2005 LEXUS ES300 Repair Manual

P12668
A78770
SST
A05246
A52900
A78772
SST
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
14-153
2245 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
31. INSTALL INTAKE VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the origi-
nal locations.
(b) Using SST, compress the spring and place the 2 retainer
locks around the valve stem.
SST 09202-70020 (09202-00010)
(c) Using a plastic-faced hammer and discarded valve (the
tip is wrapped with tape), lightly tap the installed valve to
fit into place.
NOTICE:
Be careful not to damage the installed valve stem tip.
32. INSTALL EXHAUST VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the origi-
nal locations.
(b) Using SST, compress the spring and place the 2 retainer
locks around the valve stem.
SST 09202-70020 (09202-00010)

A05246
A78791Seal Packing
A78792
: Semicircular Plug
RH Cylinder:
LH Cylinder:Front 14-154
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Using a plastic-faced hammer and discarded valve (the
tip is wrapped with tape), lightly tap the installed valve to
fit into place.
NOTICE:
Be careful not to damage the installed valve stem tip.
33. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil to the valve lifter.
NOTICE:
Install the same parts in the same combination to the original locations.
(b) Install the valve lifter.
(c) Check that the valve lifter is rotated smoothly by hand.
34. INSTALL SEMICIRCULAR PLUG
(a) Remove any old seal packing material.
(b) Apply seal packing to the plug grooves.
Seal packing: Part No. 08826-00080 or equivalent
(c) Install the 2 plugs to the cylinder heads.
NOTICE:

Install the plugs so that they are flush with the top of
the cylinder head.

Install the plugs within 3 minutes after applying seal
packing.

Do not expose the seal packing to engine oil within 2
hours after installing.

- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
35. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
(a) Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)
36. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
(a) Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)

1419L-03
A78311
1st: 25 (250, 18)
2st: Turn 90
See page (14-158)
N´m (kgf´cm, ft´lbf)
: Specified torque
 Non-reusable partPiston Pin Hole
Snap Ring
 Piston Pin Hole Snap Ring
Connecting Rod Small
End Bush
 Gasket
 Gasket  Gasket
50 (510, 37)
39 (398, 29)
18 (184, 13)
30 (306, 22)
30 (306, 22)
39 (398, 29)
Piston Ring (No. 1 Compression Ring)
Piston Ring (No. 2 Compression Ring)
Piston Ring (Side Rail)Piston Ring (Expander)
Connecting Rod Sub-assy
Connecting Rod Bearing
Connecting Rod Cap
Cylinder Block Sub-assy
Cylinder Block w/ Head
Straight Screw No. 3 Plug
Cylinder Block Water Drain Cock
Sub-assy Cylinder Block w/ Head
Straight Screw No. 2 Plug Cylinder Block w/ Head
Straight Screw No. 1 Plug Cylinder Block Water
Drain Cock Sub-assy
Water Seal Plate


Piston PinPiston
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CYLINDER BLOCK ASSY (3MZ-FE)
COMPONENTS

A78312N´m (kgf´cm, ft´lbf)
: Specified torque
27 (275, 20)
27 (275, 20)1st: 22 (224, 16)
2st: Turn 90
See page (14-158)
Cylinder Block Sub-assy
Upper Crankshaft Thrust WasherCrankshaft Bearing
Crankshaft Bearing
Lower Crankshaft Thrust Washer
Crankshaft Bearing CapCrankshaft
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

1419M-03
P12695
A78793
Plastigage
A78794
Protrusion Front 14-158
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
2. REMOVE WATER SEAL PLATE
3. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
(a) Using a socket hexagon wrench 10, remove the screw plug.
4. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
(a) Using a socket hexagon wrench 10, remove the screw plug.
5. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
(a) Using a socket hexagon wrench 10, remove the screw plug.
6. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)

If the thrust clearance is greater than maximum, re-
place the connecting rod.

If necessary, replace the crankshaft.
7. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the matchmarks on the connecting rod and
cap are aligned to ensure correct reassembly.
(b) Remove the cap bolts.
(c) Clean the crank pin, bearing and connecting rod.
(d) Check the crank pin and bearing for pitting and scratches.
(e) Lay a strip of Plastigage across the crank pin.
(f) Check that the protrusion of the cap is facing the correct
direction.
(g) Apply a light coat of engine oil to the threads of the cap
bolts.

P12697
A78795
90
Front90Painted Mark
P12698
A79803
Number Mark
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(h) Tighten the cap bolts in several steps by the specified
torque.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(i) Mark the front side of each cap bolt with paint.
(j) Retighten the cap bolts by 90 as shown in the illustration.
NOTICE:
Do not turn the crankshaft.
(k) Remove the cap bolts, cap and lower bearing.
(l) Measure the Plastigage at its widest point.
Standard oil clearance:
0.038 to 0.066 mm (0.0015 to 0.0026 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
NOTICE:
Completely remove the Plastigage.

If the oil clearance is greater than maximum, re-
place the bearing.

If necessary, grind or replace the crankshaft.
HINT:
If replacing the bearing, replace it with one having the same
number as marked on the connecting rod. There are 4 sizes of
standard bearings, marked º1 º, º2º, º3º and º4º accordingly.
Reference:
Standard bearing center wall thickness:
Markmm (in.)
º1º1.484 to 1.487 (0.0584 to 0.0585)
º2º1.487 to 1.490 (0.0585 to 0.0587)
º3º1.490 to 1.493 (0.0587 to 0.0588)
º4º1.493 to 1.496 (0.0588 to 0.0589)

A05258
A78315
P12403
A78797
80C (176F) 14-160
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2252 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
8. REMOVE PISTON SUB-ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push out the piston and connecting rod assembly from
the top of the cylinder block.
HINT:

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order so they can be returned to the original loca-
tions when reassembling.
9. REMOVE CONNECTING ROD BEARING
10. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and expander by hand.
11. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
12. REMOVE W/PIN PISTON SUB-ASSY
(a) Gradually heat the piston up to approximately 80C
(176F).