIMING PULLEY
Using SST, remove the bolt and RH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
(b)
Using SST, remove the bolt and LH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
SST
A78703
HINT:
Arrange the camshaft timing pulleys (RH and LH sides) so that
they can be returned to the original locations when reassembling.
SST
A78704
23.
24.
REMOVE TIMING BELT NO.3 COVER
REMOVE TIMING BELT IDLER BRACKET
25. REMOVE CRANKSHAFT TIMING PULLEY
(a) Remove the bolt and timing belt plate.
(b)
(c)
SST
A78705
Install the pulley bolt to the crankshaft.
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 timing pulley.
Before using SST, apply lubricating oil to the threads
and tip of the center bolt 150.
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
26.
(a)
A78535
REMOVE WATER PUMP ASSY
Remove the 3 bolts and 3 nuts, then remove the water
pump and gasket.
27. REMOVE CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being removed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
Align
A78706
(b)
Main Gear
Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
Recommended service bolt
Sub Gear
Service Bolt
A78707
1
10
4
6 mm
Thread pitch
1.0 mm
Bolt length
16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
(c)
2
6
5
8
Thread diameter
9
7
Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
3
A78708
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ENGINE MECHANICAL
5
2
6
7
3
10
8
4
A78709
REMOVE NO.2 CAMSHAFT
Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 2 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 2 camshaft.
29. REMOVE NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being removed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a)
Align
Sub Gear
Align the timing marks (1 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
A78710
Service Bolt
Main Gear
PARTIAL ENGINE ASSY (3MZ-FE)
28.
(a)
1
9
-
A78711
(b)
Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
Recommended service bolt
Thread diameter
6 mm
Thread pitch
1.0 mm
Bolt length
16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
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ENGINE MECHANICAL
9
1
5
Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 3 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
10
8
3
PARTIAL ENGINE ASSY (3MZ-FE)
(c)
2
6
7
-
4
A78712
2
1
6
10
8
4
5
9
7
3
A78713
30.
(a)
REMOVE NO.4 CAMSHAFT SUB-ASSY
Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 4 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 4 camshaft.
31.
(a)
(b)
INSPECT CAMSHAFT TIMING GEAR ASSY
Clamp the camshaft in a vise on the hexagonal lobe.
Check that the VVT-i will not turn.
A05739
(c)
Convex Portion
A78714
Cover all the oil ports with vinyl tape except the port on the
advance angle side (nearest to the convex portion)
shown in the illustration.
(d) Using the air gun, apply about 100 kPa (1 kgf/cm2, 14 psi)
of air pressure to the port on the advance angle side.
NOTICE:
Some oil spraying will occur. Be prepared to catch the
spray with a shop rag.
HINT:
This operation releases the lock pin for the most retard angle
lock.
(e) Under the condition above, turn the VVT-i to the advance
angle side (the direction of the white arrow in the illustration) by hand.
Standard: Must turn
HINT:
Depending on the air pressure, the VVT-i will turn to the advance angle side without applying force by hand. Also, if the
pressure can be hardly applied because of the air leakage from
the port, the lock pin might not be released easily.
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ENGINE MECHANICAL
(f)
(g)
-
PARTIAL ENGINE ASSY (3MZ-FE)
Check that the VVT-i moves freely within about 30
range. Avoid moving the VVT-i unit to the most retard
angle position as the lock pin will engage again.
Standard: Smooth movable range is about 30
Turn the VVT-i by hand, then lock it at the most retard
angle position.
32. REMOVE CAMSHAFT TIMING GEAR ASSY
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i)
unless you are replacing the VVT-i or camshaft.
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
A05739
(b)
A05740
Using a 46 mm socket wrench, remove the lock nut by
turning it clockwise.
NOTICE:
Remove it with the lock pin engaged and locked at the
most retard angle position.
The lock nut has LH threads.
Never use any tools other than the socket wrench.
Other tools will deform the cam angle rotor.
(c) Remove the camshaft VVT-i.
NOTICE:
Never remove the 3 bolts on the gear.
If it is difficult to remove VVT-i, tap it lightly using a plastic-faced
hammer, then remove it.
33. REMOVE CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12596
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
(b)
Using SST, turn the sub gear counterclockwise, then remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(c)
(d)
Using snap ring pliers, remove the snap ring.
Remove the wave washer, camshaft sub gear and camshaft gear bolt washer.
SST
A78715
HINT:
Arrange the camshaft sub gears and gear bolt washers (RH and
LH sides) so that they can be returned to the original locations
when reassembling.
A52353
34.
35.
REMOVE ENGINE HANGER NO.2
REMOVE CYLINDER HEAD COVER REAR
36.
(a)
REMOVE OIL CONTROL VALVE FILTER
Remove the plug, gasket and valve filter.
37.
(a)
REMOVE CYLINDER HEAD SUB-ASSY
Using a socket hexagon wrench 8, remove the hexagon
bolt.
A05275
Front
A78716
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
(b)
Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove
the 8 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the washers into the cylinder
head.
Head warpage or cracking could result from removing the bolts in an incorrect order.
Front
2
7
5
3
4
6
8
1
A78717
38.
REMOVE CYLINDER HEAD GASKET
39.
(a)
Front
REMOVE CYLINDER HEAD LH
Using a socket hexagon wrench 8, remove the hexagon
bolt.
A78718
(b)
Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove
the 8 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the washers into the cylinder
head.
Head warpage or cracking could result from removing the bolts in an incorrect order.
Front
4
6
8
1
2
7
5
3
A78719
40.
REMOVE CYLINDER HEAD GASKET NO.2
8
41.
(a)
2
10
REMOVE WATER INLET HOUSING
Remove the 8 bolts and 2 nuts, then remove the water inlet housing.
5
3
4
6
7
9
1
A78314
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ENGINE MECHANICAL
42.
(a)
SST
(b)
-
PARTIAL ENGINE ASSY (3MZ-FE)
REMOVE OIL FILTER SUB-ASSY
Using SST, remove the oil filter.
SST 09228-07501
Using a socket hexagon wrench 12, remove the oil filter
union.
A78720
43.
REMOVE OIL PAN DRAIN PLUG
44.
(a)
REMOVE OIL PAN SUB-ASSY NO.2
Remove the 10 bolts and 2 nuts.
A36750
(b)
SST
SST
A00019
45.
(a)
Insert the blade of SST between the oil pan No. 1 and oil
pan No. 2, then cut off the sealer and remove the oil pan
No. 2.
SST 09032-00100
NOTICE:
Be careful not to damage the contact surface of the oil
pan No. 1 where the oil pan No. 2 is mounted.
Do not damage the flange portion of the oil pan No. 2
when removing.
REMOVE OIL STRAINER SUB-ASSY
Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
46.
(a)
REMOVE OIL PAN SUB-ASSY
Loosen and remove the 15 bolts and 2 nuts uniformly.
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
(b)
Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the oil pan
and cylinder block.
B04137
47.
REMOVE OIL PAN BAFFLE PLATE
48.
(a)
(b)
REMOVE ENGINE REAR OIL SEAL RETAINER
Remove the 6 bolts.
Using a screwdriver, remove the oil seal retainer by prying
between the oil seal retainer and bearing cap.
49.
(a)
REMOVE ENGINE REAR OIL SEAL
Using a screwdriver and hammer, tap out the oil seal.
50.
(a)
(b)
REMOVE OIL PUMP ASSY
Remove the 9 bolts.
Using a screwdriver, remove the oil pump by prying between the oil pump and bearing cap.
Remove the O-ring.
P12508
P12589
(c)
A51990
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ENGINE MECHANICAL
51.
(a)
-
PARTIAL ENGINE ASSY (3MZ-FE)
REMOVE OIL PUMP SEAL
Using a screwdriver, pry out the oil seal.
A62375
52.
(a)
REMOVE SPARK PLUG TUBE GASKET
Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out.
NOTICE:
Be careful not to damage the baffle plate of the cylinder
head cover.
(b) Using a screwdriver and hammer, tap out the gasket.
A05245
(c) Using needle-nose pliers, pry out the gasket.
NOTICE:
Be careful not to damage the cylinder head cover.
A05243
EM3336
53. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow contact of the timing belt with oil, water
or steam.
Do not use the timing belt tension when installing or
removing the mounting bolt of the camshaft timing
pulley.
Check the belt for any defects as shown in the illustrations.
Also, check these points below.
(a) If the belt tears in a short time:
Check if the belt is installed properly.
Check if the timing cover gasket is damaged and if
it is installed properly.
(b) If the belt teeth are cracked or damaged, check if either
camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check if there are nicks on the side of the idler pulley lock
and water pump.
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
(d)
If there is wear or damage on only one side of the belt,
check the belt guide and alignment of each pulley.
(e) If there is noticeable wear on the belt teeth:
Check the timing cover for damage.
Check that the gasket has been installed correctly.
Check for foreign objects on the pulley teeth.
If there is any doubt about the belt condition, replace the timing
belt.
54.
(a)
INSPECT CAMSHAFT
Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the runout is greater than maximum, replace the camshaft.
EM1628
(b)
A51428
Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
43.132 to 43.232 mm (1.6981 to 1.7020 in.) for intake
43.010 to 43.110 mm (1.6933 to 1.6972 in.) for exhaust
Minimum cam lobe height:
42.98 mm (1.6921 in.) for intake
42.86 mm (1.6874 in.) for exhaust
If the cam lobe height is less than minimum, replace the camshaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 to 26.975 mm (1.0614 to 1.0620 in.)
If the journal diameter is not as specified, check the oil clearance.
A51429
55.
(a)
INSPECT CYLINDER HEAD SET BOLT
Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter:
8.95 to 9.05 mm (0.3524 to 0.3563 in.)
Minimum outside diameter: 8.75 mm (0.3445 in.)
If the diameter is less than minimum, replace the bolt.
Tension Portion
A78721
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ENGINE MECHANICAL
56.
(a)
SST
(b)
(c)
A78722
-
PARTIAL ENGINE ASSY (3MZ-FE)
INSTALL SPARK PLUG TUBE GASKET
Using SST and a hammer, tap in the new gasket until its
surface is flush with the upper edge of the cylinder head
cover.
SST 09950- 60010 (09951- 00430), 09950- 70010
(09951-07100)
Return the ventilation plate tab to its original position.
Apply a light coat of multi-purpose grease to the gasket
lip.
57.
(a)
SST
A78723
Seal Width 2 to 3 mm (0.08 to 0.12 in.)
A
A
B
B
A78724
INSTALL ENGINE REAR OIL SEAL
Using SST and a hammer, tap in the new oil seal until its
surface 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.
Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.
58. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing material from the contact surface.
(b)
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 the contact surface.
Install the oil seal retainer within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil seal retainer with the 6 bolts. Tighten the
bolts uniformly in several steps.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
59.
(a)
INSTALL OIL PUMP SEAL
Using SST and a hammer, tap in the new oil seal until its
surface is flush with the oil pump body edge.
SST 09223-00010
NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.
SST
A78754
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
60.
(a)
INSTALL OIL PUMP ASSY
Remove any old 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.
A36784
(c)
B
A
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.
Seal Packing
A
B
Seal Width
2 to 3 mm
(0.08 to 0.12 in.)
C
A78725
(d)
Align the key of the oil pump drive gear with the keyway
located on the crankshaft, then slide the oil pump into
place.
A36785
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ENGINE MECHANICAL
(e)
A
B
C
A
A
B
-
PARTIAL ENGINE ASSY (3MZ-FE)
Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for bolt A
20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) for bolt B
43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) for bolt C
A
A
A
A51990
61.
62.
INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
63. INSTALL OIL PAN SUB-ASSY
(a) Remove any old seal packing from the contact surface.
(b)
Region ”X”
Region ”Y”
B
A
Seal Packing
A
B
Seal Width
3 to 4 mm
(0.12 to 0.16 in.)
64.
(a)
Apply a continuous bead of seal packing (Diameter 3 to
4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the outer side of the bolt holes
in the region ”X”.
Apply seal packing to the inner side of the bolt holes
in the region ”Y”.
Install the oil pan within 3 minutes after applying seal
packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil pan with the 15 bolts and 2 nuts. Tighten the
bolts uniformly in several steps.
Torque:
8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for 10 mm head
20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) for 12 mm head
A78726
INSTALL OIL STRAINER SUB-ASSY
Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
65. INSTALL OIL PAN SUB-ASSY NO.2
(a) Remove any old seal packing from the contact surface.
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ENGINE MECHANICAL
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PARTIAL ENGINE ASSY (3MZ-FE)
(b)
Apply a continuous bead of seal packing (Diameter 4 to
5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pan within 3 minutes after applying seal
packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
Seal Packing
A
B
A
Seal Width
4 to 5 mm
(0.16 to 0.20 in.)
B
A78727
66.
(a)
INSTALL OIL PAN DRAIN PLUG
Install the drain plug with a new gasket.
Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf)
67.
(a)
INSTALL WATER INLET HOUSING
Remove any old packing material from the contact surface.
(b)
Seal Width 3 to 5 mm
(0.12 to 0.20 in.)
Seal Packing
A78728
3
(c)
9
1
6
8
5
Apply a continuous bead of seal packing (Diameter 3 to
5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the water inlet housing within 3 minutes after
applying seal packing.
Do not expose the seal packing to coolant within 2
hours after installing.
Install the water inlet housing with the 8 bolts and 2 nuts.
Using several steps, tighten the bolts and nuts uniformly
in the sequence shown in the illustration.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
7
2
4
10
A78314
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
68.
(a)
Front
A78324
INSTALL CYLINDER HEAD GASKET
Place a new cylinder head gasket on the cylinder block
with the R mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the
head.
69. INSTALL CYLINDER HEAD SUB-ASSY
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.
(c)
Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustration.
Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf)
(d)
Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
Retighten the cylinder head bolts by 90in the same sequence as step (c).
Check that each painted mark is now at a 90 angle to the
front.
Front
7
2
4
6
5
3
1
8
A78717
(e)
90
(f)
Front
Painted Mark
A78730
(g)
Front
Using a socket hexagon wrench 8, install the hexagon
bolt.
Torque: 19 N⋅m (189 kgf⋅cm, 14 ft⋅lbf)
A78716
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
70.
(a)
Front
A79822
INSTALL CYLINDER HEAD GASKET NO.2
Place a new cylinder head gasket on the cylinder block
with the L mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the
head.
71. INSTALL CYLINDER HEAD LH
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.
(c)
Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustration.
Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf)
(d)
Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
Retighten the cylinder head bolts by 90 in the same sequence as step (c).
Check that each painted mark is now at a 90 angle to the
front.
Front
5
3
1
8
7
2
4
6
A78719
(e)
90
(f)
Front
Painted Mark
A78730
(g)
Front
Using a socket hexagon wrench 8, install the hexagon
bolt.
Torque: 19 N⋅m (189 kgf⋅cm, 14 ft⋅lbf)
A78718
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ENGINE MECHANICAL
72.
(a)
(b)
(c)
-
PARTIAL ENGINE ASSY (3MZ-FE)
INSTALL OIL CONTROL VALVE FILTER
Check that no foreign object is on the mesh part of the filter.
Assemble the valve filter and plug.
Install the plug with a new gasket.
Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf)
A05418
73.
(a)
INSTALL CYLINDER HEAD COVER REAR
Install the rear cover and a new gasket.
Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
74. INSTALL CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12595
(b)
Wave Washer
Camshaft
Sub Gear
Install the camshaft gear bolt washer and camshaft sub
gear.
HINT:
Attach the pins on the gears to the gear bolt washer ends.
(c) Install the wave washer.
Camshaft Gear
Bolt Washer
A78732
(d)
Using snap ring pliers, install the snap ring.
A52353
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
(e)
SST
A78733
Using SST, align the holes of the camshaft main gear and
sub gear by turning the camshaft sub gear counterclockwise, then temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(f)
Align the gear teeth of the main gear and sub gear, then
tighten the service bolt.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
NOTICE:
Be careful not to damage the camshaft journals.
HINT:
When installing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
75.
(a)
Align
A78734
INSTALL CAMSHAFT TIMING GEAR ASSY
Align the alignment pin with the alignment pin groove,
then install the VVT-i into the camshaft.
NOTICE:
Install it with the lock pin engaged and locked at the most
retard angle position.
(b) Apply engine oil to the nut, mounting surface of the VVT-i
and screw threads.
NOTICE:
Be sure to apply the oil, otherwise the specified
torque cannot be obtained.
New nuts must be used when replacing the VVT-i
unit.
(c)
A05738
Using a 46 mm socket wrench, install and tighten a lock
nut by turning it counterclockwise.
Torque: 150 N⋅m (1,530 kgf⋅cm, 111 ft⋅lbf)
NOTICE:
The lock nut has LH threads.
Never use any tools other than the socket wrench.
Other tools will deform the cam angle rotor.
76. INSTALL NO.2 CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
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ENGINE MECHANICAL
(b)
90
(c)
-
PARTIAL ENGINE ASSY (3MZ-FE)
Place the No. 2 camshaft at a 90 angle of the timing mark
(2 dot marks) on the cylinder head.
Apply multi-purpose grease to a new oil seal lip.
A78735
(d) Install the oil seal to the camshaft.
NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops.
(e) Remove any old packing material from the contact surface.
Front
A78736
(f)
Apply seal packing to the bearing cap No. 1 as shown in
the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the bearing cap No. 1 within 5 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
Seal Packing
A78737
(g)
(h)
Install the 5 bearing caps in their proper locations.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
(i)
Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)
A05283
10
6
2
9
5
4
1
8
3
7
A78738
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
77. INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b)
(c)
Align the timing marks (2 dot marks) of the camshaft drive
and driven gears.
Place the camshaft on the cylinder head.
Align
A78739
(d)
(e)
Install the 5 bearing caps in their proper locations.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
A05204
(f)
9
5
1
10
6
3
2
4
7
8
A78740
Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)
(g) Remove the service bolt.
78. INSTALL NO.4 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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ENGINE MECHANICAL
(b)
(c)
90
-
PARTIAL ENGINE ASSY (3MZ-FE)
Place the No. 4 camshaft at a 90 angle of the timing mark
(1 dot marks) on the cylinder head.
Apply multi-purpose grease to a new oil seal lip.
A78741
(d) Install the oil seal to the camshaft.
NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops.
(e) Remove any old packing material from the contact surface.
Front
A78742
(f)
Apply seal packing to the bearing cap No. 1 as shown in
the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the bearing cap No. 1 within 5 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
Seal Packing
A78737
(g)
(h)
Install the 5 bearing caps in their proper locations.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
(i)
Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)
A05209
9
10
5
1
3
6
2
4
7
8
A78743
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Date:
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
79. INSTALL NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b)
(c)
Align the timing marks (1 dot marks) of the camshaft drive
and driven gears.
Place the camshaft on the cylinder head.
Align
A78744
(d)
(e)
Install the 5 bearing caps in their proper locations.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
(f)
Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)
Remove the service bolt.
A05214
10
9
6
2
4
5
(g)
1
3
8
7
A78745
80.
(a)
Inward
Sensor
INSTALL CRANKSHAFT TIMING PULLEY
Align the keyway of the timing pulley with the key located
on the crankshaft, then slide the timing 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 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
A78746
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Date:
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ENGINE MECHANICAL
81.
(a)
-
PARTIAL ENGINE ASSY (3MZ-FE)
INSTALL WATER PUMP ASSY
Install a new gasket and the water pump with the 3 bolts
and 3 nuts.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
A78535
82.
(a)
(b)
INSTALL OIL LEVEL GAGE GUIDE
Apply a light coat of engine oil to a new O-ring, then install it to the level gage guide.
Install the level gage guide.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
83. INSTALL OIL FILTER SUB-ASSY
(a) Using a socket hexagon wrench 12, install the oil filter
union.
Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf)
(b) Check and clean the oil filter installation surface.
(c) Apply clean engine oil to the gasket of a new oil filter.
(d) Lightly screw the oil filter into place, then tighten it until the
gasket contacts the seat.
(e)
SST
Using SST, tighten it by an additional 3/4 turn.
SST 09228-07501
Additional
3/4 Turn
A78747
84.
INSTALL TIMING BELT IDLER BRACKET
Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf)
85. INSTALL TIMING BELT NO.3 COVER
(a) Visually check for cracks and breaks on the gasket of the
timing belt cover.
HINT:
If there is a trace of water intrusion when checking visually, repair the gasket with seal packing when the crack length is within
2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack
length is 3 to 4 cm (1.18 to 1.57 in.) or longer.
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ENGINE MECHANICAL
Seal Packing
-
(b)
Gasket
A78748
If the timing belt cover gasket is needed to repair, follow
the procedure below.
(1) Repair the cracks and breaks by applying seal
packing to the damaged area.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high
as the gasket.
(c) If the timing belt cover gasket is needed to replace, follow
the procedure below.
(1) Using a screwdriver and gasket scraper, remove
the remaining gasket.
NOTICE:
Be careful not to damage the timing belt cover.
(2)
E
PARTIAL ENGINE ASSY (3MZ-FE)
F
D
Joining
Line
Joining Portion:
Gasket
E
Joining
G Line
Remove the backing paper from a new gasket, then
affix the gasket along the groove of the timing belt
cover as shown in the illustration.
NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform.
HINT:
Gasket
D
E
F
G
Length
335 mm
(13.19 in.)
180 mm
(7.09 in.)
133 mm
(5.24 in.)
72 mm
(2.83 in.)
(3)
Seal Packing
A78749
Front
Belt
Guide
Front
If there is a gap between the ends of the gasket, apply seal packing to close the gap.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high
as the gasket.
(d) Install the timing belt cover with the 6 bolts.
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf)
86.
(a)
Belt
Guide
INSTALL CAMSHAFT TIMING PULLEY
Pay attention to the orientation of the belt guide. Install
the camshaft timing pulley with the belt guide properly oriented, then tighten the bolt temporarily.
HINT:
A78750
Align the belt guide of the RH timing pulley so it faces the
front of the engine as illustrated.
Align the belt guide of the LH timing pulley so it faces the
rear of the engine as illustrated.
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
(b)
Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf)
(c)
Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf)
SST
A78703
SST
A78704
87.
88.
(a)
INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf)
INSTALL TIMING BELT IDLER SUB-ASSY NO.1
Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot
bolt.
Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf)
89. INSTALL TIMING BELT
(a) Remove any oil or water on the pulleys, then keep them
clean.
NOTICE:
If there is a trace of water and/or oil on the timing belt,
repair the leakage and install a new timing belt.
Only wipe the pulleys; do not use any cleaning agent.
(b) Check the idler pulleys.
(1) Check that the idler pulley turns smoothly.
(2) Visually check the seal portion of the idler pulley for
oil leakage.
(c) Check the water pump.
(1) Turn the pulley, then check that water pump bearing
moves smoothly and does not make a noise.
(2) Visually check the drain hole for coolant leakage.
(d) Temporarily install the crankshaft pulley bolt and washer
to the crankshaft.
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-
PARTIAL ENGINE ASSY (3MZ-FE)
(e)
Turn the crankshaft counterclockwise by approximately
60.
NOTICE:
To prevent contact of the piston head with the valve head,
set the crankshaft pulley at the 60 BTDC/compression
position.
Approximately 60
Turn
A82349
(f)
Using SST, turn the crankshaft pulley, then align the timing marks of the timing pulley with the timing belt No. 3
cover.
SST 09960-10010 (09962-01000, 09963-01000)
(g)
Turn the crankshaft, then align the timing mark of the
crankshaft timing pulley with the oil pump body.
(h)
(i)
Align the front mark on the timing belt so it faces forward.
Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
SST
A78751
A05062
(j)
A52840
(k)
(4)
Install the timing belt in this order.
1st
(2)
(5)
(3)
(6)
Crankshaft timing pulley
2nd
Water pump pulley
3rd
LH camshaft timing pulley
4th
No. 2 idler pulley
5th
RH camshaft timing pulley
6th
No. 1 idler pulley
(1)
A78702
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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Date:
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ENGINE MECHANICAL
90.
(a)
A36238
-
PARTIAL ENGINE ASSY (3MZ-FE)
INSTALL TIMING BELT TENSIONER ASSY
Set the timing belt tensioner upright on the press.
(b) Slowly press in the push rod.
NOTICE:
Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205
lbf) to the rod.
(c) Align the holes of the push rod and housing, then pass a
1.5 mm hexagon wrench through the holes to keep the
setting position of the push rod.
(d) Release the press.
(e) Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
Torque: 27 N⋅m (280 kgf⋅cm, 20 ft⋅lbf)
NOTICE:
Be sure to tighten the bolts uniformly. Installing the tensioner at an angle may cause failure of its proper operation.
(f)
Remove the 1.5 mm hexagon wrench from the tensioner.
(g) Turn the crankshaft 2 revolutions slowly, then align the
timing mark of the crankshaft timing pulley with the oil
pump body.
NOTICE:
Always turn the crankshaft clockwise.
Turn
A78326
(h)
Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the timing belt
No. 3 cover as shown in the illustration.
If the marks are not aligned, remove the timing belt and reinstall
it.
(i)
Remove the crankshaft pulley bolt.
A05052
91.
(a)
INSTALL TIMING BELT GUIDE NO.2
Install the timing belt guide with the cup side facing the engine front.
A36239
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2161
14-70
ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
92.
INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf)
93. INSTALL TIMING BELT NO.2 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf)
94. INSTALL TIMING BELT NO.1 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf)
95.
(a)
(b)
INSTALL CRANKSHAFT PULLEY
Align the keyway of the pulley with the key located on the
crankshaft, then slide the pulley into place.
Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 N⋅m (2,250 kgf⋅cm, 162 ft⋅lbf)
SST
A78753
96.
97.
98.
INSTALL VVT SENSOR
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
INSTALL ENGINE HANGER NO.2
Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf)
99.
(a)
INSPECT VALVE CLEARANCE
Turn the crankshaft pulley, then align the timing notch with
the timing mark ”0” of the timing belt No. 1 cover.
(b) Check that the valve lifters on the intake side of the No.
1 cylinder are not pushed by the cam.
If the valve lifters are pushed, turn the crankshaft 1 revolution
(360) and align the marks as above.
A52345
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2162
14-71
ENGINE MECHANICAL
PARTIAL ENGINE ASSY (3MZ-FE)
(c)
Inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance
measurements. They will be used later to select an
adjusting shim to replace.
(d)
Turn the crankshaft by 2/3 of a revolution (240), then inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance
measurements. They will be used later to select an
adjusting shim to replace.
RH Bank:
3 3
EX
IN
1 1
LH Bank:
-
Front
6 6
IN
EX
2 2
A78666
RH Bank:
5 5
EX
IN
3 3
LH Bank:
Front
2 2
IN
EX
4 4
A78667
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2163
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ENGINE MECHANICAL
(e)
RH Bank:
1 1
EX
IN
5 5
LH Bank:
Front
-
PARTIAL ENGINE ASSY (3MZ-FE)
Turn the crankshaft by 2/3 of a revolution (240), then inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance
measurements. They will be used later to select an
adjusting shim to replace.
4 4
IN
EX
6 6
A78668
100. ADJUST VALVE CLEARANCE
(a) Turn the camshaft so that the cam lobe faces upward.
(b) Turn the valve lifter with a screwdriver so that the notches
are perpendicular to the camshaft.
Upward
Notch
A78669
(c)
Front of No. 1 and No. 2 Cylinders:
SST (A)
Using SST (A), press down the valve lifter and place SST
(B) between the camshaft and valve lifter. Remove SST
(A).
SST 09248-55040 (09248-05410, 09248-05420)
HINT:
SST (B)
7
Others:
SST (A)
Apply SST (B) at a slight angle on the side marked with
”9” or ”7” at the position shown in the illustration.
When SST (B) is inserted too deeply, it will get pinched by
the shim. To prevent SST(B) from getting stuck, insert it
gently from the intake side at a slight angle.
SST (A)
09248-05410
SST (B)
09248-05420
SST (B)
9
A78670
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2164
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ENGINE MECHANICAL
-
PARTIAL ENGINE ASSY (3MZ-FE)
(d)
Using a small screwdriver and magnetic finger, remove
the adjusting shim.
(e)
Using a micrometer, measure the thickness of the removed shim.
Calculate the thickness of a new shim so that the valve
clearance comes within the specified value.
SST (B)
Magnetic Finger
A78671
(f)
EM0494
(g)
A
Thickness of new shim
B
Thickness of used shim
C
Measured valve clearance
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.0079 in.))
Exhaust A = B + (C - 0.30 mm (0.0118 in.))
Select a new shim with a thickness which is as close to the
calculated values as possible.
EXAMPLE (Intake):
Measured valve clearance = 0.45 mm (0.0177 in.)
0.45 mm (0.0177 in.) - 0.20 mm (0.0079 in.) = 0.25 mm (0.0098 in.)
(Measured - Specification = Excess clearance)
Used shim measurement = 2.80 mm (0.1102 in.)
0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) = 3.05 mm (0.1201 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 3.05 mm (0.1201 in.)
Select No. 12 shim
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm
(0.1299 in.).
Refer to New Shim Thickness table on the next 2 pages.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Adjusting Shim Selection Chart (Intake)
Installed Shim Thickness
mm (in.)
Measured Clearance
mm (in.)
ENGINE MECHANICAL
-
Author:
Shim
No.
Thickness
Shim
No.
mm (in.)
Thickness
Date:
V00719
2166
Intake valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and
the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 12 HINT: New shims have the thickness in millimeters
shim.
imprinted on the face.
PARTIAL ENGINE ASSY (3MZ-FE)
New Shim Thickness
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Adjusting Shim Selection Chart (Exhaust)
Installed Shim Thickness
mm (in.)
Measured Clearance
mm (in.)
ENGINE MECHANICAL
-
Author:
Shim
No.
Thickness
Shim
No.
mm (in.)
Thickness
PARTIAL ENGINE ASSY (3MZ-FE)
New Shim Thickness
Date:
14-75
V00720
2167
Exhaust valve clearance (Cold):
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and
the measured clearance is 0.450 mm (0.0177 in.).
HINT: New shims have the thickness in millimeters
Replace the 2.800 mm (0.1102 in.) shim with a new No. 10
imprinted on the face.
shim.
14-76
ENGINE MECHANICAL
SST (A)
SST (B)
-
PARTIAL ENGINE ASSY (3MZ-FE)
(h)
Place a new adjusting shim on the valve lifter with the imprinted number facing down.
(i)
Press down the valve lifter with SST (A), then remove SST
(B).
SST 09248-55040 (09248-05410, 09248-05420)
(j)
Recheck the valve clearance.
101. INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) Install the gasket to the cylinder head cover.
A78672
(b)
: Seal Packing
Front
A78673
Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after
applying seal packing.
Do not start the engine within 2 hours after installing.
(c) Install the cylinder head cover with the 9 bolts. Tighten the
bolts uniformly in several steps.
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
102. INSTALL CYLINDER HEAD COVER SUB-ASSY LH
(a) Install the gasket to the cylinder head cover.
(b)
: Seal Packing
Front
A78674
Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after
applying seal packing.
Do not start the engine within 2 hours after installing.
(c) Install the cylinder head cover with the 9 bolts. Tighten the
bolts uniformly in several steps.
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
103. INSTALL SPARK PLUG
Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
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ENGINE MECHANICAL
-
TIMING BELT (3MZ-FE)
TIMING BELT (3MZ-FE)
141JA-01
COMPONENTS
Front Fender Apron
Seal RH
64 (653, 47)
Vane Pump V Belt
23 (235, 17)
Radio Setting Condenser
V Belt No. 1
Engine Moving Control Rod
64 (653, 47)
28 (286, 21)
58 (591, 43)
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
A84916
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2169
14-78
ENGINE MECHANICAL
-
TIMING BELT (3MZ-FE)
Timing Belt
8.5 (87, 75 in.⋅lbf)
Timing Belt No. 2 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH
28 (286, 21)
Timing Belt No. 1 Cover
220 (2,250, 162)
8.5 (87, 75 in.⋅lbf)
Crankshaft Pulley
Engine Wire
Protector
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
A78353
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2170
14-79
ENGINE MECHANICAL
-
TIMING BELT (3MZ-FE)
141JB-01
REPLACEMENT
1.
