2005 LEXUS ES300 check engine

A05246
A78791Seal Packing
A78792
: Semicircular Plug
RH Cylinder:
LH Cylinder:Front 14-154
- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
2246 Author
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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.

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.

A88633
Thrust Direction
Axial Direction Front
10 mm (0.39 in.)
A
B
A78316
13.0 mm
(0.512 in.)
Z00064
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.

A78804
Oil Hole
A78803
SST
EM6535
P00326
A78317
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.

P12406
A37157
ZF6928
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.)
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.

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.

A78809Less than 6 mm (0.23 in.)
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 14-178
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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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)
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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)