2005 LEXUS ES300 Repair Manual

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- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using a plastic-faced hammer and brass bar, lightly tap
out the piston pin, then remove the connecting rod.
HINT:

The piston and piston pin are a matched set.

Store the pistons, piston pins, rings, connecting rods and
bearings in the correct order so that they can be returned
to the original locations when reassembling.
13. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
HINT:
The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to
0.0780 in.).
14. REMOVE CRANKSHAFT
(a) Using several steps, loosen and remove the 8 bearing
cap bolts and 8 seal washers uniformly in the sequence
shown in the illustration.
(b) Using several steps, loosen and remove the 16 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion.

P12603
A78800
Joint Surface
Z09222
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(c) Using a screwdriver, pry out the bearing caps. Remove
the 4 bearing caps and 4 lower bearings.
NOTICE:

Carefully pry out the main bearing cap by alternately
lifting each end of the bearing cap little by little.

Be careful not to damage the joint surface of the cylin-
der block and bearing cap.
15. REMOVE CRANKSHAFT THRUST WASHER SET
16. REMOVE CRANKSHAFT BEARING
17. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the warpage on the surface which contacts the cylin-
der head gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than maximum, replace the cylinder
block.

A88633
Thrust Direction
Axial Direction Front
10 mm (0.39 in.)
A
B
A78316
13.0 mm
(0.512 in.)
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18. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A and B in the thrust and axial directions.
Standard diameter:
92.000 to 92.012 mm (3.6220 to 3.6225 in.)
Maximum diameter: 92.132 mm (3.6272 in.)
If the average diameter of 4 positions is greater than maximum,
replace the cylinder block.
19. INSPECT W/PIN PISTON SUB-ASSY
(a) Using a micrometer, measure the diameter of the piston.
Align the micrometer so it is 13.0 mm (0.512 in.) from the
bottom of the piston and at a right angle (90) to the piston
pin holes as illustrated.
Piston diameter:
91.953 to 91.967 mm (3.6202 to 3.6207 in.)
20. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)

If the oil clearance is greater than maximum, replace all the 6 pistons.

If necessary, replace the cylinder block.
21. INSPECT CONNECTING ROD SUB-ASSY
(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Inspect for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If misalignment is greater than maximum, replace the connect-
ing rod assembly.

Z00065
EM6525
EM0227
A78803
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(2) Inspect for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than maximum, replace the connecting rod
assembly.
22. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
bush.
Bush inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the
bush inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)

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

If necessary, replace the piston and piston pin to-
gether.
23. REMOVE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bush.
SST 09222-30010

A78804
Oil Hole
A78803
SST
EM6535
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24. INSTALL CONNECTING ROD SMALL END BUSH
(a) Align the oil holes of a new bush and the connecting rod.
(b) Using SST and a press, press in the bushing.
SST 09222-30010
(c) Using a pin hole grinder, hone the bush to obtain the stan-
dard specified clearance between the bush and piston
pin.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
(d) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, then push it into the con-
necting rod with your thumb.
25. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the new piston ring and wall of the ring groove.
Ring groove clearance:
0.03 to 0.08 mm (0.0012 to 0.0031 in.) for No. 1 ring
0.02 to 0.06 mm (0.0008 to 0.0024 in.) for No. 2 ring
0.03 to 0.11 mm (0.0012 to 0.0043 in.) for oil ring
If the groove clearance is not as specified, replace the piston
ring.

A78805
110 mm
(4.33 in.)
A37355
EM6347A15065
EM6347A15065
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26. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring which it is a little below
the bottom of the ring travel, where is 110 mm (4.33 in.)
from the top of the cylinder block.
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
0.30 to 0.40 mm (0.0118 to 0.0157 in.) for No. 1 ring
0.50 to 0.60 mm (0.0197 to 0.0236 in.) for No. 2 ring
0.15 to 0.40 mm (0.0059 to 0.0157 in.) for oil (side rail)
ring
Maximum end gap:
0.95 mm (0.0374 in.) for No. 1 ring
1.05 mm (0.0413 in.) for No. 2 ring
1.00 mm (0.0394 in.) for oil (side rail) ring

If the end gap is greater than maximum, replace the
piston ring.

If the end gap is greater than maximum, even with
a new piston ring, replace the cylinder block.
27. INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than minimum, replace the bolt.
28. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than minimum, replace the bolt.

P12406
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ZF6928
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No. 1 and No. 4:
Upper
Lower
22.4 mm (0.882 in.)No. 2 and No. 3:
19.0 mm (0.748 in.)
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29. INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, measure the circle
runout as shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(b) Using a micrometer, measure the diameter of each main
journal.
Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
If the diameter is not as specified, check the crankshaft oil clear-
ance
(c) Check each main journal for taper and out-of-round as
shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than maximum, replace
the crankshaft.
(d) Using a micrometer, measure the diameter of each crank
pin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
If the diameter is not as specified, check the connecting rod oil
clearance.
(e) Check each crank pin for taper and out-of-round as
shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than maximum, replace
the crankshaft.
30. INSPECT CRANKSHAFT OIL CLEARANCE
HINT:
Crankshaft bearings come in widths of 22.4 mm (0.882 in.) and
19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in
the No. 1 and No. 4 cylinder block journal positions with the
bearing caps. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
(a) Clean each main journal and bearing.

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Mark
1, 2, 3 or 4
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Plastigage
A10530
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(b) Align the key of the bearing with the keyway of the cylinder
block, then push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
(c) Align the key of the bearing with the keyway of the bearing
cap, then push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
HINT:
A number is marked on each bearing cap to indicate the instal-
lation position.
(d) Place the crankshaft on the cylinder block.
(e) Lay a strip of Plastigage across each journal.
(f) Examine the front marks and numbers, then install the
bearing caps on the cylinder block.
(g) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(h) Temporarily install the 8 bearing cap bolts to the inside
positions.
(i) Install the bearing cap by hand using the inner bolt as a
guide. Stop when the bearing cap is about 6 mm (0.23 in.)
away from contact with the cylinder block.