2.
3.
4.
REMOVE FRONT WHEEL RH
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
REMOVE VANE PUMP V BELT (See page 14-5 )
5.
(a)
(b)
REMOVE ENGINE MOVING CONTROL ROD
Remove the reserve tank cap.
Remove the 4 bolts, engine moving control rod and bracket.
6.
(a)
REMOVE ENGINE MOUNTING STAY NO.2 RH
Remove the bolt, engine mounting stay No. 2 and engine
mounting bracket No. 2.
7.
(a)
REMOVE GENERATOR BRACKET NO.2
Remove the nut and generator bracket.
8.
(a)
REMOVE CRANKSHAFT PULLEY
Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
A78546
A52344
P18816
SST
A78755
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2171
14-80
ENGINE MECHANICAL
SST
-
TIMING BELT (3MZ-FE)
(b)
Using SST and the pulley bolt, remove the pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05031)
NOTICE:
Before using SST, apply lubricating oil to the threads and
tip of the center bolt 150.
A78756
9.
REMOVE TIMING BELT NO.1 COVER
10.
(a)
Clamp
Clamp
(b)
REMOVE TIMING BELT NO.2 COVER
Disconnect the 2 engine wire protector clamps from the
timing belt No. 3 cover.
Remove the 5 bolts and timing belt cover.
A78759
11.
(a)
REMOVE ENGINE MOUNTING BRACKET RH
Remove the 2 bolts, nut and engine mounting bracket
RH.
P18814
12.
REMOVE TIMING BELT GUIDE NO.2
13.
(a)
REMOVE TIMING BELT
Set the No. 1 cylinder to the TDC/compression.
(1) Temporarily install the crankshaft pulley bolt and
washer to the crankshaft.
(2) Turn the crankshaft clockwise, then align the timing
mark of the crankshaft timing pulley with the oil
pump body.
Turn
A78326
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2172
14-81
ENGINE MECHANICAL
-
TIMING BELT (3MZ-FE)
(3)
Check that the timing marks of the camshaft timing
pulleys and the timing belt No. 3 cover are aligned.
If not, turn the crankshaft by 1 revolution (360).
(4) Remove the crankshaft pulley bolt.
A05052
(b)
If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.
(1) If the installation marks have disappeared, put new
installation marks on the timing belt before removing.
A52840
(c)
Approximately 60
Turn
A78327
Set the No. 1 cylinder to approximately 60 BTDC/compression.
(1) Turn the crankshaft counterclockwise by approximately 60.
NOTICE:
If the timing belt is disengaged, having the crankshaft
pulley set at the wrong angle can cause contact of the piston head with the valve head when removing the camshaft
timing pulley and camshaft, which causes damage. So always set the crankshaft pulley at the correct angle.
(d) Remove the timing belt tensioner.
NOTICE:
Do not reinstall the tensioner with its plunger extended.
(e)
(3)
(5)
(2)
(4)
(1)
Remove the timing belt in this order.
1st
No. 1 idler pulley
2nd
RH camshaft timing pulley
3rd
No. 2 idler pulley
4th
LH camshaft timing pulley
5th
Water pump pulley
6th
Crankshaft timing pulley
(6)
A78702
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2173
14-82
ENGINE MECHANICAL
EM3336
-
TIMING BELT (3MZ-FE)
14. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow contact of the timing belt with oil, water
or steam.
Do not use the timing belt tension when installing or
removing the mounting bolt of the camshaft timing
pulley.
Check the belt for any defects as shown in the illustrations.
Also, check these points below.
(a) If the belt tears in a short time:
Check if the belt is installed properly.
Check if the timing cover gasket is damaged and if
it is installed properly.
(b) If the belt teeth are cracked or damaged, check if either
camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check if there are nicks on the side of the idler pulley lock
and water pump.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and alignment of each pulley.
(e) If there is noticeable wear on the belt teeth:
Check the timing cover for damage.
Check that the gasket has been installed correctly.
Check for foreign objects on the pulley teeth.
If there is any doubt about the belt condition, replace the timing
belt.
15. INSTALL TIMING BELT
(a) Remove any oil or water on the pulleys, then keep them
clean.
NOTICE:
If there is a trace of water and/or oil on the timing belt,
repair the leakage and install a new timing belt.
Only wipe the pulleys; do not use any cleaning agent.
(b) Check the idler pulleys.
(1) Check that the idler pulley turns smoothly.
(2) Visually check the seal portion of the idler pulley for
oil leakage.
(c) Check the water pump.
(1) Turn the pulley, then check that water pump bearing
moves smoothly and does not make a noise.
(2) Visually check the drain hole for coolant leakage.
(d) Temporarily install the crankshaft pulley bolt and washer
to the crankshaft.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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Date:
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ENGINE MECHANICAL
-
TIMING BELT (3MZ-FE)
(e)
Turn the crankshaft counterclockwise by approximately
60.
NOTICE:
To prevent contact of the piston head with the valve head,
set the crankshaft pulley at the 60 BTDC/compression
position.
Approximately 60
Turn
A82349
(f)
Using SST, turn the timing pulleys, then align the timing
marks of the timing pulleys with the timing belt No. 3 cover.
SST 09960-10010 (09962-01000, 09963-01000)
(g)
Turn the crankshaft, then align the timing mark of the
crankshaft timing pulley with the oil pump body.
(h)
(i)
Align the front mark on the timing belt so it faces forward.
Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
SST
A78751
A05062
(j)
A52840
(k)
(4)
Install the timing belt in this order.
1st
(2)
(5)
(3)
(6)
Crankshaft timing pulley
2nd
Water pump pulley
3rd
LH camshaft timing pulley
4th
No. 2 idler pulley
5th
RH camshaft timing pulley
6th
No. 1 idler pulley
(1)
A78702
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
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ENGINE MECHANICAL
16.
(a)
A36238
-
TIMING BELT (3MZ-FE)
INSTALL TIMING BELT TENSIONER ASSY
Set the timing belt tensioner upright on the press.
(b) Slowly press in the push rod.
NOTICE:
Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205
lbf) to the rod.
(c) Align the holes of the push rod and housing, then pass a
1.5 mm hexagon wrench through the holes to keep the
setting position of the push rod.
(d) Release the press.
(e) Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
Torque: 27 N⋅m (280 kgf⋅cm, 20 ft⋅lbf)
NOTICE:
Be sure to tighten the bolts uniformly. Installing the tensioner at an angle may cause failure of its proper operation.
(f)
Remove the 1.5 mm hexagon wrench from the tensioner.
(g) Turn the crankshaft 2 revolutions slowly, then align the
timing mark of the crankshaft timing pulley with the oil
pump body.
NOTICE:
Always turn the crankshaft clockwise.
Turn
A78326
(h)
Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the timing belt
No. 3 cover as shown in the illustration.
If the marks are not aligned, remove the timing belt and reinstall
it.
(i)
Remove the crankshaft pulley bolt.
A05052
17.
(a)
INSTALL TIMING BELT GUIDE NO.2
Install the timing belt guide with the cup side facing the engine front.
A36239
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
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ENGINE MECHANICAL
18.
(a)
-
TIMING BELT (3MZ-FE)
INSTALL ENGINE MOUNTING BRACKET RH
Install the engine mounting bracket RH with the 2 bolts
and nut.
Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf)
P18814
19. INSTALL TIMING BELT NO.2 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf)
20. INSTALL TIMING BELT NO.1 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf)
(c) Install the 2 engine wire protector clamps to the timing belt No. 3 cover.
21.
(a)
(b)
INSTALL CRANKSHAFT PULLEY
Align the keyway of the pulley with the key located on the
crankshaft, then slide the pulley into place.
Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 N⋅m (2250 kgf⋅cm, 162 ft⋅lbf)
SST
A78760
22.
INSTALL GENERATOR BRACKET NO.2
Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf)
23.
(a)
INSTALL ENGINE MOUNTING STAY NO.2 RH
Install the engine mounting stay No. 2 and engine mounting bracket No. 2 with the bolt.
Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf)
A52344
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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Date:
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ENGINE MECHANICAL
24.
(a)
B
A
A
-
TIMING BELT (3MZ-FE)
INSTALL ENGINE MOVING CONTROL ROD
Install the engine moving control rod and bracket with the
4 bolts.
Torque:
64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) for bolt A
23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for bolt B
A
A78546
25.
26.
27.
28.
INSTALL VANE PUMP V BELT (See page 14-5 )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL FRONT WHEEL RH (See page 14-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2178
14-87
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
CAMSHAFT (RH BANK) (3MZ-FE)
141JC-01
COMPONENTS
x2
80 (816, 59)
Spacer
x3
W/O TEMS:
Front Suspension Upper Brace Center
7.9 (81, 70 in.⋅lbf)
V-bank Cover Sub-assy
x2
80 (816, 59)
Spacer
Fuel Vapor Feed Hose
Assy
Vacuum Hose
Mass Air Flow
Meter Connector
Vacuum Hose
Air Cleaner Cap
Sub-assy
5.0 (51, 44 in.⋅lbf)
Air Cleaner Filter
Element Sub-assy
N·m (kgf·cm, ft·lbf) : Specified torque
A86358
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
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14-88
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
VSV Connector
7.8 (80, 69 in.⋅lbf)
x2
Pressure Feed
Tube Assy
x2
8.0 (82, 71 in.⋅lbf)
Emission
Control Valve Set
Fuel Vapor Feed Hose
28 (286, 21)
Bond Cable No. 1
Connector
20 (199, 14)
x3
x2
x2
20 (199, 14)
x2
Emission Control Valve Bracket
28 (286, 21)
Engine Hunger No. 1
Surge Tank Stay
No. 1
x2
20 (199, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86260
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2180
14-89
ENGINE MECHANICAL
Front Fender Apron
Seal RH
-
CAMSHAFT (RH BANK) (3MZ-FE)
64 (653, 47)
Vane Pump V Belt
23 (235, 17)
Radio Setting Condenser
V Belt No. 1
Engine Moving Control Rod
64 (653, 47)
28 (286, 21)
58 (591, 43)
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
A84916
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2181
14-90
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
Timing Belt
8.5 (87, 75 in.⋅lbf)
Timing Belt No. 2 Cover
Timing Belt Guide No. 2
8.5 (87, 75 in.⋅lbf)
Engine Mounting Bracket RH
28 (286, 21)
Timing Belt No. 1 Cover
220 (2,250, 162)
Crankshaft Pulley
Engine Wire
Protector
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
A78383
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2182
14-91
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
Camshaft Timing Pulley
Collar
Bushing
8.5 (87, 75 in.⋅lbf)
x6
125 (1,275, 92)
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
Engine Wire
N·m (kgf·cm, ft·lbf) : Specified torque
A78384
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2183
14-92
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
8.4 (85, 74 in.⋅lbf)
Engine Wire
8.0 (80, 71 in.⋅lbf)
Engine Wire
Ignition Coil Assy
8.0 (80, 71 in.⋅lbf)
x9
Cylinder Head Cover Sub-assy
Cylinder Head
Cover Gasket
Camshaft Bearing
Cap No. 4
Camshaft Bearing
Cap No. 2
16 (163, 12)
Camshaft Timing Gear
Bolt Washer
Camshaft Sub Gear
Camshaft Sub Gear
Wave Washer
Camshaft Sub Gear
Shaft Snap Ring
x10
Camshaft Bearing
Cap No. 1
Camshaft Bearing Cap No. 5
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
No. 2 Camshaft
16 (163, 12)
x10
150 (1,530, 111)
Camshaft Bearing Cap No. 2
Camshaft Timing Gear Assy
Camshaft
Camshaft Setting
Oil Seal
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78385
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2184
14-93
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
141JD-01
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE COOLANT (See page 16-9 )
REMOVE FRONT WHEEL RH
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
REMOVE IGNITION COIL ASSY
REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-7 )
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
REMOVE VANE PUMP V BELT (See page 14-5 )
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
REMOVE TIMING BELT NO.1 COVER
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
REMOVE TIMING BELT GUIDE NO.2
REMOVE TIMING BELT (See page 14-79 )
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
24.
(a)
REMOVE CAMSHAFT TIMING PULLEY
Using SST, remove the bolt and RH timing pulley.
SST 09960- 10010 (09962- 01000, 09963- 01000),
09249-63010
LH:
(b)
Using SST, remove the bolt and LH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
SST
HINT:
Arrange the camshaft timing pulleys (RH and LH sides) so that
they can be returned to the original locations when reassembling.
RH:
SST
A78761
A78762
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2185
14-94
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
25.
(a)
Clamp
Clamp
Clamp
A05077
REMOVE TIMING BELT NO.3 COVER
Disconnect the 3 engine wire harness clamps from the
timing belt No. 3 cover.
(b) Remove the 6 bolts and timing belt cover.
26. REMOVE CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being removed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a)
Align the timing marks (2 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
Align
A78706
(b)
Main Gear
Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
Recommended service bolt
Sub Gear
Service Bolt
A78707
1
10
4
6 mm
Thread pitch
1.0 mm
Bolt length
16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
(c)
2
6
5
8
Thread diameter
9
7
Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
3
A78708
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2186
14-95
ENGINE MECHANICAL
5
2
6
7
3
CAMSHAFT (RH BANK) (3MZ-FE)
27.
(a)
1
9
-
10
8
4
A78709
REMOVE NO.2 CAMSHAFT
Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 2 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 2 camshaft.
28. REMOVE CAMSHAFT TIMING GEAR ASSY
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i)
unless you are replacing the VVT-i or camshaft.
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
A05739
(b)
A05740
Using a 46 mm socket wrench, remove the lock nut by
turning it clockwise.
NOTICE:
Remove it with the lock pin engaged and locked at the
most retard angle position.
The lock nut has LH threads.
Never use any tools other than the socket wrench.
Other tools will deform the cam angle rotor.
(c) Remove the camshaft VVT-i.
NOTICE:
Never remove the 3 bolts on the gear.
If it is difficult to remove VVT-i, tap it lightly using a plastic-faced
hammer, then remove it.
29. REMOVE CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12596
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2187
14-96
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
(b)
Using SST, turn the sub gear counterclockwise, then remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(c)
(d)
Using snap ring pliers, remove the snap ring.
Remove the wave washer, camshaft sub gear and camshaft gear bolt washer.
SST
A78715
A52353
30. INSTALL CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12595
(b)
Wave Washer
Camshaft
Sub Gear
Install the camshaft gear bolt washer and camshaft sub
gear.
HINT:
Attach the pins on the gears to the gear bolt washer ends.
(c) Install the wave washer.
Camshaft Gear
Bolt Washer
A78732
(d)
Using snap ring pliers, install the snap ring.
A52353
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2188
14-97
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
(e)
SST
A78733
Using SST, align the holes of the camshaft main gear and
sub gear by turning the camshaft sub gear counterclockwise, then temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(f)
Align the gear teeth of the main gear and sub gear, then
tighten the service bolt.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
NOTICE:
Be careful not to damage the camshaft journals.
HINT:
When installing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
31.
(a)
Align
A78734
INSTALL CAMSHAFT TIMING GEAR ASSY
Align the alignment pin with the alignment pin groove,
then install the VVT-i on the camshaft.
NOTICE:
Install it with the lock pin engaged and locked at the most
retard angle position.
(b) Apply engine oil to the nut, mounting surface of the VVT-i
and screw threads.
NOTICE:
Be sure to apply the oil, otherwise the specified
torque cannot be obtained.
New nut must be used when replacing the VVT-i unit.
(c)
A05738
Using a 46 mm socket wrench, install and tighten a lock
nut by turning it counterclockwise.
Torque: 150 N⋅m (1,530 kgf⋅cm, 111 ft⋅lbf)
NOTICE:
The lock nut has LH threads.
Never use any tools other than the socket wrench.
Other tools will deform the cam angle rotor.
32. INSTALL NO.2 CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2189
14-98
ENGINE MECHANICAL
(b)
90
(c)
-
CAMSHAFT (RH BANK) (3MZ-FE)
Place the No. 2 camshaft at a 90 angle of the timing mark
(2 dot marks) on the cylinder head.
Apply multi-purpose grease to a new oil seal lip.
A78735
(d) Install the oil seal to the camshaft.
NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops.
(e) Remove any old packing material from the contact surface.
Front
A78736
(f)
Apply seal packing to the bearing cap No. 1 as shown in
the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the bearing cap No. 1 within 5 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
Seal Packing
A78737
(g)
(h)
Install the 5 bearing caps in their proper locations.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
(i)
Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)
A05283
10
6
2
9
5
4
1
8
3
7
A78738
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2190
14-99
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
33. INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b)
(c)
Align the timing marks (2 dot marks) of the camshaft drive
and driven gears.
Place the camshaft on the cylinder head.
Align
A78739
(d)
(e)
Install the 5 bearing caps in their proper locations.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
(f)
Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)
Remove the service bolt.
INSTALL TIMING BELT NO.3 COVER
Visually check for cracks and breaks on the gasket of the
timing belt cover.
A05204
9
5
1
10
(g)
34.
(a)
6
3
2
4
7
8
A78740
HINT:
If there is a trace of water intrusion when checking visually, repair the gasket with seal packing when the crack length is within
2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack
length is 3 to 4 cm (1.18 to 1.57 in.) or longer.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2191
14-100
ENGINE MECHANICAL
Seal Packing
-
(b)
Gasket
A78748
If the timing belt cover gasket is needed to repair, follow
the procedure below.
(1) Repair the cracks and breaks by applying seal
packing to the damaged area.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high
as the gasket.
(c) If the timing belt cover gasket is needed to replace, follow
the procedure below.
(1) Using a screwdriver and gasket scraper, remove
the remaining gasket.
NOTICE:
Be careful not to damage the timing belt cover.
(2)
E
CAMSHAFT (RH BANK) (3MZ-FE)
F
D
Joining
Line
Joining Portion:
Gasket
E
Joining
G Line
Remove the backing paper from a new gasket, then
affix the gasket along the groove of the timing belt
cover as shown in the illustration.
NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform.
HINT:
Gasket
D
E
F
G
Length
335 mm
(13.19 in.)
180 mm
(7.09 in.)
133 mm
(5.24 in.)
72 mm
(2.83 in.)
(3)
Seal Packing
A78749
Front
Belt
Guide
Front
Belt
Guide
If there is a gap between the ends of the gasket, apply seal packing to close the gap.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high
as the gasket.
(d) Install the timing belt cover with the 6 bolts.
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf)
35.
(a)
INSTALL CAMSHAFT TIMING PULLEY
Pay attention to the orientation of the belt guide. Install
the camshaft timing pulley with the belt guide properly oriented, then tighten the bolt temporarily.
HINT:
A78750
Align the belt guide of the RH timing pulley so it faces the
front of the engine as illustrated.
Align the belt guide of the LH timing pulley so it faces the
rear of the engine as illustrated.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2192
14-101
ENGINE MECHANICAL
-
CAMSHAFT (RH BANK) (3MZ-FE)
(b)
RH:
SST
150 mm
(5.91 in.)
A78763
Using SST, tighten the RH pulley bolt.
SST 09960- 10010 (09962- 01000, 09963- 01000),
09249-63010
Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf)
NOTICE:
The torque indicated above is used without SST on the extension tool. If you are using the extension tool, find the
reading of the torque wrench by the formula (see page
01-5 ).
Extended length:
SST (09249-63010) 150mm (5.91 in.)
(c)
LH:
Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 N⋅m (1275 kgf⋅cm, 92 ft⋅lbf)
SST
A78762
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf)
INSPECT TIMING BELT (See page 14-79 )
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
INSPECT VALVE CLEARANCE (See page 14-7 )
ADJUST VALVE CLEARANCE (See page 14-7 )
SST 09248-55040 (09248-05410, 09248-05420)
INSTALL VANE PUMP V BELT (See page 14-5 )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-7 )
INSTALL IGNITION COIL ASSY (See page 14-7 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2193
14-102
ENGINE MECHANICAL
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
-
CAMSHAFT (RH BANK) (3MZ-FE)
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
INSTALL FRONT WHEEL RH (See page 14-5 )
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2194
14-103
ENGINE MECHANICAL
-
CAMSHAFT (LH BANK) (3MZ-FE)
CAMSHAFT (LH BANK) (3MZ-FE)
141JE-01
COMPONENTS
Front Fender Apron
Seal RH
64 (653, 47)
Vane Pump V Belt
23 (235, 17)
Radio Setting Condenser
V Belt No. 1
Engine Moving Control Rod
64 (653, 47)
28 (286, 21)
58 (591, 43)
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
A84916
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2195
14-104
ENGINE MECHANICAL
-
CAMSHAFT (LH BANK) (3MZ-FE)
Timing Belt
8.5 (87, 75 in.⋅lbf)
Timing Belt No. 2 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH
28 (286, 21)
Timing Belt No. 1 Cover
220 (2,250, 162)
8.5 (87, 75 in.⋅lbf)
Crankshaft Pulley
Engine Wire
Protector
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
A78353
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2196
14-105
ENGINE MECHANICAL
-
CAMSHAFT (LH BANK) (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
Camshaft Timing Pulley
Collar
Bushing
8.5 (87, 75 in.⋅lbf)
x6
125 (1,275, 92)
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
Engine Wire
N·m (kgf·cm, ft·lbf) : Specified torque
A78384
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2197
14-106
ENGINE MECHANICAL
V-bank Cover Sub-assy
-
CAMSHAFT (LH BANK) (3MZ-FE)
7.9 (81, 70 in.⋅lbf)
x3
8.0 (80, 71 in.⋅lbf)
Ignition Coil Assy
Cylinder Head Cover
Sub-assy LH
8.0 (80, 71 in.⋅lbf)
x9
8.4 (85, 74 in.⋅lbf)
Cylinder Head Cover Gasket No. 2
Engine Wire
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 6
Camshaft Bearing Cap No. 5
150 (1,530, 111)
16 (163, 12)
x10
Camshaft Bearing Cap No. 2
No. 3 Camshaft
Sub-assy
Camshaft Timing Gear Assy
Camshaft Bearing Cap No. 2
x10
Camshaft Bearing Cap No. 4
16 (163, 12)
Camshaft Sub Gear
Shaft Snap Ring
Camshaft Bearing Cap No. 1
Camshaft Sub Gear
Wave Washer
No. 4 Camshaft Sub-assy
Camshaft Sub Gear
Camshaft Timing Gear
Bolt Washer
Camshaft Setting
Oil Seal
Radiator Hose Inlet
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78386
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2198
14-107
ENGINE MECHANICAL
-
CAMSHAFT (LH BANK) (3MZ-FE)
141JF-01
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE COOLANT (See page 16-9 )
REMOVE FRONT WHEEL RH
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
REMOVE RADIATOR HOSE INLET
REMOVE IGNITION COIL ASSY
REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7 )
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
REMOVE VANE PUMP V BELT (See page 14-5 )
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
REMOVE TIMING BELT NO.1 COVER
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
REMOVE TIMING BELT GUIDE NO.2
REMOVE TIMING BELT (See page 14-79 )
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
23. REMOVE NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being removed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a)
Align
Align the timing marks (1 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
A78710
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2199
14-108
ENGINE MECHANICAL
Service Bolt
Main Gear
Sub Gear
9
A78711
1
5
(b)
Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
Recommended service bolt
Thread diameter
6 mm
Thread pitch
1.0 mm
Bolt length
16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 3 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
10
8
3
CAMSHAFT (LH BANK) (3MZ-FE)
(c)
2
6
7
-
4
A78712
2
1
6
10
8
4
5
9
7
3
A78713
25.
26.
27.
28.
24.
(a)
REMOVE NO.4 CAMSHAFT SUB-ASSY
Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 4 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 4 camshaft.
REMOVE CAMSHAFT TIMING GEAR ASSY (See page 14-93 )
REMOVE CAMSHAFT SUB GEAR NO.3 (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-00500)
INSTALL CAMSHAFT SUB GEAR NO.3 (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-00500)
INSTALL CAMSHAFT TIMING GEAR ASSY (See page 14-93 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2200
14-109
ENGINE MECHANICAL
-
CAMSHAFT (LH BANK) (3MZ-FE)
29. INSTALL NO.4 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b)
(c)
90
Place the No. 4 camshaft at a 90 angle of the timing mark
(1 dot marks) on the cylinder head.
Apply multi-purpose grease to a new oil seal lip.
A78741
(d) Install the oil seal to the camshaft.
NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops.
(e) Remove any old packing material from the contact surface.
Front
A78742
(f)
Apply seal packing to the bearing cap No. 1 as shown in
the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the bearing cap No. 1 within 5 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
Seal Packing
A78737
(g)
(h)
Install the 5 bearing caps in their proper locations.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
A05209
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2201
14-1 10
ENGINE MECHANICAL
10
5
3
6
2
4
7
CAMSHAFT (LH BANK) (3MZ-FE)
(i)
9
1
-
8
A78743
Using several steps, install and tighten the 10 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)
30. INSTALL NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b)
(c)
Align the timing marks (1 dot marks) of the camshaft drive
and driven gears.
Place the camshaft to the cylinder head.
Align
A78744
(d)
(e)
Install the 5 bearing caps in their proper locations.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
(f)
Using several steps, install and tighten the 10 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)
Remove the service bolt.
A05214
10
9
6
2
4
5
(g)
1
3
8
7
A78745
31.
32.
33.
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2202
14-1 11
ENGINE MECHANICAL
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
-
CAMSHAFT (LH BANK) (3MZ-FE)
INSPECT TIMING BELT (See page 14-79 )
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
INSPECT VALVE CLEARANCE (See page 14-7 )
ADJUST VALVE CLEARANCE (See page 14-7 )
SST 09248-55040 (09248-05410, 09248-05420)
INSTALL VANE PUMP V BELT (See page 14-5 )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7 )
INSTALL IGNITION COIL ASSY (See page 14-7 )
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
INSTALL FRONT WHEEL RH (See page 14-5 )
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2203
14-1 12
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET (3MZ-FE)
CYLINDER HEAD GASKET (3MZ-FE)
141JG-01
COMPONENTS
x2
80 (816, 59)
Spacer
x3
W/O TEMS:
Front Suspension Upper Brace Center
7.9 (81, 70 in.⋅lbf)
V-bank Cover Sub-assy
x2
80 (816, 59)
Spacer
Fuel Vapor Feed Hose
Assy
Vacuum Hose
Mass Air Flow
Meter Connector
Vacuum Hose
Air Cleaner Cap
Sub-assy
5.0 (51, 44 in.⋅lbf)
Air Cleaner Filter
Element Sub-assy
N·m (kgf·cm, ft·lbf) : Specified torque
A86358
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2204
14-1 13
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET (3MZ-FE)
VSV Connector
7.8 (80, 69 in.⋅lbf)
x2
Pressure Feed
Tube Assy
x2
8.0 (82, 71 in.⋅lbf)
Emission
Control Valve Set
Fuel Vapor Feed Hose
28 (286, 21)
Bond Cable No. 1
Connector
20 (199, 14)
x3
x2
x2
20 (199, 14)
x2
Emission Control Valve Bracket
28 (286, 21)
Engine Hunger No. 1
Surge Tank Stay
No. 1
x2
20 (199, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86260
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2205
14-1 14
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET (3MZ-FE)
8.4 (86, 74 in.⋅lbf)
Ground Cable
Fuel Injector
Connector
x9
x2
15 (153, 11)
Washer
Engine Coolant
Temperature Sensor
Connector
x2
15 (153, 11)
x2
15 (153, 11)
Washer
Bond Cable No. 1
Connector
Pipe
Intake Manifold
Water Outlet
Fuel Injector Connector
Fuel Pipe
Clamp
Clamp
Intake Manifold
to Head Gasket No. 1
Radiator Hose Inlet
Heater Inlet
Water Hose
Intake Manifold
to Head Gasket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86583
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2206
14-1 15
ENGINE MECHANICAL
Front Fender Apron
Seal RH
-
CYLINDER HEAD GASKET (3MZ-FE)
64 (653, 47)
Vane Pump V Belt
23 (235, 17)
Radio Setting Condenser
V Belt No. 1
Engine Moving Control Rod
64 (653, 47)
28 (286, 21)
Engine Mounting Stay No. 2 RH
58 (591, 43)
Generator Bracket No. 2
56 (571, 41)
Exhaust Pipe Gasket
Exhaust Pipe
Gasket
Exhaust Pipe
Assy Front
62 (633, 46)
Exhaust Pipe Gasket
Exhaust Pipe No. 1
Support Bracket Rear
62 (633, 46)
Exhaust Pipe No. 1
Support Bracket Front
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
33 (337, 24)
33 (337, 24)
A84917
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2207
14-1 16
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET (3MZ-FE)
Timing Belt
8.5 (87, 75 in.⋅lbf)
Timing Belt No. 2 Cover
Timing Belt Guide No. 2
8.5 (87, 75 in.⋅lbf)
Engine Mounting Bracket RH
28 (286, 21)
Timing Belt No. 1 Cover
220 (2,250, 162)
Crankshaft Pulley
Engine Wire
Protector
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
A78383
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2208
14-1 17
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
Camshaft Timing Pulley
Collar
Bushing
8.5 (87, 75 in.⋅lbf)
x6
125 (1,275, 92)
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
Engine Wire
N·m (kgf·cm, ft·lbf) : Specified torque
A78384
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2209
14-1 18
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET (3MZ-FE)
8.5 (87, 75 in.⋅lbf)
x3
x6
Exhaust Manifold Heat Insulator No. 1
Exhaust Manifold Sub-assy RH
49 (500, 36)
Exhaust Manifold to Head Gasket
Vane Pump Assy
43 (439, 32)
43 (439, 32)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A84918
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2210
14-1 19
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET (3MZ-FE)
8.4 (85, 74 in.⋅lbf)
Engine Wire
8.0 (80, 71 in.⋅lbf)
Engine Wire
Ignition Coil Assy
8.0 (80, 71 in.⋅lbf)
x9
Cylinder Head Cover Sub-assy
Cylinder Head Cover Gasket
Camshaft Bearing
Cap No. 2
16 (163, 12)
Camshaft Bearing Cap No. 4
x10
No. 2 Camshaft
Camshaft Bearing Cap No. 1
16 (163, 12)
x10
Camshaft Bearing Cap No. 5
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
Camshaft
Camshaft Bearing Cap No. 2
See page 14-120
1st: 54 (550, 40)
2st: Turn 90
19 (189, 14)
x8
Cylinder Head Sub-assy
Camshaft Setting
Oil Seal
Cylinder Head Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78390
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2211
14-120
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET (3MZ-FE)
141JH-01
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE COOLANT (See page 16-9 )
DRAIN ENGINE OIL (See page 17-20 )
REMOVE FRONT WHEEL RH
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
REMOVE INTAKE MANIFOLD (See page 10-16 )
REMOVE WATER OUTLET (See page 10-16 )
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
REMOVE VANE PUMP V BELT (See page 14-5 )
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
REMOVE TIMING BELT NO.1 COVER
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
REMOVE TIMING BELT GUIDE NO.2
REMOVE TIMING BELT (See page 14-79 )
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
SEPARATE VANE PUMP ASSY
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2 )
32. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the air fuel ratio sensor connector.
(b)
Remove the 3 bolts and exhaust manifold heat insulator.
A86571
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2212
14-121
ENGINE MECHANICAL
3
6
1
33.
(a)
(b)
2
5
-
CYLINDER HEAD GASKET (3MZ-FE)
REMOVE EXHAUST MANIFOLD SUB-ASSY RH
Using several steps, loosen and remove the 6 nuts in the
sequence shown in the illustration.
