engine LEXUS ES300 2005 Repair Manual

110XX-02
A79487
(b)
(c)
A91017
Nylon Tube Fuel Tube Joint
O-ring
Tube Joint Clip Fuel Suction Plate
A79488
Tube Joint Clip
A79489
(b)
(b)
(b)(b)(b)
(b)
(b)
(b) 11-20
- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
2048 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Removal & Installation and Disassembly & Reassembly
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3. REMOVE REAR SEAT CUSHION ASSY (See page 72-39)
4. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Remove the rear floor service hole cover.
(b) Disconnect the vapor pressure sensor connector.
(c) Disconnect the fuel pump connector.
5. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY
(a) Remove the tube joint clip, then pull out the fuel pump
tube.
NOTICE:

Check around the connector for dirt or mud before
this operation. Remove the dirt if necessary.

Be careful of mud because the fuel tube joint has an
O-ring which seals the pipe and connector that can
be contaminated.

Do not use any tools in this operation.

Do not bend or twist the nylon tube. Protect the con-
nector by covering it with a vinyl or plastic bag.

When the pipe and connector are stuck, push and pull
the connector to release. Pull the connector carefully.
(b) Remove the 8 bolts, then remove the fuel tank vent tube
set plate.

A79489Mark
A81595
Tube Joint ClipCollar
A79487
New Butyl Tape
11-24- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
2052 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
24. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY
(a) Install a new gasket to the fuel suction tube w/ pump &
gauge.
(b) Install the fuel suction tube w/ pump & gauge to the fuel
tank.
NOTICE:

Do not damage the fuel pump filter.

Do not bend the arm of the fuel sender gauge.
(c) Align the mark of the fuel tank vent tube set plate with the
fuel suction tube w/ pump & gauge.
(d) Install the fuel tank bent tube set plate with the 8 bolts.
Torque: 5.9 NVm (60 kgfVcm, 52 in.Vlbf)
(e) Install the fuel pump tube with the tube joint clip.
NOTICE:

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

Check that the fuel tube joint is inserted securely.

Check that the tube joint clip is on the collar of the fuel
tube joint.

After installing the tube joint clip, check that the fuel
tube joint has not been pulled off.
25. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
26. CHECK FOR FUEL LEAKS (See page 11-5)
27. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the fuel pump connector.
(b) Connect the vapor pressure sensor connector.
(c) Using new butyl tape, install the rear floor service hole
cover.
28. INSTALL REAR SEAT CUSHION ASSY
29. SYSTEM INITIALIZATION (See page 19-15)

110XZ-01
A86274
(a)
(b)
(a)
(a)
(a)
(b)
A79472
11-28
- FUELFUEL TANK ASSY (3MZ-FE)
2056 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Removal & Installation and Disassembly & Reassembly
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3. REMOVE REAR SEAT CUSHION ASSY (See page 72-39)
4. REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-20)
5. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20)
6. DRAIN FUEL
7. REMOVE FLOOR PANEL BRACE REAR (See page 15-2)
8. REMOVE EXHAUST PIPE ASSY CENTER
(a) Remove the 2 bolts and 4 nuts.
(b) Remove the exhaust pipe center and 2 gaskets from the
2 exhaust pipe supports.
9. DISCONNECT PARKING BRAKE CABLE ASSY NO.2
(a) Remove the bolt and nut, then disconnect the parking
brake cable No. 2.

A81598
Retainer
Push
- FUELFUEL TANK ASSY (3MZ-FE)
11-33
2061 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(i) Connect the fuel pump tube.
(1) Push in the quick connector to the pipe until the
quick connector makes a ºclickº sound, then push
up the retainer until the claws lock.
NOTICE:

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

After connecting, check if the connector and pipe are
securely connected by pulling on them.
22. INSTALL FUEL TANK PROTECTOR LOWER CENTER
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
23. INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
24. INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
25. INSTALL EXHAUST PIPE ASSY CENTER
(a) Install 2 new gaskets and the exhaust pipe center to the 2 exhaust pipe supports.
(b) Tighten the 2 bolts and 4 new nuts.
Torque: 56 NVm (571 kgfVcm, 41 ftVlbf)
26. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20)
27. ADD FUEL
28. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
29. CHECK FOR FUEL LEAKS (See page 11-5)
30. CHECK FOR EXHAUST GAS LEAKS
31. INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20)
32. INSTALL REAR SEAT CUSHION ASSY
33. INSTALL FLOOR PANEL BRACE REAR (See page 15-2)
34. SYSTEM INITIALIZATION (See page 19-15)

