2005 LEXUS ES300 Repair Manual

A78668
LH Bank:EX
IN
5
6
1
4 Front
5
1 RH Bank:
4
6
IN
EX
A78669
Upward
Notch
A78670
Front of No. 1 and No. 2 Cylinders:
Others:
SST (A)
SST (B)
SST (B)
SST (A)
7
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(e) Turn the crankshaft by 2/3 of a revolution (240), then in-
spect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance be-
tween 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. 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.
(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)
HINT:

Apply SST (B) at a slight angle on the side marked with
º9º or º7º 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

A78671
SST (B)
Magnetic Finger
EM0494
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
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(d) Using a small screwdriver and magnetic finger, remove
the adjusting shim.
(e) Using a micrometer, measure the thickness of the re-
moved shim.
(f) Calculate the thickness of a new shim so that the valve
clearance comes within the specified value.
AThickness of new shim
BThickness of used shim
CMeasured 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.))
(g) Select a new shim with a thickness which is as close to the
calculated values as possible.
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.

V00719
Adjusting Shim Selection Chart (Intake)
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.New Shim Thickness mm (in.)
HINT: New shims have the thickness in millimeters
imprinted on the face.Thickness
Thickness Shim
No. Shim
No.
Installed Shim Thickness
Measured Clearance
mm (in.)mm (in.)
- ENGINE MECHANICALVALVE CLEARANCE (3MZ-FE)
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V00720
Adjusting Shim Selection Chart (Exhaust)
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.New Shim Thickness mm (in.)
ThicknessThickness Shim
No. Shim
No.
HINT: New shims have the thickness in millimeters
imprinted on the face.
Installed Shim Thickness
Measured Clearance
mm (in.)mm (in.)
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A78672
SST (B)
SST (A)
A78673
: Seal Packing
Front
A78674
: Seal Packing
Front
- ENGINE MECHANICALVALVE CLEARANCE (3MZ-FE)
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(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)

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26. SYSTEM INITIALIZATION (See page 19-15)

141J8-01
A84923
N´m (kgf´cm, ft´lbf)
: Specified torquex3
V-bank Cover Sub-assy
7.9 (81, 70 in.Vlbf)
Front Fender Apron Seal RH
Clip x7
Clip
Radiator Lower Air Deflector
Engine Under Cover No. 1
Engine Under Cover No. 2
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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PARTIAL ENGINE ASSY (3MZ-FE)
COMPONENTS

A84924: Specified torqueBattery Clamp
Sub-assy
Battery
Battery Tray
VSV Connector
Air Cleaner
Inlet Assy
Air Cleaner Inlet
No. 1
Air Cleaner Bracket Air Cleaner CaseAir Cleaner
Filter Element
Sub-assy Air Cleaner Cap
Sub-assyMass
Air Flow Meter
Connector Vacuum Hose
5.0 (51, 44 in.Vlbf)
x2
x2 x3
5.0 (51, 44 in.Vlbf)
5.0 (51, 44 in.Vlbf)
Air Cleaner Hose No. 1
9.0 (92, 80 in.Vlbf)
N´m (kgf´cm, ft´lbf)Vacuum Hose
Intake Air Resonator
Sub-assy
Clip
5.0 (51, 44 in.Vlbf)
5.0 (51, 44 in.Vlbf)
7.5 (76, 66 in.Vlbf)
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