2005 LEXUS ES300 gas tank

P19471
Compression Gauge
- ENGINE MECHANICALENGINE (3MZ-FE)
14-3
2095 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the intake air surge tank (see page 11-13).
(c) Disconnect the injector connectors.
(d) Remove the ignition coils.
(e) Remove the spark plugs.
(f) Inspect the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
SST 09992-00500
(2) Fully open the throttle.
(3) While cranking the engine, measure the compres-
sion pressure.
Compression pressure:
1.5 MPa (15.3 kgf/cm
2, 218 psi)
Minimum pressure:
1.0 MPa (10.2 kgf/cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 15 psi)
NOTICE:

Always use a fully-charged battery to obtain engine
speed of 250 rpm or more.

Check the other cylinder's compression pressure in
the same way.

This measurement must be done as quickly as pos-
sible.
(4) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
spark plug hole, then inspect again.
HINT:

If adding oil increases the compression, the piston rings
and/or cylinder bore may be worn or damaged.

If pressure stays low, the valve may be sticking or seated
improperly, or there may be leakage past the gasket.
10. INSPECT CO/HC
HINT:
The ECM properly controls the CO/HC concentration in the emission gas.
(a) Start the engine.
(b) Run the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Check the CO/HC concentration at idle and/or at 2,500 rpm.
HINT:
When doing the 2 mode (with the engine is at idle and at 2,500 rpm) tests, these measuring order are pre-
scribed by the applicable local regulations.
If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.
(1) Check the heated oxygen sensor operation (see page 05-126).

A86169
: Specified torque
 Non-reusable part Air Surge Tank to
Intake Manifold Gasket
8.0 (80, 71 in.Vlbf)
83 (846, 61)
15 (153, 11)
15 (153, 11)
8.4 (86, 74 in.Vlbf)15 (153, 11)
15 (153, 11)
28 (286, 21)
20 (199, 14)
28 (286, 21)
8.0 (82, 71 in.Vlbf)
20 (199, 14)
20 (199, 14)
Emission Control Valve Set
Emission Control
Valve Bracket
Engine Hanger No. 1Surge Tank Stay No. 1Surge Tank
Stay No. 2
Intake Air Surge Tank
Intake Manifold
 Intake Manifold to
Head Gasket No. 1
 Intake Manifold to
Head Gasket No. 2 Water Outlet
Ignition Coil Assy
Drive Plate
Spacer Front
Drive Plate & Ring Gear
Sub-assyDrive Plate
Spacer Rear
x8
N´m (kgf´cm, ft´lbf)
15 (153, 11)x2
x5 x4
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-21
2113 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A86565
A86566
A86567
3
472
5
6
1
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-33
2125 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
67. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-140)
SST 09213-54015 (91651-60855), 09330-00021
68. INSTALL ENGINE STAND
69. REMOVE ENGINE HANGER NO.2
70. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
71. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
72. REMOVE INTAKE MANIFOLD (See page 10-16)
73. REMOVE WATER OUTLET (See page 10-16)
74. REMOVE IGNITION COIL ASSY
75. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-120)
76. REMOVE EXHAUST MANIFOLD SUB-ASSY RH (See page 14-120)
77. REMOVE MANIFOLD CONVERTER INSULATOR NO.3
(a) Remove the bolt and nut, then remove the insulator.
78. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.2
(a) Remove the 2 bolts and insulator.
79. REMOVE EXHAUST MANIFOLD CONVERTER
SUB-ASSY NO.2
(a) Using several steps, loosen and remove the 7 nuts in the
sequence shown in the illustration.
(b) Remove the exhaust manifold converter No. 2 and gasket
from the cylinder head LH.

A86567
3
4
7
25
61
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-35
2127 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
93. INSTALL THERMOSTAT (See page 16-16)
94. INSTALL WATER INLET (See page 16-16)
95. INSTALL WATER INLET PIPE (See page 16-16)
96. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-9)
97. INSTALL GENERATOR BRACKET NO.1
Torque: 58 NVm (591 kgfVcm, 43 ftVlbf)
98. INSTALL PUMP BRACKET
Torque: 32 NVm (326 kgfVcm, 24 ftVlbf)
99. INSTALL ENGINE MOUNTING BRACKET RH (See page 17-9)
100. INSTALL MANIFOLD STAY NO.2
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
101. I N S TA L L E XHAUST MANIFOLD CONVERTER
SUB-ASSY NO.2
(a) Install a new gasket and the exhaust manifold converter
No. 2 with the 7 nuts. Using several steps, tighten the nuts
uniformly in the sequence shown in the illustration.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
(b) Retighten nuts 1 and 2 as shown in the illustration.
102. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
103. INSTALL MANIFOLD CONVERTER INSULATOR NO.3
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
104. INSTALL EXHAUST MANIFOLD SUB-ASSY RH (See page 14-120)
105. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-120)
106. INSTALL IGNITION COIL ASSY (See page 14-7)
107. INSTALL WATER OUTLET (See page 10-16)
108. INSTALL INTAKE MANIFOLD (See page 10-16)
109. INSTALL INTAKE AIR SURGE TANK (See page 11-13)
110. INSTALL EMISSION CONTROL VALVE SET (See page 11-13)
111. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-140)
SST 09213-54015 (91651-60855), 09330-00021
112. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 NVm (650 kgfVcm, 47 in.Vlbf)
113. INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40-9)
114. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9)
115. INSTALL ENGINE MOUNTING BRACKET FR (See page 40-9)
116. INSTALL STARTER ASSY (See page 19-5)