120C1-02
G37992
Voltmeter E9 E8
A86347DLC3
Hand-held Tester
A86385
Lean
14.7 3.3 V
RichAir
Fuel
Ratio
Time Keep the engine speed
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-3
2064 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ON-VEHICLE INSPECTION
1. INSPECT AIR FUEL RATIO COMPENSATION SYSTEM
(a) Inspect the voltage.
(1) Turn the ignition switch ON.
(2) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Standard:
Tester ConnectionSpecified Condition
A1A+ (E9-22) - E1 (E8-1)3.3 V
A1A- (E9-30) - E1 (E8-1)3.0 V
A2A+ (E9-23) - E1 (E8-1)3.3 V
A2A- (E9-31) - E1 (E8-1)3.0 V
CAUTION:
Connect the test leads from the back side of the ECM con-
nector to the terminals.
HINT:
The voltage between the terminals of the ECM is constant re-
gardless of the voltage output from the air fuel ratio sensor (A/F
sensor).
(b) Check the operation.
(1) Connect the hand-held tester to the DLC3.
(2) Enter ºDIAGNOSIS/ENHANCED OBD II/DATA
LISTº, then select ºAFS B1 S1º and ºAFS B2 S1º to
display the monitor.
(3) Warm up the A/F sensor with the engine speed at
2,500 rpm for approximately 2 minutes.
(4) Keep the engine speed at 2,500 rpm, then confirm
that the waveform of ºAFS B1 S1º and ºAFS B2 S1º
are similar as shown in the illustration.
HINT:

The waveform in the illustration is a sample.

Only the hand-held tester displays the waveform of the
A/F sensor.
(c) Confirm that the display of ºDATA LISTº - ºO2S B1 S2º
and ºO2S B2 S2º fluctuates up and down between 0 V
and 1 V with the engine speed at 2,500 rpm.

A86346
A59499
Vacuum Gauge
A86347DLC3
Hand-held Tester
12-4
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2065 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
2. INSPECT FUEL CUT OFF RPM
(a) Check the operation.
(1) Increase the engine speed to at least 3,500 rpm.
(2) Use a sound scope to check the fuel injector operating noise.
(3) Check that when the throttle lever is released, the fuel injector operation noise stops momentarily
at 2,500 rpm and then resumes at 1,200 rpm.
2,500 rpm: Fuel cut off rpm
1,200 rpm: Fuel return rpm
3. VISUALLY INSPECT HOSES, CONNECTIONS AND
GASKETS
(a) Check the appearance.
(1) Check the engine assembly to see if the indicated
portions by the arrows have cracks, leaks or dam-
age.
HINT:
Separation of the engine oil level gauge, oil filler cap, PCV
hose, etc. may cause the engine to run improperly. Disconnec-
tion, looseness or cracks in the parts of the air induction system
between the throttle body and cylinder head will allow air suc-
tion and cause the engine to run improperly.
If necessary, repair the engine assembly.
4. INSPECT EVAP SYSTEM LINE
(a) Warm up the engine to the normal operating temperature.
(b) Connect the vacuum gauge (EVAP control system test
equipment vacuum gauge) to the EVAP service port on
the purge line. Then stop the engine.
(c) If you have the hand-held tester:
Force the VSV for EVAP to operate.
(1) Connect the hand-held tester to the DLC3.
(2) Start the engine.
(3) Turn the hand-held tester ON.
(4) Use the ACTIVE TEST mode on the hand-held tes-
ter to operate the VSV for EVAP.

A86348Battery
A59500
Vacuum Gauge
A72589
Pressure Gauge
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-5
2066 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) If you have no hand-held tester:
Force the VSV for EVAP to operate.
(1) Disconnect the VSV for EVAP connector.
(2) Connect the positive (+) and negative (-) leads of
the battery to the VSV for EVAP terminals.
(3) Start the engine.
(e) Check the vacuum at idle.
Vacuum:
Maintain at 0.368 to 19.713 in.Hg (5 to 268 in.Aq) for
over 5 seconds.
HINT:
If the vacuum does not change, it can be concluded that the
hose which connects the VSV to the service port is loose or
blocked, or the VSV is malfunctioning.
(f) If you have the hand-held tester:
Return to the normal VSV for EVAP.
(1) Stop the engine.
(2) Disconnect the hand-held tester from the DLC3.
(g) If you have no hand-held tester:
Return to the normal VSV for EVAP.
(1) Stop the engine.
(2) Disconnect the positive (+) and negative (-) leads
of the battery from the VSV for EVAP terminals.
(3) Reconnect the VSV for EVAP connector.
(h) Disconnect the vacuum gauge from the EVAP service
port on the purge line.
(i) Connect a pressure gauge to the EVAP service port on
the purge line.

