2005 LEXUS ES300 Repair Manual

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.

A78702
(5)
(6) (1)(4) (2)(3)
A78703
SST
A78704
SST
A78705
SST 14-42
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2134 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Remove the timing belt in this order.
1stNo. 1 idler pulley
2ndRH camshaft timing pulley
3rdNo. 2 idler pulley
4thLH camshaft timing pulley
5thWater pump pulley
6thCrankshaft timing pulley
19. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
(a) Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
20. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
21. REMOVE CRANKSHAFT POSITION SENSOR
22. REMOVE CAMSHAFT TIMING PULLEY
(a) 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)
HINT:
Arrange the camshaft timing pulleys (RH and LH sides) so that
they can be returned to the original locations when reassem-
bling.
23. REMOVE TIMING BELT NO.3 COVER
24. REMOVE TIMING BELT IDLER BRACKET
25. REMOVE CRANKSHAFT TIMING PULLEY
(a) Remove the bolt and timing belt plate.
(b) Install the pulley bolt to the crankshaft.
(c) 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 tim-
ing pulley.

Before using SST, apply lubricating oil to the threads
and tip of the center bolt 150.

A78535
A78706Align
A78707
Main GearSub Gear
Service Bolt
A78708
101
2
3
4
5
6
7
89
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2135 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
26. REMOVE WATER PUMP ASSY
(a) 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.
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 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) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. 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.

A78709
10
1
2
3
4
5
67
8
9
A78710Align
A78711Main GearSub Gear
Service Bolt 14-44
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2136 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
28. REMOVE NO.2 CAMSHAFT
(a) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. 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 the timing marks (1 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 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.

A78712
10
12
3
4
5
67
89
A78713
10
1
2
3
4
5
6
7
89
A05739
A78714Convex Portion
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2137 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. 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.
30. REMOVE NO.4 CAMSHAFT SUB-ASSY
(a) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. 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. INSPECT CAMSHAFT TIMING GEAR ASSY
(a) Clamp the camshaft in a vise on the hexagonal lobe.
(b) Check that the VVT-i will not turn.
(c) 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/cm
2, 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 illustra-
tion) by hand.
Standard: Must turn
HINT:
Depending on the air pressure, the VVT-i will turn to the ad-
vance 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.

A05739
A05740
P12596
14-46
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2138 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) 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
(g) 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.
(b) 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.

A78715
SST
A52353
A05275
A78716
Front
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-47
2139 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using SST, turn the sub gear counterclockwise, then re-
move the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, camshaft sub gear and cam-
shaft gear bolt washer.
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.
34. REMOVE ENGINE HANGER NO.2
35. REMOVE CYLINDER HEAD COVER REAR
36. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the plug, gasket and valve filter.
37. REMOVE CYLINDER HEAD SUB-ASSY
(a) Using a socket hexagon wrench 8, remove the hexagon
bolt.

A78717
Front
1
23
8
7
6
5
4
A78718
Front
A78719
Front
1
23
8
7
6
5
4
A78314
1
2
3
8
7
6
5
4
9
10 14-48
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2140 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using several steps, loosen the 8 cylinder head bolts uni-
formly 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 remov-
ing the bolts in an incorrect order.
38. REMOVE CYLINDER HEAD GASKET
39. REMOVE CYLINDER HEAD LH
(a) Using a socket hexagon wrench 8, remove the hexagon
bolt.
(b) Using several steps, loosen the 8 cylinder head bolts uni-
formly 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 remov-
ing the bolts in an incorrect order.
40. REMOVE CYLINDER HEAD GASKET NO.2
41. REMOVE WATER INLET HOUSING
(a) Remove the 8 bolts and 2 nuts, then remove the water in-
let housing.