Remove the exhaust manifold RH and gasket from the
cylinder head RH.
4
A86572
34.
35.
36.
37.
REMOVE
REMOVE
REMOVE
REMOVE
IGNITION COIL ASSY
CYLINDER HEAD COVER SUB-ASSY (See page 14-7 )
CAMSHAFT (See page 14-93 )
NO.2 CAMSHAFT (See page 14-93 )
38.
(a)
(b)
(c)
REMOVE CYLINDER HEAD SUB-ASSY
Disconnect the VVT sensor connector.
Disconnect the camshaft timing oil control valve connector.
Remove the nut, then disconnect the engine wire harness
clamp.
A78401
(d)
Front
Using a socket hexagon wrench 8, remove the hexagon
bolt.
A78716
(e)
Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove
the 8 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the washers into the cylinder
head.
Head warpage or cracking could result from removing the bolts in an incorrect order.
Front
2
7
5
3
4
6
8
1
A78717
39.
REMOVE CYLINDER HEAD GASKET
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2213
14-122
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET (3MZ-FE)
40.
(a)
INSPECT CYLINDER HEAD SET BOLT
Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter:
8.95 to 9.05 mm (0.3524 to 0.3563 in.)
Minimum outside diameter: 8.75 mm (0.3445 in.)
If the diameter is less than minimum, replace the bolt.
Tension Portion
A78721
41.
(a)
Front
A78324
INSTALL CYLINDER HEAD GASKET
Place a new cylinder head gasket on the cylinder block
with the R mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the
head.
42. INSTALL CYLINDER HEAD SUB-ASSY
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.
(c)
Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustration.
Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf)
(d)
Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
Retighten the cylinder head bolts by 90in the same sequence as step (c).
Check that each painted mark is now at a 90 angle to the
front.
Front
7
2
4
6
5
3
1
8
A78717
(e)
90
(f)
Front
Painted Mark
A78730
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2214
14-123
ENGINE MECHANICAL
(g)
Front
(h)
-
CYLINDER HEAD GASKET (3MZ-FE)
Using a socket hexagon wrench 8, install the hexagon
bolt.
Torque: 19 N⋅m (189 kgf⋅cm, 14 ft⋅lbf)
Connect the engine wire harness clamp with the nut.
Torque: 8.4 N⋅m (85 kgf⋅cm, 74 in.⋅lbf)
A78716
43.
44.
45.
46.
INSTALL NO.2 CAMSHAFT (See page 14-93 )
INSTALL CAMSHAFT (See page 14-93 )
INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-7 )
INSTALL IGNITION COIL ASSY (See page 14-7 )
4
1
6
47.
(a)
(b)
5
2
INSTALL EXHAUST MANIFOLD SUB-ASSY RH
Install a new gasket and the exhaust manifold RH with the
6 nuts. Using several steps, tighten the nuts uniformly in
the sequence shown in the illustration.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
Retighten nuts 1 and 2 shown in the illustration.
3
A86572
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 ft⋅lbf)
INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 )
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
INSTALL VANE PUMP ASSY (See page 14-29 )
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
INSPECT TIMING BELT (See page 14-79 )
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
INSTALL VANE PUMP V BELT (See page 14-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2215
14-124
ENGINE MECHANICAL
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
-
CYLINDER HEAD GASKET (3MZ-FE)
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL WATER OUTLET (See page 10-16 )
INSTALL INTAKE MANIFOLD (See page 10-16 )
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
INSTALL FRONT WHEEL RH (See page 14-5 )
ADD ENGINE OIL (See page 17-20 )
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
INSPECT FOR FUEL LEAKS
CHECK FOR EXHAUST GAS LEAKS
INSPECT IGNITION TIMING (See page 14-1 )
SST 09843-18040
INSPECT ENGINE IDLE SPEED (See page 14-1 )
INSPECT COMPRESSION (See page 14-1 )
SST 09992-00500
INSPECT CO/HC (See page 14-1 )
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2216
14-125
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
141JI-01
COMPONENTS
80 (816, 59)
x2
W/O TEMS:
Front Suspension Upper Brace Center
Spacer
x3
7.9 (81, 70 in.⋅lbf)
80 (816, 59)
V-bank Cover Sub-assy
x2
Fuel Vapor Feed
Hose No. 1
Spacer
Vacuum Hose
Air Cleaner Cap
Sub-assy
Mass Air Flow
Meter Connector
Vacuum Hose
5.0 (51, 44 in.⋅lbf)
x7
5.0 (51, 44 in.⋅lbf)
x2
Clip
Air Cleaner
Inlet Assy
5.0 (51, 44 in.⋅lbf)
x3
Air Cleaner Filter
Element Sub-assy
VSV Connector
Clip
Radiator Lower
Air Deflector
Air Cleaner Case
N·m (kgf·cm, ft·lbf) : Specified torque
A84919
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2217
14-126
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
VSV Connector
7.8 (80, 69 in.⋅lbf)
x2
Pressure Feed
Tube Assy
x2
8.0 (82, 71 in.⋅lbf)
Emission
Control Valve Set
Fuel Vapor Feed Hose
28 (286, 21)
Bond Cable No. 1
Connector
20 (199, 14)
x3
x2
x2
20 (199, 14)
x2
Emission Control Valve Bracket
28 (286, 21)
Engine Hunger No. 1
Surge Tank Stay
No. 1
x2
20 (199, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86260
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2218
14-127
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
8.4 (86, 74 in.⋅lbf)
Ground Cable
Fuel Injector
Connector
x9
x2
15 (153, 11)
Washer
Engine Coolant
Temperature Sensor
Connector
x2
15 (153, 11)
x2
15 (153, 11)
Washer
Bond Cable No. 1
Connector
Pipe
Intake Manifold
Water Outlet
Fuel Injector Connector
Clamp
Intake Manifold
to Head Gasket No. 1
Radiator Hose Inlet
Fuel Pipe
Clamp
Heater Inlet
Water Hose
Intake Manifold
to Head Gasket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86583
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2219
14-128
ENGINE MECHANICAL
Front Fender Apron
Seal RH
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
64 (653, 47)
Vane Pump V Belt
23 (235, 17)
Radio Setting Condenser
V Belt No. 1
Engine Moving Control Rod
64 (653, 47)
28 (286, 21)
58 (591, 43)
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
A84916
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2220
14-129
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
Timing Belt
8.5 (87, 75 in.⋅lbf)
Timing Belt No. 2 Cover
Timing Belt Guide No. 2
8.5 (87, 75 in.⋅lbf)
Engine Mounting Bracket RH
28 (286, 21)
Timing Belt No. 1 Cover
220 (2,250, 162)
Crankshaft Pulley
Engine Wire
Protector
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
A78383
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2221
14-130
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
Camshaft Timing Pulley
Collar
Bushing
8.5 (87, 75 in.⋅lbf)
x6
125 (1,275, 92)
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
Engine Wire
N·m (kgf·cm, ft·lbf) : Specified torque
A78384
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2222
14-131
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
Oil Level Gage Guide
8.0 (82, 71 in.⋅lbf)
Oil Level Gage
Sub-assy
Exhaust Pipe
Assy Front
Gasket
O-ring
49 (500, 36)
Manifold Stay No. 2
49 (500, 36)
62 (633, 46)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A84920
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2223
14-132
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
8.0 (80, 71 in.⋅lbf)
Ignition Coil Assy
8.0 (80, 71 in.⋅lbf)
x9
8.4 (85, 74 in.⋅lbf)
Cylinder Head Cover Sub-assy LH
Cylinder Head Cover Gasket No. 2
Camshaft Bearing Cap No. 3
Engine Wire
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 5
16 (163, 12)
Camshaft Bearing
Cap No. 6
x10
No. 3 Camshaft Sub-assy
Camshaft Bearing Cap No. 2
Camshaft Bearing
Cap No. 2
16 (163, 12)
Camshaft Bearing Cap No. 4
x10
No. 4 Camshaft Sub-assy
Camshaft Bearing Cap No. 1
See page 14-133
19 (189, 14)
x8
5.4 (55, 48 in.⋅lbf)
1st: 54 (550, 40)
2st: Turn 90
5.4 (55, 48 in.⋅lbf)
Camshaft Setting
Oil Seal
O-ring
20 (199, 14)
Water Inlet Pipe
Cylinder Head LH
Cylinder Head
Gasket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86599
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2224
14-133
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
141JJ-01
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE COOLANT (See page 16-9 )
DRAIN ENGINE OIL (See page 17-20 )
REMOVE FRONT WHEEL RH
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
REMOVE AIR CLEANER CASE (See page 19-5 )
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
REMOVE INTAKE MANIFOLD (See page 10-16 )
REMOVE WATER OUTLET (See page 10-16 )
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
REMOVE VANE PUMP V BELT (See page 14-5 )
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
REMOVE TIMING BELT NO.1 COVER
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
REMOVE TIMING BELT GUIDE NO.2
REMOVE TIMING BELT (See page 14-79 )
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
REMOVE MANIFOLD STAY NO.2 (See page 14-29 )
SEPARATE EXHAUST PIPE ASSY FRONT (See page 15-2 )
33.
(a)
(b)
(c)
REMOVE OIL LEVEL GAGE GUIDE
Remove the bolt which secures the oil level gage guide
from the cylinder head LH.
Pull out the oil level gage guide and oil level gage together
from the cylinder block.
Remove the O-ring from the oil level gage guide.
A86574
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2225
14-134
ENGINE MECHANICAL
34.
35.
36.
37.
38.
REMOVE
REMOVE
REMOVE
REMOVE
REMOVE
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
WATER INLET PIPE (See page 16-16 )
IGNITION COIL ASSY
CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7 )
NO.3 CAMSHAFT SUB-ASSY (See page 14-107 )
NO.4 CAMSHAFT SUB-ASSY (See page 14-107 )
39. REMOVE CYLINDER HEAD LH
(a) Disconnect the VVT sensor connector.
(b) Disconnect the camshaft timing oil control valve connector.
(c) Disconnect the air fuel ratio sensor connector.
(d) Remove the bolt, then disconnect the ground cable.
(e) Remove the bolt and wire harness clamp bracket.
A86575
(f)
Using a socket hexagon wrench 8, remove the hexagon
bolt.
Front
A78718
(g)
Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove
the 8 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the washers into the cylinder
head.
Head warpage or cracking could result from removing the bolts in an incorrect order.
Front
4
6
8
1
2
7
5
3
A78719
40.
41.
REMOVE CYLINDER HEAD GASKET NO.2
INSPECT CYLINDER HEAD SET BOLT (See page 14-120 )
42.
(a)
Front
A79822
INSTALL CYLINDER HEAD GASKET NO.2
Place a new cylinder head gasket on the cylinder block
with the L mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the
head.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2226
14-135
ENGINE MECHANICAL
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
43. INSTALL CYLINDER HEAD LH
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washer to the cylinder head bolt.
(c)
Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustration.
Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf)
(d)
Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
Retighten the cylinder head bolts by 90in the same sequence as step (c).
Check that each painted mark is now at a 90 angle to the
front.
Front
5
3
1
8
7
2
4
6
A78719
(e)
90
(f)
Front
Painted Mark
A78730
(g)
Front
(h)
(i)
Using a socket hexagon wrench 8, install the hexagon
bolt.
Torque: 19 N⋅m (189 kgf⋅cm, 14 ft⋅lbf)
Install the wire harness clamp bracket with the bolt.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
Connect the ground cable with the bolt.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
A78718
44.
45.
46.
47.
48.
INSTALL NO.4 CAMSHAFT SUB-ASSY (See page 14-107 )
INSTALL NO.3 CAMSHAFT SUB-ASSY (See page 14-107 )
INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7 )
INSTALL IGNITION COIL ASSY (See page 14-7 )
INSTALL WATER INLET PIPE (See page 16-16 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2227
14-136
ENGINE MECHANICAL
49.
(a)
(b)
(c)
(d)
O-ring
(e)
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
INSTALL OIL LEVEL GAGE GUIDE
Install a new O-ring to the oil level gage guide.
Apply soapy water to the O-ring.
Push in the oil level gage guide end into the guide hole of
the cylinder block.
Install the oil level gage guide with the bolt.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
Install the oil level gage.
A86573
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 )
INSTALL MANIFOLD STAY NO.2 (See page 14-29 )
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
INSPECT TIMING BELT (See page 14-79 )
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
INSTALL VANE PUMP V BELT (See page 14-5 )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL WATER OUTLET (See page 10-16 )
INSTALL INTAKE MANIFOLD (See page 10-16 )
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
INSTALL AIR CLEANER CASE (See page 19-5 )
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
INSTALL FRONT WHEEL RH (See page 14-5 )
ADD ENGINE OIL (See page 17-20 )
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
INSPECT FOR FUEL LEAKS
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2228
14-137
ENGINE MECHANICAL
85.
86.
87.
88.
89.
90.
-
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
CHECK FOR EXHAUST GAS LEAKS
INSPECT IGNITION TIMING (See page 14-1 )
SST 09843-18040
INSPECT ENGINE IDLE SPEED (See page 14-1 )
INSPECT COMPRESSION (See page 14-1 )
SST 09992-00500
INSPECT CO/HC (See page 14-1 )
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2229
14-138
ENGINE MECHANICAL
-
OIL PUMP SEAL (3MZ-FE)
OIL PUMP SEAL (3MZ-FE)
141JK-01
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
REMOVE FRONT WHEEL RH
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
REMOVE VANE PUMP V BELT (See page 14-5 )
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
REMOVE TIMING BELT NO.1 COVER
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
REMOVE TIMING BELT GUIDE NO.2
REMOVE TIMING BELT (See page 14-79 )
14. REMOVE CRANKSHAFT TIMING PULLEY
(a) Remove the bolt and timing belt plate.
(b)
(c)
SST
A78764
Install the pulley bolt to the crankshaft.
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 timing pulley.
Before using SST, apply lubricating oil to the threads
and tip of the center bolt 150.
15.
(a)
(b)
Cut Position
REMOVE OIL PUMP SEAL
Using a knife, cut off the oil seal lip.
Using a screwdriver with the tip wrapped in tape, pry out
the oil seal.
NOTICE:
After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
A78765
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2230
14-139
ENGINE MECHANICAL
-
OIL PUMP SEAL (3MZ-FE)
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.
SST
A78766
17.
(a)
Inward
Sensor
INSTALL CRANKSHAFT TIMING PULLEY
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 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
A78746
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
INSPECT TIMING BELT (See page 14-79 )
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
INSTALL VANE PUMP V BELT (See page 14-5 )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL FRONT WHEEL RH (See page 14-5 )
CHECK FOR ENGINE OIL LEAKS
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2231
14-140
ENGINE MECHANICAL
-
ENGINE REAR OIL SEAL (3MZ-FE)
ENGINE REAR OIL SEAL (3MZ-FE)
141JL-02
REPLACEMENT
1.
REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40-9 )
2.
(a)
(b)
REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
Remove the 8 bolts, rear spacer, drive plate and front
spacer.
SST
A78767
3.
(a)
(b)
REMOVE ENGINE REAR OIL SEAL
Using a knife, cut off the oil seal lip.
Using a screwdriver with the tip wrapped in tape, pry out
the oil seal.
NOTICE:
After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
Cut Position
Cut Position
A78768
SST
A78769
SST
A78767
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 surface 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.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2232
14-141
ENGINE MECHANICAL
7
3
4
8
2
6.
ENGINE REAR OIL SEAL (3MZ-FE)
(e)
1
5
-
Using several steps, install and tighten the 8 bolts uniformly in the sequence shown in the illustration.
Torque: 83 N⋅m (846 kgf⋅cm, 61 ft⋅lbf)
NOTICE:
Do not start the engine within 1 hour after installing.
6
A78771
INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40-9 )
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Date:
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
CYLINDER HEAD ASSY (3MZ-FE)
1419J-03
COMPONENTS
Valve Adjusting Shim
Valve Lifter
Valve Spring Retainer Lock
Valve Spring Retainer
RH Cylinder:
W/ Head Straight Screw
Plug No. 1
Inner Compression Spring
LH Cylinder:
W/ Head Straight Screw
Plug No. 2
Valve Stem Oil O Seal or Ring
Valve Spring Seat
Exhaust Valve Guide Bush
Gasket
Intake Valve Guide Bush
Semicircular Plug
44 (449, 32)
Intake Valve
Exhaust Valve
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78310
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2234
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
1419K-03
OVERHAUL
1.
REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
(a) Using a straight hexagon wrench 14, remove the 2 screw plugs.
2.
REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
(a) Using a straight hexagon wrench 14, remove the 2 screw plugs.
3.
REMOVE VALVE LIFTER
HINT:
Store the lifters in the correct order so that they can be returned to the original locations when reassembling.
4.
(a)
REMOVE INTAKE VALVE
Using SST, compress the spring, then remove the 2 retainer locks, retainer, spring and valve.
SST 09202-70020 (09202-00010)
HINT:
Store the valves, springs, seats and retainers in the correct order so that they can be returned to the original locations when
reassembling.
SST
A78770
5.
(a)
REMOVE EXHAUST VALVE
Using SST, compress the spring, then remove the 2 retainer locks, retainer, spring and valve.
SST 09202-70020 (09202-00010)
HINT:
Store the valves, springs, seats and retainers in the correct order so that they can be returned to the original locations when
reassembling.
SST
A78772
6.
(a)
7.
8.
REMOVE VALVE STEM OIL O SEAL OR RING
Using needle-nose pliers, remove the oil seal.
REMOVE VALVE SPRING SEAT
REMOVE SEMICIRCULAR PLUG
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
9.
(a)
INSPECT CYLINDER HEAD FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the warpage on the surfaces which contacts the cylinder 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.
Cylinder Block Surface:
Intake Manifold Surface:
Exhaust Manifold Surface:
A78773
10.
(a)
INSPECT CYLINDER HEAD FOR CRACKS
Using a dye penetrate, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
A05227
11.
(a)
Overall Length
INSPECT INTAKE VALVE
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.
EM2534
(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.)
Z00052
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
(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.
Margin
Thickness
A78774
12.
(a)
Overall Length
INSPECT EXHAUST VALVE
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.
EM2534
(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.)
Z00052
(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.
Margin
Thickness
A78774
13.
(a)
INSPECT INNER COMPRESSION SPRING
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.
EM0801
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
(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.
Deviation
A78775
(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.
EM0281
14.
(a)
P12754
INSPECT VALVE GUIDE BUSH OIL CLEARANCE
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).
A05234
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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ENGINE MECHANICAL
(b)
SST
-
CYLINDER HEAD ASSY (3MZ-FE)
Using SST and a hammer, tap out the valve guide bush.
SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
A78776
16.
(a)
P12956
Intake:
34.5 mm
(1.358 in.)
Exhaust:
INSTALL VALVE GUIDE BUSH
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 dimension of 10.345 to 10.363 mm (0.4073 to 0.4080 in.).
HINT:
Bush diameter:
STD
10.333 to 10.344 mm (0.4068 to 0.4072 in.)
O/S
10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Bush length:
40.5 mm
(1.594 in.)
Intake
34.5 mm (1.358 in.)
Exhaust
40.5 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
A78777
SST
A78778
Z09124
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
17.
(a)
INSPECT VALVE SEATS
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)
Width
A78779
45
30
1.0 to 1.4 mm
(0.039 to 0.055 in.)
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.
A78780
(b)
(c)
60
45
1.0 to 1.4 mm
(0.039 to 0.055 in.)
(d)
If the seating is too low on the valve face, use the 60 and
45 cutters to correct the seat.
Lap the valve and valve seat by hand with an abrasive
compound.
Recheck the valve seating position.
A78781
19.
(a)
INSPECT VALVE LIFTER
Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
EM6368
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
20.
(a)
P12685
INSPECT VALVE LIFTER OIL CLEARANCE
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, replace 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 removed.
Install the camshafts with their timing marks
matched.
(c)
(d)
A33264
22.
(a)
(b)
A05238
23.
(a)
(b)
(c)
Set the dial indicator to the teeth of the intake camshaft
at a right angle (90).
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.)
INSPECT CAMSHAFT THRUST CLEARANCE
Install the camshafts.
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, replace the camshaft.
If necessary, replace the bearing caps and cylinder
head together.
INSPECT CAMSHAFT OIL CLEARANCE
Clean the bearing caps and camshaft journals.
Clean the camshafts.
Place the camshafts on the cylinder head.
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Date:
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
(d)
Lay a strip of Plastigage across each of the camshaft journals.
(e) Install the bearing caps.
Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf)
NOTICE:
Do not turn the camshaft.
(f)
Remove the bearing caps.
A05239
(g)
A05240
RH Cylinder:
10 mm (0.39 in.)
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, replace the camshaft.
If necessary, replace the bearing caps and cylinder
head together.
NOTICE:
Completely remove the Plastigage.
24.
(a)
INSTALL RING W/HEAD PIN (RH CYLINDER)
Using a plastic-faced hammer, tap in a new ring pin to the
specified protrusion height.
Protrusion height: 3 mm (0.12 in.)
25.
(a)
INSTALL RING PIN (LH CYLINDER)
Using a plastic-faced hammer, tap in a new ring pin to the
specified protrusion height.
Protrusion height: 3 mm (0.12 in.)
8 mm (0.31 in.)
A78782
LH Cylinder:
10 mm (0.39 in.)
8 mm (0.31 in.)
A78783
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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Date:
2242
14-151
ENGINE MECHANICAL
26.
(a)
Protrusion Height
Mark
A78784
CYLINDER HEAD ASSY (3MZ-FE)
INSTALL SPARK PLUG TUBE
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 applying adhesive.
Do not deform the spark plug tube.
Do not expose the spark plug tube to coolant within
1 hour after installing.
(c)
Press
Wooden
Block
-
Protrusion
Height
Using a press and wooden block, install the spark plug
tube to the required protrusion height.
NOTICE:
Be careful not to drip the adhesive.
A78785
27.
(a)
INSTALL PCV PIPE (RH CYLINDER)
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.
Wooden
Block
Flush
A78786
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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Date:
2243
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ENGINE MECHANICAL
28.
(a)
RH Cylinder:
-
CYLINDER HEAD ASSY (3MZ-FE)
INSTALL STUD BOLT
Install the stud bolts on the intake side.
Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf)
49 mm
(1.93 in.)
M8
A78787
LH Cylinder:
49 mm
(1.93 in.)
M8
A78788
29.
(a)
INSTALL STUD BOLT
Install the stud bolts on the exhaust side.
Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf)
Intake:
Exhaust:
Light Brown
Gray
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 opposite 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.
A78789
(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 improperly seated.
SST
A78790
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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Date:
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
31. INSTALL INTAKE VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the original locations.
P12668
(b)
Using SST, compress the spring and place the 2 retainer
locks around the valve stem.
SST 09202-70020 (09202-00010)
SST
A78770
(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.
A05246
32. INSTALL EXHAUST VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the original locations.
A52900
(b)
Using SST, compress the spring and place the 2 retainer
locks around the valve stem.
SST 09202-70020 (09202-00010)
SST
A78772
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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ENGINE MECHANICAL
-
CYLINDER HEAD ASSY (3MZ-FE)
(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.
A05246
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.
(a)
(b)
Seal Packing
INSTALL SEMICIRCULAR PLUG
Remove any old seal packing material.
Apply seal packing to the plug grooves.
Seal packing: Part No. 08826-00080 or equivalent
A78791
(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.
: Semicircular Plug
RH Cylinder:
Front
LH Cylinder:
A78792
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Date:
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ENGINE MECHANICAL
35.
(a)
36.
(a)
-
CYLINDER HEAD ASSY (3MZ-FE)
INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf)
INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2247
14-156
ENGINE MECHANICAL
-
CYLINDER BLOCK ASSY (3MZ-FE)
CYLINDER BLOCK ASSY (3MZ-FE)
1419L-03
COMPONENTS
Piston Ring (No. 1 Compression Ring)
Piston Ring (No. 2 Compression Ring)
Piston Ring (Expander)
Piston Ring (Side Rail)
Piston Pin Hole
Snap Ring
Piston
Piston Pin
Piston Pin Hole Snap Ring
Connecting Rod Small
End Bush
Connecting Rod Sub-assy
Connecting Rod Bearing
Connecting Rod Cap
Cylinder Block Sub-assy
See page (14-158 )
1st: 25 (250, 18)
2st: Turn 90
Gasket
50 (510, 37)
Cylinder Block w/ Head
Straight Screw No. 3 Plug
39 (398, 29)
Cylinder Block Water
Drain Cock Sub-assy
30 (306, 22)
Cylinder Block w/ Head
Straight Screw No. 1 Plug
Gasket
Gasket
30 (306, 22)
Cylinder Block w/ Head
Straight Screw No. 2 Plug
39 (398, 29)
Cylinder Block Water Drain Cock
Sub-assy
Water Seal Plate
18 (184, 13)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78311
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2248
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ENGINE MECHANICAL
-
CYLINDER BLOCK ASSY (3MZ-FE)
Cylinder Block Sub-assy
27 (275, 20)
Crankshaft Bearing
Upper Crankshaft Thrust Washer
Crankshaft
Lower Crankshaft Thrust Washer
Crankshaft Bearing
Crankshaft Bearing Cap
See page (14-158 )
1st: 22 (224, 16)
2st: Turn 90
27 (275, 20)
N·m (kgf·cm, ft·lbf) : Specified torque
A78312
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2249
14-158
ENGINE MECHANICAL
-
CYLINDER BLOCK ASSY (3MZ-FE)
1419M-03
OVERHAUL
1.
2.
3.
(a)
4.
(a)
5.
(a)
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
REMOVE WATER SEAL PLATE
REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
Using a socket hexagon wrench 10, remove the screw plug.
REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
Using a socket hexagon wrench 10, remove the screw plug.
REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
Using a socket hexagon wrench 10, remove the screw plug.
6.
(a)
P12695
7.
(a)
(b)
(c)
(d)
(e)
Plastigage
INSPECT CONNECTING ROD THRUST CLEARANCE
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, replace the connecting rod.
If necessary, replace the crankshaft.
INSPECT CONNECTING ROD OIL CLEARANCE
Check that the matchmarks on the connecting rod and
cap are aligned to ensure correct reassembly.
Remove the cap bolts.
Clean the crank pin, bearing and connecting rod.
Check the crank pin and bearing for pitting and scratches.
Lay a strip of Plastigage across the crank pin.
A78793
(f)
Front
(g)
Check that the protrusion of the cap is facing the correct
direction.
Apply a light coat of engine oil to the threads of the cap
bolts.
Protrusion
A78794
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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ENGINE MECHANICAL
(h)
-
CYLINDER BLOCK ASSY (3MZ-FE)
Tighten the cap bolts in several steps by the specified
torque.
Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf)
P12697
(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.
Painted Mark
90
90
Front
A78795
(l)
P12698
Number Mark
A79803
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, replace 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 ”1 ”, ”2”, ”3” and ”4” accordingly.
Reference:
Standard bearing center wall thickness:
Mark
mm (in.)
”1”
1.484 to 1.487 (0.0584 to 0.0585)
”2”
1.487 to 1.490 (0.0585 to 0.0587)
”3”
1.490 to 1.493 (0.0587 to 0.0588)
”4”
1.493 to 1.496 (0.0588 to 0.0589)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2251
14-160
ENGINE MECHANICAL
8.
(a)
(b)
-
CYLINDER BLOCK ASSY (3MZ-FE)
REMOVE PISTON SUB-ASSY W/CONNECTING ROD
Using a ridge reamer, remove all the carbon from the top
of the cylinder.
Push out the piston and connecting rod assembly from
the top of the cylinder block.
HINT:
A05258
9.
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 locations when reassembling.
REMOVE CONNECTING ROD BEARING
10.
(a)
(b)
REMOVE PISTON RING SET
Using a piston ring expander, remove the 2 compression
rings.
Remove the 2 side rails and expander by hand.
11.
(a)
REMOVE PISTON PIN HOLE SNAP RING
Using a small screwdriver, pry out the 2 snap rings.
12.
(a)
REMOVE W/PIN PISTON SUB-ASSY
Gradually heat the piston up to approximately 80C
(176F).
A78315
P12403
80C (176F)
A78797
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ENGINE MECHANICAL
(b)
-
CYLINDER BLOCK ASSY (3MZ-FE)
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.
P12415
13.
(a)
P12799
5
INSPECT CRANKSHAFT THRUST CLEARANCE
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.
(a)
REMOVE CRANKSHAFT
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 illustration.
8
7
6
2
3
4
1
A78798
4 12
8
6
2
10
14
13
9
1
11
16
15
3
7
5
A78799
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-
CYLINDER BLOCK ASSY (3MZ-FE)
(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 cylinder block and bearing cap.
P12603
Joint Surface
A78800
15.
16.
REMOVE CRANKSHAFT THRUST WASHER SET
REMOVE CRANKSHAFT BEARING
17.
(a)
INSPECT CYLINDER BLOCK FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the warpage on the surface which contacts the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than maximum, replace the cylinder
block.
Z09222
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ENGINE MECHANICAL
-
CYLINDER BLOCK ASSY (3MZ-FE)
18.
(a)
INSPECT CYLINDER BORE
Using a cylinder gauge, measure the cylinder bore diameter 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.
Thrust Direction
Front
Axial Direction
A
10 mm (0.39 in.)
B
A88633
19.
(a)
13.0 mm
(0.512 in.)
INSPECT W/PIN PISTON SUB-ASSY
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.)
A78316
20.
(a)
INSPECT PISTON OIL CLEARANCE
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 connecting 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 connecting rod assembly.
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-
CYLINDER BLOCK ASSY (3MZ-FE)
(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.
Z00065
22.
(a)
INSPECT PISTON PIN OIL CLEARANCE
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.)
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, replace the bush.
If necessary, replace the piston and piston pin together.
EM6525
(c)
EM0227
23.
(a)
SST
REMOVE CONNECTING ROD SMALL END BUSH
Using SST and a press, press out the bush.
SST 09222-30010
A78803
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ENGINE MECHANICAL
-
CYLINDER BLOCK ASSY (3MZ-FE)
24.
(a)
INSTALL CONNECTING ROD SMALL END BUSH
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 standard 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 connecting rod with your thumb.
Oil Hole
A78804
SST
A78803
EM6535
P00326
25.
(a)
A78317
INSPECT RING GROOVE CLEARANCE
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.
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ENGINE MECHANICAL
-
CYLINDER BLOCK ASSY (3MZ-FE)
26.
(a)
INSPECT PISTON RING END GAP
Using a piston, push the piston ring which it is a little below
the bottom of the ring travel, where is 110 mm (4.33 in.)
from the top of the cylinder block.
(b)
Using a feeler gauge, measure the end gap.
Standard end gap:
0.30 to 0.40 mm (0.0118 to 0.0157 in.) for No. 1 ring
0.50 to 0.60 mm (0.0197 to 0.0236 in.) for No. 2 ring
0.15 to 0.40 mm (0.0059 to 0.0157 in.) for oil (side rail)
ring
Maximum end gap:
0.95 mm (0.0374 in.) for No. 1 ring
1.05 mm (0.0413 in.) for No. 2 ring
1.00 mm (0.0394 in.) for oil (side rail) ring
If the end gap is greater than maximum, replace the
piston ring.
If the end gap is greater than maximum, even with
a new piston ring, replace the cylinder block.
110 mm
(4.33 in.)
A78805
A37355
27.
(a)
INSPECT CONNECTING ROD BOLT
Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than minimum, replace the bolt.
EM6347
A15065
28.
(a)
INSPECT CRANKSHAFT BEARING CAP SET BOLT
Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than minimum, replace the bolt.
EM6347
A15065
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ENGINE MECHANICAL
-
CYLINDER BLOCK ASSY (3MZ-FE)
29.
(a)
INSPECT CRANKSHAFT
Using a dial indicator and V-blocks, measure the circle
runout as shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crankshaft.
