LEXUS ES300 2005 Repair Manual

Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005
Pages: 969, PDF Size: 24.08 MB

Page 631 of 969

120BW-01
A86357
A A
Push
Pinch
Pinch
PushPinch
Pinch
(b)
A86388
Push
Push 12-18
- EMISSION CONTROLCHARCOAL CANISTER FILTER SUB-ASSY (3MZ-FE)
2079 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CHARCOAL CANISTER FILTER SUB-ASSY (3MZ-FE)
REPLACEMENT
1. REMOVE CHARCOAL CANISTER FILTER SUB-ASSY
(a) Disconnect the 2 fuel tank vent hoses.
(1) Deeply push the quick connector to release the lock
pin.
(2) Pinch portion A.
(3) Pull out the 2 fuel tank vent hoses.
(b) Remove the bolt, then remove the charcoal canister filter.
2. INSTALL CHARCOAL CANISTER FILTER SUB-ASSY
(a) Install the charcoal canister filter with the bolt.
Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf)
(b) Connect the 2 fuel tank vent hoses.
(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.

Page 632 of 969

120BU-01
A79751
(b)(a)
(a)
A86217
(c)
(d)
(e)(f)
(g)
(g)
A86278
(a)
(b)
(a)
- EMISSION CONTROLDUTY VACUUM SWITCHING VALVE (3MZ-FE)
12-19
2080 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
DUTY VACUUM SWITCHING VALVE (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 EMISSION CONTROL VALVE SET
(a) Disconnect the 2 VSV connectors.
(b) Remove the wire harness clamp.
(c) Disconnect the fuel vapor feed hose No. 1.
(d) Disconnect the fuel vapor feed hose No. 2.
(e) Disconnect the vacuum hose.
(f) Remove the vacuum hose from the clamp.
(g) Remove the 2 nuts, then remove the emission control
valve set.
4. REMOVE DUTY VACUUM SWITCHING VALVE
(a) Disconnect the 2 vacuum hoses.
(b) Remove the screw, then remove the duty vacuum switch-
ing valve.
5. INSTALL DUTY VACUUM SWITCHING VALVE
6. INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
7. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
8. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
9. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
10. SYSTEM INITIALIZATION (See page 19-15)

Page 633 of 969

120BV-02
A91017
Nylon Tube Fuel Tube Joint
O-ring
Tube Joint Clip Fuel Suction Plate
A79488
Tube Joint Clip
A79489
A79491
Cover
Tube Joint Clip
12-20
- EMISSION CONTROLVAPOR PRESSURE SENSOR ASSY (3MZ-FE)
2081 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
VAPOR PRESSURE SENSOR 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. DISCONNECT FUEL PUMP TUBE SUB-ASSY
(a) Remove the tube joint clip, then pull out the fuel pump
tube.
NOTICE:
Check around the quick connector for dirt or mud be-
fore this operation. Remove the dirt if necessary.
Be careful of mud because the quick connector has
an O-ring which seals the pipe and quick connector
that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the quick
connector by covering it with a vinyl or plastic bag.
When the pipe and quick connector are stuck, push
and pull the quick connector to release. Pull the quick
connector carefully.
6. REMOVE FUEL TANK VENT TUBE SET PLATE
(a) Remove the 8 bolts, then remove the fuel tank vent tube
set plate.
7. REMOVE VAPOR PRESSURE SENSOR ASSY
(a) Remove the cover.
(b) Remove the tube joint clip, then pull out the vapor pres-
sure sensor.

Page 634 of 969

A86272
Cover
Tube Joint Clip
A79489Mark
A81595
Tube Joint ClipCollar
- EMISSION CONTROLVAPOR PRESSURE SENSOR ASSY (3MZ-FE)
12-21
2082 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
8. 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.
9. INSTALL FUEL TANK VENT TUBE SET PLATE
(a) Align the mark of the fuel tank vent tube set plate with the
fuel suction tube w/ pump & gauge.
(b) Install the fuel tank vent tube set plate with the 8 bolts.
Torque: 5.9 NVm (60 kgfVcm, 52 in.Vlbf)
10. CONNECT FUEL PUMP TUBE SUB-ASSY
(a) 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.
11. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
12. CHECK FOR FUEL LEAKS (See page 11-5)
13. INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20)
14. INSTALL REAR SEAT CUSHION ASSY
15. SYSTEM INITIALIZATION (See page 19-15)

