2005 LEXUS ES300 Repair Manual

A10529
A78810
1
3
4
5
6
7
8
2
10
11
13
12
14
15
16
9
A78811
Painted Mark
90
Front90
A78812
1
2
3
4
5
6
7
8
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(j) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure proper fit.
(k) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(l) Using several steps, install and tighten the 16 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 22 NVm (224 kgfVcm, 16 ftVlbf)
(m) Mark the front side of the bearing cap bolts with paint.
(n) Retighten the bearing cap bolts by 90 in the same se-
quence as step (l).
(o) Check that each painted mark is now at a 90 angle to the
front.
NOTICE:
Do not turn the crankshaft.
(p) Using several steps, install and tighten the 8 bearing cap
bolts uniformly in the sequence shown in the illustration.
Torque: 27 NVm (275 kgfVcm, 20 ftVlbf)
HINT:
Use the short bolt for the position marked with the arrow.
(q) Remove the bearing caps.

P12993
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(r) Measure the Plastigage at its widest point.
Standard oil clearance:
0.014 to 0.034 mm (0.0006 to 0.0013 in.) for No. 1 and
No. 2 journals
0.026 to 0.046 mm (0.0010 to 0.0018 in.) for No. 3 and
No. 4 journals
Maximum clearance:
0.05 mm (0.0020 in.) for No. 1 and No. 2 journals
0.06 mm (0.0024 in.) for No. 3 and No. 4 journals

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

If necessary, replace the crankshaft.
NOTICE:
Completely remove the Plastigage.

A78813
No. 1
Number
MarkNo. 2No. 3
No. 4
No. 1 No. 2
No. 3
No. 4 Number Mark
Number Mark
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(s) If replacing a bearing, replace it with one having the same
number. If the number of the bearing cannot be deter-
mined, select the correct bearing by adding together the
numbers imprinted on the cylinder block and crankshaft,
then refer to the table below for the appropriate bearing
number. The No. 1 and No. 2 journal bearing come in 5
sizes, marked º3º, º4º, º5º, º6º and º7º. The No. 3 and No.
4 journal bearings come in 5 standard bearing sizes,
marked º1º, º2º, º3º, º4º and º5º.
No. 1 and No. 2 journal bearings:
Cylinder
block
+
Crankshaft
=
0 to 56 to 1112 to 1718 to 2324 to 28
Replace-
ment
Bearing
º3ºº4ºº5ºº6ºº7º
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked º5º
No. 3 and No. 4 journal bearings:
Cylinder
block
+
Crankshaft
=
0 to 56 to 1112 to 1718 to 2324 to 28
Replace-
ment
Bearing
º1ºº2ºº3ºº4ºº5º
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked º3º

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2005 LEXUS ES330 REPAIR MANUAL (RM1124U) Item
Markmm (in.)
Cylinder block main journal bore diameter (A)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º
º13º
º14º
º15º
º16º66.000 (2.5984)
66.001 (2.5985)
66.002 (2.5985)
66.003 (2.5985)
66.004 (2.5986)
66.005 (2.5986)
66.006 (2.5987)
66.007 (2.5987)
66.008 (2.5987)
66.009 (2.5988)
66.010 (2.5988)
66.011 (2.5989)
66.012 (2.5989)
66.013 (2.5989)
66.014 (2.5990)
66.015 (2.5990)
66.016 (2.5990)
Crankshaft main journal diameter (B)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º61.000 (2.4016)
60.999 (2.4015)
60.998 (2.4015)
60.997 (2.4015)
60.996 (2.4014)
60.995 (2.4014)
60.994 (2.4013)
60.993 (2.4012)
60.992 (2.4012)
60.991 (2.4012)
60.990 (2.4012)
60.989 (2.4011)
60.988 (2.4011)
Standard bearing center wall thicknessº1º
º2º
º3º
º4º
º5º
º6º
º7º2.486 to 2.489 (0.0979 to 0.0980)
2.489 to 2.492 (0.0980 to 0.0981)
2.492 to 2.495 (0.0981 to 0.0982)
2.495 to 2.498 (0.0982 to 0.0983)
2.498 to 2.501 (0.0983 to 0.0985)
2.501 to 2.504 (0.0985 to 0.0986)
2.504 to 2.507 (0.0986 to 0.0987)