A86260
Non-reusable part
: Specified torque VSV Connector
8.0 (82, 71 in.Vlbf)x2
Emission
Control Valve Set
Emission Control Valve Bracket
Intake Air Surge Tank

Air Surge Tank
to Intake Manifold
Gasket
Throttle Motor Connector
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N´m (kgf´cm, ft´lbf)
Union to Check Valve Hose
Fuel Vapor Feed Hose
x2 x3
Engine Hunger No. 1Surge Tank Stay
No. 1
Surge Tank Stay
No. 2
20 (199, 14)
20 (199, 14)
20 (199, 14)
7.8 (80, 69 in.Vlbf)
x2
x2 Pressure Feed
Tube Assy
28 (286, 21)
x2
x2
Bond Cable No. 1
Connector
28 (286, 21)
14-88
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
2180 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A86260 Non-reusable part
: Specified torque VSV Connector
8.0 (82, 71 in.Vlbf)x2
Emission
Control Valve Set
Emission Control Valve Bracket
Intake Air Surge Tank
 Air Surge Tank
to Intake Manifold
Gasket
Throttle Motor Connector
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N´m (kgf´cm, ft´lbf)
Union to Check Valve Hose
Fuel Vapor Feed Hose
x2 x3
Engine Hunger No. 1Surge Tank Stay
No. 1
Surge Tank Stay
No. 2
20 (199, 14)
20 (199, 14)
20 (199, 14)
7.8 (80, 69 in.Vlbf)
x2
x2 Pressure Feed
Tube Assy
28 (286, 21)
x2
x2
Bond Cable No. 1
Connector
28 (286, 21)
- ENGINE MECHANICALCYLINDER HEAD GASKET (3MZ-FE)
14-1 13
2205 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

141JH-01
A86571
14-120
- ENGINE MECHANICALCYLINDER HEAD GASKET (3MZ-FE)
2212 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. DRAIN ENGINE COOLANT (See page 16-9)
4. DRAIN ENGINE OIL (See page 17-20)
5. REMOVE FRONT WHEEL RH
6. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
7. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
8. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
9. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
10. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
11. REMOVE INTAKE MANIFOLD (See page 10-16)
12. REMOVE WATER OUTLET (See page 10-16)
13. REMOVE FRONT FENDER APRON SEAL RH
14. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
15. REMOVE VANE PUMP V BELT (See page 14-5)
16. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
17. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
18. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
19. REMOVE CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
20. REMOVE TIMING BELT NO.1 COVER
21. REMOVE TIMING BELT NO.2 COVER (See page 14-79)
22. REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79)
23. REMOVE TIMING BELT GUIDE NO.2
24. REMOVE TIMING BELT (See page 14-79)
25. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
26. REMOVE CAMSHAFT TIMING PULLEY (See page 14-93)
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
27. REMOVE TIMING BELT NO.3 COVER (See page 14-93)
28. SEPARATE VANE PUMP ASSY
29. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2)
30. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2)
31. REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2)
32. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the 3 bolts and exhaust manifold heat insulator.

14-124
- ENGINE MECHANICALCYLINDER HEAD GASKET (3MZ-FE)
2216 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
68. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
69. INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1)
70. INSTALL WATER OUTLET (See page 10-16)
71. INSTALL INTAKE MANIFOLD (See page 10-16)
72. INSTALL INTAKE AIR SURGE TANK (See page 11-13)
73. INSTALL EMISSION CONTROL VALVE SET (See page 11-13)
74. INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
75. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
76. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
77. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
78. INSTALL FRONT WHEEL RH (See page 14-5)
79. ADD ENGINE OIL (See page 17-20)
80. ADD ENGINE COOLANT (See page 16-9)
81. CHECK FOR ENGINE OIL LEAKS
82. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
83. INSPECT FOR FUEL LEAKS
84. CHECK FOR EXHAUST GAS LEAKS
85. INSPECT IGNITION TIMING (See page 14-1)
SST 09843-18040
86. INSPECT ENGINE IDLE SPEED (See page 14-1)
87. INSPECT COMPRESSION (See page 14-1)
SST 09992-00500
88. INSPECT CO/HC (See page 14-1)
89. SYSTEM INITIALIZATION (See page 19-15)