P12406
(b)
A37157
Using a micrometer, measure the diameter of each main
journal.
Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
If the diameter is not as specified, check the crankshaft oil clearance
(c) Check each main journal for taper and out-of-round as
shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than maximum, replace
the crankshaft.
(d)
ZF6928
No. 1 and No. 4:
No. 2 and No. 3:
Upper
Lower
22.4 mm (0.882 in.)
19.0 mm (0.748 in.)
Using a micrometer, measure the diameter of each crank
pin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
If the diameter is not as specified, check the connecting rod oil
clearance.
(e) Check each crank pin for taper and out-of-round as
shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than maximum, replace
the crankshaft.
30. INSPECT CRANKSHAFT OIL CLEARANCE
HINT:
Crankshaft bearings come in widths of 22.4 mm (0.882 in.) and
19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in
the No. 1 and No. 4 cylinder block journal positions with the
bearing caps. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
(a) Clean each main journal and bearing.
A78806
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-
CYLINDER BLOCK ASSY (3MZ-FE)
(b)
Align the key of the bearing with the keyway of the cylinder
block, then push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact surface.
P12599
(c)
Mark
1, 2, 3 or 4
A78807
Plastigage
Align the key of the bearing with the keyway of the bearing
cap, then push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact surface.
HINT:
A number is marked on each bearing cap to indicate the installation position.
(d) Place the crankshaft on the cylinder block.
(e)
Lay a strip of Plastigage across each journal.
(f)
Examine the front marks and numbers, then install the
bearing caps on the cylinder block.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
A78808
(g)
A10530
(h)
(i)
Temporarily install the 8 bearing cap bolts to the inside
positions.
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.
Less than 6 mm (0.23 in.)
A78809
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ENGINE MECHANICAL
(j)
(k)
-
CYLINDER BLOCK ASSY (3MZ-FE)
Using a plastic-faced hammer, lightly tap the bearing cap
to ensure proper fit.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
A10529
(l)
13 5
9
6
11
1
15
2
3
8
14
10
4
7
12
16
A78810
(m)
(n)
Mark the front side of the bearing cap bolts with paint.
Retighten the bearing cap bolts by 90 in the same sequence as step (l).
(o) Check that each painted mark is now at a 90 angle to the
front.
NOTICE:
Do not turn the crankshaft.
Painted Mark
90
Front
Using several steps, install and tighten the 16 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 22 N⋅m (224 kgf⋅cm, 16 ft⋅lbf)
90
A78811
1
(p)
4
2
3
7
Using several steps, install and tighten the 8 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 27 N⋅m (275 kgf⋅cm, 20 ft⋅lbf)
HINT:
Use the short bolt for the position marked with the arrow.
(q) Remove the bearing caps.
6
5
8
A78812
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-
CYLINDER BLOCK ASSY (3MZ-FE)
(r)
P12993
Measure the Plastigage at its widest point.
Standard oil clearance:
0.014 to 0.034 mm (0.0006 to 0.0013 in.) for No. 1 and
No. 2 journals
0.026 to 0.046 mm (0.0010 to 0.0018 in.) for No. 3 and
No. 4 journals
Maximum clearance:
0.05 mm (0.0020 in.) for No. 1 and No. 2 journals
0.06 mm (0.0024 in.) for No. 3 and No. 4 journals
If the oil clearance is greater than maximum, replace the bearings.
If necessary, replace the crankshaft.
NOTICE:
Completely remove the Plastigage.
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ENGINE MECHANICAL
No. 2
No. 1
CYLINDER BLOCK ASSY (3MZ-FE)
(s)
No. 3
No. 4
Number Mark
No. 2 No. 3
No. 4
No. 1
Number
Mark
-
Number Mark
A78813
If replacing a bearing, replace it with one having the same
number. If the number of the bearing cannot be determined, select the correct bearing by adding together the
numbers imprinted on the cylinder block and crankshaft,
then refer to the table below for the appropriate bearing
number. The No. 1 and No. 2 journal bearing come in 5
sizes, marked ”3”, ”4”, ”5”, ”6” and ”7”. The No. 3 and No.
4 journal bearings come in 5 standard bearing sizes,
marked ”1”, ”2”, ”3”, ”4” and ”5”.
No. 1 and No. 2 journal bearings:
Cylinder
block
+
Crankshaft
=
0 to 5
6 to 11
12 to 17
18 to 23
24 to 28
Replacement
Bearing
”3”
”4”
”5”
”6”
”7”
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked ”5”
No. 3 and No. 4 journal bearings:
Cylinder
block
+
Crankshaft
=
0 to 5
6 to 11
12 to 17
18 to 23
24 to 28
Replacement
Bearing
”1”
”2”
”3”
”4”
”5”
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked ”3”
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ENGINE MECHANICAL
Item
-
CYLINDER BLOCK ASSY (3MZ-FE)
Mark
mm (in.)
Cylinder block main journal bore diameter (A)
”00”
”01”
”02”
”03”
”04”
”05”
”06”
”07”
”08”
”09”
”10”
”11”
”12”
”13”
”14”
”15”
”16”
66.000 (2.5984)
66.001 (2.5985)
66.002 (2.5985)
66.003 (2.5985)
66.004 (2.5986)
66.005 (2.5986)
66.006 (2.5987)
66.007 (2.5987)
66.008 (2.5987)
66.009 (2.5988)
66.010 (2.5988)
66.011 (2.5989)
66.012 (2.5989)
66.013 (2.5989)
66.014 (2.5990)
66.015 (2.5990)
66.016 (2.5990)
Crankshaft main journal diameter (B)
”00”
”01”
”02”
”03”
”04”
”05”
”06”
”07”
”08”
”09”
”10”
”11”
”12”
61.000 (2.4016)
60.999 (2.4015)
60.998 (2.4015)
60.997 (2.4015)
60.996 (2.4014)
60.995 (2.4014)
60.994 (2.4013)
60.993 (2.4012)
60.992 (2.4012)
60.991 (2.4012)
60.990 (2.4012)
60.989 (2.4011)
60.988 (2.4011)
Standard bearing center wall thickness
”1”
”2”
”3”
”4”
”5”
”6”
”7”
2.486 to 2.489 (0.0979 to 0.0980)
2.489 to 2.492 (0.0980 to 0.0981)
2.492 to 2.495 (0.0981 to 0.0982)
2.495 to 2.498 (0.0982 to 0.0983)
2.498 to 2.501 (0.0983 to 0.0985)
2.501 to 2.504 (0.0985 to 0.0986)
2.504 to 2.507 (0.0986 to 0.0987)
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ENGINE MECHANICAL
31.
-
CYLINDER BLOCK ASSY (3MZ-FE)
INSTALL STUD BOLT
Front Side:
Front Side:
99 mm
(3.90 in.)
29 mm
(1.14 in.)
M8
M6
Torque: 6.0 N⋅m (60 kgf⋅cm, 53 in.⋅lbf)
Torque: 15 N⋅m (145 kgf⋅cm, 11 ft⋅lbf)
Front Side:
Left Side:
80 mm
(3.15 in.)
28.5mm
(1.12 in.)
M8
M10
Torque: 21 N⋅m (220 kgf⋅cm, 15 ft⋅lbf)
Torque: 7.0 N⋅m (70 kgf⋅cm, 62 in.⋅lbf)
Upper Side:
Upper Side:
52.5 mm
(2.07 in.)
27.5 mm
(1.08 in.)
M6
Torque: 4.0 N⋅m (40 kgf⋅cm, 35 in.⋅lbf)
Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf)
A78318
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ENGINE MECHANICAL
32.
-
CYLINDER BLOCK ASSY (3MZ-FE)
INSTALL STRAIGHT PIN
Front Side:
Right Side:
4 mm
(0.16 in)
4 mm
(0.16 in)
12 mm
(0.47 in.)
12 mm
(0.47 in.)
Protrusion Height: 6 mm (0.24 in.)
Protrusion Height: 6 mm (0.24 in.)
Upper Side:
Lower Side:
4 mm
(0.16 in)
4 mm
(0.16 in)
12 mm
(0.47 in.)
Protrusion Height: 6 mm (0.24 in.)
12 mm
(0.47 in.)
Protrusion Height: 6 mm (0.24 in.)
Back Side:
Back Side:
4 mm
(0.16 in)
10 mm
(0.39 in.)
12 mm
(0.47 in.)
Protrusion Height: 6 mm (0.24 in.)
22 mm
(0.87 in.)
Protrusion Height: 11 mm (0.43 in.)
A78319
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ENGINE MECHANICAL
33.
-
CYLINDER BLOCK ASSY (3MZ-FE)
INSTALL RING PIN
Upper Side:
11 mm
(0.43 in.)
16 mm
(0.63 in.)
8 mm
(0.31 in.)
20 mm
(0.79 in.)
Protrusion Height: 10 mm (0.39 in.)
Protrusion Height: 4 mm (0.16 in.)
A78816
34.
(a)
INSTALL PISTON PIN HOLE SNAP RING
Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not aligned with the
pin hole cutout of the piston.
A32958
P12418
80C (176F)
35.
(a)
INSTALL W/PIN PISTON SUB-ASSY
Gradually heat the piston up to approximately 80C
(176F).
(b)
(c)
Coat the piston pin with engine oil.
Align the front marks of the piston and connecting rod,
then push in the piston pin with your thumb until the pin
contacts the snap ring.
A78817
Front Mark
Front Mark
(Mold Mark)
A78376
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ENGINE MECHANICAL
36.
(a)
-
CYLINDER BLOCK ASSY (3MZ-FE)
INSTALL PISTON PIN HOLE SNAP RING
Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
HINT:
Be sure that the end of gap of the snap ring is not aligned with
the pin hole cutout of the piston.
37. INSTALL PISTON RING SET
(a) Install the expander and 2 side rails by hand.
A32958
P12418
(b)
No. 1:
Using a piston ring expander, install the 2 compression
rings.
HINT:
The No. 2 compression ring is installed with the code mark ”2A”
facing upward as shown in the illustration.
2A
No. 2:
A78320
(c)
No. 1
Compression
Expander
Lower Side
Rail
Front Mark
Upper Side
Rail
Position the piston rings so that the ring ends are arranged as shown in the illustration.
NOTICE:
Do not align the ring ends.
No. 2
Compression
A86598
38.
(a)
INSTALL CONNECTING ROD BEARING
Align the key of the bearing with the keyway of the connecting rod or cap.
NOTICE:
Clean the backside of the bearing and bearing surface of
the connecting rod. The surface should be free of dust and
oils.
P12402
No. 1 and No. 4:
No. 2 and No. 3:
Upper
Lower
22.4 mm (0.882 in.)
19.0 mm (0.748 in.)
39. INSTALL CRANKSHAFT BEARING
HINT:
Crankshaft bearings come in widths of 22.4 mm (0.882 in.) and
19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in
the No. 1 and No. 4 cylinder block journal positions with the
main bearing caps. Install the 19.0 mm (0.748 in.) bearings in
the No. 2 and No. 3 positions.
(a) Clean each main journal and the bearing.
A78806
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-
CYLINDER BLOCK ASSY (3MZ-FE)
(b)
Align the key of the bearing with the keyway of the cylinder
block, then push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact surface.
P12599
(c)
Align the key of the bearing with the keyway of the bearing
cap, then push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact surface.
HINT:
A number is marked on each bearing cap to indicate the installation position.
Mark
1, 2, 3 or 4
A78807
40.
(a)
INSTALL CRANKSHAFT THRUST WASHER SET
Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
(b)
Install the 2 thrust washers on the No. 2 bearing cap with
the grooves facing outward.
INSTALL CRANKSHAFT
Apply engine oil to the upper bearing, then install the
crankshaft on the cylinder block.
P12600
41.
(a)
A05264
(b)
(c)
Examine the front marks and numbers, then install the
bearing caps on the cylinder block.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
A10530
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ENGINE MECHANICAL
(d)
(e)
-
CYLINDER BLOCK ASSY (3MZ-FE)
Temporarily install the 8 bearing cap bolts to the inside
positions.
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.
Less than 6 mm (0.23 in.)
A78809
(f)
(g)
Using a plastic-faced hammer, lightly tap the bearing cap
to ensure proper fit.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
A10529
1
2
3
12
16
A78810
Painted Mark
90
Front
Mark the front side of the bearing cap bolts with paint.
Retighten the bearing cap bolts by 90 in the same sequence as step (h).
Check that each painted mark is now at a 90 angle to the
front.
Check that the crankshaft turns smoothly.
14
10
4
8
(i)
(j)
6
11
7
Using several steps, install and tighten the 16 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 22 N⋅m (224 kgf⋅cm, 16 ft⋅lbf)
13 5
9
15
(h)
(k)
90
(l)
A78811
1
(m)
4
2
3
7
Using several steps, install and tighten the 8 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 27 N⋅m (275 kgf⋅cm, 20 ft⋅lbf)
HINT:
Use the short bolt for the position marked with the arrow.
6
5
8
A78812
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2270
14-179
ENGINE MECHANICAL
-
CYLINDER BLOCK ASSY (3MZ-FE)
42.
(a)
Front Mark (Cavity)
Front
A78322
Front
INSTALL PISTON SUB-ASSY W/CONNECTING ROD
Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the numbered piston 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 connecting 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.
Protrusion
A78794
(f)
Tighten the cap bolts in several steps by the specified
torque.
Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf)
(g)
(h)
(i)
Mark the front side of each cap bolt with paint.
Retighten the cap bolts by 90 as shown in the illustration.
Check that the crankshaft turns smoothly.
43.
INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.1 PLUG
Using a socket hexagon wrench 10, install a new gasket
and the screw plug.
Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf)
P12697
Painted Mark
90
90
Front
A78795
Front Side:
(a)
A78822
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2271
14-180
ENGINE MECHANICAL
44.
Left Side:
(a)
-
CYLINDER BLOCK ASSY (3MZ-FE)
INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.2 PLUG
Using a socket hexagon wrench 10, install a new gasket
and the screw plug.
Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf)
A78823
45.
Back Side :
(a)
46.
(a)
INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.3 PLUG
Using a socket hexagon wrench 10, install a new gasket
and the screw plug.
Torque: 50 N⋅m (510 kgf⋅cm, 37 ft⋅lbf)
INSTALL WATER SEAL PLATE
Remove any old seal packing from the contact surface.
A78824
(b)
A
A
B
B
Seal Width
3 to 5 mm (0.12 to 0.20 in.)
A62377
Apply a continuous bead of seal packing (Diameter 3 to
5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the seal plate within 3 minutes after applying
seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the seal plate with the 2 nuts.
Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf)
47. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSY
(a) Apply adhesive to 2 or 3 threads of the drain cock end.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2272
14-181
ENGINE MECHANICAL
-
CYLINDER BLOCK ASSY (3MZ-FE)
(b)
After applying the specified torque, rotate the drain cock
clockwise as shown in the illustration.
Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf)
NOTICE:
Install the drain cock within 3 minutes after applying
adhesive.
Do not expose the drain cock to coolant within 1 hour
after installing.
Do not rotate the drain cock by more than 1 revolution
(360) after tightening the drain cock with the specified torque.
Do not loosen the drain cock after setting it correctly.
10
45
A78323
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2273
10-1
ENGINE CONTROL SYSTEM
-
SFI SYSTEM (3MZ-FE)
SFI SYSTEM (3MZ-FE)
100IZ-01
ON-VEHICLE INSPECTION
1.
Hand-held Tester
(a)
DLC3
A86347
INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
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 Operation
Specified Condition
OCV is OFF
Normal engine speed
OCV is ON
Rough 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 ).
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:
DLC3
A86347
60 % or more
NOTICE:
When checking the standard throttle valve opening percentage, 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 ).
Hand-held Tester
(b)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2006
10-2
ENGINE CONTROL SYSTEM
-
SFI SYSTEM (3MZ-FE)
100J0-01
INSPECTION
1.
Ohmmeter
A86282
Spool Valve
Battery A86283
(a)
INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
1 (-) - 2 (+)
6.9 to 7.9 Ω at 20C (68F)
If the resistance is not as specified, replace the camshaft timing
oil control valve.
(b) Check the operation.
(1) Connect the positive (+) lead from the battery to terminal 2 (+) and negative (-) lead to terminal 1 (-),
then check the movement of the spool valve.
NOTICE:
Confirm that the spool valve moves freely and does not get
stuck in any position.
HINT:
Bad returning of the spool valve resulted from catching foreign
objects causes subtle pressure leak to the advanced direction.
In that case, DTC can be detected.
2.
(a)
INSPECT MASS AIR FLOW METER
Check the operation.
(1) Apply battery voltage across terminals 1 (+B) and 2
(E2G).
(2) Using voltmeter, connect the positive (+) tester
probe to terminal 3 (VC), and negative (-) tester
probe to terminal 2 (E2G).
(3) Blow air into the mass air flow sensor, then check
that the voltage fluctuates.
If the operation is not as specified, replace the mass air flow
sensor.
Voltmeter
Air
Battery
A84676
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2007
10-3
ENGINE CONTROL SYSTEM
(b)
Ohmmeter
Resistance kΩ
30
20
-
SFI SYSTEM (3MZ-FE)
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
4 (THA) - 5 (E2)
13.6 to 18.4 kΩ at -20C (-4F)
4 (THA) - 5 (E2)
2.21 to 2.69 kΩ at 20C (68F)
4 (THA) - 5 (E2)
0.493 to 0.667 kΩ at 60C (140F)
If the resistance is not as specified, replace the mass air flow
sensor.
10
5
1
0.5
0.2
-20 0 20 40 60 80
(-4) (32)(68)(104)(140)(176)
Temperature C (F)
A84677
3.
Ohmmeter
(a)
30
20
Resistance kΩ
Tester Connection
Specified Condition
1 (E2) - 2 (THW)
2.32 to 2.59 kΩ at 20C (68F)
1 (E2) - 2 (THW)
0.310 to 0.326 kΩ at 80C (176F)
NOTICE:
When checking the engine coolant temperature sensor in
water, be careful not to allow water to intrude into the terminals. Then dry the engine coolant temperature sensor after
checking.
If the resistance is not as specified, replace the engine coolant
temperature sensor.
10
5
1
0.5
0.2
INSPECT ENGINE COOLANT TEMPERATURE
SENSOR
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
-20 0 20 40 60 80
(-4) (32)(68)(104)(140)(176)
Temperature C (F)
A84678
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2008
10-4
ENGINE CONTROL SYSTEM
4.
(a)
Ohmmeter
-
SFI SYSTEM (3MZ-FE)
INSPECT THROTTLE BODY ASSY
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
1 (M-) - 2 (M+)
0.3 to 100 Ω at 20C (68F)
3 (E2) - 5 (VC)
1.2 to 3.2 kΩ at 20C (68F)
If the resistance is not as specified, replace the throttle body.
A86281
5.
(a)
Ohmmeter
INSPECT KNOCK SENSOR
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
1 (Output)- 2 (Ground)
120 to 280 Ω at 20C (68F)
If the resistance is not specified, replace the knock sensor.
A84680
6.
Ohmmeter
(a)
INSPECT ACCELERATOR PEDAL ASSY (NORMAL
PEDAL)
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
2 (VPA2) - 3 (EP1)
5.0 kΩ or less
1 (EP2) - 5 (VPA1)
5.0 kΩ or less
3 (EP1) - 6 (VCP1)
2.25 to 4.75 kΩ
1 (EP2) - 4 (VCP2)
2.25 to 4.75 kΩ
If the resistance is not specified, replace the accelerator pedal.
A86284
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2009
10-5
ENGINE CONTROL SYSTEM
7.
Ohmmeter
(a)
-
SFI SYSTEM (3MZ-FE)
INSPECT ACCELERATOR & BRAKE PEDAL ASSY
(POWER PEDAL)
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
3 (EP1) - 5 (VPA1)
5.0 kΩ or less
1 (EP2) - 2 (VPA2)
5.0 kΩ or less
3 (EP1) - 6 (VCP1)
2.25 to 4.75 kΩ
1 (EP2) - 4 (VCP2)
2.25 to 4.75 kΩ
If the resistance is not specified, replace the accelerator &
brake pedal.
A86285
8.
(a)
Battery
Ohmmeter
INSPECT MAIN RELAY
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
3-5
10 kΩ or higher
3-5
Below 1Ω
(Apply battery voltage to terminals 1 and 2
A84683
If the result is not as specified, replace the main relay.
9.
INSPECT CIRCUIT OPENING RELAY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Battery
Ohmmeter
A84683
Tester Connection
Specified Condition
3-5
10 kΩ or higher
3-5
Below 1Ω
(Apply battery voltage to terminals 1 and 2
If the result is not as specified, replace the circuit opening relay.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2010
10-6
ENGINE CONTROL SYSTEM
-
CAMSHAFT TIMING OIL CONTROL VALVE
ASSY (3MZ-FE)
CAMSHAFT TIMING OIL CONTROL VALVE ASSY (3MZ-FE)
100J1-01
REPLACEMENT
1.
2.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
3.
RH Bank:
(a)
(b)
(b)
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
Disconnect the 2 camshaft timing oil control valve connectors.
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.
(a)
A86244
LH Bank:
(b)
(a)
A86306
4.
(a)
(b)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Apply a light coat of engine oil to the O-ring on each camshaft timing oil control valve.
Install the 2 camshaft timing oil control valves with the 2 bolts.
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
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 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
7.
CHECK FOR ENGINE OIL LEAKS
8.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2011
10-7
ENGINE CONTROL SYSTEM
-
MASS AIR FLOW METER (3MZ-FE)
MASS AIR FLOW METER (3MZ-FE)
100J2-02
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
(b)
2.
(a)
(b)
(a)
REMOVE MASS AIR FLOW METER
Disconnect the mass air flow meter connector.
Remove the 2 screws, then remove the mass air flow meter.
(b)
A86246
3.
4.
5.
INSTALL MASS AIR FLOW METER
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2012
10-8
ENGINE CONTROL SYSTEM
-
ENGINE COOLANT TEMPERATURE
SENSOR (3MZ-FE)
ENGINE COOLANT TEMPERATURE SENSOR (3MZ-FE)
100J3-02
REPLACEMENT
1.
2.
3.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
DRAIN ENGINE COOLANT (See page 16-9 )
(a)
4.
Deep Socket
Wrench 19
(a)
(b)
REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
Disconnect the engine coolant temperature sensor connector.
Using a deep socket wrench 19, remove the engine coolant temperature sensor and gasket.
(b)
A86247
5.
(a)
(b)
6.
7.
8.
9.
10.
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Using a deep socket wrench 19, install a new gasket and the engine coolant temperature sensor.
Torque: 20 N⋅m (200 kgf⋅cm, 14 ft⋅lbf)
Connect the engine coolant temperature sensor connector.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
INSTALL RADIATOR LOWER AIR DEFLECTOR
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2013
10-9
ENGINE CONTROL SYSTEM
-
THROTTLE BODY ASSY (3MZ-FE)
THROTTLE BODY ASSY (3MZ-FE)
100J4-01
COMPONENTS
x2
80 (816, 59)
Spacer
x3
W/O TEMS:
Front Suspension Upper Brace Center
7.9 (81, 70 in.⋅lbf)
V-bank Cover Sub-assy
x2
80 (816, 59)
Spacer
Fuel Vapor Feed Hose
Assy
Vacuum Hose
Mass Air Flow
Meter Connector
Vacuum Hose
Air Cleaner Cap
Sub-assy
5.0 (51, 44 in.⋅lbf)
Air Cleaner Filter
Element Sub-assy
N·m (kgf·cm, ft·lbf) : Specified torque
A86358
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2014
10-10
ENGINE CONTROL SYSTEM
-
THROTTLE BODY ASSY (3MZ-FE)
Intake Air Connector
Gasket
Throttle Body Assy
11 (112, 8)
x4
Water By-pass Hose No. 2
Water By-pass Hose No. 3
Throttle Motor Connector
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86249
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2015
10-1 1
ENGINE CONTROL SYSTEM
-
THROTTLE BODY ASSY (3MZ-FE)
100J5-01
REPLACEMENT
1.
2.
3.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
DRAIN ENGINE COOLANT (See page 19-5 )
4.
(b)
REMOVE FRONT SUSPENSION UPPER BRACE
CENTER (W/O TEMS)
Remove the 4 nuts, then remove the front suspension upper brace center and 4 spacers.
Temporarily tighten the 4 nuts.
5.
(a)
(b)
REMOVE V-BANK COVER SUB-ASSY
Using a socket hexagon wrench 5, remove the 3 nuts.
Unfasten the 2 retainers, then remove the V-bank cover.
6.
(a)
(b)
(c)
(d)
(g)
REMOVE AIR CLEANER CAP SUB-ASSY
Disconnect the mass air flow meter connector.
Disconnect the 4 vacuum hoses.
Disconnect the ventilation hose No. 2.
Disconnect the fuel vapor feed hose from the 2 hose
clamps.
Loosen the 2 air cleaner cap bolts.
Loosen the air cleaner hose clamp bolt, then remove the
air cleaner cap.
Remove the air cleaner filter element.
7.
(a)
(b)
(c)
REMOVE THROTTLE BODY ASSY
Disconnect the throttle motor connector.
Disconnect the water by-pass hose No. 2.
Disconnect the water by-pass hose No. 3.
(a)
A86250
Socket Hexagon
Wrench 5
(a)
(a)
(a)
(b) 2 Retainers
A86251
(b)
(b)
(d)
(b)
(d)
(f)
(a)
(e)
(f)
(c)
(e)
(b)
(e)
A86252
(a)
(b)
(c)
A86253
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2016
10-12
ENGINE CONTROL SYSTEM
(d)
(e)
(d)
-
THROTTLE BODY ASSY (3MZ-FE)
Remove the 4 bolts, then remove the throttle body.
Remove the gasket from the intake air connector.
(d)
(d)
(d)
8.
(a)
(b)
(c)
(d)
(e)
9.
10.
11.
12.
13.
14.
(a)
(b)
15.
16.
17.
A86254
INSTALL THROTTLE BODY ASSY
Install a new gasket to the intake air connector.
Install the throttle body with the 4 bolts.
Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf)
Connect the water by-pass hose No. 3.
Connect the water by-pass hose No. 2.
Connect the throttle motor connector.
INSTALL AIR CLEANER CAP SUB-ASSY
Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
INSTALL V-BANK COVER SUB-ASSY
Fit the 2 retainers, then install the V-bank cover.
Using a socket hexagon wrench 5, tighten the 3 nuts.
Torque: 7.9 N⋅m (81 kgf⋅cm, 70 in.⋅lbf)
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS)
Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf)
INSTALL RADIATOR LOWER AIR DEFLECTOR
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2017
10-13
ENGINE CONTROL SYSTEM
-
KNOCK SENSOR (3MZ-FE)
KNOCK SENSOR (3MZ-FE)
100J6-02
COMPONENTS
x2
80 (816, 59)
Spacer
x3
W/O TEMS:
Front Suspension Upper Brace Center
7.9 (81, 70 in.⋅lbf)
V-bank Cover Sub-assy
x2
80 (816, 59)
Spacer
Fuel Vapor Feed Hose
Assy
Vacuum Hose
Mass Air Flow
Meter Connector
Vacuum Hose
Air Cleaner Cap
Sub-assy
5.0 (51, 44 in.⋅lbf)
Air Cleaner Filter
Element Sub-assy
N·m (kgf·cm, ft·lbf) : Specified torque
A86358
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2018
10-14
ENGINE CONTROL SYSTEM
-
KNOCK SENSOR (3MZ-FE)
VSV Connector
7.8 (80, 69 in.⋅lbf)
x2
Pressure Feed
Tube Assy
x2
8.0 (82, 71 in.⋅lbf)
Emission
Control Valve Set
Fuel Vapor Feed Hose
28 (286, 21)
Bond Cable No. 1
Connector
20 (204, 14)
x3
x2
x2
20 (204, 14)
x2
Emission Control Valve Bracket
28 (286, 21)
Engine Hunger No. 1
Surge Tank Stay
No. 1
x2
20 (204, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86260
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2019
10-15
ENGINE CONTROL SYSTEM
-
KNOCK SENSOR (3MZ-FE)
64 (653, 47)
23 (235, 17)
64 (653, 47)
8.4 (86, 74 in.⋅lbf)
Radio Setting
Condenser
x2
Ground Cable
Fuel Injector
Connector
x9
x2
15 (153, 11)
Washer
Engine Coolant
Temperature Sensor
Connector
Engine Moving
Control Rod
x2
15 (153, 11)
x2
15 (153, 11)
Washer
Bond Cable No. 1
Connector
Pipe
Intake Manifold
Water Outlet
Fuel Injector Connector
Clamp
Intake Manifold
to Head Gasket No. 1
Radiator Hose Inlet
Fuel Pipe
Clamp
Heater Inlet
Water Hose
Intake Manifold
to Head Gasket No. 2
Knock Sensor Connector
Knock Sensor
20 (204, 14)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86261
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2020
10-16
ENGINE CONTROL SYSTEM
-
KNOCK SENSOR (3MZ-FE)
100J7-02
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
DRAIN ENGINE COOLANT (See page 16-9 )
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
9.
(a)
(b)
(b)
(a)
(b)
(b)
(b)
REMOVE ENGINE MOVING CONTROL ROD
Remove the pipe from the clamp.
Remove the 4 bolts, then remove the engine moving control rod and radio setting condenser.
A86262
10.
(a)
Pinch
Pull Out
Pinch
Fuel Pipe
Clamp
Nylon Tube
A86263
Tube Connector
O-ring
Quick Connector
REMOVE INTAKE MANIFOLD
Disconnect the fuel pipe No. 1.
(1) Remove the fuel pipe clamp.
(2) Pinch the tube connector, then pull out the fuel pipe
No. 1.
NOTICE:
Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
Be careful of mud because the quick connector has
an O-ring which seals the pipe and quick connector
that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the quick
connector by covering it with a vinyl or plastic bag.
When the pipe and quick connector are stuck, push
and pull the quick connector to release and pull the
quick connector out carefully.
Pipe
A75650
(b)
Disconnect the heater inlet water hose.
(b)
A86264
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2021
10-17
ENGINE CONTROL SYSTEM
(d)
(c)
(d)
-
KNOCK SENSOR (3MZ-FE)
(c)
(d)
Remove the nut, then disconnect the ground cable.
Disconnect the 6 fuel injector connectors.
(e)
In order to remove the intake manifold, using several
steps, remove the 9 bolts and 2 nuts in the sequence
shown in the illustration.
11.
(a)
(b)
(c)
REMOVE WATER OUTLET
Disconnect the bond cable No. 1 connector.
Disconnect the pipe of the radiator reserve tank.
Lock the hose clamp as shown in the illustration, then disconnect the radiator hose inlet.
(d)
(d)
(d)
(d)
A86265
4
10
2
6
8
11
3
5
7
1
9
A86266
(a)
(c)
(b)
A86267
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2022
10-18
ENGINE CONTROL SYSTEM
(d)
(f)
KNOCK SENSOR (3MZ-FE)
(h)
Disconnect the engine coolant temperature sensor connector.
Remove the clamp.
Remove the 2 bolts, 2 nuts and 2 washers.
Lock the hose clamp as shown in the illustration. Then remove the water outlet together with water by-pass hose
No. 1.
Remove the 2 gaskets from the 2 cylinder heads.
12.
(a)
(b)
REMOVE KNOCK SENSOR
Disconnect the 2 knock sensor connectors.
Remove the 2 nuts, then remove the 2 knock sensors.
13.
(a)
INSTALL KNOCK SENSOR
Install the 2 knock sensors with the 2 nuts as shown in the
illustration.
Torque: 20 N⋅m (204 kgf⋅cm, 14 ft⋅lbf)
Connect the 2 knock sensor connectors.