A78318
Front Side: Front Side:
Front Side:
Upper Side:Left Side:
80 mm
(3.15 in.)
M1099 mm
(3.90 in.)
M8
27.5 mm
(1.08 in.)28.5mm
(1.12 in.) M6
M6M8 29 mm
(1.14 in.)
Torque: 6.0 NVm (60 kgfVcm, 53 in.Vlbf)
Torque: 7.0 NVm (70 kgfVcm, 62 in.Vlbf)
Torque: 4.0 NVm (40 kgfVcm, 35 in.Vlbf) Torque: 21 NVm (220 kgfVcm, 15 ftVlbf)Torque: 15 NVm (145 kgfVcm, 11 ftVlbf)
52.5 mm
(2.07 in.) Upper Side:
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
31. INSTALL STUD BOLT

A78319
Front Side:
Upper Side:Right Side:
Lower Side:
Back Side: Back Side: Protrusion Height: 6 mm (0.24 in.)
Protrusion Height: 11 mm (0.43 in.) 4 mm
(0.16 in)
10 mm
(0.39 in.)
22 mm
(0.87 in.)12 mm
(0.47 in.) 12 mm
(0.47 in.)4 mm
(0.16 in)
4 mm
(0.16 in)
12 mm
(0.47 in.)4 mm
(0.16 in)
12 mm
(0.47 in.)
4 mm
(0.16 in)
12 mm
(0.47 in.) Protrusion Height: 6 mm (0.24 in.)
Protrusion Height: 6 mm (0.24 in.)Protrusion Height: 6 mm (0.24 in.) Protrusion Height: 6 mm (0.24 in.) 14-174
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. INSTALL STRAIGHT PIN

A78816
Upper Side:
Protrusion Height: 10 mm (0.39 in.) Protrusion Height: 4 mm (0.16 in.)16 mm
(0.63 in.)
20 mm
(0.79 in.)11 mm
(0.43 in.)
8 mm
(0.31 in.)
P12418A32958
A78817
80C (176F)
A78376
Front Mark
Front Mark
(Mold Mark)
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
33. INSTALL RING PIN
34. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not aligned with the
pin hole cutout of the piston.
35. INSTALL W/PIN PISTON SUB-ASSY
(a) Gradually heat the piston up to approximately 80C
(176F).
(b) Coat the piston pin with engine oil.
(c) Align the front marks of the piston and connecting rod,
then push in the piston pin with your thumb until the pin
contacts the snap ring.

P12418A32958
A78320
No. 1:
No. 2:2A
A86598
Lower Side
Rail
No. 2
Compression Expander No. 1
Compression
Front Mark
Upper Side
Rail
P12402
A78806
No. 1 and No. 4:
Upper
Lower
22.4 mm (0.882 in.)No. 2 and No. 3:
19.0 mm (0.748 in.) 14-176
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
36. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
HINT:
Be sure that the end of gap of the snap ring is not aligned with
the pin hole cutout of the piston.
37. INSTALL PISTON RING SET
(a) Install the expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings.
HINT:
The No. 2 compression ring is installed with the code mark º2Aº
facing upward as shown in the illustration.
(c) Position the piston rings so that the ring ends are ar-
ranged as shown in the illustration.
NOTICE:
Do not align the ring ends.
38. INSTALL CONNECTING ROD BEARING
(a) Align the key of the bearing with the keyway of the con-
necting rod or cap.
NOTICE:
Clean the backside of the bearing and bearing surface of
the connecting rod. The surface should be free of dust and
oils.
39. INSTALL CRANKSHAFT BEARING
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
main 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 the bearing.