2005 LEXUS ES300 Repair Manual

A86572
1
542
36
A78401
A78716
Front
A78717
Front
1
23
8
7
6
5
4
- ENGINE MECHANICALCYLINDER HEAD GASKET (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
33. REMOVE EXHAUST MANIFOLD SUB-ASSY RH
(a) Using several steps, loosen and remove the 6 nuts in the
sequence shown in the illustration.
(b) Remove the exhaust manifold RH and gasket from the
cylinder head RH.
34. REMOVE IGNITION COIL ASSY
35. REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-7)
36. REMOVE CAMSHAFT (See page 14-93)
37. REMOVE NO.2 CAMSHAFT (See page 14-93)
38. REMOVE CYLINDER HEAD SUB-ASSY
(a) Disconnect the VVT sensor connector.
(b) Disconnect the camshaft timing oil control valve connec-
tor.
(c) Remove the nut, then disconnect the engine wire harness
clamp.
(d) Using a socket hexagon wrench 8, remove the hexagon
bolt.
(e) 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.
39. REMOVE CYLINDER HEAD GASKET

A78721
Tension Portion
A78324
Front
A78717
1
2
3
4
5
67
8
Front
A78730
90
Front
Painted Mark 14-122
- ENGINE MECHANICALCYLINDER HEAD GASKET (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
40. 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.
41. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
with the R mark upward.
NOTICE:

Remove any oil from the contact surface.

Be careful of the installing orientation.

Place the cylinder head on the gasket carefully in or-
der not to damage the gasket at the bottom part of the
head.
42. INSTALL CYLINDER HEAD SUB-ASSY
NOTICE:
The cylinder head bolts are tightened in 2 successive
steps.
(a) Apply a light coat of engine oil to the threads of the cylin-
der head bolts.
(b) Install the plate washers to the cylinder head bolts.
(c) Using several steps, install and tighten the 8 cylinder
head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 54 NVm (550 kgfVcm, 40 ftVlbf)
(d) Mark the front side of each cylinder head bolt head with
paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90in the same se-
quence as step (c).
(f) Check that each painted mark is now at a 90 angle to the
front.

A78716
Front
A86572
6
235
41
- ENGINE MECHANICALCYLINDER HEAD GASKET (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(g) Using a socket hexagon wrench 8, install the hexagon
bolt.
Torque: 19 NVm (189 kgfVcm, 14 ftVlbf)
(h) Connect the engine wire harness clamp with the nut.
Torque: 8.4 NVm (85 kgfVcm, 74 in.Vlbf)
43. INSTALL NO.2 CAMSHAFT (See page 14-93)
44. INSTALL CAMSHAFT (See page 14-93)
45. INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-7)
46. INSTALL IGNITION COIL ASSY (See page 14-7)
47. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
(a) Install a new gasket and the exhaust manifold RH with the
6 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 shown in the illustration.
48. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 8.5 NVm (87 kgfVcm, 75 ftVlbf)
49. INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2)
50. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2)
51. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2)
52. INSTALL VANE PUMP ASSY (See page 14-29)
53. INSTALL TIMING BELT NO.3 COVER (See page 14-93)
54. INSTALL CAMSHAFT TIMING PULLEY (See page 14-93)
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
55. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93)
56. INSPECT TIMING BELT (See page 14-79)
57. INSTALL TIMING BELT (See page 14-79)
SST 09960-10010 (09962-01000, 09963-01000)
58. INSTALL TIMING BELT TENSIONER ASSY (See page 14-79)
59. INSTALL TIMING BELT GUIDE NO.2 (See page 14-79)
60. INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79)
61. INSTALL TIMING BELT NO.2 COVER (See page 14-79)
62. INSTALL TIMING BELT NO.1 COVER (See page 14-79)
63. INSTALL CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021
64. INSTALL GENERATOR BRACKET NO.2 (See page 14-79)
65. INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
66. INSTALL ENGINE MOVING CONTROL ROD (See page 14-79)
67. INSTALL VANE PUMP V BELT (See page 14-5)

