2005 LEXUS ES300 width

D03569
D03629
O-ring
D03630Seal Bend Width 1.2 mm (0.047 in.) FIPG
40-64
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
88 Author
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
Bearing and bearing race diameter: mm (in.)
InsideOutside
Bearing57.2 (2.252)84.96 (3.345)
Bearing race56.4 (2.22)83 (3.268)
130. INSTALL OIL PUMP ASSY
(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22.0 NVm (226 kgfVcm, 16 ftVlbf)
(b) Coat the O-ring of oil pump with ATF.
NOTICE:
Confirm the input shaft rotates smoothly with the manual
operation after assembling the oil pump.
131. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and be careful not to get oil
on the contacting surface of the transaxle case or trans-
axle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent

A78722
SST
A78723
SST
A78724
Seal Width 2 to 3 mm (0.08 to 0.12 in.)
A
A
B
B
A78754
SST
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2145 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
56. INSTALL SPARK PLUG TUBE GASKET
(a) Using SST and a hammer, tap in the new gasket until its
surface is flush with the upper edge of the cylinder head
cover.
SST 09950- 60010 (09951- 00430), 09950- 70010
(09951-07100)
(b) Return the ventilation plate tab to its original position.
(c) Apply a light coat of multi-purpose grease to the gasket
lip.
57. INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, tap in the new oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:

Be careful not to tap the oil seal at an angle.

Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.
58. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing material from the contact sur-
face.
(b) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the oil seal retainer within 3 minutes after ap-
plying seal packing.

Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil seal retainer with the 6 bolts. Tighten the
bolts uniformly in several steps.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
59. INSTALL OIL PUMP SEAL
(a) Using SST and a hammer, tap in the new oil seal until its
surface is flush with the oil pump body edge.
SST 09223-00010
NOTICE:

Be careful not to tap the oil seal at an angle.

Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.

A36784
A78725
Seal Packing
Seal Width
2 to 3 mm
(0.08 to 0.12 in.) A
A
BB
C
C
A36785
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- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
60. INSTALL OIL PUMP ASSY
(a) Remove any old packing material from the contact sur-
face.
(b) Apply a light coat of engine oil to a new O-ring, then place
it on the cylinder block.
(c) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from contact surface.

Apply seal packing to the inner side of the bolt holes.

Install the oil pump within 3 minutes after applying
seal packing.

Do not expose the seal packing to engine oil within 2
hours after installing.
(d) Align the key of the oil pump drive gear with the keyway
located on the crankshaft, then slide the oil pump into
place.

A51990
AB
C
B
A
AA
A
A
A78726
Seal Packing
Seal Width
3 to 4 mm
(0.12 to 0.16 in.) AAB
B Region ºXº Region ºYº
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
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2147 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Install the oil pump with the 9 bolts. Tighten the bolts uni-
formly in several steps.
Torque:
8.0 NVm (82 kgfVcm, 71 in.Vlbf) for bolt A
20 NVm (199 kgfVcm, 14 ftVlbf) for bolt B
43 NVm (439 kgfVcm, 32 ftVlbf) for bolt C
61. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
62. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
63. INSTALL OIL PAN SUB-ASSY
(a) Remove any old seal packing from the contact surface.
(b) Apply a continuous bead of seal packing (Diameter 3 to
4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Apply seal packing to the outer side of the bolt holes
in the region ºXº.

Apply seal packing to the inner side of the bolt holes
in the region ºYº.

Install the oil pan within 3 minutes after applying seal
packing.

Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil pan with the 15 bolts and 2 nuts. Tighten the
bolts uniformly in several steps.
Torque:
8.0 NVm (82 kgfVcm, 71 in.Vlbf) for 10 mm head
20 NVm (199 kgfVcm, 14 ftVlbf) for 12 mm head
64. INSTALL OIL STRAINER SUB-ASSY
(a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
65. INSTALL OIL PAN SUB-ASSY NO.2
(a) Remove any old seal packing from the contact surface.

A78727
Seal Packing
Seal Width
4 to 5 mm
(0.16 to 0.20 in.) AA
BB
A78728
Seal PackingSeal Width 3 to 5 mm
(0.12 to 0.20 in.)
A78314
10
1
2
3
4
5
6
78
9 14-56
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2148 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Apply a continuous bead of seal packing (Diameter 4 to
5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Apply seal packing to the inner side of the bolt holes.

Install the oil pan within 3 minutes after applying seal
packing.

Do not expose the seal packing to engine oil within 2
hours after installing.
(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
66. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 45 NVm (459 kgfVcm, 33 ftVlbf)
67. INSTALL WATER INLET HOUSING
(a) Remove any old packing material from the contact sur-
face.
(b) Apply a continuous bead of seal packing (Diameter 3 to
5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the water inlet housing within 3 minutes after
applying seal packing.

Do not expose the seal packing to coolant within 2
hours after installing.
(c) Install the water inlet housing with the 8 bolts and 2 nuts.
Using several steps, tighten the bolts and nuts uniformly
in the sequence shown in the illustration.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)

A78779
Width
A78780
45
1.0 to 1.4 mm
(0.039 to 0.055 in.)30
A78781
45 60
1.0 to 1.4 mm
(0.039 to 0.055 in.)
EM6368
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- ENGINE MECHANICALCYLINDER HEAD ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
NOTICE:
Do not rotate the valve.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360 around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360 around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the width between 1.0 and 1.4 mm
(0.039 to 0.055 in.).
18. REPAIR VALVE SEATS
NOTICE:
Releasing the seat cutter pressure gradually helps to make
smoother valve seat faces.
(a) If the seating is too high on the valve face, use the 30 and
45 cutters to correct the seat.
(b) If the seating is too low on the valve face, use the 60 and
45 cutters to correct the seat.
(c) Lap the valve and valve seat by hand with an abrasive
compound.
(d) Recheck the valve seating position.
19. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)

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.

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
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
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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.