2005 LEXUS ES300 check engine

P19471
Compression Gauge
- ENGINE MECHANICALENGINE (3MZ-FE)
14-3
2095 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the intake air surge tank (see page 11-13).
(c) Disconnect the injector connectors.
(d) Remove the ignition coils.
(e) Remove the spark plugs.
(f) 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 compres-
sion pressure.
Compression pressure:
1.5 MPa (15.3 kgf/cm
2, 218 psi)
Minimum pressure:
1.0 MPa (10.2 kgf/cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 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 pos-
sible.
(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 pre-
scribed 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).

141J7-02
A78541
(b)
(b)
(b)(a)
(a)
A36719
P18805
- ENGINE MECHANICALVALVE CLEARANCE (3MZ-FE)
14-7
2099 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
VALVE CLEARANCE (3MZ-FE)
ADJUSTMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT (See page 16-9)
3. REMOVE FRONT FENDER APRON SEAL RH
4. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
5. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
6. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
7. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
8. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
9. REMOVE RADIATOR HOSE INLET
10. REMOVE IGNITION COIL ASSY
11. REMOVE CYLINDER HEAD COVER SUB-ASSY
(a) Remove the 2 engine wire harness clamps.
(b) Remove the 3 nuts, then disconnect the engine wire har-
ness.
(c) Remove the 9 bolts and cylinder head cover.
12. REMOVE CYLINDER HEAD COVER SUB-ASSY LH
(a) Using an E6 Torx) socket wrench, remove the 2 bolts and
disconnect the engine wire harness protector.
(b) Remove the 9 bolts and cylinder head cover.
13. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft pulley, then align the timing notch with
the timing mark º0º 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.

A78672
SST (B)
SST (A)
A78673
: Seal Packing
Front
A78674
: Seal Packing
Front
- ENGINE MECHANICALVALVE CLEARANCE (3MZ-FE)
14-13
2105 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(h) Place a new adjusting shim on the valve lifter with the im-
printed 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.
15. INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) 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 NVm (80 kgfVcm, 71 in.Vlbf)
(c) Install the engine wire harness with the 3 nuts.
Torque: 8.4 NVm (85 kgfVcm, 74 in.Vlbf)
16. INSTALL CYLINDER HEAD COVER SUB-ASSY LH
(a) 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 NVm (80 kgfVcm, 71 in.Vlbf)
(c) Using an E6 Torx) socket wrench, install the engine wire
harness protector with the 2 bolts.
Torque: 8.4 NVm (85 kgfVcm, 74 in.Vlbf)
17. INSTALL IGNITION COIL ASSY
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
18. INSTALL INTAKE AIR SURGE TANK (See page 11-13)
19. INSTALL EMISSION CONTROL VALVE SET (See page 11-13)
20. INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
21. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
22. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
23. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
24. ADD ENGINE COOLANT (See page 16-9)
25. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)

A84925N´m (kgf´cm, ft´lbf)
: Specified torque
58 (591, 43)
28 (286, 21)
8.4 (85, 74 in.Vlbf)
43 (438, 32)
18 (178, 13)
18 (184, 13)
9.8 (100, 7)
64 (653, 47)
64 (653, 47)
23 (235, 17)
25 (250, 18)
V Belt No. 1
Generator Bracket No. 2
Engine Moving
Control Rod
Generator Assy
Generator Belt Adjusting BarEngine Mounting
Stay No. 2 RH
Fuel Vapor
Feed Hose No. 1
Union to Check
Valve Hose
Heater Inlet
Water Hose
Fuel Pipe
Sub-assy No. 1
Fuel Pipe Clamp No. 1
Transmission Control
Cable Assy
Heater Outlet
Water Hose
Radiator Hose Outlet
Steering Gear Outlet
Return Tube
Radiator Hose Inlet
Oil Reservoir to Pump Hose No. 1
Fan Belt Adjusting
Bar Bracket
25 (250, 18)
25 (250, 18)15 (153, 11)
Oil Cooler Inlet Hose
Oil Cooler Outlet Hose
Radio Setting
Condenser
Compressor and
Magnetic Clutch
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-17
2109 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