(e)
(f)
(g)
(d)
-
(f)
(f)
(e)
(f)
(g)
A86268
(a)
(b)
(b)
(a)
A79749
Upper
0 to 5
(b)
Engine
Front
A79750
14.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
INSTALL WATER OUTLET
Install 2 new gaskets to the 2 cylinder heads.
Install the water outlet together with water by-pass hose No. 1, then unlock the hose clamp.
Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf)
Install the clamp.
Connect the engine coolant temperature sensor connector.
Connect the bond cable No. 3 connector.
Connect the pipe of the radiator reserve tank.
Connect the radiator hose inlet, then unlock the hose clamp.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2023
10-19
ENGINE CONTROL SYSTEM
15.
(a)
(b)
(c)
(d)
8
2
4
-
KNOCK SENSOR (3MZ-FE)
INSTALL INTAKE MANIFOLD
Install the intake manifold with the 9 bolts, 2 nuts and 2
washers. Using several steps, tighten the 9 bolts and 2
nuts uniformly in the sequence shown in the illustration.
Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf)
Retighten the 9 water outlet mounting bolts and 2 nuts.
Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf)
Install the ground cable with the nut.
Torque: 8.4 N⋅m (86 kgf⋅cm, 74 in.⋅lbf)
Connect the heater inlet water hose.
10
6
1
9
7
11
3
5
A86266
(e)
Push
Fuel Pipe
Clamp
A86269
16.
B
A
B
B
17.
18.
19.
20.
21.
22.
23.
24.
25.
Connect the fuel pipe No. 1.
(1) Push in the quick connector to the pipe until it
makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the quick connector and
pipe are securely connected by pulling them.
(2) Install the fuel pipe clamp.
INSTALL ENGINE MOVING CONTROL ROD
Torque:
23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for bolt A
64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) for bolt B
A86262
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
CHECK FOR FUEL LEAKS (See page 11-5 )
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2024
10-20
ENGINE CONTROL SYSTEM
26.
27.
-
KNOCK SENSOR (3MZ-FE)
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2025
ENGINE CONTROL SYSTEM
-
ACCELERATOR PEDAL ASSY (3MZ-FE (NORMAL
PEDAL))
10-21
ACCELERATOR PEDAL ASSY (3MZ-FE (NORMAL PEDAL))
100J8-01
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
(a)
(b)
(a)
(b)
REMOVE ACCELERATOR PEDAL ASSY
Disconnect the accelerator position sensor connector.
Remove the 2 bolts, then remove the accelerator pedal
rod.
(b)
A86338
3.
4.
5.
INSTALL ACCELERATOR PEDAL ASSY
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2026
10-22
ENGINE CONTROL SYSTEM
-
ECM (3MZ-FE)
ECM (3MZ-FE)
100J9-02
REPLACEMENT
1.
2.
3.
4.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE FRONT DOOR SCUFF PLATE RH (See page 71-1 1)
REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (See page 71-1 1)
REMOVE INSTRUMENT PANEL SUB-ASSY LOWER (See page 71-1 1)
(b)
5.
(a)
(b)
REMOVE STEREO COMPONENT AMPLIFIER ASSY
Disconnect the 3 stereo component amplifier connectors.
Remove the 2 nuts, then remove the stereo component
amplifier.
6.
(a)
(b)
(c)
REMOVE ECM
Remove the wire harness clamp.
Disconnect the 5 ECM connectors.
Remove the 2 nuts, then remove the ECM.
7.
(a)
REMOVE ECM BRACKET
Remove the 2 screws, then remove the ECM bracket.
8.
(a)
REMOVE ECM BRACKET NO.2
Remove the 2 screws, then remove the ECM bracket No.
2.
(a)
(a)
(a) (b)
A86255
(c)
(b)
(b)
(b)
(b)
(b)
(c)
(a)
A86256
(a)
(a)
A86257
(a)
(a)
A86258
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2027
10-23
ENGINE CONTROL SYSTEM
9.
(a)
-
ECM (3MZ-FE)
REMOVE ECM BRACKET NO.3
Remove the 2 screws, then remove the ECM bracket No
3.
(a)
(a)
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
A86259
INSTALL ECM BRACKET NO.3
INSTALL ECM BRACKET NO.2
INSTALL ECM BRACKET
INSTALL ECM
Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf)
INSTALL STEREO COMPONENT AMPLIFIER ASSY
Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf)
INSTALL INSTRUMENT PANEL SUB-ASSY LOWER
INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1
INSTALL FRONT DOOR SCUFF PLATE RH
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
RESET MEMORY (See page 05-604 )
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2028
11-1
FUEL
-
FUEL SYSTEM (3MZ-FE)
FUEL SYSTEM (3MZ-FE)
110XR-01
PRECAUTION
1.
(a)
(b)
(c)
PRECAUTION
Before working on the fuel system, disconnect the engine wire No. 3 (battery negative terminal) from
battery.
Do not smoke or work near open flame when working on the fuel system.
Keep gasoline away from the rubber or leather parts.
2.
DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
Do not disconnect any parts of the fuel system pressure until you have discharging the fuel system pressure.
Even after discharge the fuel pressure, place a shop
rag over fittings as you separate them in order to reduce risk of fuel spray on yourself or in the engine
compartment.
(a) Disconnect the engine wire No. 3 (battery negative terminal).
Circuit Opening Relay
(b)
(c)
(d)
A62391
Remove the circuit opening relay from the engine room
relay block.
Connect the engine wire No. 3 (battery negative terminal).
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
Start the engine. After the engine has stopped on its own,
turn the ignition switch OFF.
HINT:
There is a case that DTC P0171 (system to lean) is output.
(e) Check that the engine does not start.
(f)
Remove the fuel tank cap, then let the air out of the fuel
tank.
(g) Disconnect battery negative terminal.
(h) Reinstall the circuit opening relay.
3.
FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out. So observe these procedures.
(1) Work in order to prevent gasoline from spilling out.
(2) Disconnect the fuel pump tube (see page 11-20 ).
(3) Drain the fuel remaining inside the fuel pump tube.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2029
11-2
FUEL
(4)
(5)
-
FUEL SYSTEM (3MZ-FE)
In order to prevent the disconnected fuel pump tube
from being damaged and foreign objects from being
introduced, cover the disconnected fuel pump tube
with a vinyl or plastic bag.
Place a tray under the vehicle or point of disconnection to catch any fuel that may spill.
B00679
(6)
Put a container under the connection.
B00347
New O-ring
CORRECT
Grommet Delivery Pipe
Injector
WRONG
FI6372
Delivery Pipe
(b)
Take the following precautions when removing and installing the fuel injectors.
NOTICE:
Never reuse the O-ring.
(1) When installing a new O-ring on the fuel injector, be
careful not to damage it.
(2) Coat a new O-ring with spindle oil or gasoline before installing. Never use engine oil, gear oil or
brake oil.
(c)
Install the fuel injector to the fuel delivery pipe and intake
manifold as shown in the illustration. Before installing the
fuel injector, be sure to apply spindle oil or gasoline to the
place where the fuel delivery pipe or intake manifold
touches the O-ring of the fuel injector.
(d)
Take the following precautions when disconnecting the
quick connector.
(1) Remove the fuel pipe clamp.
(2) Check the pipe and around the quick connector for
dirt or mud before disconnecting them. Remove the
dirt if necessary.
O-ring
Grommet
Spacer
Insulator
A62371
Fuel Pipe
Clamp
A60083
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2030
11-3
FUEL
-
FUEL SYSTEM (3MZ-FE)
(3)
Disconnect the quick connector from the pipe while
pinching portion A with your fingers as shown in the
illustration.
(4)
If the quick connector and pipe are stuck, pinch the
pipe, then push and pull the quick connector to release and pull it out.
A
A
B12941
NOTICE:
Do not use any tools.
(5) If there is dirt or any other substances on the sealing
surface that might interfere with the seal, clean the
area thoroughly before assembling.
B12944
(6)
Vinyl Bag
In order to prevent the disconnected pipe and quick
connector from damage or dirt, cover them with a vinyl or plastic bag.
A52581
(e)
Push
A71366
Take the following precautions when connecting the quick
connector.
(1) Check the connected part of the pipe for damage or
foreign objects.
(2) Align the axis of the quick connector with the axis of
the pipe, then push into the quick connector until the
quick connector makes a ”click” sound. In case that
the connection is tight, apply a little amount of fresh
engine oil to the tip of the pipe.
(3)
(4)
(5)
Pull
After connecting, check if the pipe and quick connector are securely connected by pulling on them.
Install the fuel pipe clamp.
Check if there is any leakage.
A71366
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2031
11-4
FUEL
4.
(a)
-
FUEL SYSTEM (3MZ-FE)
CHECK FOR FUEL LEAKS
Check that there are no fuel leaks after doing maintenance anywhere on the fuel system (see page
11-5 ).
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2032
11-5
FUEL
-
FUEL SYSTEM (3MZ-FE)
110XS-01
ON-VEHICLE INSPECTION
1.
(a)
Fuel Tube Connector
(b)
(c)
A50710
(d)
HINT:
Part No. 23801-20190
(e)
Fuel Pipe
Clamp
CHECK FUEL PRESSURE
Discharge the fuel pressure and take precautions against
possible fuel spillage (see page 11-1 ).
Check that tha battery voltage is above 12 V.
Disconnect the engine wire No. 3 (battery negative terminal).
Pull out the fuel tube connector from a new fuel tube.
Remove the fuel pipe clamp.
A60083
(f)
Disconnect the quick connector from the fuel pipe by
pinching portion A with your fingers as shown in the illustration.
CAUTION:
After taking the precautions, disconnect the quick
connector.
As pressure remains in the fuel line, prevent it from
splashing inside the engine compartment.
A
A
B12941
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2033
11-6
FUEL
(g)
SST
(T-joint)
SST
(h)
(i)
SST
(Hose)
-
FUEL SYSTEM (3MZ-FE)
Install SST (a pressure gauge) and fuel tube connector
using SST as shown in the illustration.
SST 09268-41047 (95336-08070), 09268-45014
(09268-41250, 09268-41200, 09268-41220)
Wipe up any gasoline.
Reconnect the engine wire No. 3 (battery negative terminal).
SST
(Hose)
Fuel Inlet Tube
Fuel Tube
Connector
A71359
(j)
(k)
Hand-held Tester
DLC3
A86347
Connect the hand-hand tester to the DLC3.
Measure the fuel pressure.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi)
If the pressure is high, replace the fuel pressure regulator.
If the pressure is low, check the fuel hose connections, fuel
pump, fuel filter and fuel pressure regulator.
(l)
Disconnect the hand-held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more
If the pressure is not as specified, check the fuel pump, pressure regulator and/or fuel injectors.
(q) After checking the fuel pressure, disconnect the battery
negative terminal and carefully remove SST and the fuel
tube connector to prevent gasoline splash.
(r)
Reconnect the No. 1 fuel pipe (the fuel tube connector).
CAUTION:
After taking the precautions, connect the quick connector.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2034
11-7
FUEL
FUEL SYSTEM (3MZ-FE)
2.
(a)
Hand-held Tester
DLC3
-
A86347
CHECK FUEL PUMP OPERATION AND FUEL LEAK
When using the hand-held tester.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON and the hand-held tester ON.
NOTICE:
Do not start the engine.
(3) Select the ACTIVE TEST mode on the hand-held
tester.
(4) If you need help to select the ACTIVE TEST mode
on the hand-held tester, refer to the hand-held tester operator’s manual.
(b)
When not using the hand-held tester.
(1) Remove the circuit opening relay.
(2) Using a service wire, connect terminals FP and +B
of the engine room relay block.
NOTICE:
Pay due attention to the terminal connecting position to
avoid a malfunction.
(3) Turn the ignition switch ON, and check that the fuel
pump operates.
NOTICE:
Do not start the engine.
(c) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
FP
+B
A62390
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2035
11-8
FUEL
-
FUEL SYSTEM (3MZ-FE)
110XT-02
INSPECTION
1.
(a)
INSPECT FUEL INJECTOR ASSY
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
1-2
13.4 to 14.2 Ω at 20C (68F)
If the resistance is not as specified, replace the fuel injector.
(b) Check the operation.
CAUTION:
This test involves high-pressure fuel and electricity.
Keep the injector free of sparks during the test.
Take every precaution regarding safe handling of
both the fuel and electricity.
Perform this test in a safe area, and avoid any sparks
or flame.
Do not smoke.
(1)
Fuel Tube Connector
Pull out the fuel tube connector from a new fuel
tube.
HINT:
Part No. 23801 - 20190
A50710
(2)
Connect SST and the fuel tube connector to the fuel
pipe.
SST 09268-41047 (95336-08070)
CAUTION:
After taking the precautions, connect the quick connector.
Fuel Tube Connector
SST
(Hose)
B12947
SST
(Union)
O-ring
(3)
(4)
SST
(Hose)
SST
(Clamp)
Vinyl Tube
A86391
Install the grommet and O-ring to the fuel injector.
Connect SST (a union and hose) to the fuel injector,
then hold the fuel injector and union with SST (a
clamp).
SST 09268- 41047 (09268- 41110, 09268- 41300,
95336-08070)
(5) Put the fuel injector into a graduated cylinder.
HINT:
Install a suitable vinyl tube to the fuel injector to contain the gasoline spray.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2036
11-9
FUEL
-
(6)
FUEL SYSTEM (3MZ-FE)
Operate the fuel pump (see page 11-5 ).
(7)
Connect SST (a wire) to the fuel injector and battery
for 15 seconds, then measure the injection volume
with the graduated cylinder. Test each fuel injector
2 or 3 times.
SST 09842-30070
Standard:
SST
A86390
Injection Volume
Difference between Cylenders
60 to 73 cm3 (3.7 to 4.5 cu in.)
per 15 seconds
13 cm3 (0.8 cu in.) or less
NOTICE:
Always do the switching at the battery side.
If the injection volume is not as specified, replace the fuel injector.
(c)
Inspect the leakage.
(1) In the condition of step (7), disconnect the test
probes of SST (a wire) from the battery, then check
the fuel leakage from the fuel injector.
Fuel drop: 1 drop or less per 12 minutes
If the fuel drop is not as specified, replace the fuel injector.
B05331
Ohmmeter
2.
(a)
INSPECT FUEL PUMP
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
1-2
0.2 to 3.0 Ω at 20C (68F)
If the resistance is not as specified, replace the fuel pump.
A84685
(b)
Battery
A84686
Check the operation.
(1) Apply battery positive voltage across the terminals.
(2) Check that the fuel pump operates.
NOTICE:
These tests must be performed quickly (within 10 seconds) to prevent burnout of the coil.
Keep the fuel pump as far away from the battery as
possible.
Always do the switching at the battery side.
If the operation is not as specified, replace the fuel pump.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2037
11-10
FUEL
-
FUEL INJECTOR ASSY (3MZ-FE)
FUEL INJECTOR ASSY (3MZ-FE)
110XU-01
COMPONENTS
x2
80 (816, 59)
Spacer
x3
W/O TEMS:
Front Suspension Upper Brace Center
7.9 (81, 70 in.⋅lbf)
V-bank Cover Sub-assy
x2
80 (816, 59)
Spacer
Fuel Vapor Feed Hose
Assy
Vacuum Hose
Mass Air Flow
Meter Connector
Vacuum Hose
Air Cleaner Cap
Sub-assy
5.0 (51, 44 in.⋅lbf)
Air Cleaner Filter
Element Sub-assy
N·m (kgf·cm, ft·lbf) : Specified torque
A86358
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2038
11-1 1
FUEL
-
FUEL INJECTOR ASSY (3MZ-FE)
VSV Connector
7.8 (80, 69 in.⋅lbf)
x2
Pressure Feed
Tube Assy
x2
8.0 (82, 71 in.⋅lbf)
Emission
Control Valve Set
Fuel Vapor Feed Hose
28 (286, 21)
Bond Cable No. 1
Connector
20 (199, 14)
x3
x2
x2
20 (199, 14)
x2
Emission Control Valve Bracket
28 (286, 21)
Engine Hunger No. 1
Surge Tank Stay
No. 1
x2
20 (199, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86260
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2039
11-12
FUEL
-
FUEL INJECTOR ASSY (3MZ-FE)
Fuel Injector O-ring
Fuel Injector Grommet
Fuel Injector Assy
10 (102, 7)
Fuel Injector
Connector
Fuel Delivery Pipe
Sub-assy
Injector Vibration Insulator
Delivery Pipe No. 1 Spacer
10 (102, 7)
Fuel Delivery Pipe No. 2
20 (199, 14)
Fuel Pump Hose Gasket
Fuel Pressure
Pulsation Damper Assy
Injector
Vibration Insulator
33 (331, 24)
Fuel Pipe
No. 2 Gasket
Delivery Pipe No. 1 Spacer
Fuel Pipe Sub-assy No. 1
33 (331, 24)
Fuel Pipe No. 2 Union Bolt
Fuel Injector
Connector
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86296
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2040
11-13
FUEL
-
FUEL INJECTOR ASSY (3MZ-FE)
110XV-01
REPLACEMENT
1.
2.
3.
4.
5.
6.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
DRAIN ENGINE COOLANT (See page 16-9 )
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
(a)
7.
(a)
(b)
REMOVE EMISSION CONTROL VALVE SET
Disconnect the 2 VSV connectors.
Remove the wire harness clamp.
(c)
(d)
(e)
(f)
(g)
Disconnect the fuel vapor feed hose No. 1.
Disconnect the fuel vapor feed hose No. 2.
Disconnect the 2 vacuum hoses.
Remove the clamp.
Remove the 2 nuts, then remove the emission control
valve set.
8.
(a)
(b)
(c)
(d)
REMOVE INTAKE AIR SURGE TANK
Disconnect the throttle motor connector.
Disconnect the water by-pass hose No. 3.
Disconnect the water by-pass hose No. 2.
Disconnect the union to check valve hose.
(e)
Disconnect the ventilation hose.
(b)
(a)
A79751
(d)
(e)
(e)
(g)
(f)
(g)
(c)
A86300
(d)
(a)
(c)
(b)
A86297
(e)
A79706
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2041
11-14
FUEL
-
FUEL INJECTOR ASSY (3MZ-FE)
(f)
Remove the 2 nuts, then remove the pressure feed tube.
(g)
Remove the 2 bolts, then remove the engine hunger No.
1.
Remove the 2 bolts, then remove the surge tank stay No.
1.
Remove the 2 bolts, then remove the surge tank stay No.
2.
(f)
(f)
A86298
(g)
(h)
(i)
(h)
(i)
(i)
(h)
(g)
A86299
(j)
(k)
(l)
(l)
(k)
(i)
(k)
(k)
(m)
Disconnect the bond cable No. 1 connector.
Using a socket hexagon wrench 8, remove the 4 bolts.
Remove the 2 nuts, then remove the emission control
valve bracket and intake air surge tank.
Remove the gasket from the intake air surge tank.
(l)
(k)
A86301
9.
(a)
(a)
(b)
(b)
(c)
SEPARATE FUEL PIPE SUB-ASSY NO.1
Remove the fuel pressure pulsation damper and 2 gaskets.
Remove the fuel pipe No. 2 union bolt and 2 gaskets.
Remove the bolt, then separate the fuel pipe No. 1.
10.
(a)
REMOVE FUEL INJECTOR ASSY
Disconnect the 6 fuel injector connectors.
(c)
A79710
(a)
(a)
(a)
(a)
(a)
(a)
A86302
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2042
11-15
FUEL
-
FUEL INJECTOR ASSY (3MZ-FE)
(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.
(b)
(b)
(b)
(b)
A86303
(d)
(c)
(d)
(c)
(c)
(d)
(c)
(d)
(d)
Remove the 4 delivery pipe No. 1 spacers from the intake
manifold.
Remove the 6 insulators from the intake manifold.
(e)
Pull out the fuel injector from the fuel delivery pipe.
11.
(a)
(b)
INSTALL FUEL INJECTOR ASSY
Install new grommets to each fuel injector.
Apply a light coat of spindle oil or gasoline to new O-rings,
then install them to each fuel injector.
(d)
(c)
(d)
A86304
A81137
New O-ring
New Grommet
A79762
(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.
Turn
Push
A81139
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2043
11-16
FUEL
(e)
-
FUEL INJECTOR ASSY (3MZ-FE)
Install 6 new insulators and the 4 delivery pipe No. 1
spacers to the intake manifold.
(f)
12.
(a)
(b)
(c)
13.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
14.
15.
16.
17.
Place the 2 fuel delivery pipes together with the 6 fuel injectors to the intake manifold.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(g) Temporarily install the 4 bolts which attach the fuel delivery pipe to the intake manifold.
(h) Check that the fuel injectors rotate smoothly.
Turn
If the fuel injectors do not rotate smoothly, the probable cause
A86305
is incorrect installation of the O-ring. Replace it with a new one.
(i)
Tighten the 4 bolts.
Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
(j)
Connect the 6 fuel injector connectors.
INSTALL FUEL PIPE SUB-ASSY NO.1
Install 2 new gaskets and fuel pipe No. 2 union bolt.
Torque: 33 N⋅m (331 kgf⋅cm, 24 ft⋅lbf)
Install 2 new gaskets and fuel pressure pulsation damper.
Torque: 33 N⋅m (331 kgf⋅cm, 24 ft⋅lbf)
Install the fuel pipe No. 1 with the bolt.
Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf)
INSTALL INTAKE AIR SURGE TANK
Install a new gasket to the intake air surge tank.
Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf)
Using a socket hexagon wrench 8, tighten the 4 bolts.
Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf)
Install the surge tank stay No. 2 with the 2 bolts.
Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf)
Install the surge tank stay No. 1 with the 2 bolts.
Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf)
Install the engine hunger No. 1 with the 2 bolts.
Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf)
Install the pressure feed tube with the 2 nuts.
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf)
Connect the ventilation hose.
Connect the union to check valve hose.
Connect the water by-pass hose No. 2.
Connect the water by-pass hose No. 3.
Connect the throttle motor connector.
INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2044
11-17
FUEL
18.
19.
20.
21.
22.
23.
-
FUEL INJECTOR ASSY (3MZ-FE)
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
CHECK FOR FUEL LEAKS (See page 11-5 )
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2045
11-18
FUEL
-
FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (3MZ-FE)
110XW-02
COMPONENTS
Rear Seat Cushion Assy
Rear Floor Service Hole Cover
Fuel Pump Connector
Vapor Pressure Sensor Connector
x8
Fuel Pump Tube Sub-assy
5.9 (60, 52 in.⋅lbf)
Fuel Tank Bent Tube Set Plate
Tube Joint Clip
Fuel Suction
w/ Pump & Gauge Tube Assy
Fuel Suction Tube Set Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A79485
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2046
FUEL
-
FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
11-19
Vapor Pressure Sensor Assy
Fuel Suction Plate Sub-assy
Tube Joint Clip
Fuel Pump Harness
Fuel Sender Gauge Assy
Fuel Tank Fuel Filter
Fuel Pressure Regulator
O-ring
Fuel Pressure Regulator Assy
Fuel Pump Assy
Fuel Pump Filter
Fuel Pump Filter Clip
Fuel Pump Cushion Rubber
Fuel Suction Support No. 2
Non-reusable part
A79486
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2047
11-20
FUEL
-
FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
110XX-02
Removal & Installation and Disassembly & Reassembly
1.
2.
3.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE REAR SEAT CUSHION ASSY (See page 72-39 )
4.
(a)
(b)
(c)
(c)
REMOVE REAR FLOOR SERVICE HOLE COVER
Remove the rear floor service hole cover.
Disconnect the vapor pressure sensor connector.
Disconnect the fuel pump connector.
(b)
A79487
5.
Tube Joint Clip
A79488
Fuel Tube Joint
Nylon Tube
REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY
(a) Remove the tube joint clip, then pull out the fuel pump
tube.
NOTICE:
Check around the connector for dirt or mud before
this operation. Remove the dirt if necessary.
Be careful of mud because the fuel tube joint has an
O-ring which seals the pipe and connector that can
be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull
the connector to release. Pull the connector carefully.
O-ring
Tube Joint Clip
Fuel Suction Plate
A91017
(b)
(b)
(b)
(b)
Remove the 8 bolts, then remove the fuel tank vent tube
set plate.
(b)
(b)
(b)
(b)
(b)
A79489
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2048
FUEL
-
FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
11-21
(c)
Remove the fuel suction tube w/ pump & gauge from the
fuel tank.
NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gauge.
(d) Remove the gasket from the fuel suction tube w/ pump &
gauge.
A79490
Cover
6.
(a)
(b)
Tube Joint Clip
REMOVE VAPOR PRESSURE SENSOR ASSY
Remove the cover.
Remove the tube joint clip, then pull out the vapor pressure sensor.
A79491
7.
(a)
REMOVE FUEL SUCTION SUPPORT NO.2
Using a screwdriver with the tip wrapped in tape, unfasten
the 5 claws. Then remove the fuel suction support No. 2.
NOTICE:
Do not damage the fuel suction support No. 2.
Tape
A77832
8.
REMOVE FUEL PUMP CUSHION RUBBER
9.
(a)
(b)
REMOVE FUEL SENDER GAUGE ASSY
Disconnect the fuel sender gauge connector.
Using a screwdriver with the tip wrapped in tape, unfasten
the clamp to release the fuel sender gauge. Then slide the
fuel sender gauge to remove it from the fuel pump.
A79492
(a)
Tape
Slide
A79494
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2049
11-22
FUEL
-
FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
10.
(a)
(b)
REMOVE FUEL SUCTION PLATE SUB-ASSY
Disconnect the fuel pump connector.
Using a screwdriver with the tip wrapped in tape, unfasten
the 4 claws. Then pull out the fuel suction plate.
NOTICE:
Do not damage the fuel suction plate.
Tape
(a)
A79493
(b)
11.
(a)
(b)
REMOVE FUEL PUMP HARNESS
Disconnect the connector.
Using a small screwdriver, pry out the fuel pump harness.
12.
(a)
REMOVE FUEL PUMP
Pull out the fuel pump from the fuel tank fuel filter.
13.
(a)
(b)
REMOVE FUEL PUMP FILTER
Using a small screwdriver, pry out the clip.
Pull out the fuel pump filter from the fuel pump.
14.
(a)
REMOVE FUEL PRESSURE REGULATOR ASSY
Pull out the fuel pressure regulator from the fuel tank fuel
filter.
Remove the O-ring from the fuel pressure regulator.
(a)
(b)
A79495
A79496
A79497
(b)
A65037
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2050
FUEL
15.
(a)
New O-ring
(b)
-
FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
11-23
INSTALL FUEL PRESSURE REGULATOR ASSY
Apply a light coat of spindle oil or gasoline to a new Oring, then install it to the fuel pressure regulator.
Push in the fuel pressure regulator to the fuel tank fuel filter.
A65038
16.
(a)
INSTALL FUEL PUMP FILTER
Install the fuel pump filter with a new clip.
17.
(a)
O-ring
(b)
INSTALL FUEL PUMP
Apply a light coat of gasoline or spindle oil to the O-ring
on the fuel pump.
Push in the fuel pump to the fuel tank fuel filter.
A65040
18.
19.
20.
21.
22.
INSTALL FUEL PUMP HARNESS
INSTALL FUEL SUCTION PLATE SUB-ASSY
INSTALL FUEL SENDER GAUGE ASSY
INSTALL FUEL PUMP CUSHION RUBBER
INSTALL FUEL SUCTION SUPPORT NO.2
23. INSTALL VAPOR PRESSURE SENSOR ASSY
Cover
(a) Install the vapor pressure sensor with the tube joint clip.
NOTICE:
Check the connected part for scratch or foreign obTube Joint Clip
jects.
Check that the vapor pressure sensor is inserted securely.
Check that the tube joint clip is on the collar of the vapor pressure sensor.
A86272
After installing the tube joint clip, check that the vapor
pressure sensor has not been pulled off.
(b) Install the cover.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2051
11-24
FUEL
-
FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
24.
Mark
A79489
Collar
Tube Joint Clip
A81595
25.
26.
INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY
(a) Install a new gasket to the fuel suction tube w/ pump &
gauge.
(b) Install the fuel suction tube w/ pump & gauge to the fuel
tank.
NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gauge.
(c) Align the mark of the fuel tank vent tube set plate with the
fuel suction tube w/ pump & gauge.
(d) Install the fuel tank bent tube set plate with the 8 bolts.
Torque: 5.9 N⋅m (60 kgf⋅cm, 52 in.⋅lbf)
(e) Install the fuel pump tube with the tube joint clip.
NOTICE:
Check the connected part for scratch or foreign objects.
Check that the fuel tube joint is inserted securely.
Check that the tube joint clip is on the collar of the fuel
tube joint.
After installing the tube joint clip, check that the fuel
tube joint has not been pulled off.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
CHECK FOR FUEL LEAKS (See page 11-5 )
27.
(a)
(b)
(c)
INSTALL REAR FLOOR SERVICE HOLE COVER
Connect the fuel pump connector.
Connect the vapor pressure sensor connector.
Using new butyl tape, install the rear floor service hole
cover.
New Butyl Tape
A79487
28.
29.
INSTALL REAR SEAT CUSHION ASSY
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2052
11-25
FUEL
-
FUEL TANK ASSY (3MZ-FE)
FUEL TANK ASSY (3MZ-FE)
110XY-01
COMPONENTS
Rear Seat Cushion Assy
Rear Floor Service Hole Cover
Fuel Pump Connector
Vapor Pressure Sensor Connector
x8
Fuel Pump Tube Sub-assy
5.9 (60, 52 in.⋅lbf)
Fuel Tank Bent Tube Set Plate
Tube Joint Clip
Fuel Suction
w/ Pump & Gauge Tube Assy
Fuel Suction Tube Set Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A79485
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2053
11-26
FUEL
-
FUEL TANK ASSY (3MZ-FE)
Fuel Tube No. 1
Fuel Tank Inlet Pipe
Sub-assy
Fuel Tank Assy
Fuel Tank Protector Lower Center
5.4 (55, 48 in.⋅lbf)
x4
39 (400, 29)
Fuel Tank Band Sub-assy No. 1 RH
39 (400, 29)
Fuel Tank Band Sub-assy No. 1 LH
Pin
Pin Exhaust Pipe Gasket
5.4 (55, 48 in.⋅lbf)
Parking Brake Cable Assy No. 2
5.4 (55, 48 in.⋅lbf)
x2
5.4 (55, 48 in.⋅lbf)
Parking Brake Cable Assy No. 3
56 (571, 41)
5.4 (55, 48 in.⋅lbf)
Exhaust Pipe Assy Center
Floor Panel Brace Rear
Exhaust Pipe Gasket
x2
20 (199, 14)
x2
56 (571, 41)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86273
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2054
11-27
FUEL
-
FUEL TANK ASSY (3MZ-FE)
Fuel Pump Tube Sub-assy
Fuel Tank Cushion
No. 2
x7
Fuel Tank Vent Hose
Fuel Tank Assy
x4
Clip Nut
5.4 (55, 48 in.⋅lbf)
Fuel Main Tube Support
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A79483
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2055
11-28
FUEL
-
FUEL TANK ASSY (3MZ-FE)
110XZ-01
Removal & Installation and Disassembly & Reassembly
1.
2.
3.
4.
5.
6.
7.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE REAR SEAT CUSHION ASSY (See page 72-39 )
REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20 )
DRAIN FUEL
REMOVE FLOOR PANEL BRACE REAR (See page 15-2 )
8.
REMOVE EXHAUST PIPE ASSY CENTER
(a) Remove the 2 bolts and 4 nuts.
(b) Remove the exhaust pipe center and 2 gaskets from the
2 exhaust pipe supports.
(b)
(b)
(a)
(a)
(a)
(a)
A86274
9.
(a)
DISCONNECT PARKING BRAKE CABLE ASSY NO.2
Remove the bolt and nut, then disconnect the parking
brake cable No. 2.