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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
68. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
69. INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1)
70. INSTALL WATER OUTLET (See page 10-16)
71. INSTALL INTAKE MANIFOLD (See page 10-16)
72. INSTALL INTAKE AIR SURGE TANK (See page 11-13)
73. INSTALL EMISSION CONTROL VALVE SET (See page 11-13)
74. INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
75. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
76. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
77. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
78. INSTALL FRONT WHEEL RH (See page 14-5)
79. ADD ENGINE OIL (See page 17-20)
80. ADD ENGINE COOLANT (See page 16-9)
81. CHECK FOR ENGINE OIL LEAKS
82. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
83. INSPECT FOR FUEL LEAKS
84. CHECK FOR EXHAUST GAS LEAKS
85. INSPECT IGNITION TIMING (See page 14-1)
SST 09843-18040
86. INSPECT ENGINE IDLE SPEED (See page 14-1)
87. INSPECT COMPRESSION (See page 14-1)
SST 09992-00500
88. INSPECT CO/HC (See page 14-1)
89. SYSTEM INITIALIZATION (See page 19-15)

141JI-01
A84919N´m (kgf´cm, ft´lbf) : Specified torque
7.9 (81, 70 in.Vlbf)x3
V-bank Cover Sub-assy
Mass Air Flow
Meter Connector Fuel Vapor Feed
Hose No. 1Vacuum Hose
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
5.0 (51, 44 in.Vlbf)
W/O TEMS:
Front Suspension Upper Brace Center
80 (816, 59)
Spacer
x2
80 (816, 59)
x2
Spacer
Vacuum Hose
Clip x7
Radiator Lower
Air DeflectorClipAir Cleaner
Inlet Assy
5.0 (51, 44 in.Vlbf)x2
VSV Connector
Air Cleaner Casex3
5.0 (51, 44 in.Vlbf)
- ENGINE MECHANICALCYLINDER HEAD GASKET NO.2 (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CYLINDER HEAD GASKET NO.2 (3MZ-FE)
COMPONENTS

A86260 Non-reusable part
: Specified torque VSV Connector
8.0 (82, 71 in.Vlbf)x2
Emission
Control Valve Set
Emission Control Valve Bracket
Intake Air Surge Tank
 Air Surge Tank
to Intake Manifold
Gasket
Throttle Motor Connector
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N´m (kgf´cm, ft´lbf)
Union to Check Valve Hose
Fuel Vapor Feed Hose
x2 x3
Engine Hunger No. 1Surge Tank Stay
No. 1
Surge Tank Stay
No. 2
20 (199, 14)
20 (199, 14)
20 (199, 14)
7.8 (80, 69 in.Vlbf)
x2
x2 Pressure Feed
Tube Assy
28 (286, 21)
x2
x2
Bond Cable No. 1
Connector
28 (286, 21)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A86583 Non-reusable part
: Specified torqueN´m (kgf´cm, ft´lbf) Intake Manifold
to Head Gasket No. 2 Intake Manifold
to Head Gasket No. 1
Radiator Hose InletWater Outlet
Heater Inlet
Water Hose Intake Manifold Ground Cable
Washer
8.4 (86, 74 in.Vlbf)
x2x9
x2
Washer
15 (153, 11)
15 (153, 11)
Fuel Pipe
Clamp
15 (153, 11)
Fuel Injector
Connector
Clamp
Fuel Injector Connector
x2
Engine Coolant
Temperature Sensor
Connector
Bond Cable No. 1
Connector
Pipe
- ENGINE MECHANICALCYLINDER HEAD GASKET NO.2 (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A84916
64 (653, 47)
64 (653, 47)
Front Fender Apron
Seal RH
Vane Pump V Belt
V Belt No. 1
Generator Bracket No. 2
Engine Mounting Stay No. 2 RHEngine Moving Control Rod
N´m (kgf´cm, ft´lbf)
: Specified torque
23 (235, 17)
58 (591, 43)
28 (286, 21)
Radio Setting Condenser
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)