Page 438 of 969
A78739
Align
A05204
A78740
101
23
4
5
6
7
8
9 14-62
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2154 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears.
(c) Place the camshaft on the cylinder head.
(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(f) Using several steps, tighten the 10 bearing cap bolts uni-
formly in the sequence shown in the illustration.
Torque: 16 NVm (163 kgfVcm, 12 ftVlbf)
(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.
Page 439 of 969
A78741
90
A78742
Front
A78737Seal Packing
A05209
A78743
10
1
23
4
5
6
7
8
9
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-63
2155 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Place the No. 4 camshaft at a 90 angle of the timing mark
(1 dot marks) on the cylinder head.
(c) Apply multi-purpose grease to a new oil seal lip.
(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 sur-
face.
(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 ap-
plying seal packing.
Do not expose the seal packing to engine oil within 2
hours after installing.
(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(i) Using several steps, tighten the 10 bearing cap bolts uni-
formly in the sequence shown in the illustration.
Torque: 16 NVm (163 kgfVcm, 12 ftVlbf)
Page 440 of 969
A78744
Align
A05214
A78745
10
1
2
3
45
6
7
8
9
A78746
Inward
Sensor 14-64
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2156 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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) Align the timing marks (1 dot marks) of the camshaft drive
and driven gears.
(c) Place the camshaft on the cylinder head.
(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(f) Using several steps, tighten the 10 bearing cap bolts uni-
formly in the sequence shown in the illustration.
Torque: 16 NVm (163 kgfVcm, 12 ftVlbf)
(g) Remove the service bolt.
80. INSTALL CRANKSHAFT TIMING PULLEY
(a) 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 NVm (82 kgfVcm, 71 in.Vlbf)
Page 441 of 969
A78535
A78747
SST
Additional
3/4 Turn
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-65
2157 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
81. INSTALL WATER PUMP ASSY
(a) Install a new gasket and the water pump with the 3 bolts
and 3 nuts.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
82. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to a new O-ring, then install it to the level gage guide.
(b) Install the level gage guide.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
83. INSTALL OIL FILTER SUB-ASSY
(a) Using a socket hexagon wrench 12, install the oil filter
union.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
(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) Using SST, tighten it by an additional 3/4 turn.
SST 09228-07501
84. INSTALL TIMING BELT IDLER BRACKET
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
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, re-
pair 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.
Page 442 of 969
A78748
Seal Packing
Gasket
A78749
E
F
Joining
Line D
G
Gasket Joining Portion:
Seal Packing E
Joining
Line
A78750
FrontFront
Belt
GuideBelt
Guide
14-66
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2158 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) 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) 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 uni-
form.
HINT:
GasketDEFG
Length335 mm
(13.19 in.)180 mm
(7.09 in.)133 mm
(5.24 in.)72 mm
(2.83 in.)
(3) If there is a gap between the ends of the gasket, ap-
ply 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 NVm (87 kgfVcm, 75 in.Vlbf)
86. INSTALL CAMSHAFT TIMING PULLEY
(a) Pay attention to the orientation of the belt guide. Install
the camshaft timing pulley with the belt guide properly ori-
ented, then tighten the bolt temporarily.
HINT:
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.
Page 443 of 969
A78703
SST
A78704
SST
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-67
2159 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 NVm (1,275 kgfVcm, 92 ftVlbf)
(c) Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 NVm (1,275 kgfVcm, 92 ftVlbf)
87. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 NVm (438 kgfVcm, 32 ftVlbf)
88. INSTALL TIMING BELT IDLER SUB-ASSY NO.1
(a) Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot
bolt.
Torque: 34 NVm (347 kgfVcm, 25 ftVlbf)
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.
Page 444 of 969
A82349
Approximately 60
Turn
A78751
SST
A05062
A52840
A78702(1) (2)
(3) (4)
(5)
(6) 14-68
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2160 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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.
(f) Using SST, turn the crankshaft pulley, then align the tim-
ing 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) Align the front mark on the timing belt so it faces forward.
(i) Align the installation mark on the timing belt with the tim-
ing mark of the crankshaft timing pulley.
(j) Align the installation marks on the timing belt with the tim-
ing marks of the camshaft timing pulleys.
(k) Install the timing belt in this order.
1stCrankshaft timing pulley
2ndWater pump pulley
3rdLH camshaft timing pulley
4thNo. 2 idler pulley
5thRH camshaft timing pulley
6thNo. 1 idler pulley
Page 445 of 969
A36238
A78326
Turn
A05052
A36239
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-69
2161 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
90. INSTALL TIMING BELT TENSIONER ASSY
(a) 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. Alter-
nately tighten the 2 bolts.
Torque: 27 NVm (280 kgfVcm, 20 ftVlbf)
NOTICE:
Be sure to tighten the bolts uniformly. Installing the ten-
sioner 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.
(h) Check that the timing marks of the RH and LH timing pul-
leys 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.
91. INSTALL TIMING BELT GUIDE NO.2
(a) Install the timing belt guide with the cup side facing the en-
gine front.