A79472
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2056
11-29
FUEL
-
FUEL TANK ASSY (3MZ-FE)
10.
(a)
DISCONNECT PARKING BRAKE CABLE ASSY NO.3
Remove the bolt and nut, then disconnect the parking
brake cable No. 3.
11.
(a)
REMOVE FUEL TANK PROTECTOR LOWER CENTER
Remove the 4 bolts, then remove the fuel tank protector
lower center.
A79473
A79476
12.
(a)
Pinch
Retainer
Pull Out
Pinch
Quick Connector
Nylon Tube
O-ring
A79474
Retainer
Pipe
REMOVE FUEL TANK ASSY
Disconnect the fuel pump tube.
(1) Pinch the projection of the retainer to remove the
lock claws, then pull it down as shown in the illustration.
(2) Pull out the fuel pump tube.
NOTICE:
Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
Be careful of mud because the quick connector has
an O-ring which seals the pipe and quick connector
that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the quick
connector by covering it with a vinyl or plastic bag.
When the pipe and quick connector are stuck, push
and pull the quick connector to release. Pull out the
quick connector from the pipe.
A81596
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2057
11-30
FUEL
-
FUEL TANK ASSY (3MZ-FE)
(b)
Pull Out
Pinch
Pinch
A86275
Nylon Tube
Quick Connector
Tube Connector
O-ring
Disconnect the fuel tube No. 1.
(1) Pinch the tube connector, then pull out the fuel tube
No. 1.
NOTICE:
Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
Be careful of mud because the quick connector has
an O-ring which seals the pipe and quick connector
that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the quick
connector by covering it with a vinyl or plastic bag.
When the pipe and quick connector are stuck, push
and pull the quick connector to release. Pull out the
quick connector carefully.
Pipe
A75650
(c)
(d)
(e)
(f)
(g)
(d)
Pinch
(d)
(h)
Push
Set up a transmission jack underneath the fuel tank.
Remove the 2 bolts which hold the fuel tank bands.
Loosen the clamp bolt.
Operate the transmission jack, then disconnect the fuel
tank inlet pipe.
Disconnect the fuel tank vent hose from the charcoal canister.
(1) Deeply push the quick connector to release the lock
pin.
(2) Pinch portion A.
(3) Pull out the fuel tank vent hose.
Operate the transmission jack, then remove the fuel tank.
(e)
A
Pinch
A
A86276
(i)
Remove the 2 pins, then remove the 2 fuel tank bands as
shown in the illustration.
A79478
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2058
11-31
FUEL
(j)
(j)
(j)
-
FUEL TANK ASSY (3MZ-FE)
(j)
Remove the 4 clip nuts.
13.
(a)
(b)
(c)
REMOVE FUEL TANK VENT HOSE
Deeply push the quick connector to release the lock pin.
Pinch portion A.
Pull out the fuel tank vent hose.
14.
(a)
REMOVE FUEL PUMP TUBE SUB-ASSY
Remove the fuel pump tube from the fuel main tube support.
15.
(a)
REMOVE FUEL MAIN TUBE SUPPORT
Remove the bolt, then remove the fuel main tube support.
16.
(a)
REMOVE FUEL TANK CUSHION NO.2
Remove the 7 fuel tank cushions from the fuel tank.
(j)
A79482
Push A
A
Pinch
Pinch
A86277
A79480
A79481
A79484
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2059
11-32
FUEL
17.
(a)
18.
19.
-
FUEL TANK ASSY (3MZ-FE)
INSTALL FUEL TANK CUSHION NO.2
Install 7 new fuel tank cushions to the fuel tank.
INSTALL FUEL MAIN TUBE SUPPORT
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
INSTALL FUEL PUMP TUBE SUB-ASSY
20.
(a)
INSTALL FUEL TANK VENT HOSE
Push in the quick connector to the pipe until the quick connector makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the quick connector and
pipe are securely connected by pulling on them.
Push
A86279
21.
(a)
(b)
(c)
(d)
INSTALL FUEL TANK ASSY
Install the 4 clip nuts.
Install the 2 fuel tank bands with the 2 pins.
Set up the fuel tank to the transmission jack.
Connect the fuel tank vent hose to the charcoal canister.
(1) Push in the quick connector to the pipe until the
quick connector makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the connector and pipe are
securely connected by pulling on them.
(e) Operate the transmission jack, then connect the fuel tank
filler pipe.
(f)
Tighten the clamp bolt.
(g) Tighten the 2 bolts which hold the fuel tank bands.
Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)
Push
A86339
(h)
Connect the fuel tube No. 1.
(1) Push in the quick connector to the pipe until the
quick connector makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the quick connector and
pipe are securely connected by pulling on them.
Push
A86280
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2060
11-33
FUEL
-
FUEL TANK ASSY (3MZ-FE)
(i)
Push
Retainer
A81598
22.
23.
24.
25.
(a)
(b)
26.
27.
28.
29.
30.
31.
32.
33.
34.
Connect the fuel pump tube.
(1) Push in the quick connector to the pipe until the
quick connector makes a ”click” sound, then push
up the retainer until the claws lock.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the connector and pipe are
securely connected by pulling on them.
INSTALL FUEL TANK PROTECTOR LOWER CENTER
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
INSTALL EXHAUST PIPE ASSY CENTER
Install 2 new gaskets and the exhaust pipe center to the 2 exhaust pipe supports.
Tighten the 2 bolts and 4 new nuts.
Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf)
INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20 )
ADD FUEL
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
CHECK FOR FUEL LEAKS (See page 11-5 )
CHECK FOR EXHAUST GAS LEAKS
INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
INSTALL REAR SEAT CUSHION ASSY
INSTALL FLOOR PANEL BRACE REAR (See page 15-2 )
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2061
12-1
EMISSION CONTROL
-
EMISSION CONTROL SYSTEM (3MZ-FE)
EMISSION CONTROL SYSTEM (3MZ-FE)
120C0-01
LOCATION
Ventilation Valve Sub-assy
Vacuum Surge Tank
EVAP Service Port
VSV for EVAP
Air Fuel Ratio Sensor
(Bank 1 Sensor 1)
Charcoal Canister Assy
Air Fuel Ratio Sensor
(Bank 2 Sensor 1)
Fuel Tank Cap Assy
Heated Oxygen Sensor
(Bank 2 Sensor 2)
Heated Oxygen Sensor
(Bank 1 Sensor 2)
VSV for CCV
Charcoal Canister Filter
Sub-assy
Vapor Pressure Sensor Assy
A86341
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2062
12-2
EMISSION CONTROL
-
EMISSION CONTROL SYSTEM (3MZ-FE)
Air Cleaner Assy
Ventilation Valve Assy
Air Fuel Ratio Sensor
(Bank 2 Sensor 1)
Air Fuel Ratio Sensor
(Bank 1 Sensor 1)
VSV
Vacuum
Surge Tank for EVAP
EVAP
Service Port
Purge Line
Heated Oxygen Sensor
(Bank 1 Sensor 2)
Heated Oxygen Sensor
(Bank 2 Sensor 2)
Fuel Tank Cap
Assy
Vapor Pressure Sensor
Assy
Fuel Tank Assy
Vent Line
Charcoal Canister Assy
Charcoal Canister Filter
Sub-assy
VSV for CCV
Air Inlet Line
A86342
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2063
12-3
EMISSION CONTROL
-
EMISSION CONTROL SYSTEM (3MZ-FE)
120C1-02
ON-VEHICLE INSPECTION
E9
1.
(a)
E8
INSPECT AIR FUEL RATIO COMPENSATION SYSTEM
Inspect the voltage.
(1) Turn the ignition switch ON.
(2) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Standard:
Tester Connection
Specified Condition
A1A+ (E9-22) - E1 (E8-1)
3.3 V
A1A- (E9-30) - E1 (E8-1)
3.0 V
A2A+ (E9-23) - E1 (E8-1)
3.3 V
A2A- (E9-31) - E1 (E8-1)
3.0 V
CAUTION:
Connect the test leads from the back side of the ECM connector to the terminals.
HINT:
The voltage between the terminals of the ECM is constant regardless of the voltage output from the air fuel ratio sensor (A/F
sensor).
Voltmeter
G37992
(b)
Hand-held Tester
DLC3
Check the operation.
(1) Connect the hand-held tester to the DLC3.
(2) Enter ”DIAGNOSIS/ENHANCED OBD II/DATA
LIST”, then select ”AFS B1 S1” and ”AFS B2 S1” to
display the monitor.
(3) Warm up the A/F sensor with the engine speed at
2,500 rpm for approximately 2 minutes.
A86347
(4)
Keep the engine speed
Lean
Keep the engine speed at 2,500 rpm, then confirm
that the waveform of ”AFS B1 S1” and ”AFS B2 S1”
are similar as shown in the illustration.
HINT:
14.7 Air
Fuel
Ratio
Rich
3.3 V
Time
A86385
(c)
The waveform in the illustration is a sample.
Only the hand-held tester displays the waveform of the
A/F sensor.
Confirm that the display of ”DATA LIST” - ”O2S B1 S2”
and ”O2S B2 S2” fluctuates up and down between 0 V
and 1 V with the engine speed at 2,500 rpm.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2064
12-4
EMISSION CONTROL
2.
(a)
-
EMISSION CONTROL SYSTEM (3MZ-FE)
INSPECT FUEL CUT OFF RPM
Check the operation.
(1) Increase the engine speed to at least 3,500 rpm.
(2) Use a sound scope to check the fuel injector operating noise.
(3) Check that when the throttle lever is released, the fuel injector operation noise stops momentarily
at 2,500 rpm and then resumes at 1,200 rpm.
2,500 rpm: Fuel cut off rpm
1,200 rpm: Fuel return rpm
3.
(a)
A86346
Vacuum Gauge
VISUALLY INSPECT HOSES, CONNECTIONS AND
GASKETS
Check the appearance.
(1) Check the engine assembly to see if the indicated
portions by the arrows have cracks, leaks or damage.
HINT:
Separation of the engine oil level gauge, oil filler cap, PCV
hose, etc. may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system
between the throttle body and cylinder head will allow air suction and cause the engine to run improperly.
If necessary, repair the engine assembly.
4.
(a)
(b)
INSPECT EVAP SYSTEM LINE
Warm up the engine to the normal operating temperature.
Connect the vacuum gauge (EVAP control system test
equipment vacuum gauge) to the EVAP service port on
the purge line. Then stop the engine.
(c)
If you have the hand-held tester:
Force the VSV for EVAP to operate.
(1) Connect the hand-held tester to the DLC3.
(2) Start the engine.
(3) Turn the hand-held tester ON.
(4) Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for EVAP.
A59499
Hand-held Tester
DLC3
A86347
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2065
12-5
EMISSION CONTROL
Battery
-
EMISSION CONTROL SYSTEM (3MZ-FE)
(d)
If you have no hand-held tester:
Force the VSV for EVAP to operate.
(1) Disconnect the VSV for EVAP connector.
(2) Connect the positive (+) and negative (-) leads of
the battery to the VSV for EVAP terminals.
(3) Start the engine.
(e)
Check the vacuum at idle.
Vacuum:
Maintain at 0.368 to 19.713 in.Hg (5 to 268 in.Aq) for
over 5 seconds.
A86348
Vacuum Gauge
A59500
Pressure Gauge
HINT:
If the vacuum does not change, it can be concluded that the
hose which connects the VSV to the service port is loose or
blocked, or the VSV is malfunctioning.
(f)
If you have the hand-held tester:
Return to the normal VSV for EVAP.
(1) Stop the engine.
(2) Disconnect the hand-held tester from the DLC3.
(g) If you have no hand-held tester:
Return to the normal VSV for EVAP.
(1) Stop the engine.
(2) Disconnect the positive (+) and negative (-) leads
of the battery from the VSV for EVAP terminals.
(3) Reconnect the VSV for EVAP connector.
(h) Disconnect the vacuum gauge from the EVAP service
port on the purge line.
(i)
Connect a pressure gauge to the EVAP service port on
the purge line.
A72589
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2066
12-6
EMISSION CONTROL
A86347
Battery
If you have the hand-held tester:
Force the VSV for CCV to operate.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Turn the hand-held tester ON.
(4) Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for CCV.
NOTICE:
Do not start the engine during this operation.
HINT:
If the check is not completed within 10 minutes, the forced close
of the VSV for CCV will be tested.
(k)
If you have no hand-held tester:
Force the VSV for CCV to operate.
(1) Disconnect the VSV for CCV connector.
(2) Connect the positive (+) and negative (-) leads of
the battery to the VSV for CCV terminals.
(l)
Check the pressure.
(1) Add the pressure (13.5 to 15.5 in.Aq) from the
EVAP service port.
Pressure:
2 minutes after the pressure is added, the gauge
should be over 7.7 to 8.8 in.Aq.
A86349
Pressure Gauge
Pressure
A59501
Fuel Tank Cap
EMISSION CONTROL SYSTEM (3MZ-FE)
(j)
Hand-held Tester
DLC3
-
Pressure Gauge
A52634
HINT:
If you cannot add the pressure, it can be concluded that the
hose which connects the VSV for EVAP canister fuel tank is
slipped off or the VSV is open.
(2) Check if the pressure decreases when the fuel tank
cap is removed while adding the pressure.
HINT:
If the pressure does not decrease when the filler cap is removed, it can be concluded that the hose which connects the
service port to the fuel tank is blocked, etc.
(m) If you have the hand-held tester:
Return to the normal VSV for CCV operation.
(1) Turn the ignition switch ON.
(2) Disconnect the hand-held tester from the DLC3.
(n) If you have no hand-held tester:
Return to the normal VSV for CCV operation.
(1) Disconnect the positive (+) and negative (-) leads
of the battery to the VSV for CCV terminals.
(2) Reconnect the VSV for CCV connector.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2067
12-7
EMISSION CONTROL
(o)
-
EMISSION CONTROL SYSTEM (3MZ-FE)
Disconnect the pressure gauge from the EVAP service
port on the purge line.
5.
Pressure Gauge
A86387
CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER
PIPE
(a) Check the operation.
(1) Remove the fuel tank (see page 11-28 ).
(2) Remove the fuel tank vent hose from the fuel tank
(see page 11-28 ).
(3) Connect the pressure gauge to the fuel tank vent
hose port of the fuel tank.
(4) Apply pressure to the fuel tank, so that the internal
pressure of the fuel tank is 4 kPa (41 gf/cm2, 0.58
psi).
(5) Check that the internal fuel tank pressure is maintained for 1 minute.
(6) Check the connected portions of each hose and
pipe.
(7) Check the installed parts on the fuel tank.
If there is no abnormality, replace the fuel tank and fuel tank filler
pipe.
(8) Reinstall the fuel tank vent hose to the fuel tank (see
page 11-28 ).
(9) Reinstall fuel tank (see page 11-28 ).
6.
Pressure Gauge
(a)
A86386
INSPECT FUEL CUT OFF VALVE AND FILL CHECK
VALVE
Check the operation.
(1) Remove the fuel tank (see page 11-28 ).
(2) Remove the fuel tank vent hose from the fuel tank
(see page 11-28 ).
(3) Connect the pressure gauge to the fuel tank vent
hose port of the fuel tank.
(4) Fully fill the fuel tank with fuel.
HINT:
In the condition that the fuel is full, there is no ventilation as the
float valve of the fill check valve is closed.
(5) Install the fuel suction w/ pump & gauge tube (see
page 11-20 ).
(6) Securely cover the fuel pump tube, fuel tube No. 1
port and fuel tank to filler pipe port with vinyl or plastic bags to perform the accurate pressure test.
(7) Apply 4 kPa (41 gf/cm2, 0.58 psi) of pressure to the
fuel tank vent hose port of the fuel tank.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2068
12-8
EMISSION CONTROL
-
EMISSION CONTROL SYSTEM (3MZ-FE)
(8)
Remove the vinyl or plastic bag from the fuel tank
to filler pipe port, then check that the pressure
drops.
If the pressure does not drop, replace the fuel tank.
(9) Drain fuel from the fuel tank.
(10) Reinstall the fuel tank vent hose to the fuel tank (see
page 11-28 ).
(11) Reinstall the fuel tank (see page 11-28 ).
7.
CHECK AIR INLET LINE
(a) Disconnect the fuel tank vent hose (see page 12-18 ).
(b) Check that there is ventilation in fuel tank vent hose.
If necessary, replace the charcoal canister filter.
(c) Reconnect the fuel tank vent hose (see page 12-18 ).
Air
A86352
8.
(a)
E10
INSPECT VAPOR PRESSURE SENSOR
Inspect the voltage (power source).
(1) Turn the ignition switch ON.
(2) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Voltage:
Tester Connection
Specified Condition
VC (E10-18) - E2 (E10-28)
4.5 to 5.5 V
CAUTION:
Connect the test leads from the back side of the ECM connector to the terminals.
(3) Turn the ignition switch OFF.
Voltmeter
A86344
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2069
12-9
EMISSION CONTROL
E10
(b)
E6
-
EMISSION CONTROL SYSTEM (3MZ-FE)
Inspect the voltage (power output).
(1) Turn the ignition switch ON.
(2) Remove the fuel tank cap.
(3) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Voltage:
Tester Connection
Specified Condition
PTNK (E6-21) - E2 (E10-28)
3.0 to 3.6 V
CAUTION:
Connect the test leads from the back side of the ECM connector to the terminals.
(4) Reinstall the fuel tank cap.
(5) Turn the ignition switch OFF.
Voltmeter
G37993
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2070
12-10
EMISSION CONTROL
-
EMISSION CONTROL SYSTEM (3MZ-FE)
120C2-01
INSPECTION
1.
(a)
INSPECT VENTILATION VALVE SUB-ASSY
Check the operation.
(1) Install a clean hose as shown in the illustration.
(2) Blow air into the cylinder head side, then check that
air passes through easily.
CAUTION:
Do not suck air through the ventilation valve. Petroleum
substances inside the ventilation valve are harmful.
Cylinder Head Side:
Clean Hose
A59511
(3)
Blow air into the intake manifold side, then check
that air passes through with difficulty.
If the operation is not as specified, replace the ventilation valve.
Intake Manifold Side:
Clean Hose
A59512
2.
(a)
INSPECT FUEL TANK CAP ASSY
Check the appearance.
(1) Visually check if the fuel tank cap and gasket are deformed or damaged.
If necessary, replace the fuel tank cap.
Gasket
A76682
3.
(a)
INSPECT CHARCOAL CANISTER ASSY
Check the appearance.
(1) Visually check the charcoal canister to see if the indicated portions by the arrows are cracked or damaged.
If necessary, replace the charcoal canister.
A86329
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2071
12-1 1
EMISSION CONTROL
-
EMISSION CONTROL SYSTEM (3MZ-FE)
(b)
Check the operation.
(1) While holding the purge port closed, blow air (0.39
kPa (4.0 gf/cm2, 0.06 psi)) into the vent port, then
check that the air flows from the air inlet port.
If the operation is not as specified, replace the charcoal canister.
Purge Port
Air Inlet Port
Vent Port
Air
A86330
(2)
Air Inlet Port
While holding the air inlet port closed, blow air (0.39
kPa (4.0 gf/cm2, 0.06 psi)) into the vent port, then
check that the air flows from the purge port.
If the operation is not as specified, replace the charcoal canister.
Purge Port
Vent Port
Air
A86331
(3)
Air Inlet Port
Purge Port
Vent Port
While holding the air inlet port closed, apply vacuum
(3.43 kPa (25.7 mm/Hg, 1.01 in.Hg)) to the vent
port, then check that the air is sucked from the
purge port.
If the operation is not as specified, replace the charcoal canister.
Vacuum
A86332
(c)
Purge Port
Air Inlet Port
Vacuum
Vent Port
A86333
Check the air tightness.
(1) While holding the vent and air inlet ports closed, apply vacuum (3.43 kPa (25.7 mmHg, 1.01 in.Hg)) to
the purge port, then check that the vacuum is maintained for 1 minute.
HINT:
In order to maintain air tightness, the check should be performed with the VSV (for CCV) terminal port held closed by your
finger.
If the operation is not as specified, replace the charcoal canister.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2072
12-12
EMISSION CONTROL
(d)
-
EMISSION CONTROL SYSTEM (3MZ-FE)
Inspect the diaphragm.
(1) Remove the air hose.
A86334
(2)
A
Vacuum
B
Air Inlet Port
Purge Port
While holding the vent, purge and air inlet ports
closed, apply vacuum (1.42 kPa (11 mmHg, 0.42
in.Hg)) into port A, then check that the air is sucked
from port B.
If the operation is not as specified, replace the charcoal canister.
Vent Port
A86335
(3)
A
Vacuum
B
Air Inlet Port
Purge Port
Vent Port
While holding the vent, purge and air inlet ports
closed, apply vacuum (1.42 kPa (11 mmHg, 0.42
in.Hg)) into port A, then measure how long it takes
for vacuum to drop.
Vacuum drop time: 10 seconds or longer
If the operation is not as specified, replace the charcoal canister.
(4) Reinstall the air hose.
A86336
(e)
(f)
Disconnect the air hose.
Remove the 2 bolts, then remove the VSV.
(g)
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
(f)
(f)
(e)
A86337
Ohmmeter
Tester Connection
A86286
Specified Condition
1-2
25 to 30 Ω at 20C (68F)
1-2
32 to 40 Ω at 100C (212F)
If the resistance is not as specified, replace the charcoal canister.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2073
12-13
EMISSION CONTROL
(h)
-
EMISSION CONTROL SYSTEM (3MZ-FE)
Check the operation.
(1) Check that air flows from port A to B and C.
B
C
A
Air
A86287
(2)
(3)
Valve
Apply battery voltage across the terminals.
Check that the valve is closed.
Closed
Battery
A86288
(4) Check that air does not flow from port A to B.
(5) Check that air flows from port A to C.
If the operation is not as specified, replace the charcoal canister.
(i)
Install the VSV with the 2 bolts.
(j)
Connect the air hose.
B
C
Air
A
Battery
A86289
4.
(a)
Ohmmeter
A86290
Tester Connection
Specified Condition
1-2
26 to 30 Ω at 20C (68F)
If the resistance is not as specified, replace the vacuum switching valve No. 1.
(b)
Air
INSPECT VACUUM SWITCHING VALVE ASSY NO.1
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Check the operation.
(1) Check that air does not flow from port E to F.
E
F
A86292
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2074
12-14
EMISSION CONTROL
-
EMISSION CONTROL SYSTEM (3MZ-FE)
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to F.
If the operation is not as specified, replace the vacuum switching valve No. 1.
Air
E
F
BatteryA86293
5.
(a)
Ohmmeter
A86294
Bank 1 Sensor 2 Bank 2 Sensor 2
Tester Connection
Specified Condition
1 (HT) - 2 (+B)
1.8 to 3.4 Ω at 20C (68F)
If the resistance is not as specified, replace the air fuel ratio sensor.
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between terminals 2 (+B) and 4 (AF-).
If there is continuity, replace the air fuel ratio sensor.
6.
(a)
Ohmmeter
INSPECT AIR FUEL RATIO SENSOR
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
INSPECT HEATED OXYGEN SENSOR
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
1 (HT) - 2 (+B)
11 to 16 Ω at 20C (68F)
If the resistance is not as specified, replace the heated oxygen
sensor.
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between terminals 1 (HT) and 4 (E).
If there is continuity, replace the heated oxygen sensor.
A86295
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2075
12-15
EMISSION CONTROL
7.
(a)
Battery
Ohmmeter
A84683
-
EMISSION CONTROL SYSTEM (3MZ-FE)
INSPECT AIR FUEL RATIO SENSOR HEATER RELAY
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
Specified Condition
3-5
10 kΩ or higher
3-5
Below 1Ω
(Apply battery voltage to terminals 1 and 2
If the result is not as specified, replace the air fuel ratio sensor
heater relay.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2076
12-16
EMISSION CONTROL
-
CHARCOAL CANISTER ASSY (3MZ-FE)
CHARCOAL CANISTER ASSY (3MZ-FE)
120BT-01
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE REAR SEAT CUSHION ASSY (See page 72-39 )
REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20 )
DRAIN FUEL
REMOVE FLOOR PANEL BRACE REAR (See page 15-2 )
REMOVE EXHAUST PIPE ASSY CENTER (See page 11-28 )
DISCONNECT PARKING BRAKE CABLE ASSY NO.2 (See page 11-28 )
DISCONNECT PARKING BRAKE CABLE ASSY NO.3 (See page 11-28 )
REMOVE FUEL TANK PROTECTOR LOWER CENTER (See page 11-28 )
REMOVE FUEL TANK ASSY (See page 11-28 )
(c)
(b)
(b)
13.
(a)
(b)
(c)
REMOVE CHARCOAL CANISTER ASSY
Disconnect the VSV connector.
Remove the 2 wire harness clamps.
Disconnect the fuel hose No. 1.
(d)
Disconnect the fuel tank vent hose.
(1) Deeply push the quick connector to release the lock
pin.
(2) Pinch portion A.
(3) Pull out the fuel tank vent hose.
(e)
(f)
Remove the 2 bolts.
Unfasten the claw, then remove the charcoal canister.
(a)
A86270
A
A
Pinch
Push
Pinch
A86393
(f)
(e)
(e)
A86360
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2077
12-17
EMISSION CONTROL
14.
(a)
-
CHARCOAL CANISTER ASSY (3MZ-FE)
REMOVE FUEL EMISSION TUBE FUEL HOSE
Remove the fuel emission tube fuel hose.
A87557
15.
INSTALL FUEL EMISSION TUBE FUEL HOSE
16.
(a)
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
INSTALL CHARCOAL CANISTER ASSY
Install the charcoal canister with the 2 bolts.
Torque: 40 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)
(b) Connect the fuel tank vent hose.
(1) Push in the quick connector to the pipe until the
quick connector makes a ”click” sound.
NOTICE:
Push
Check the connected part for damage or foreign objects.
A86389
After connecting, check if the quick connector and
pipe are securely connected by pulling on them.
(c) Connect the fuel hose No. 1.
(d) Install the 3 wire harness clamps.
(e) Connect the VSV connector.
INSTALL FUEL TANK ASSY (See page 11-28 )
INSTALL FUEL TANK PROTECTOR LOWER CENTER (See page 11-28 )
INSTALL PARKING BRAKE CABLE ASSY NO.3 (See page 11-28 )
INSTALL PARKING BRAKE CABLE ASSY NO.2 (See page 11-28 )
INSTALL EXHAUST PIPE ASSY CENTER (See page 11-28 )
INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20 )
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
ADD FUEL
CHECK FOR FUEL LEAKS (See page 11-5 )
CHECK FOR EXHAUST GAS LEAKS
INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
INSTALL REAR SEAT CUSHION ASSY
INSTALL FLOOR PANEL BRACE REAR (See page 15-2 )
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2078
12-18
EMISSION CONTROL
-
CHARCOAL CANISTER FILTER SUB-ASSY (3MZ-FE)
CHARCOAL CANISTER FILTER SUB-ASSY (3MZ-FE)
120BW-01
REPLACEMENT
1.
(a)
A
Pinch
A
Pinch
(b)
REMOVE CHARCOAL CANISTER FILTER SUB-ASSY
Disconnect the 2 fuel tank vent hoses.
(1) Deeply push the quick connector to release the lock
pin.
(2) Pinch portion A.
(3) Pull out the 2 fuel tank vent hoses.
Remove the bolt, then remove the charcoal canister filter.
Push
(b)
Pinch
Push
Pinch
A86357
2.
(a)
INSTALL CHARCOAL CANISTER FILTER SUB-ASSY
Install the charcoal canister filter with the bolt.
Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf)
(b) Connect the 2 fuel tank vent hoses.
(1) Push in the quick connector to the pipe until the
quick connector makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the quick connector and
pipe are securely connected by pulling on them.
Push
Push
A86388
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2079
12-19
EMISSION CONTROL
-
DUTY VACUUM SWITCHING VALVE (3MZ-FE)
DUTY VACUUM SWITCHING VALVE (3MZ-FE)
120BU-01
REPLACEMENT
1.
2.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
(a)
3.
(a)
(b)
REMOVE EMISSION CONTROL VALVE SET
Disconnect the 2 VSV connectors.
Remove the wire harness clamp.
(c)
(d)
(e)
(f)
(g)
Disconnect the fuel vapor feed hose No. 1.
Disconnect the fuel vapor feed hose No. 2.
Disconnect the vacuum hose.
Remove the vacuum hose from the clamp.
Remove the 2 nuts, then remove the emission control
valve set.
4.
(a)
(b)
REMOVE DUTY VACUUM SWITCHING VALVE
Disconnect the 2 vacuum hoses.
Remove the screw, then remove the duty vacuum switching valve.
(b)
(a)
A79751
(d)
(f)
(e)
(g)
(g)
(c)
A86217
(a)
(a)
(b)
A86278
5.
6.
7.
8.
9.
10.
INSTALL DUTY VACUUM SWITCHING VALVE
INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2080
12-20
EMISSION CONTROL
-
VAPOR PRESSURE SENSOR ASSY (3MZ-FE)
VAPOR PRESSURE SENSOR ASSY (3MZ-FE)
120BV-02
REPLACEMENT
1.
2.
3.
4.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE REAR SEAT CUSHION ASSY (See page 72-39 )
REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
5.
(a)
Tube Joint Clip
A79488
Fuel Tube Joint
Nylon Tube
DISCONNECT FUEL PUMP TUBE SUB-ASSY
Remove the tube joint clip, then pull out the fuel pump
tube.
NOTICE:
Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
Be careful of mud because the quick connector has
an O-ring which seals the pipe and quick connector
that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the quick
connector by covering it with a vinyl or plastic bag.
When the pipe and quick connector are stuck, push
and pull the quick connector to release. Pull the quick
connector carefully.
O-ring
Tube Joint Clip
Fuel Suction Plate
A91017
6.
(a)
REMOVE FUEL TANK VENT TUBE SET PLATE
Remove the 8 bolts, then remove the fuel tank vent tube
set plate.
7.
(a)
(b)
REMOVE VAPOR PRESSURE SENSOR ASSY
Remove the cover.
Remove the tube joint clip, then pull out the vapor pressure sensor.
A79489
Cover
Tube Joint Clip
A79491
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2081
12-21
EMISSION CONTROL
Cover
Tube Joint Clip
A86272
(b)
11.
12.
13.
14.
15.
VAPOR PRESSURE SENSOR ASSY (3MZ-FE)
8.
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 objects.
Check that the vapor pressure sensor is inserted securely.
Check that the tube joint clip is on the collar of the vapor pressure sensor.
After installing the tube joint clip, check that the vapor
pressure sensor has not been pulled off.
(b) Install the cover.
9.
(a)
Mark
-
INSTALL FUEL TANK VENT TUBE SET PLATE
Align the mark of the fuel tank vent tube set plate with the
fuel suction tube w/ pump & gauge.
Install the fuel tank vent tube set plate with the 8 bolts.
Torque: 5.9 N⋅m (60 kgf⋅cm, 52 in.⋅lbf)
A79489
10. CONNECT FUEL PUMP TUBE SUB-ASSY
(a) Install the fuel pump tube with the tube joint clip.
NOTICE:
Check the connected part for scratch or foreign obCollar
jects.
Check that the fuel tube joint is inserted securely.
Tube Joint Clip
Check that the tube joint clip is on the collar of the fuel
tube joint.
After installing the tube joint clip, check that the fuel
A81595
tube joint has not been pulled off.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
CHECK FOR FUEL LEAKS (See page 11-5 )
INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
INSTALL REAR SEAT CUSHION ASSY
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2082
12-22
EMISSION CONTROL
-
AIR FUEL RATIO SENSOR (3MZ-FE (RH BANK))
AIR FUEL RATIO SENSOR (3MZ-FE (RH BANK))
120BY-01
REPLACEMENT
1.