Page 635 of 969

120BY-01
A86340
(a)
(b)
(b)(b)
A86354
SST
A86354
SST
12-22
- EMISSION CONTROLAIR FUEL RATIO SENSOR (3MZ-FE (RH BANK))
2083 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AIR FUEL RATIO SENSOR (3MZ-FE (RH BANK))
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2)
3. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2)
4. REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2)
5. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the 3 bolts, then remove the exhaust manifold
heat insulator No. 1.
6. REMOVE AIR FUEL RATIO SENSOR
(a) Using SST, remove the air fuel ratio sensor.
SST 09224-00010
7. INSTALL AIR FUEL RATIO SENSOR
(a) Using SST, install the air fuel ratio sensor.
SST 09224-00010
Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)
8. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 8.5 NVm (87 kgfVcm, 75 in.Vlbf)
9. INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2)
10. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2)
11. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2)
12. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
13. CHECK FOR EXHAUST GAS LEAKS
14. SYSTEM INITIALIZATION (See page 19-15)

Page 636 of 969

120BZ-01
A86359
(a)
(b)
A86353
(c)
SST
A86353
SST
- EMISSION CONTROLAIR FUEL RATIO SENSOR (3MZ-FE (LH BANK))
12-23
2084 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AIR FUEL RATIO SENSOR (3MZ-FE (LH BANK))
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE AIR FUEL RATIO SENSOR
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the wire harness clamp.
(c) Using SST, remove the air fuel ratio sensor.
SST 09224-00010
3. INSTALL AIR FUEL RATIO SENSOR
(a) Using SST, install the air fuel ratio sensor.
SST 09224-00010
Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)
(b) Install the wire harness clamp.
(c) Connect the air fuel ratio sensor connector.
4. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
5. CHECK FOR EXHAUST GAS LEAKS
6. SYSTEM INITIALIZATION (See page 19-15)

Page 637 of 969

Page 638 of 969

1307V-01
A82242
3-way
Connector Vacuum Gauge
A86347DLC3
Hand-held Tester
- INTAKEINTAKE AIR CONTROL SYSTEM (3MZ-FE)
13-1
2086 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INTAKE AIR CONTROL SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1. INSPECT INTAKE CONTROL VALVE ASSY NO. 2
(a) Check the operation.
(1) Using a 3-way connector, connect the vacuum
gauge to the actuator hose as shown in the illustra-
tion.
(2) Connect the hand-held tester to the DLC3.
(3) Start the engine.
(4) Turn the hand-held tester switch ON.
(5) Select the item ºDIAGNOSIS/ENHANCED OBD II/
ACTIVE TEST/INTAKE CTL VSV1º and operate
the VSV for AICS.
Vacuum:
Tester OperationSpecified Condition
VSV is ONApproximately 27.6 kpa (200 mmHg, 7.9 in.Hg)
VSV is OFF0 kPa (0 mmHg, 0 in.Hg)
If the operation is not as specified, replace the intake air control
valve No. 2.

Page 639 of 969

1307W-01
A82243
Hand-held
Vacuum PumpValve
A86222
Hand-held
Vacuum Pump
Valve
A86223
Ohmmeter
A86224
Ohmmeter
Body
13-2
- INTAKEINTAKE AIR CONTROL SYSTEM (3MZ-FE)
2087 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INSPECTION
1. INSPECT INTAKE AIR CONTROL VALVE ASSY NO.2
(a) Check the operation.
(1) With vacuum of 26.7 kPa (200 mmHg, 7.9 in.Hg) ap-
plied to the actuator, check that the valve closes.
(2) 1 minute after applying the vacuum, check that the
valve remains closed.
NOTICE:
Do not adjust the adjust screw.
If the operation is not as specified, replace the intake air control
valve No. 2.
2. INSPECT INTAKE AIR CONTROL VALVE ASSY NO.3
(a) Check the operation.
(1) With vacuum of 26.7 kPa (200 mmHg, 7.9 in.Hg) ap-
plied to the actuator, check that the valve opens.
(2) 1 minute after applying the vacuum, check that the
valve remains opened.
If the operation is not as specified, replace the intake air control
valve No. 3.
(b) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
Tester ConnectionSpecified Condition
1 - 237 to 44W at 20C (68 F)
If the resistance is not as specified, replace the intake air control
valve No. 3.
(c) Check the continuity.
(1) Using an ohmmeter, check that there is no continu-
ity between each terminal and the body.
If there is continuity, replace the intake air control valve No. 3.

Page 640 of 969

A86225
Air
E
Filter
A86226
Battery E
FAir
A86227
Ohmmeter
A86228
Ohmmeter
Body
A86229
Air
E
Filter
- INTAKEINTAKE AIR CONTROL SYSTEM (3MZ-FE)
13-3
2088 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Check the operation.
(1) Check that air flows from port E to the filter.
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to F.
If the operation is not as specified, replace the intake air control
valve No. 3.
3. INSPECT VACUUM SWITCHING VALVE ASSY NO.1
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
Tester ConnectionSpecified Condition
1 - 233 to 39W at 20C (68F)
If the resistance is not as specified, replace the vacuum switch-
ing valve No. 1.
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continu-
ity between each terminal and the body.
If there is continuity, replace the vacuum switching valve No. 1.
(c) Check the operation.
(1) Check that air flows from port E to the filter.

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