2005 LEXUS ES300 Repair Manual

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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
42. REMOVE OIL FILTER SUB-ASSY
(a) Using SST, remove the oil filter.
SST 09228-07501
(b) Using a socket hexagon wrench 12, remove the oil filter
union.
43. REMOVE OIL PAN DRAIN PLUG
44. REMOVE OIL PAN SUB-ASSY NO.2
(a) Remove the 10 bolts and 2 nuts.
(b) Insert the blade of SST between the oil pan No. 1 and oil
pan No. 2, then cut off the sealer and remove the oil pan
No. 2.
SST 09032-00100
NOTICE:

Be careful not to damage the contact surface of the oil
pan No. 1 where the oil pan No. 2 is mounted.

Do not damage the flange portion of the oil pan No. 2
when removing.
45. REMOVE OIL STRAINER SUB-ASSY
(a) Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
46. REMOVE OIL PAN SUB-ASSY
(a) Loosen and remove the 15 bolts and 2 nuts uniformly.

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(b) Using a screwdriver, remove the oil pan by prying be-
tween the cylinder block and oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the oil pan
and cylinder block.
47. REMOVE OIL PAN BAFFLE PLATE
48. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
between the oil seal retainer and bearing cap.
49. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal.
50. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Using a screwdriver, remove the oil pump by prying be-
tween the oil pump and bearing cap.
(c) Remove the O-ring.

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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
51. REMOVE OIL PUMP SEAL
(a) Using a screwdriver, pry out the oil seal.
52. REMOVE SPARK PLUG TUBE GASKET
(a) Bend up the tab on the ventilation baffle plate which pre-
vents the gasket from slipping out.
NOTICE:
Be careful not to damage the baffle plate of the cylinder
head cover.
(b) Using a screwdriver and hammer, tap out the gasket.
(c) Using needle-nose pliers, pry out the gasket.
NOTICE:
Be careful not to damage the cylinder head cover.
53. INSPECT TIMING BELT
NOTICE:

Do not bend, twist or turn the timing belt inside out.

Do not allow contact of the timing belt with oil, water
or steam.

Do not use the timing belt tension when installing or
removing the mounting bolt of the camshaft timing
pulley.
Check the belt for any defects as shown in the illustrations.
Also, check these points below.
(a) If the belt tears in a short time:

Check if the belt is installed properly.

Check if the timing cover gasket is damaged and if
it is installed properly.
(b) If the belt teeth are cracked or damaged, check if either
camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check if there are nicks on the side of the idler pulley lock
and water pump.

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(d) If there is wear or damage on only one side of the belt,
check the belt guide and alignment of each pulley.
(e) If there is noticeable wear on the belt teeth:

Check the timing cover for damage.

Check that the gasket has been installed correctly.

Check for foreign objects on the pulley teeth.
If there is any doubt about the belt condition, replace the timing
belt.
54. INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the runout is greater than maximum, replace the camshaft.
(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
43.132 to 43.232 mm (1.6981 to 1.7020 in.) for intake
43.010 to 43.110 mm (1.6933 to 1.6972 in.) for exhaust
Minimum cam lobe height:
42.98 mm (1.6921 in.) for intake
42.86 mm (1.6874 in.) for exhaust
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 to 26.975 mm (1.0614 to 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
55. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard outside diameter:
8.95 to 9.05 mm (0.3524 to 0.3563 in.)
Minimum outside diameter: 8.75 mm (0.3445 in.)
If the diameter is less than minimum, replace the bolt.

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Seal Width 2 to 3 mm (0.08 to 0.12 in.)
A
A
B
B
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56. INSTALL SPARK PLUG TUBE GASKET
(a) Using SST and a hammer, tap in the new gasket until its
surface is flush with the upper edge of the cylinder head
cover.
SST 09950- 60010 (09951- 00430), 09950- 70010
(09951-07100)
(b) Return the ventilation plate tab to its original position.
(c) Apply a light coat of multi-purpose grease to the gasket
lip.
57. INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, tap in the new oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:

Be careful not to tap the oil seal at an angle.

Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.
58. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing material from the contact sur-
face.
(b) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the oil seal retainer within 3 minutes after ap-
plying seal packing.

Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil seal retainer with the 6 bolts. Tighten the
bolts uniformly in several steps.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
59. INSTALL OIL PUMP SEAL
(a) Using SST and a hammer, tap in the new oil seal until its
surface is flush with the oil pump body edge.
SST 09223-00010
NOTICE:

Be careful not to tap the oil seal at an angle.

Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.

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Seal Packing
Seal Width
2 to 3 mm
(0.08 to 0.12 in.) A
A
BB
C
C
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60. INSTALL OIL PUMP ASSY
(a) Remove any old packing material from the contact sur-
face.
(b) Apply a light coat of engine oil to a new O-ring, then place
it on the cylinder block.
(c) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from contact surface.

Apply seal packing to the inner side of the bolt holes.

Install the oil pump within 3 minutes after applying
seal packing.

Do not expose the seal packing to engine oil within 2
hours after installing.
(d) Align the key of the oil pump drive gear with the keyway
located on the crankshaft, then slide the oil pump into
place.

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C
B
A
AA
A
A
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Seal Packing
Seal Width
3 to 4 mm
(0.12 to 0.16 in.) AAB
B Region ºXº Region ºYº
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(e) Install the oil pump with the 9 bolts. Tighten the bolts uni-
formly in several steps.
Torque:
8.0 NVm (82 kgfVcm, 71 in.Vlbf) for bolt A
20 NVm (199 kgfVcm, 14 ftVlbf) for bolt B
43 NVm (439 kgfVcm, 32 ftVlbf) for bolt C
61. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
62. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
63. INSTALL OIL PAN SUB-ASSY
(a) Remove any old seal packing from the contact surface.
(b) Apply a continuous bead of seal packing (Diameter 3 to
4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Apply seal packing to the outer side of the bolt holes
in the region ºXº.

Apply seal packing to the inner side of the bolt holes
in the region ºYº.

Install the oil pan within 3 minutes after applying seal
packing.

Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil pan with the 15 bolts and 2 nuts. Tighten the
bolts uniformly in several steps.
Torque:
8.0 NVm (82 kgfVcm, 71 in.Vlbf) for 10 mm head
20 NVm (199 kgfVcm, 14 ftVlbf) for 12 mm head
64. INSTALL OIL STRAINER SUB-ASSY
(a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
65. INSTALL OIL PAN SUB-ASSY NO.2
(a) Remove any old seal packing from the contact surface.

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Seal Packing
Seal Width
4 to 5 mm
(0.16 to 0.20 in.) AA
BB
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Seal PackingSeal Width 3 to 5 mm
(0.12 to 0.20 in.)
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(b) Apply a continuous bead of seal packing (Diameter 4 to
5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Apply seal packing to the inner side of the bolt holes.

Install the oil pan within 3 minutes after applying seal
packing.

Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
66. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 45 NVm (459 kgfVcm, 33 ftVlbf)
67. INSTALL WATER INLET HOUSING
(a) Remove any old packing material from the contact sur-
face.
(b) Apply a continuous bead of seal packing (Diameter 3 to
5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the water inlet housing within 3 minutes after
applying seal packing.

Do not expose the seal packing to coolant within 2
hours after installing.
(c) Install the water inlet housing with the 8 bolts and 2 nuts.
Using several steps, tighten the bolts and nuts uniformly
in the sequence shown in the illustration.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)