A86347DLC3
Hand-held Tester
A86349Battery
A59501
Pressure Gauge
Pressure
A52634
Fuel Tank CapPressure Gauge
12-6
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2067 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(j) If you have the hand-held tester:
Force the VSV for CCV to operate.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Turn the hand-held tester ON.
(4) Use the ACTIVE TEST mode on the hand-held tes-
ter to operate the VSV for CCV.
NOTICE:
Do not start the engine during this operation.
HINT:
If the check is not completed within 10 minutes, the forced close
of the VSV for CCV will be tested.
(k) If you have no hand-held tester:
Force the VSV for CCV to operate.
(1) Disconnect the VSV for CCV connector.
(2) Connect the positive (+) and negative (-) leads of
the battery to the VSV for CCV terminals.
(l) Check the pressure.
(1) Add the pressure (13.5 to 15.5 in.Aq) from the
EVAP service port.
Pressure:
2 minutes after the pressure is added, the gauge
should be over 7.7 to 8.8 in.Aq.
HINT:
If you cannot add the pressure, it can be concluded that the
hose which connects the VSV for EVAP canister fuel tank is
slipped off or the VSV is open.
(2) Check if the pressure decreases when the fuel tank
cap is removed while adding the pressure.
HINT:
If the pressure does not decrease when the filler cap is re-
moved, it can be concluded that the hose which connects the
service port to the fuel tank is blocked, etc.
(m) If you have the hand-held tester:
Return to the normal VSV for CCV operation.
(1) Turn the ignition switch ON.
(2) Disconnect the hand-held tester from the DLC3.
(n) If you have no hand-held tester:
Return to the normal VSV for CCV operation.
(1) Disconnect the positive (+) and negative (-) leads
of the battery to the VSV for CCV terminals.
(2) Reconnect the VSV for CCV connector.

120BT-01
A86270
(a)
(b)
(b)(c)
A86393
A A
PushPinch
Pinch
A86360
(e)
(e)
(f) 12-16
- EMISSION CONTROLCHARCOAL CANISTER ASSY (3MZ-FE)
2077 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CHARCOAL CANISTER ASSY (3MZ-FE)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3. REMOVE REAR SEAT CUSHION ASSY (See page 72-39)
4. REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-20)
5. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20)
6. DRAIN FUEL
7. REMOVE FLOOR PANEL BRACE REAR (See page 15-2)
8. REMOVE EXHAUST PIPE ASSY CENTER (See page 11-28)
9. DISCONNECT PARKING BRAKE CABLE ASSY NO.2 (See page 11-28)
10. DISCONNECT PARKING BRAKE CABLE ASSY NO.3 (See page 11-28)
11. REMOVE FUEL TANK PROTECTOR LOWER CENTER (See page 11-28)
12. REMOVE FUEL TANK ASSY (See page 11-28)
13. REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the VSV connector.
(b) Remove the 2 wire harness clamps.
(c) Disconnect the fuel hose No. 1.
(d) Disconnect the fuel tank vent hose.
(1) Deeply push the quick connector to release the lock
pin.
(2) Pinch portion A.
(3) Pull out the fuel tank vent hose.
(e) Remove the 2 bolts.
(f) Unfasten the claw, then remove the charcoal canister.

A87557
A86389
Push
- EMISSION CONTROLCHARCOAL CANISTER ASSY (3MZ-FE)
12-17
2078 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. REMOVE FUEL EMISSION TUBE FUEL HOSE
(a) Remove the fuel emission tube fuel hose.
15. INSTALL FUEL EMISSION TUBE FUEL HOSE
16. INSTALL CHARCOAL CANISTER ASSY
(a) Install the charcoal canister with the 2 bolts.
Torque: 40 NVm (400 kgfVcm, 29 ftVlbf)
(b) Connect the fuel tank vent hose.
(1) Push in the quick connector to the pipe until the
quick connector makes a ºclickº sound.
NOTICE:

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

After connecting, check if the quick connector and
pipe are securely connected by pulling on them.
(c) Connect the fuel hose No. 1.
(d) Install the 3 wire harness clamps.
(e) Connect the VSV connector.
17. INSTALL FUEL TANK ASSY (See page 11-28)
18. INSTALL FUEL TANK PROTECTOR LOWER CENTER (See page 11-28)
19. INSTALL PARKING BRAKE CABLE ASSY NO.3 (See page 11-28)
20. INSTALL PARKING BRAKE CABLE ASSY NO.2 (See page 11-28)
21. INSTALL EXHAUST PIPE ASSY CENTER (See page 11-28)
22. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20)
23. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
24. ADD FUEL
25. CHECK FOR FUEL LEAKS (See page 11-5)
26. CHECK FOR EXHAUST GAS LEAKS
27. INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20)
28. INSTALL REAR SEAT CUSHION ASSY
29. INSTALL FLOOR PANEL BRACE REAR (See page 15-2)
30. SYSTEM INITIALIZATION (See page 19-15)