141J9-02
A60072
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-29
2121 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER NO.1
5. REMOVE ENGINE UNDER COVER NO.2
6. REMOVE FRONT FENDER APRON SEAL RH
7. DRAIN ENGINE COOLANT (See page 16-9)
8. DRAIN ENGINE OIL (See page 17-20)
9. DRAIN AUTOMATIC TRANSAXLE FLUID (See page 30-8)
10. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
11. REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5)
12. REMOVE BATTERY
13. REMOVE BATTERY TRAY
14. REMOVE AIR CLEANER INLET ASSY (See page 19-5)
15. REMOVE AIR CLEANER ASSY (See page 19-5)
16. REMOVE AIR CLEANER BRACKET (See page 19-5)
17. REMOVE AIR CLEANER INLET NO.1 (See page 19-5)
18. REMOVE INTAKE AIR RESONATOR SUB-ASSY
(a) Remove the clip and bolt, then remove the intake air resonator.
19. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
20. REMOVE GENERATOR ASSY (See page 19-21)
21. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
22. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
23. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
24. REMOVE GENERATOR BELT ADJUSTING BAR (See page 17-9)
25. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (See page 17-9)
26. SEPARATE TRANSMISSION CONTROL CABLE ASSY (See page 40-44)
27. DISCONNECT UNION TO CHECK VALVE HOSE
28. DISCONNECT FUEL VAPOR FEED HOSE NO.1
29. DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See page 11-1)
30. DISCONNECT HEATER INLET WATER HOSE
31. DISCONNECT HEATER OUTLET WATER HOSE
32. DISCONNECT RADIATOR HOSE INLET
33. DISCONNECT RADIATOR HOSE OUTLET
34. DISCONNECT OIL COOLER INLET HOSE
35. DISCONNECT OIL COOLER OUTLET HOSE
36. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1

A86570
From Canister
Vacuum Tank
Actuator Actuator
Vacuum Surge
TankVSV for EVAP
VSV for ACIS
Engine Mounting
Insulator FR
VSV for Active Control
Engine MountCapVSV Vacuum Hose Routing Diagram:
14-38
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2130 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
140. CONNECT TRANSMISSION CONTROL CABLE ASSY (See page 40-44)
141. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See page 17-9)
142. INSTALL GENERATOR BELT ADJUSTING BAR (See page 17-9)
143. INSTALL GENERATOR BRACKET NO.2 (See page 14-79)
144. INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
145. INSTALL ENGINE MOVING CONTROL ROD (See page 14-79)
146. INSTALL GENERATOR ASSY (See page 19-21)
147. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
148. INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1)
149. INSTALL INTAKE AIR RESONATOR SUB-ASSY
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
150. INSTALL AIR CLEANER INLET NO.1 (See page 19-5)
151. INSTALL AIR CLEANER BRACKET (See page 19-5)
152. INSTALL AIR CLEANER ASSY (See page 19-5)
153. INSTALL AIR CLEANER INLET ASSY (See page 19-5)
154. CHECK CONNECTION OF VACUUM HOSE
155. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
156. INSTALL FRONT WHEELS (See page 14-5)

- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-39
2131 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
157. ADD AUTOMATIC TRANSAXLE FLUID
158. ADD ENGINE OIL (See page 17-20)
159. ADD COOLANT (See page 16-9)
160. ADD POWER STEERING FLUID
161. BLEED POWER STEERING FLUID
162. INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40-1)
163. CHECK FOR ENGINE OIL LEAKS
164. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
165. CHECK POWER STEERING FLUID LEAKAGE
166. INSPECT FOR FUEL LEAKS
167. CHECK FOR EXHAUST GAS LEAKS
168. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-5)
169. INSPECT STEERING WHEEL CENTER POINT
170. INSPECT IGNITION TIMING (See page 14-1)
SST 09843-18040
171. INSPECT ENGINE IDLE SPEED (See page 14-1)
172. INSPECT CO/HC (See page 14-1)
173. CHECK ABS SPEED SENSOR SIGNAL (See page 05-420, 05-471)
174. SYSTEM INITIALIZATION (See page 19-15)

A78326
Turn
A05052
A52840
A78327
Approximately 60
Turn
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-41
2133 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
18. REMOVE TIMING BELT
(a) 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.
(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.
(b) If reusing the timing belt, check that there are 3 installa-
tion 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 remov-
ing.
(c) Set the No. 1 cylinder to approximately 60 BTDC/com-
pression.
(1) Turn the crankshaft counterclockwise by approxi-
mately 60.
NOTICE:
If the timing belt is disengaged, having the crankshaft
pulley set at the wrong angle can cause contact of the pis-
ton head with the valve head when removing the camshaft
timing pulley and camshaft, which causes damage. So al-
ways set the crankshaft pulley at the correct angle.
(d) Remove the timing belt tensioner.
NOTICE:
Do not reinstall the tensioner with its plunger extended.