2.
3.
4.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2 )
5.
(b)
(a)
(a)
(b)
(b)
REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
Disconnect the air fuel ratio sensor connector.
Remove the 3 bolts, then remove the exhaust manifold
heat insulator No. 1.
(b)
A86340
6.
(a)
REMOVE AIR FUEL RATIO SENSOR
Using SST, remove the air fuel ratio sensor.
SST 09224-00010
7.
(a)
INSTALL AIR FUEL RATIO SENSOR
Using SST, install the air fuel ratio sensor.
SST 09224-00010
Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf)
SST
A86354
SST
A86354
8.
9.
10.
11.
12.
13.
14.
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf)
INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 )
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
CHECK FOR EXHAUST GAS LEAKS
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2083
12-23
EMISSION CONTROL
-
AIR FUEL RATIO SENSOR (3MZ-FE (LH BANK))
AIR FUEL RATIO SENSOR (3MZ-FE (LH BANK))
120BZ-01
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
(a)
(b)
REMOVE AIR FUEL RATIO SENSOR
Disconnect the air fuel ratio sensor connector.
Remove the wire harness clamp.
(c)
Using SST, remove the air fuel ratio sensor.
SST 09224-00010
3.
(a)
INSTALL AIR FUEL RATIO SENSOR
Using SST, install the air fuel ratio sensor.
SST 09224-00010
Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf)
Install the wire harness clamp.
Connect the air fuel ratio sensor connector.
(a)
(b)
A86359
SST
(c)
A86353
SST
(b)
(c)
A86353
4.
5.
6.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
CHECK FOR EXHAUST GAS LEAKS
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2084
12-23
EMISSION CONTROL
-
AIR FUEL RATIO SENSOR (3MZ-FE (LH BANK))
AIR FUEL RATIO SENSOR (3MZ-FE (LH BANK))
120BZ-01
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
(a)
(b)
REMOVE AIR FUEL RATIO SENSOR
Disconnect the air fuel ratio sensor connector.
Remove the wire harness clamp.
(c)
Using SST, remove the air fuel ratio sensor.
SST 09224-00010
3.
(a)
INSTALL AIR FUEL RATIO SENSOR
Using SST, install the air fuel ratio sensor.
SST 09224-00010
Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf)
Install the wire harness clamp.
Connect the air fuel ratio sensor connector.
(a)
(b)
A86359
SST
(c)
A86353
SST
(b)
(c)
A86353
4.
5.
6.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
CHECK FOR EXHAUST GAS LEAKS
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2084
13-1
INTAKE
-
INTAKE AIR CONTROL SYSTEM (3MZ-FE)
INTAKE AIR CONTROL SYSTEM (3MZ-FE)
1307V-01
ON-VEHICLE INSPECTION
1.
(a)
Vacuum Gauge
3-way
Connector
INSPECT INTAKE CONTROL VALVE ASSY NO. 2
Check the operation.
(1) Using a 3-way connector, connect the vacuum
gauge to the actuator hose as shown in the illustration.
A82242
(2)
(3)
(4)
(5)
Connect the hand-held tester to the DLC3.
Start the engine.
Turn the hand-held tester switch ON.
Select the item ”DIAGNOSIS/ENHANCED OBD II/
ACTIVE TEST/INTAKE CTL VSV1” and operate
the VSV for AICS.
Vacuum:
Hand-held Tester
DLC3
A86347
Tester Operation
Specified Condition
VSV is ON
Approximately 27.6 kpa (200 mmHg, 7.9 in.Hg)
VSV is OFF
0 kPa (0 mmHg, 0 in.Hg)
If the operation is not as specified, replace the intake air control
valve No. 2.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2086
13-2
INTAKE
-
INTAKE AIR CONTROL SYSTEM (3MZ-FE)
1307W-01
INSPECTION
Valve
Hand-held
Vacuum Pump
A82243
Hand-held
Vacuum Pump
Valve
1.
(a)
INSPECT INTAKE AIR CONTROL VALVE ASSY NO.2
Check the operation.
(1) With vacuum of 26.7 kPa (200 mmHg, 7.9 in.Hg) applied to the actuator, check that the valve closes.
(2) 1 minute after applying the vacuum, check that the
valve remains closed.
NOTICE:
Do not adjust the adjust screw.
If the operation is not as specified, replace the intake air control
valve No. 2.
2.
INSPECT INTAKE AIR CONTROL VALVE ASSY NO.3
(a) Check the operation.
(1) With vacuum of 26.7 kPa (200 mmHg, 7.9 in.Hg) applied to the actuator, check that the valve opens.
(2) 1 minute after applying the vacuum, check that the
valve remains opened.
If the operation is not as specified, replace the intake air control
valve No. 3.
A86222
(b)
Ohmmeter
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance:
Tester Connection
Specified Condition
1-2
37 to 44Ω at 20C (68 F)
If the resistance is not as specified, replace the intake air control
valve No. 3.
A86223
(c)
Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between each terminal and the body.
If there is continuity, replace the intake air control valve No. 3.
Ohmmeter
Body
A86224
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2087
13-3
INTAKE
(d)
Air
-
INTAKE AIR CONTROL SYSTEM (3MZ-FE)
Check the operation.
(1) Check that air flows from port E to the filter.
E
Filter
A86225
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to F.
If the operation is not as specified, replace the intake air control
valve No. 3.
Air
E
F
Battery
A86226
3.
(a)
Ohmmeter
A86227
INSPECT VACUUM SWITCHING VALVE ASSY NO.1
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance:
Tester Connection
Specified Condition
1-2
33 to 39Ω at 20C (68F)
If the resistance is not as specified, replace the vacuum switching valve No. 1.
(b)
Ohmmeter
Body
Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between each terminal and the body.
If there is continuity, replace the vacuum switching valve No. 1.
A86228
(c)
Air
Check the operation.
(1) Check that air flows from port E to the filter.
E
Filter
A86229
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2088
13-4
INTAKE
Air
E
F
-
INTAKE AIR CONTROL SYSTEM (3MZ-FE)
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to F.
If the operation is not as specified, replace the vacuum switching valve No. 1.
Battery
A86230
4.
(a)
C
A
B
A86231
INSPECT AIR CLEANER CAP SUB-ASSY
Check the operation.
(1) Cover port C with your finger, then check that the air
flow from port B to A.
(2) Cover port C with your finger, then check that the air
does not flow from port A to B.
(3) Cover ports A and C with your fingers, then apply 60
kPa (450 mmHg, 18 in.Hg) of vacuum to port B.
Check that there is no vacuum change after 1 minute.
If the operation is not as specified, replace the air cleaner cap.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2089
13-5
INTAKE
-
INTAKE AIR CONTROL VALVE ASSY NO.2 (3MZ-FE)
INTAKE AIR CONTROL VALVE ASSY NO.2 (3MZ-FE)
1307X-01
REPLACEMENT
(a)
1.
(a)
REMOVE INTAKE AIR CONTROL VALVE ASSY NO.2
Remove the wire harness clamp.
(b)
Disconnect the vacuum hose.
(c)
(d)
Remove the 3 bolts and nut.
Rotate the lever to the closed position as shown in the illustration, then pull out the intake air control valve No. 2.
Remove the gasket from the intake air surge tank.
A79700
(b)
A79701
(c)
Lever
(c)
(c)
(e)
(c)
A79702
2.
(a)
(b)
(c)
(d)
INSTALL INTAKE AIR CONTROL VALVE ASSY NO.2
Install a new gasket to the intake air surge tank.
Install the intake air control valve No. 2 with the 3 bolts and nut.
Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
Connect the vacuum hose.
Install the wire harness clamp.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2090
13-6
INTAKE
-
INTAKE AIR CONTROL VALVE ASSY NO.3 (3MZ-FE)
INTAKE AIR CONTROL VALVE ASSY NO.3 (3MZ-FE)
1307Y-01
REPLACEMENT
1.
2.
3.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
(b)
(b)
(b)
(c)
4.
(a)
(b)
(c)
(d)
(e)
REMOVE AIR CLEANER CAP SUB-ASSY
Disconnect the mass air flow meter connector.
Disconnect the 4 vacuum hoses.
Loosen the hose clamp bolt.
Loosen the 2 bolts, then remove the air cleaner cap.
Remove the air cleaner filter element.
5.
(a)
(b)
(c)
REMOVE INTAKE AIR CONTROL VALVE ASSY NO.3
Disconnect the VSV connector.
Disconnect the vacuum hose.
Unfasten the 2 claws, then remove the intake air control
valve No. 3.
(a)
(d)
(b)
(d)
A86220
(b)
(a)
(c)
(c)
A86221
6.
7.
8.
9.
10.
11.
12.
INSTALL INTAKE AIR CONTROL VALVE ASSY NO.3
INSTALL AIR CLEANER CAP SUB-ASSY
Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
INSTALL RADIATOR LOWER AIR DEFLECTOR
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2091
13-7
INTAKE
-
VACUUM SWITCHING VALVE ASSY NO.1 (3MZ-FE)
VACUUM SWITCHING VALVE ASSY NO.1 (3MZ-FE)
1307Z-01
REPLACEMENT
1.
2.
3.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
REMOVE EMISSION CONTROL VALVE SET (See page 12-19 )
(a)
4.
(a)
REMOVE VACUUM SWITCHING VALVE ASSY NO.1
Remove the 2 screws, then remove the vacuum surge
tank.
(b)
(c)
(d)
Disconnect the vacuum hose.
Remove the vacuum hose.
Remove the screw, then remove the vacuum switching
valve No. 1.
(a)
A86218
(b)
(c)
(d)
A86219
5.
6.
7.
8.
9.
10.
INSTALL VACUUM SWITCHING VALVE ASSY NO.1
INSTALL EMISSION CONTROL VALVE SET (See page 12-19 )
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2092
15-1
EXHAUST
-
EXHAUST PIPE ASSY (3MZ-FE)
EXHAUST PIPE ASSY (3MZ-FE)
150B7-01
COMPONENTS
Exhaust Pipe Gasket
Exhaust Pipe Assy Front
Heated Oxygen Sensor
44 (450, 33)
62 (633, 46)
Exhaust Pipe
Gasket
Exhaust Pipe
Gasket
x2
Exhaust Pipe No. 1
Support Bracket Rear
44 (450, 33)
Heated Oxygen Sensor
62 (633, 46)
x2
Exhaust Pipe No. 1
Support Bracket Front
x2
33 (337, 24)
x2
33 (337, 24)
Exhaust Pipe Assy Tail
Tail Pipe Baffle
Exhaust Pipe Gasket
x2
Exhaust Pipe Assy Center
56 (574, 41)
Floor Panel Brace Rear
x2
20 (199, 14)
x2
56 (574, 41)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86208
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2274
15-2
EXHAUST
-
EXHAUST PIPE ASSY (3MZ-FE)
150B8-01
Removal & Installation and Disassembly & Reassembly
1.
2.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE HEATED OXYGEN SENSOR (See page 12-24 )
SST 09224-00010
3.
(a)
REMOVE FLOOR PANEL BRACE REAR
Remove the 2 bolts, then remove the floor panel brace
rear.
4.
(a)
(b)
REMOVE EXHAUST PIPE ASSY TAIL
Remove the 2 nuts.
Remove the exhaust pipe tail and gasket from the 3 exhaust pipe supports.
A86209
(b)
(b)
(a)
(b)
(a)
A86210
5.
(a)
Plastic-faced Hammer
REMOVE TAIL PIPE BAFFLE
Using a plastic-faced hammer, uniformly tap the tail pipe
baffle to remove.
A86211
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2275
15-3
EXHAUST
6.
(a)
(b)
-
EXHAUST PIPE ASSY (3MZ-FE)
REMOVE EXHAUST PIPE ASSY CENTER
Remove the 2 bolts and 2 nuts.
Remove the exhaust pipe center and gasket from the 2
exhaust pipe supports.
(b)
(b)
(a)
(a)
A86212
7.
(a)
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
FRONT
Remove the 2 nuts, then remove the exhaust pipe No. 1
support bracket front.
A86213
8.
(a)
(b)
(b)
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
REAR
Remove the 2 bolts.
Remove the exhaust pipe No. 1 support bracket rear from
the exhaust pipe front.
(a)
(a)
A86214
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2276
15-4
EXHAUST
9.
(a)
-
EXHAUST PIPE ASSY (3MZ-FE)
REMOVE EXHAUST PIPE ASSY FRONT
Remove the 2 bolts and 2 nuts, then remove the exhaust
pipe front and 2 gaskets.
(a)
(a)
(a)
(a)
A86215
10.
(a)
(b)
INSTALL EXHAUST PIPE ASSY FRONT
Install 2 new gaskets and the exhaust pipe front with the 2 bolts.
Torque: 62 N⋅m (633 kgf⋅cm, 46 ft⋅lbf)
Tighten 2 new nuts.
Torque: 62 N⋅m (633 kgf⋅cm, 46 ft⋅lbf)
11. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
REAR
Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf)
HINT:
Be careful not to install the exhaust pipe No. 1 support bracket
rear in the wrong direction.
Exhaust Pipe
No. 1 Support Bracket
A60823
12.
13.
(a)
(b)
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT
Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf)
INSTALL EXHAUST PIPE ASSY CENTER
Install a new gasket and the exhaust pipe center to the 2 exhaust pipe supports.
Tighten the 2 bolts and 2 new nuts.
Torque: 56 N⋅m (574 kgf⋅cm, 41 ft⋅lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2277
15-5
EXHAUST
14.
(a)
Keyway
(b)
-
EXHAUST PIPE ASSY (3MZ-FE)
INSTALL TAIL PIPE BAFFLE
Align the keyway of the tail pipe baffle with the key on the
exhaust pipe tail.
Using a plastic-faced hammer, tap the tail pipe baffle to
install.
Plastic-faced
Hammer
Key
15.
(a)
(b)
16.
17.
18.
19.
20.
A86216
INSTALL EXHAUST PIPE ASSY TAIL
Install a new gasket and the exhaust pipe tail to the 3 exhaust pipe supports.
Tighten the 2 new nuts.
Torque: 56 N⋅m (574 kgf⋅cm, 41 ft⋅lbf)
INSTALL HEATED OXYGEN SENSOR (See page 12-24 )
SST 09224-00010
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
CHECK FOR EXHAUST GAS LEAKS
INSTALL FLOOR PANEL BRACE REAR
Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2278
16-1
COOLING
-
COOLING SYSTEM (3MZ-FE)
COOLING SYSTEM (3MZ-FE)
160QB-01
ON-VEHICLE INSPECTION
1.
INSPECT COOLING SYSTEM FOR LEAKS
(a) Remove the water outlet cap.
CAUTION:
To avoid the danger of being burned, do not remove the water outlet cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and
Radiator Cap
steam to blow out from the radiator.
Tester
(b) Fill the radiator with coolant, then attach a radiator cap
tester.
A60522
(c) Warm up the engine.
(d) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), then check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(e) Reinstall the water outlet cap.
2.
CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ”LOW” and ”FULL” lines when the engine is cold.
If low, check for leaks and add ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based
non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology
up to the ”FULL” line.
3.
CHECK ENGINE COOLANT QUALITY
(a) Remove the water outlet cap.
CAUTION:
To avoid the danger of being burned, do not remove the water outlet cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there are any excessive deposits of rust or scale around the water outlet cap and water outlet
filler hole; the coolant should free of oil.
If excessively dirty, replace the coolant.
(c) Reinstall the water outlet cap.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2279
16-2
COOLING
-
COOLING SYSTEM (3MZ-FE)
4.
(a)
INSPECT FIN BLOCKAGE
If the fins are clogged, wash them with water or a steam
cleaner, then dry with compressed air.
NOTICE:
If the distance between the steam cleaner and core is
too close, there is a possibility of damaging the fins,
so keep the following injection distance.
A73603
Injection Pressure
kPa (kgf/cm2, psi)
Injection Distance
mm (in.)
2,942 to 4,903
(30 to 50, 427 to 711)
300 (11.811)
4,903 to 7,845
(50 to 80, 711 to 1,138)
500 (19.685)
If the fins are bent, straighten them with a screwdriver
or pliers.
Be careful not to expose electronic components to
water.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2280
16-5
COOLING
-
COOLING FAN SYSTEM (3MZ-FE)
COOLING FAN SYSTEM (3MZ-FE)
160QD-01
ON-VEHICLE INSPECTION
1.
(a)
CHECK COOLING FAN OPERATION AT LOW TEMPERATURE (Below 83C (181F))
Turn the ignition switch ON.
(b) Check that the fan and fan No. 2 stops.
If not, check the cooling fan relays and temperature detect
switches.
(c) Disconnect the temperature detect switch connector.
A86555
(d)
Connect the terminals of the temperature detect switch
wire connector.
A86554
(e) Check that the fan rotates at high speed.
If not, check the cooling fan relay and fan.
(f)
Reconnect the temperature detect switch connector.
(g) Disconnect the temperature detect switch No. 2 connector.
A86556
(h)
Ground the terminal on the temperature detect switch No.
2 wire harness side connector.
B09432
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2283
16-6
COOLING
-
COOLING FAN SYSTEM (3MZ-FE)
(i)
Check that the fan and fan No. 2 rotates at low speed.
If not, check the cooling fan relay No. 2, cooling fan relay No.
3 and No. 2 fan.
(j)
Reconnect the temperature detect switch No. 2 connector.
A86557
Ammeter
2.
(a)
(b)
(c)
(d)
INSPECT FAN
Disconnect the fan connector.
Connect battery and ammeter to the fan connector.
Check that the fan rotates smoothly, then check the reading on the ammeter.
Standard amperage: 10.2 to 16.2 A at 20C (68F)
Reconnect the fan connector.
Battery
A86558
3.
(a)
(b)
Ammeter
(c)
(d)
Battery
INSPECT NO. 2 FAN
Disconnect the No. 2 fan connector.
Connect the battery and ammeter to the No. 2 fan connector.
Check that the No. 2 fan rotates smoothly, then check the
reading on the ammeter.
Standard amperage: 10.2 to 16.2 A at 20C (68F)
Reconnect the No. 2 fan connector.
A86559
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2284
16-3
COOLING
-
COOLING SYSTEM (3MZ-FE)
160QC-01
INSPECTION
1.
INSPECT THERMOSTAT
HINT:
The thermostat is inscribed with the valve opening temperature.
P13560
(a)
Immerse the thermostat in water, then gradually heat the
water.
(b) Inspect the valve opening temperature of the thermostat.
Valve opening temperature:
80 to 84C (176 to 183F)
If the valve opening temperature is not as specified, replace the
thermostat.
P00436
(c)
10 mm
(0.39 in.)
A85445
Inspect the valve lift.
Valve lift: 10 mm (0.39 in.) or more at 95C (203F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat
is at low temperature (below 77C (171F)).
If not fully closed, replace the thermostat.
2.
INSPECT WATER OUTLET CAP SUB-ASSY
NOTICE:
If the water outlet cap is contaminated, rinse it with
water.
Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.
When performing the following steps (a) and (b), keep
the tester at an angle of over 30 above horizontal.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2281
16-4
COOLING
-
COOLING SYSTEM (3MZ-FE)
(a)
Radiator Cap Tester
30 or more
Water Outlet Cap
A85446
Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push / 3 seconds or more
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the water
outlet cap.
(b) Pump the tester, then measure the relief valve opening
pressure.
Pump speed: 1 push within 1 second
NOTICE:
The above pump speed is for the first pump only (in order
to close the vacuum valve). After the first pump, the pump
speed can be reduced.
Standard opening pressure:
83 to 113 kPa (0.85 to 1.15 kgf/cm2, 12.1 to 16.4 psi)
Minimum opening pressure:
69 kPa (0.7 kgf/cm2, 10.0 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the water
outlet cap.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2282
16-7
COOLING
-
COOLING FAN SYSTEM (3MZ-FE)
160QE-01
INSPECTION
1.
(a)
Ohmmeter
INSPECT COOLING FAN RELAY
Check the continuity.
(1) Using an ohmmeter, check for continuity between
the terminals.
Standard:
Tester Connection
A86576
Specified Condition
1-2
Continuity
3-5
No continuity
If the result is not as specified, replace the cooling fan relay.
(b)
Check the operation.
(1) Apply battery positive voltage across terminals 1
and 2.
(2) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
If there is no continuity, replace the cooling fan relay.
Battery
Ohmmeter
A86577
2.
(a)
Ohmmeter
Ohmmeter
INSPECT COOLING FAN RELAY NO.2
Check the continuity.
(1) Using an ohmmeter, check for continuity between
the terminals.
Standard:
Tester Connection
Specified Condition
1-2
Continuity
3-4
Continuity
3-5
No continuity
If the result is not as specified, replace the cooling fan relay.
A86578
(b)
Battery
Ohmmeter
Ohmmeter
A86579
Check the operation.
(1) Apply battery positive voltage across terminals 1
and 2.
(2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4.
If there is continuity, replace the cooling fan relay.
(3) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
If there is no continuity, replace the cooling fan relay.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2285
16-8
COOLING
3.
(a)
Ohmmeter
-
COOLING FAN SYSTEM (3MZ-FE)
INSPECT COOLING FAN RELAY NO.3
Check the continuity.
(1) Using an ohmmeter, check for continuity between
the terminals.
Standard:
Tester Connection
A86576
Specified Condition
1-2
Continuity
3-5
No continuity
If the result is not as specified, replace the cooling fan relay.
(b)
Check the operation.
(1) Apply battery positive voltage across terminals 1
and 2.
(2) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
If there is no continuity, replace the cooling fan relay.
Battery
Ohmmeter
A86577
Ohmmeter
4.
(a)
INSPECT TEMPERATURE DETECT SWITCH
Check the continuity.
(1) Using an ohmmeter, check for continuity between
the terminals.
Standard:
Coolant Temperature
A86580
Ohmmeter
A86581
Specified Condition
Above 98C (208F)
Continuity
Below 88C (190F)
No continuity
If the result is not as specified, replace the temperature detect
switch.
5.
(a)
INSPECT TEMPERATURE DETECT SWITCH NO.2
Check the continuity.
(1) Using an ohmmeter, check for continuity between
the terminals.
Standard:
Coolant Temperature
Specified Condition
Above 93C (199F)
Continuity
Below 83C (181F)
No continuity
If the result is not as specified, replace the temperature detect
switch.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2286
16-9
COOLING
-
ENGINE COOLANT (3MZ-FE)
ENGINE COOLANT (3MZ-FE)
160QF-01
REPLACEMENT
Water Outlet Cap
Drain Cock Plug
Drain Cock Plug
Radiator Drain Plug
A86582
2.
(a)
1.
DRAIN ENGINE COOLANT
(a) Remove the water outlet cap from the water outlet.
CAUTION:
To avoid the danger of being burned, do not remove the water outlet cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and
steam to blow out from the radiator.
(b) Loosen the radiator drain plug and 2 drain cock plugs,
then drain the coolant.
(c) Close the radiator drain plug.
(d) Tighten the 2 drain cock plugs.
Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)
ADD ENGINE COOLANT
Slowly fill the cooling system with coolant.
Capacity: 9.2 liters (9.7 US qts, 8.1 lmp. qts)
HINT:
Use of improper coolants may damage the engine cooling system.
Use ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non-silicate, nonamine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology.
New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethyleneglycol concentration is approximately 50% and freezing temperature is -35C (-31F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended.
Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several
times by hand. If the coolant level goes down, add the coolant.
NOTICE:
Do not use plain water alone.
3.
CHECK FOR ENGINE COOLANT LEAKS
(a) Fill the radiator with coolant, then attach a radiator cap tester.
(b) Pump it to 118 kPa (1.2 kgf/cm2 17.1 psi), then check for leakage.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2287
16-10
COOLING
-
WATER PUMP ASSY (3MZ-FE)
WATER PUMP ASSY (3MZ-FE)
160QG-01
COMPONENTS
Front Fender Apron
Seal RH
64 (653, 47)
Vane Pump V Belt
23 (235, 17)
Radio Setting Condenser
V Belt No. 1
Engine Moving Control Rod
64 (653, 47)
28 (286, 21)
58 (591, 43)
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
A84916
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2288
16-1 1
COOLING
-
WATER PUMP ASSY (3MZ-FE)
Timing Belt
8.5 (87, 75 in.⋅lbf)
Timing Belt No. 2 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH
28 (286, 21)
Timing Belt No. 1 Cover
220 (2,250, 162)
8.5 (87, 75 in.⋅lbf)
Crankshaft Pulley
Engine Wire
Protector
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
A78353
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2289
16-12
COOLING
-
WATER PUMP ASSY (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
Collar
8.5 (87, 75 in.⋅lbf)
Bushing
x6
43 (438, 32)
Camshaft Timing
Pulley
Timing Belt Idler
Sub-assy No. 2
125 (1,275, 92)
Engine Wire
Water Pump Assy
Water Pump Gasket
8.0 (82, 71 in.⋅lbf)
8.0 (82, 71 in.⋅lbf)
Timing Belt Idler Sub-assy No. 1
34 (347, 25)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78394
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2290
16-13
COOLING
-
WATER PUMP ASSY (3MZ-FE)
160QH-01
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
(a)
DRAIN ENGINE COOLANT (See page 16-9 )
REMOVE FRONT WHEEL RH
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
REMOVE VANE PUMP V BELT (See page 14-5 )
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
REMOVE TIMING BELT NO.1 COVER
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
REMOVE TIMING BELT GUIDE NO.2
REMOVE TIMING BELT (See page 14-79 )
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
REMOVE TIMING BELT IDLER SUB-ASSY NO.1
Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
19.
(a)
REMOVE WATER PUMP ASSY
Remove the 3 bolts and 3 nuts, then remove the water
pump and gasket.
A78535
20.
(a)
21.
(a)
22.
23.
24.
25.
26.
INSTALL WATER PUMP ASSY
Install a new gasket and the water pump with the 3 bolts and 3 nuts.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
INSTALL TIMING BELT IDLER SUB-ASSY NO.1
Using a socket hexagon wrench 10, install the plate washer and timing belt idler No.1 with the pivot
bolt.
Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf)
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
INSPECT TIMING BELT (See page 14-79 )
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2291
16-14
COOLING
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
-
WATER PUMP ASSY (3MZ-FE)
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
INSTALL VANE PUMP V BELT (See page 14-5 )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL FRONT WHEEL RH (See page 14-5 )
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2292
16-15
COOLING
-
WATER PUMP ASSY (3MZ-FE)
160LM-03
INSPECTION
1.
(a)
(b)
INSPECT WATER PUMP ASSY
Visually check the drain hole for coolant leakage.
Turn the pulley, then check that the water pump bearing
moves smoothly without making a niose.
If not, replace the water pump.
P12487
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2293
16-16
COOLING
-
THERMOSTAT (3MZ-FE)
THERMOSTAT (3MZ-FE)
160QI-01
REPLACEMENT
1.
2.
3.
4.
5.
DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE COOLANT (See page 16-9 )
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
REMOVE AIR CLEANER ASSY (See page 19-5 )
6.
(a)
(b)
REMOVE WATER INLET PIPE
Remove the bolt and water inlet pipe.
Remove the O-ring from the water inlet pipe.
7.
(a)
(b)
REMOVE WATER INLET
Disconnect the wire harness clamp.
Remove the 3 nuts and water inlet.
9.
(a)
(b)
INSTALL THERMOSTAT
Install a new gasket to the thermostat.
Align the thermostat jiggle valve with the upper stud bolt,
then insert the thermostat in the water inlet housing.
A80823
A80824
8.
REMOVE THERMOSTAT
15
15
HINT:
The jiggle valve may be set within 15 of either side of the prescribed position.
Jiggle Valve
A80298
10.
INSTALL WATER INLET
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2294
16-17
COOLING
11.
(a)
(b)
(c)
(d)
12.
13.
14.
15.
16.
-
THERMOSTAT (3MZ-FE)
INSTALL WATER INLET PIPE
Install a new O-ring to the water inlet pipe.
Apply soapy water to the O-ring.
Connect the water inlet pipe to the water inlet.
Install the bolt which is used to fixes the water inlet pipe to the cylinder head.
Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf)
INSTALL AIR CLEANER ASSY (See page 19-5 )
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2295
16-18
COOLING
-
RADIATOR ASSY (3MZ-FE)
RADIATOR ASSY (3MZ-FE)
160QJ-01
COMPONENTS
Clip
x7
Clip
Radiator Lower Air Deflector
Air Cleaner Hose No. 1
5.5 (56, 49 in.⋅lbf)
Mass
Air Flow Sensor
Connector
Vacuum Hose
Battery Clamp
Sub-assy
VSV Connector
Vacuum Hose
5.0 (51, 44 in.⋅lbf)
Battery
Air Cleaner Cap
Sub-assy
5.0 (51, 44 in.⋅lbf)
x2
Air Cleaner
Inlet Assy
Air Cleaner
Filter Element
Sub-assy
x3
5.0 (51, 44 in.⋅lbf)
5.0 (51, 44 in.⋅lbf)
Battery Tray
Air Cleaner Inlet
No. 1
Air Cleaner Case
Engine Under Cover No. 1
x2
7.5 (76, 66 in.⋅lbf)
Air Cleaner Bracket
Engine Under Cover No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
A86584
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2296
16-19
COOLING
-
RADIATOR ASSY (3MZ-FE)
14 (142, 10)
x5
Radiator Support Upper
Hood Lock Assy
8.0 (82, 71 in.⋅lbf)
x3
Hood Lock Release
Lever Protector
Radiator Support
Cushion
5.0 (51, 44 in.⋅lbf)
Radiator Hose Inlet
x3
Fan Shroud
Sub-assy
Radiator Assy
Oil Cooler
Inlet Hose
Oil Cooler
Outlet Hose
Radiator Hose Outlet
Temperature Detect
Switch
Radiator Support
Lower
N·m (kgf·cm, ft·lbf) : Specified torque
A86585
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2297
16-20
COOLING
-
RADIATOR ASSY (3MZ-FE)
Radiator Tank Upper
O-ring
Radiator Core Sub-assy
O-ring
O-ring
ATM Oil Cooler
O-ring
Radiator Drain
Cock Plug
8.3 (85, 74 in.⋅lbf)
Washer
15 (150, 11)
Inlet No. 1
O-ring
Radiator Tank Lower
15 (150, 11)
Inlet No. 2
Washer
8.3 (85, 74 in.⋅lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86586
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2298
16-21
COOLING
-
RADIATOR ASSY (3MZ-FE)
160QK-01
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE COOLANT (See page 16-9 )
REMOVE ENGINE UNDER COVER NO.1
REMOVE ENGINE UNDER COVER NO.2
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
REMOVE BATTERY
REMOVE BATTERY TRAY
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
REMOVE AIR CLEANER ASSY (See page 19-5 )
REMOVE AIR CLEANER BRACKET (See page 19-5 )
REMOVE AIR CLEANER INLET NO.1 (See page 19-5 )
DISCONNECT RADIATOR HOSE INLET
DISCONNECT RADIATOR HOSE OUTLET
DISCONNECT OIL COOLER INLET HOSE
DISCONNECT OIL COOLER OUTLET HOSE
16.
REMOVE HOOD LOCK RELEASE LEVER
PROTECTOR
(a) Using a screwdriver with the tip wrapped in tape, remove
the protector.
NOTICE:
Removing the protector damages the clips inside the protector, therefore it is necessary to use a new protector
when installing.
Clip
A61350
17.
(a)
(b)
SEPARATE HOOD LOCK ASSY
Disconnect the hood switch connector.
Remove the 3 bolts, then separate the hood lock.
18.
(a)
(b)
REMOVE RADIATOR SUPPORT UPPER
Disconnect the horn connectors.
Remove the 5 bolts, then remove the radiator support upper.
A86560
A86561
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2299
16-22
COOLING
19.
