2005 LEXUS ES300 Repair Manual

A86565
A86566
A86567
3
472
5
6
1
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2125 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
67. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-140)
SST 09213-54015 (91651-60855), 09330-00021
68. INSTALL ENGINE STAND
69. REMOVE ENGINE HANGER NO.2
70. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
71. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
72. REMOVE INTAKE MANIFOLD (See page 10-16)
73. REMOVE WATER OUTLET (See page 10-16)
74. REMOVE IGNITION COIL ASSY
75. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-120)
76. REMOVE EXHAUST MANIFOLD SUB-ASSY RH (See page 14-120)
77. REMOVE MANIFOLD CONVERTER INSULATOR NO.3
(a) Remove the bolt and nut, then remove the insulator.
78. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.2
(a) Remove the 2 bolts and insulator.
79. REMOVE EXHAUST MANIFOLD CONVERTER
SUB-ASSY NO.2
(a) Using several steps, loosen and remove the 7 nuts in the
sequence shown in the illustration.
(b) Remove the exhaust manifold converter No. 2 and gasket
from the cylinder head LH.

A86568
A05189
A80061
Oil Pressure
Switch 14-34
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
80. REMOVE MANIFOLD STAY NO.2
(a) Remove the 2 bolts and manifold stay.
81. REMOVE ENGINE MOUNTING BRACKET RH (See page 17-9)
82. REMOVE PUMP BRACKET
(a) Remove the 3 bolts and pump bracket.
83. REMOVE GENERATOR BRACKET NO.1
84. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-9)
85. REMOVE WATER INLET PIPE (See page 16-16)
86. REMOVE WATER INLET (See page 16-16)
87. REMOVE THERMOSTAT
88. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
(a) Using a deep socket wrench 24 mm, remove the oil pres-
sure switch.
89. REMOVE KNOCK SENSOR (See page 10-16)
90. REPLACE PARTIAL ENGINE ASSY
91. INSTALL KNOCK SENSOR (See page 10-16)
92. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080 THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 NVm (153 kgfVcm, 11 ftVlbf)

A86567
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4
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25
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
93. INSTALL THERMOSTAT (See page 16-16)
94. INSTALL WATER INLET (See page 16-16)
95. INSTALL WATER INLET PIPE (See page 16-16)
96. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-9)
97. INSTALL GENERATOR BRACKET NO.1
Torque: 58 NVm (591 kgfVcm, 43 ftVlbf)
98. INSTALL PUMP BRACKET
Torque: 32 NVm (326 kgfVcm, 24 ftVlbf)
99. INSTALL ENGINE MOUNTING BRACKET RH (See page 17-9)
100. INSTALL MANIFOLD STAY NO.2
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
101. I N S TA L L E XHAUST 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 NVm (500 kgfVcm, 36 ftVlbf)
(b) Retighten nuts 1 and 2 as shown in the illustration.
102. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
103. INSTALL MANIFOLD CONVERTER INSULATOR NO.3
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
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 NVm (650 kgfVcm, 47 in.Vlbf)
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)

A78403
RH: LH:
A60501
A52890
A78549
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
117. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-8)
118. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30-8)
119. INSTALL FRONT FRAME ASSY
(a) Install the engine mounting insulator RH and LH with the
2 nuts.
Torque: 95 NVm (969 kgfVcm, 70 ftVlbf)
(b) Install the engine mounting insulator FR with the bolt.
Torque: 87 NVm (887 kgfVcm, 64 ftVlbf)
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 NVm (439 kgfVcm, 32 ftVlbf)
(c) Connect the power steering pressure tube with the 2 nuts.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
121. INSTALL VANE PUMP V BELT (See page 14-5)

A59877
BNut
A
BNut
A
A59878
Nut
D
CNut
D
C
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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 NVm (867 kgfVcm, 63 ftVlbf) for bolt A
32 NVm (326 kgfVcm, 24 ftVlbf) for bolt B and nut
(d) Install the front suspension member brace rear RH and
LH with the 4 bolts and 2 nuts.
Torque:
85 NVm (867 kgfVcm, 63 ftVlbf) for bolt C
32 NVm (326 kgfVcm, 24 ftVlbf) for bolt D and nut
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)

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:
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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)
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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)

141CR-02
A78700
SST
A78701
SST 14-40
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2132 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSY
3. REMOVE OIL FILLER CAP GASKET
4. REMOVE CYLINDER HEAD COVER SUB-ASSY LH
5. REMOVE CYLINDER HEAD COVER GASKET NO.2
6. REMOVE CYLINDER HEAD COVER SUB-ASSY
7. REMOVE CYLINDER HEAD COVER GASKET
8. REMOVE VENTILATION VALVE SUB-ASSY
9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
10. REMOVE VVT SENSOR
(a) Remove both the camshaft oil control valves.
(b) Remove the O-ring from each camshaft oil control valve.
11. REMOVE OIL LEVEL GAGE SUB-ASSY
12. REMOVE OIL LEVEL GAGE GUIDE
13. REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
(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.
14. REMOVE TIMING BELT NO.1 COVER
15. REMOVE TIMING BELT NO.2 COVER
16. REMOVE ENGINE MOUNTING BRACKET RH
17. REMOVE TIMING BELT GUIDE NO.2