2005 LEXUS ES300 light

A10529
A78810
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3
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8
2
10
11
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16
9
A78811
Painted Mark
90
Front90
A78812
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8
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-169
2261 Author
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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.

P12599
A78807
Mark
1, 2, 3 or 4
P12600
A05264
A10530
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-177
2269 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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.
40. INSTALL CRANKSHAFT THRUST WASHER SET
(a) Install the 2 thrust washers under the No. 2 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
(b) Install the 2 thrust washers on the No. 2 bearing cap with
the grooves facing outward.
41. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, then install the
crankshaft on the cylinder block.
(b) Examine the front marks and numbers, then install the
bearing caps on the cylinder block.
(c) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.

A78809Less than 6 mm (0.23 in.)
A10529
A78810
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3
4
5
6
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8
2
10
11
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12
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16
9
A78811
Painted Mark
90
Front90
A78812
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8 14-178
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2270 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Temporarily install the 8 bearing cap bolts to the inside
positions.
(e) 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.
(f) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure proper fit.
(g) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(h) 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)
(i) Mark the front side of the bearing cap bolts with paint.
(j) Retighten the bearing cap bolts by 90 in the same se-
quence as step (h).
(k) Check that each painted mark is now at a 90 angle to the
front.
(l) Check that the crankshaft turns smoothly.
(m) 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.

A78322
Front Mark (Cavity)
Front
A78794
Protrusion Front
P12697
A78795
90
Front90Painted Mark
A78822
Front Side:
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-179
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
42. INSTALL PISTON SUB-ASSY W/CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and sur-
faces of the connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the numbered pis-
ton and connecting rod assemblies correctly into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.
(d) Check that the protrusion of the cap is facing the correct
direction.
(e) Apply a light coat of engine oil to the threads of the cap
bolts.
(f) Tighten the cap bolts in several steps by the specified
torque.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(g) Mark the front side of each cap bolt with paint.
(h) Retighten the cap bolts by 90 as shown in the illustration.
(i) Check that the crankshaft turns smoothly.
43. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.1 PLUG
(a) Using a socket hexagon wrench 10, install a new gasket
and the screw plug.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)

100IZ-01
A86347DLC3
Hand-held Tester
A86347DLC3
Hand-held Tester
- ENGINE CONTROL SYSTEMSFI SYSTEM (3MZ-FE)
10-1
2006 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
SFI SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Check the operation.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Start the engine and allow it to warm up.
(4) Connect the hand-held tester, then select VVT from
the ACTIVE TEST menu.
(5) Check the engine speed when the OCV is operated
with the hand-held tester.
Standard:
Tester OperationSpecified Condition
OCV is OFFNormal engine speed
OCV is ONRough idle or engine stall
If the operation is not as specified, inspect the camshaft timing
oil control valve (see page 10-2).
2. INSPECT THROTTLE BODY ASSY
(a) Check the operation (throttle control motor).
(1) Turn the ignition switch ON.
(2) When turning the accelerator pedal position sensor
lever, check the running sound of the motor. Also,
check that there is no friction sound.
If the operation is not as specified, inspect the throttle body (see
page 10-2).
(b) Check the operation (throttle position sensor).
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Check that the check engine warning light does not
light up.
(4) Check that the throttle valve opening percentage
(THROTTLE POS) of CURRENT DATA showns the
standard value.
Standard throttle valve opening percentage:

60 % or more
NOTICE:
When checking the standard throttle valve opening per-
centage, the transmission is in the neutral position.
3. INSPECT ACCELERATOR PEDAL POSITION SENSOR
(a) Inspect the voltage.
(1) After turning the ignition switch ON, check CURRENT DATA, then verify that the throttle position
sensor voltage is within the standard value.
Standard voltage: 0.6 to 1.0 V
If the voltage is not as specified, inspect the accelerator pedal (see page 10-2).

100J1-01
A86244
(a)
(b)
RH Bank:
A86306
(a)
(b)
LH Bank: 10-6
- ENGINE CONTROL SYSTEMCAMSHAFT TIMING OIL CONTROL VALVE
ASSY (3MZ-FE)
2011 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CAMSHAFT TIMING OIL CONTROL VALVE ASSY (3MZ-FE)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Disconnect the 2 camshaft timing oil control valve con-
nectors.
(b) Remove the 2 bolts, then remove the 2 camshaft timing
oil control valves.
HINT:
The camshaft timing oil control valve is installed with the bolt.
4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Apply a light coat of engine oil to the O-ring on each camshaft timing oil control valve.
(b) Install the 2 camshaft timing oil control valves with the 2 bolts.
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
NOTICE:
Be careful not to twist the O-ring.
(c) Connect the 2 camshaft timing oil control valve connectors.
5. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
6. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
7. CHECK FOR ENGINE OIL LEAKS
8. SYSTEM INITIALIZATION (See page 19-15)

A86303
(b)
(b)
(b)
(b)
A86304
(c)
(d)(c)
(c)
(c)(d)
(d)
(d)
(d)
(d)
A81137
A79762
New O-ring
New Grommet
A81139
Turn
Push
- FUELFUEL INJECTOR ASSY (3MZ-FE)
11-15
2043 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Remove the 4 bolts, then remove the 2 fuel delivery pipes
together with the 6 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when removing the
fuel delivery pipe.
(c) Remove the 4 delivery pipe No. 1 spacers from the intake
manifold.
(d) Remove the 6 insulators from the intake manifold.
(e) Pull out the fuel injector from the fuel delivery pipe.
11. INSTALL FUEL INJECTOR ASSY
(a) Install new grommets to each fuel injector.
(b) Apply a light coat of spindle oil or gasoline to new O-rings,
then install them to each fuel injector.
(c) Apply a light coat of spindle oil or gasoline to the place
where the fuel delivery pipe contacts the O-ring.
(d) Push the fuel injector while twisting it back and forth to
install it in the fuel delivery pipe.
NOTICE:

Be careful not to twist the O-ring.

After installing the fuel injectors, check that they turn
smoothly. If not, replace O-ring with a new O-ring.

A65038
New O-ring
A65040
O-ring
A86272
Cover
Tube Joint Clip
- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)11-23
2051 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
15. INSTALL FUEL PRESSURE REGULATOR ASSY
(a) Apply a light coat of spindle oil or gasoline to a new O-
ring, then install it to the fuel pressure regulator.
(b) Push in the fuel pressure regulator to the fuel tank fuel fil-
ter.
16. INSTALL FUEL PUMP FILTER
(a) Install the fuel pump filter with a new clip.
17. INSTALL FUEL PUMP
(a) Apply a light coat of gasoline or spindle oil to the O-ring
on the fuel pump.
(b) Push in the fuel pump to the fuel tank fuel filter.
18. INSTALL FUEL PUMP HARNESS
19. INSTALL FUEL SUCTION PLATE SUB-ASSY
20. INSTALL FUEL SENDER GAUGE ASSY
21. INSTALL FUEL PUMP CUSHION RUBBER
22. INSTALL FUEL SUCTION SUPPORT NO.2
23. INSTALL VAPOR PRESSURE SENSOR ASSY
(a) Install the vapor pressure sensor with the tube joint clip.
NOTICE:

Check the connected part for scratch or foreign ob-
jects.

Check that the vapor pressure sensor is inserted se-
curely.

Check that the tube joint clip is on the collar of the va-
por pressure sensor.

After installing the tube joint clip, check that the vapor
pressure sensor has not been pulled off.
(b) Install the cover.