(a)
(b)
-
RADIATOR ASSY (3MZ-FE)
REMOVE RADIATOR ASSY
Disconnect the 2 wire harness connectors.
Remove the radiator from the vehicle.
A86562
20.
(a)
21.
(a)
REMOVE RADIATOR SUPPORT CUSHION
Remove the 2 radiator support cushions from the radiator.
REMOVE RADIATOR SUPPORT LOWER
Remove the 2 radiator support lowers from the radiator.
22.
(a)
(b)
REMOVE FAN SHROUD SUB-ASSY
Disconnect the temperature detect switch connector.
Remove the 3 bolts, then remove the fan shroud with motor.
A86563
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
REMOVE TEMPERATURE DETECT SWITCH
REPLACE RADIATOR ASSY
INSTALL FAN SHROUD SUB-ASSY
Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)
INSTALL RADIATOR SUPPORT UPPER
Torque: 14 N⋅m (142 kgf⋅cm, 10 ft⋅lbf)
INSTALL HOOD LOCK ASSY
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
INSTALL AIR CLEANER INLET NO.1 (See page 19-5 )
INSTALL AIR CLEANER BRACKET (See page 19-5 )
INSTALL AIR CLEANER ASSY (See page 19-5 )
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
ADD ENGINE COOLANT (See page 16-9 )
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2300
16-23
COOLING
-
RADIATOR ASSY (3MZ-FE)
160QL-01
OVERHAUL
1.
(a)
(b)
REMOVE RADIATOR DRAIN COCK PLUG
Remove the drain cock plug.
Remove the O-ring from the drain cock plug.
2.
Part ”A”
Dimension ”B” SST
Claw
Stopper Bolt
Overhaul Handle
A87082
Radiator Tank
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 ”A” as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that
dimension ”B” is as shown in the illustration.
Dimension ”B”: 0.2 to 0.3 mm (0.008 to 0.012 in)
NOTICE:
If the stopper bolt is not adjusted, the claw may be damaged.
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)
Core Plate
SST
Stopper Bolt
A86587
4.
(a)
(b)
Tap
REMOVE RADIATOR TANK UPPER
Lightly tap the bracket of the radiator tank (or radiator tank
pipe) with a soft-faced hammer, then remove the radiator
tank.
Remove the O-ring.
A86588
5.
REMOVE RADIATOR TANK LOWER
HINT:
Perform the same procedures as the radiator tank upper.
6.
(a)
(b)
REMOVE INLET NO.1
Remove the bolt.
Remove the nut and inlet No. 1.
A86589
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2301
16-24
COOLING
-
RADIATOR ASSY (3MZ-FE)
7.
(a)
REMOVE INLET NO.2
Remove the nut and inlet No. 2.
8.
(a)
REMOVE ATM OIL COOLER
Remove the 2 nuts and 2 washers, then remove the oil
cooler from the radiator tank.
Remove the 2 O-rings from the oil cooler.
A86590
(b)
A86591
Core Plate
Core Plate
A87087
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 necessary.
NOTICE:
The radiator can only be recaulked 2 times. After being recaulked 2 times, the radiator core must be replaced.
10.
(a)
(b)
(c)
INSTALL ATM OIL COOLER
Install the 2 new O-rings to the oil cooler.
Install the oil cooler to the radiator tank.
Install the 2 nuts and 2 washers.
Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf)
A86592
11.
12.
INSTALL INLET NO.2
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
INSTALL INLET NO.1
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2302
16-25
COOLING
13.
(a)
Normal X Twisted
-
RADIATOR ASSY (3MZ-FE)
INSTALL RADIATOR TANK UPPER
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 sandpaper without scratching it.
O-ring
X Twisted
A87088
Radiator Tank
CORRECT
(b)
(c)
Core
Plate
Install the radiator tank without damaging the O-ring.
Tap the core plate with a soft-faced hammer so that there
is no gap between the core plate and radiator tank.
WRONG
Tap
A86593
14. INSTALL RADIATOR TANK LOWER
HINT:
Perform the same procedures as the radiator tank upper.
15.
Part ”A”
(a)
Dimension ”B” SST
Punch Assembly
(b)
Stopper Bolt
Overhaul Handle
ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01020)
Install the punch assembly to the overhaul handle by inserting it in the hole in part ”A” as shown in the illustration.
While gripping the handle, adjust the stopper bolt so that
dimension ”B” is as shown in the illustration.
Dimension ”B”: 8.4 mm (0.341 in.)
A87090
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2303
16-26
COOLING
5
3
16.
(a)
7
1
2
6
4
8
-
RADIATOR ASSY (3MZ-FE)
CAULK CORE PLATE
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)
SST
Stopper
Bolt
Radiator
Tank
Core
Plate
A86594
HINT:
Rib
Do not tap the areas protruding around the pipes, brackets or tank ribs.
The points shown in the illustration and oil cooler near
here cannot be tapped with the SST. Use pliers or a similar tool and be careful not to damage the core plate.
Bracket
A86595
A86596
(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.
H
A86597
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2304
16-27
COOLING
17.
(a)
(b)
-
RADIATOR ASSY (3MZ-FE)
INSTALL RADIATOR DRAIN COCK PLUG
Install a new O-ring to the drain cock plug.
Install the drain cock plug.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2305
17-1
LUBRICATION
-
LUBRICATION SYSTEM (3MZ-FE)
LUBRICATION SYSTEM (3MZ-FE)
170FZ-02
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.
(a)
Recommended Viscosity (SAE)
5W-30
C -29 -18
F -20 0
-7
20
4
16
40 60
27
38
80 100
A66623
CHECK ENGINE OIL QUALITY
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 ”Energy-Conserving”, 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 pressure switch.
Oil Pressure
Switch
A90353
(c)
(d)
(e)
Oil Pressure Gauge
Install the oil pressure gauge.
Warm up the engine.
Inspect the oil pressure.
Oil pressure:
At idle
29 kPa (0.3 kgf/cm2, 4.3 psi) or more
At 3,000 rpm
245 to 539 kPa (2.5 to 5.5 kgf/cm2, 36 to 78 psi)
A90354
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2306
17-2
LUBRICATION
-
LUBRICATION SYSTEM (3MZ-FE)
(f)
Adhesive
A85603
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 pressure switch.
Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf)
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.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2307
17-3
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
OIL PUMP ASSY (3MZ-FE)
170HM-01
COMPONENTS
Front Fender Apron
Seal RH
64 (653, 47)
Vane Pump V Belt
V Belt No. 1
23 (235, 17)
Radio Setting Condenser
28 (286, 21)
64 (653, 47)
Engine Moving Control Rod
58 (591, 43)
Generator Bracket No. 2
9.8 (100, 7)
Engine Mounting Stay No. 2 RH
18 (178, 13)
Generator Assy
Engine Under Cover No. 1
Engine Under Cover No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
A84921
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2308
17-4
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
Timing Belt
8.5 (87, 75 in.⋅lbf)
Timing Belt No. 2 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH
28 (286, 21)
Timing Belt No. 1 Cover
220 (2,250, 162)
8.5 (87, 75 in.⋅lbf)
Crankshaft Pulley
Engine Wire
Protector
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
A78353
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2309
17-5
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
Collar
8.5 (87, 75 in.⋅lbf)
Bushing
x6
43 (438, 32)
Camshaft Timing
Pulley
Timing Belt Idler
Sub-assy No. 2
125 (1,275, 92)
Engine Wire
Timing Belt Idler Sub-assy No. 1
34 (347, 25)
Crankshaft Timing Pulley
Timing Belt Plate
8.0 (82, 71 in.⋅lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
A78396
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2310
17-6
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
54 (551, 40)
95 (969, 70)
43 (439, 32)
54 (551, 40)
54 (551, 40)
Engine Mounting Bracket RH
Engine Mounting Insulator RH
87 (887, 64)
8.4 (85, 74 in.⋅lbf)
87 (887, 64)
43 (438, 32)
Generator Belt
Adjusting Bar
Engine Mounting
Insulator FR
18 (184, 13)
52 (530, 38)
25 (250, 18)
8.0 (82, 71 in.⋅lbf)
Compressor Mounting
Bracket No. 1
Oil Level Gage Guide
Oil Level Gage
Sub-assy
Compressor and Magnetic Clutch
O-ring
25 (250, 18)
26 (260, 19)
Exhaust Pipe Support
Bracket No. 1
56 (571, 41)
Exhaust Pipe Assy Front
25 (250, 18)
21 (214, 15)
62 (633, 46)
Fan Belt Adjusting
Bar Bracket
Exhaust Pipe
Gasket
Exhaust Pipe
Gasket
25 (250, 18)
Exhaust Pipe No. 1
Support Bracket Rear
62 (633, 46)
Exhaust Pipe No. 1 Support Bracket Front
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Exhaust Pipe
Gasket
33 (337, 24)
33 (337, 24)
A84922
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2311
17-7
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
Oil Pump Assy
43 (439, 32)
20 (199, 14)
O-ring
Crankshaft Position Sensor
8.0 (82, 71 in.⋅lbf)
8.0 (80, 71 in.⋅lbf)
Oil Pump Seal
20 (199, 14)
Oil Pan Sub-assy
20 (199, 14)
8.0 (82, 71 in.⋅lbf)
20 (199, 14)
20 (199, 14)
8.0 (82, 71 in.⋅lbf)
20 (199, 14)
Gasket
20 (199, 14)
37 (379, 27)
Oil Strainer Sub-assy
Flywheel Housing
Under Cover
8.0 (82, 71 in.⋅lbf)
8.0 (82, 71 in.⋅lbf)
Gasket
7.8 (80, 69 in.⋅lbf)
45 (459, 33)
Oil Pan Drain Plug
8.0 (82, 71 in.⋅lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
Oil Pan Sub-assy No. 2
Non-reusable part
A86564
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2312
17-8
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
Oil Pump Cover
10 (105, 8)
x10
Driven Rotor
Drive Rotor
Oil Pump Assy
Oil Pump Relief Valve
Oil Pump Relief Valve Spring
49 (500, 36)
Oil Pump Relief Valve Plug
N·m (kgf·cm, ft·lbf) : Specified torque
A80109
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2313
17-9
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
170HN-02
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
DISCONNECT BATTERY NEGATIVE TERMINAL
DRAIN ENGINE OIL (See page 17-20 )
REMOVE FRONT WHEEL RH
REMOVE ENGINE UNDER COVER NO.1
REMOVE ENGINE UNDER COVER NO.2
REMOVE FRONT FENDER APRON SEAL RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
REMOVE GENERATOR ASSY (See page 19-21 )
REMOVE VANE PUMP V BELT (See page 14-5 )
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
REMOVE TIMING BELT NO.1 COVER
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
REMOVE TIMING BELT GUIDE NO.2
REMOVE TIMING BELT (See page 14-79 )
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
REMOVE TIMING BELT IDLER SUB-ASSY NO.1 (See page 16-13 )
REMOVE CRANKSHAFT TIMING PULLEY (See page 14-138 )
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2 )
REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9 )
REMOVE OIL LEVEL GAGE GUIDE (See page 14-133 )
29.
(a)
REMOVE GENERATOR BELT ADJUSTING BAR
Remove the 2 bolts and 2 nuts, then remove the adjusting
bar.
A52889
Author:
Date:
2314
17-10
LUBRICATION
30.
(a)
(b)
(b)
-
OIL PUMP ASSY (3MZ-FE)
SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
Remove the bolt and nut, then remove the adjusting bar
bracket.
Remove the 3 bolts and compressor.
(b)
HINT:
Secure the hoses off to the side instead of detaching.
(a)
(b)
(a)
Adjusting Bar Bracket
A78827
31.
(a)
REMOVE COMPRESSOR MOUNTING BRACKET
NO.1
Remove the 2 bolts and compressor mounting bracket.
A36749
32.
(a)
SEPARATE ENGINE MOUNTING INSULATOR FR
Remove the 3 nuts and bolt, then separate the engine
mounting insulator FR.
NOTICE:
Do not remove the engine mounting insulator FR.
33. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the bolt, then disconnect the power steering return hose clamp from the frame.
A60523
(b)
(c)
(d)
Remove the 4 nuts.
Place a wooden block on a jack underneath the engine.
Jack up the engine, then remove the engine mounting insulator RH.
NOTICE:
Be careful not to damage the oil pan.
A86600
Author:
Date:
2315
17-1 1
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
34.
(a)
REMOVE ENGINE MOUNTING BRACKET RH
Remove the 4 bolts and nut, then remove the bracket.
35.
(a)
REMOVE OIL PAN SUB-ASSY NO.2
Remove the 10 bolts and 2 nuts.
A52015
A36750
(b)
SST
SST
A00019
36.
(a)
Insert the blade of SST between the oil pan No. 1 and oil
pan No. 2, then cut off the sealer and remove the oil pan
No. 2.
SST 09032-00100
NOTICE:
Be careful not to damage the contact surface of the oil
pan No. 1 where the oil pan No. 2 is mounted.
Do not damage the flange portion of the oil pan No. 2
when removing.
REMOVE OIL STRAINER SUB-ASSY
Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
37. REMOVE OIL PAN SUB-ASSY
(a) Remove the 2 bolts and nut, then disconnect the engine
oil level sensor connector.
(b)
Remove the 2 bolts and flywheel housing under cover.
A78379
Author:
Date:
2316
17-12
LUBRICATION
(c)
-
OIL PUMP ASSY (3MZ-FE)
Loosen and remove the 17 bolts and 2 nuts uniformly.
A36754
(d)
Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the oil pan
and cylinder block.
B04137
38.
(a)
(b)
REMOVE CRANKSHAFT POSITION SENSOR
Disconnect the crankshaft position sensor connector.
Remove the bolt and crankshaft position sensor.
39.
(a)
(b)
(c)
REMOVE OIL PUMP ASSY
Remove the 9 bolts.
Using a screwdriver, remove the oil pump by prying between the oil pump and bearing cap.
Remove the O-ring.
A51990
40.
(a)
INSTALL OIL PUMP SEAL
Using SST and a hammer, tap in the new oil seal until its
surface is flush with the oil pump body edge.
SST 09223-00010
NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.
SST
A78754
Author:
Date:
2317
17-13
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
41.
(a)
INSTALL OIL PUMP ASSY
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.
A36784
(c)
B
A
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.
Seal Packing
A
B
Seal Width
2 to 3 mm
(0.08 to 0.12 in.)
C
A78725
(d)
Align the key of the oil pump drive gear with the keyway
located on the crankshaft, then slide the oil pump into
place.
A36785
Author:
Date:
2318
17-14
LUBRICATION
(e)
A
B
C
A
A
B
A
A
-
OIL PUMP ASSY (3MZ-FE)
Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for bolt A
20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) for bolt B
43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) for bolt C
A
A51990
42.
INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
43. INSTALL OIL PAN SUB-ASSY
(a) Remove any old seal packing from the contact surface.
(b)
Apply a continuous bead of seal packing (Diameter 3 to
4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Region ”X”
Region ”Y”
NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the outer side of the bolt holes
in the region ”X”.
Apply seal packing to the inner side of the bolt holes
in the region ”Y”.
Install the oil pan within 3 minutes after applying seal
packing.
B
A
Do not expose the seal packing to engine oil within 2
hours after installing.
Seal Packing
B
A
(c) Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts uniformly in several steps.
Torque:
8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for 10 mm head
Seal Width
20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) for 12 mm head
3 to 4 mm
(0.12 to 0.16 in.) A78726
37 N⋅m (379 kgf⋅cm, 27 ft⋅lbf) for 14 mm head
(d) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf)
(e) Install the engine oil level sensor connector with the 2
bolts and nut.
Torque: 8.4 N⋅m (85 kgf⋅cm, 74 in.⋅lbf)
44. INSTALL OIL STRAINER SUB-ASSY
(a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
Author:
Date:
2319
17-15
LUBRICATION
45.
(a)
-
OIL PUMP ASSY (3MZ-FE)
INSTALL OIL PAN SUB-ASSY NO.2
Remove any old seal packing from the contact surface.
(b)
Apply a continuous bead of seal packing (Diameter 4 to
5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pan within 3 minutes after applying seal
packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
Seal Packing
A
B
A
Seal Width
4 to 5 mm
(0.16 to 0.20 in.)
B
A78727
A
C
46.
INSTALL ENGINE MOUNTING BRACKET RH
Torque:
54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) for bolt A
54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) for nut B
43 N⋅m (439 kgf⋅cm, 32 ft⋅lbf) for bolt C
47.
INSTALL ENGINE MOUNTING INSULATOR RH
Torque:
95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) for nut A
87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) for nut B
B
A
A
A78825
A
B
B
B
A86600
Author:
Date:
2320
17-16
LUBRICATION
48.
A
-
OIL PUMP ASSY (3MZ-FE)
INSTALL ENGINE MOUNTING INSULATOR FR
Torque:
87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) for bolt A
52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf) for nut B
B
B
B
49.
A60523
INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf)
50.
(a)
(a)
(a)
(b)
(b)
(a)
(b)
Adjusting Bar Bracket
A78827
51.
(a)
A
C
INSTALL COMPRESSOR AND MAGNETIC CLUTCH
Install the compressor with the 3 bolts.
Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf)
Install the adjusting bar bracket with the bolt and nut.
Torque:
25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) for bolt
26 N⋅m (260 kgf⋅cm, 19 ft⋅lbf) for nut
INSTALL GENERATOR BELT ADJUSTING BAR
Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for nut A
18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for bolt B
8.4 N⋅m (85 kgf⋅cm, 74 in.⋅lbf) for bolt C
B
A78828
52.
53.
54.
55.
INSTALL
INSTALL
INSTALL
INSTALL
OIL LEVEL GAGE GUIDE (See page 14-133 )
EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9 )
EXHAUST PIPE ASSY FRONT (See page 15-2 )
EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
Author:
Date:
2321
17-17
LUBRICATION
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
-
OIL PUMP ASSY (3MZ-FE)
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
INSTALL CRANKSHAFT TIMING PULLEY (See page 14-138 )
INSTALL TIMING BELT IDLER SUB-ASSY NO.1 (See page 16-13 )
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
INSPECT TIMING BELT (See page 14-79 )
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
INSTALL VANE PUMP V BELT (See page 14-5 )
INSTALL GENERATOR ASSY (See page 19-21 )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
INSTALL FRONT WHEEL RH (See page 14-5 )
ADD ENGINE OIL (See page 17-20 )
CHECK FOR ENGINE OIL LEAKS
CHECK FOR EXHAUST GAS LEAKS
SYSTEM INITIALIZATION (See page 19-15 )
Author:
Date:
2322
17-18
LUBRICATION
-
OIL PUMP ASSY (3MZ-FE)
170F4-03
OVERHAUL
1.
(a)
REMOVE OIL PUMP RELIEF VALVE
Remove the plug, spring and relief valve.
2.
(a)
(b)
A33002
INSPECT OIL PUMP RELIEF VALVE
Apply a light coat of engine oil to the relief valve.
Check that the relief valve falls smoothly into the valve
hole by its own weight.
3.
INSPECT OIL PUMP ASSY
(a) Remove the oil pump cover.
(1) Remove the 10 screws and oil pump cover.
(b) Remove the oil pump rotor set.
NOTICE:
Do not change the combination or turn over the 2 removed
rotors.
(c) Inspect the oil pump rotor set.
(1) Apply a light coat of engine oil to the oil pump rotor
set, then place them into the oil pump body. Check
that the rotors revolve smoothly.
(d) Inspect the tip clearance.
(1) Using a feeler gauge, measure the clearance between the drive and driven rotor tips.
Standard tip clearance:
0.06 to 0.18 mm (0.0024 to 0.0071 in.)
Maximum tip clearance: 0.35 mm (0.0138 in.)
A33003
(e)
Inspect the body clearance.
(1) Using a feeler gauge, measure the clearance between the driven rotor and body.
Standard body clearance:
0.250 to 0.325 mm (0.0098 to 0.0128 in.)
Maximum body clearance: 0.30 mm (0.0118 in.)
(f)
Inspect the side clearance.
(1) Using a feeler gauge and precision straight edge,
measure the clearance between the rotors and precision straight edge.
Standard side clearance:
0.03 to 0.09 mm (0.0012 to 0.0035 in.)
Maximum side clearance: 0.15 mm (0.0059 in.)
A33004
A33005
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2323
17-19
LUBRICATION
(g)
Marks
(h)
-
OIL PUMP ASSY (3MZ-FE)
Install the oil pump rotor set.
(1) Apply a light coat of engine oil to the oil pump gear
set, then place it into the pump body with the marks
facing the pump body cover side.
Install the oil pump cover.
(1) Install the 10 screws and oil pump cover.
Torque: 10 N⋅m (105 kgf⋅cm, 8 ft⋅lbf)
A78905
4.
(a)
(b)
INSTALL OIL PUMP RELIEF VALVE
Apply a light coat of engine oil to the relief valve, then insert the relief valve and spring into the pump
body hole.
Install the oil pump relief valve plug.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2324
17-20
LUBRICATION
-
OIL FILTER SUB-ASSY (3MZ-FE)
OIL FILTER SUB-ASSY (3MZ-FE)
170F5-03
REPLACEMENT
CAUTION:
Prolonged and repeated contact with engine oil will cause removal of natural oils from the skin,
leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
Precautions should be taken when replacing engine oil to minimize the risk of your skin making
contact with used engine oil. Wear protective clothing and gloves. Wash your skin thoroughly
with soap and water, or use water-less hand cleaner to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
For environmental protection used oil and used oil filter must be disposed of at designated disposal sites.
1.
REMOVE ENGINE UNDER COVER NO.1
2.
DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, then drain the oil into a container.
(c) Clean and install the oil drain plug with a new gasket.
Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf)
3.
(a)
SST
4.
(a)
(b)
(c)
REMOVE OIL FILTER SUB-ASSY
Using SST, remove the oil filter.
SST 09228-07501
INSTALL OIL FILTER SUB-ASSY
Check and clean the oil filter installation surface.
Apply clean engine oil to the gasket of a new oil filter.
Lightly screw the oil filter into place, then tighten it until the
gasket contacts the seat.
A78720
(d)
Using SST, tighten it an additional 3/4 turn.
SST 09228-07501
SST
Additional
3/4 Turn
P12582
5.
(a)
6.
ADD ENGINE OIL
Fill with fresh engine oil.
Capacity:
Drain and refill with oil filter change
4.7 liters (5.0 US qts, 4.1 lmp. qts)
Drain and refill without oil filter change
4.5 liters (4.8 US qts, 4.0 lmp. qts)
Dry fill
5.5 liters (5.8 US qts, 4.8 lmp. qts)
CHECK FOR ENGINE OIL LEAKS
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2325
18-1
IGNITION
-
IGNITION SYSTEM (3MZ-FE)
IGNITION SYSTEM (3MZ-FE)
1809A-01
ON-VEHICLE INSPECTION
NOTICE:
”Cold” and ”Hot” in this section mean temperature of the coils themselves. ”Cold” is from -10C
(14F) to 50C (122F) and ”Hot” is from 50C (122F) to 100C (212F).
1.
INSPECT IGNITION COIL AND SPARK TEST
(a) Check the DTCs.
NOTICE:
If a DTC is present, perform troubleshooting in accordance with a procedure for that DTC.
(b) Check that a spark occurs.
(1) Remove the 6 ignition coils (see page 18-7 ).
(2) Using a spark plug wrench 16 mm, remove the 6 spark plugs.
Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf)
(3) Install the spark plugs to each ignition coil, then connect the ignition coil connectors.
(4) Disconnect the 6 fuel injector connectors.
(5) Ground the spark plugs.
(6) Check that the spark plug occurs at each spark plug while the engine is being cranked.
NOTICE:
Be sure to ground the spark plugs when checking.
Replace the ignition coil if physical impact is felt.
Do not crank the engine for more than 2 seconds.
If a spark does not occur, perform the following test.
1
SPARK TEST
NG
2
CHECK CONNECTION OF IGNITION COIL CONNECTOR
NG
CONNECT SECURELY
OK
3
REPLACE IT WITH NORMAL IGNITION COIL AND PERFORM SPARK TEST AGAIN
OK
REPLACE IGNITION COIL ASSY
(See page 18-7 )
NG
4
(a)
(b)
CHECK POWER SUPPLY TO IGNITION COIL
Turn the ignition switch ON.
Check that there is battery voltage at the ignition coil positive (+) terminal.
NG
CHECK WIRE HARNESS (BETWEEN IGNITION
(START) SWITCH ASSY AND IGNITION COIL
ASSY)
OK
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2326
18-2
IGNITION
5
-
IGNITION SYSTEM (3MZ-FE)
INSPECT VVT SENSOR (See page 18-3 )
NG
REPLACE VVT SENSOR (See page 18-5 )
OK
6
INSPECT CRANKSHAFT POSITION SENSOR (See page 18-3 )
NG
REPLACE CRANKSHAFT POSITION SENSOR
(See page 18-6 )
OK
7
INSPECT IGT SIGNAL FROM ECM (See page 05-34 )
NG
REPLACE ECM (See page 10-22 )
OK
REPAIR WIRE HARNESS (BETWEEN IGNITION COIL ASSY AND IGNITION (START)
SWITCH ASSY)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2327
18-3
IGNITION
-
IGNITION SYSTEM (3MZ-FE)
1809B-01
INSPECTION
1.
INSPECT SPARK PLUG
NOTICE:
Do not use a wire brush to clean the spark plug.
Do not try to adjust the electrode gap of a used spark
plug.
(a)
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the insulation and body ground.
Resistance: 10 MΩ or more
If the resistance is not as specified, check the electrode gap.
Ohmmeter
Ground
IG0147
(b)
Alternative inspection method.
(1) Quickly accelerate the engine speed to 4,000 rpm
5 times.
(2) Remove the spark plug.
(3) Visually check the spark plug.
(4) If the electrode is dry...OK.
(5) If the electrode is wet...Proceed to step (c).
(6) Reinstall the spark plug.
B01301
(c)
Check the appearance.
(1) Check the thread and insulator of the spark plug for
damage.
If damaged, replace the spark plug.
Recommended spark plug:
Supplier
Type
DENSO
SK20R11
NGK
IFR6A11
IG0316
(d)
Spark Plug Gauge
1.0 to 1.1 mm
(0.039 to 0.043 in.)
B02101
Inspect the electrode gap.
(1) Using a spark plug gauge, measure the electrode
gap.
Maximum electrode gap of used spark plug:
1.3 mm (0.051 in.)
If the electrode gap is greater than maximum, replace the spark
plug.
Electrode gap of new spark plug:
1.0 to 1.1 mm (0.039 to 0.043 in.)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2328
18-4
IGNITION
-
IGNITION SYSTEM (3MZ-FE)
(e) Clean the spark plugs.
If the electrode has traces of wet carbon, clean the electrode
with a spark plug cleaner, then dry it.
Air pressure: Blow 588 kPa (6 kgf/cm2, 85 psi)
Duration: 20 seconds or shorter
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
B62019
2.
(a)
Ohmmeter
INSPECT VVT SENSOR
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance:
Tester Connection
A84690
A84688
1 (G+) - 2 (G-)
835 to 1,400 Ω at cold
1 (G+) - 2 (G-)
1,060 to 1,645 Ω at hot
NOTICE:
”Cold” and ”Hot” mean temperature of the coils themselves. ”Cold” is from -10C (14F) to 50C (122F) and
”Hot” is from 50C (122F) to 100C (212F).
If the resistance is not as specified, replace the VVT sensor.
3.
(a)
Ohmmeter
Specified Condition
INSPECT CRANKSHAFT POSITION SENSOR
Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance:
Tester Connection
Specified Condition
1 (NE+) - 2 (NE-)
1,630 to 2,740 Ω at cold
1 (NE+) - 2 (NE-)
2,065 to 3,225 Ω at hot
NOTICE:
”Cold” and ”Hot” mean temperature of the coils themselves. ”Cold” is from -10C (14F) to 50C (122F) and
”Hot” is from 50C (122F) to 100C (212F).
If the resistance is not as specified, replace the crankshaft position sensor.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2329
18-5
IGNITION
-
VVT SENSOR (3MZ-FE)
VVT SENSOR (3MZ-FE)
1809C-01
REPLACEMENT
1.
2.
3.
4.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
REMOVE AIR CLEANER ASSY (See page 19-5 )
5.
REMOVE VVT SENSOR
(a) Remove the 2 VVT sensor connectors.
(b) Remove the 2 bolts, then remove the 2 VVT sensors.
HINT:
The VVT sensor is installed with the bolt.
RH Bank:
(b)
(a)
A79541
LH Bank:
(b)
(a)
A78529
6.
(a)
(b)
INSTALL VVT SENSOR
Apply a light coat of engine oil to the O-ring on each VVT sensor.
Install the 2 VVT sensors with the 2 bolts.
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
NOTICE:
Be careful not to twist the O-ring.
(c) Connect the 2 VVT sensor connectors.
7.
INSTALL AIR CLEANER ASSY (See page 19-5 )
8.
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
9.
INSTALL RADIATOR LOWER AIR DEFLECTOR
10. CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
11. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
12. CHECK FOR ENGINE OIL LEAKS
13. SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2330
18-6
IGNITION
-
CRANKSHAFT POSITION SENSOR (3MZ-FE)
CRANKSHAFT POSITION SENSOR (3MZ-FE)
1809D-01
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
(a)
REMOVE ENGINE UNDER COVER NO.1
Remove the 3 clips and 5 screws, then remove the engine
under cover No. 1.
3.
(a)
REMOVE FRONT FENDER APRON SEAL RH
Remove the clip and 2 bolts, then remove the front fender
apron seal.
4.
(a)
(b)
REMOVE CRANKSHAFT POSITION SENSOR
Remove the crankshaft position sensor connector.
Remove the bolt, then remove the crankshaft position
sensor.
A86232
A86233
(a)
(b)
A79763
5.
6.
7.
8.
9.
INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
INSTALL FRONT FENDER APRON SEAL RH
INSTALL ENGINE UNDER COVER NO.1
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2331
18-7
IGNITION
-
IGNITION COIL ASSY (3MZ-FE)
IGNITION COIL ASSY (3MZ-FE)
1809E-02
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
DRAIN ENGINE COOLANT (RH BANK) (See page 10-1 1)
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS, RH BANK)
(See page 16-9 )
REMOVE V-BANK COVER SUB-ASSY (See page 16-9 )
REMOVE AIR CLEANER CAP SUB-ASSY (RH BANK) (See page 16-9 )
REMOVE EMISSION CONTROL VALVE SET (RH BANK) (See page 11-13 )
REMOVE INTAKE AIR SURGE TANK (RH BANK) (See page 11-13 )
RH Bank:
(b)
(a)
(b)
(a) (b)
(a)
8.
REMOVE IGNITION COIL ASSY
(a) Disconnect the 6 connectors.
(b) Remove the 6 bolts, then remove the 6 ignition coils.
HINT:
The ignition coil is installed with the bolt.
A86234
LH Bank:
(a)
(b)
(b)
(a)
(b)
(a)
A86235
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
INSTALL IGNITION COIL ASSY
Torque: 8.0 N⋅m (80 kgf⋅cm, 71 in.⋅lbf)
INSTALL INTAKE AIR SURGE TANK (RH BANK) (See page 11-13 )
INSTALL EMISSION CONTROL VALVE SET (RH BANK) (See page 11-13 )
INSTALL AIR CLEANER CAP SUB-ASSY (RH BANK) (See page 16-9 )
CHECK CONNECTION OF VACUUM HOSE (RH BANK) (See page 14-29 )
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
ADD ENGINE COOLANT (RH BANK) (See page 10-1 1)
CHECK FOR ENGINE COOLANT LEAKS (RH BANK) (See page 16-1 )
INSTALL V-BANK COVER SUB-ASSY (See page 16-9 )
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS, RH BANK)
(See page 16-9 )
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Date:
2332
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