stop start LEXUS ES300 2005 Repair Manual

G23361DLC3
Hand-held Tester
C80826
- BRAKEBRAKE FLUID
32-5
2439 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Repeat the above procedure to bleed the air out of the
brake line for each wheel.
4. BLEED BRAKE ACTUATOR ASSY (W/ VSC)
NOTICE:
After performing the usual air bleeding in the brake system,
if the height or feel of the brake pedal cannot be obtained,
perform air bleeding in the brake actuator assy with a
hand-held tester by following procedures below.
(a) Depress the brake pedal more than 20 times with the en-
gine off.
(b) Connect the hand-held tester to the DLC3, then turn the
ignition switch to the ON position.
NOTICE:
Do not start the engine.
(c) Select ºAIR BLEEDINGº on the hand-held tester.
HINT:
Please refer to the Hand-Held Tester Operator's Manual for fur-
ther details.
(d) Bleed the air out of the regular brake line in ºStep1: In-
creaseº on the hand-held tester display.
NOTICE:

Perform the air bleeding by following the steps dis-
played on the hand-held tester.

Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect the vinyl tube to either one of the bleeder
plugs.
(2) Depress the brake pedal several times, then loosen
the bleeder plug of one of the above wheels with the
pedal depressed.
(3) When fluid stops coming out, tighten the bleeder
plug, then release the brake pedal.
(4) Repeat (2) and (3) until all air in the fluid is complete-
ly bled out.
(5) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) Repeat the above procedure to bleed the air out of
the brake line for each wheel.
(e) Bleed the air out of the suction line in ºStep2: Inhalationº
on the hand-held tester display.
NOTICE:

Perform the air bleeding by following the steps dis-
played on the hand-held tester.

Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.

3203F-08
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
C16481
Ventilation
No Ventilation 32-26
- BRAKEBRAKE BOOSTER ASSY
2460 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE BOOSTER ASSY (From July, 2003)
ON-VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Air tightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press the brake pedal several times slowly.
HINT:
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is air tight.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion switch OFF and check that there is no change
in the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Check vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.

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).

110XR-01
A62391
Circuit Opening Relay
- FUELFUEL SYSTEM (3MZ-FE)
11-1
2029 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FUEL SYSTEM (3MZ-FE)
PRECAUTION
1. PRECAUTION
(a) Before working on the fuel system, disconnect the engine wire No. 3 (battery negative terminal) from
battery.
(b) Do not smoke or work near open flame when working on the fuel system.
(c) Keep gasoline away from the rubber or leather parts.
2. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any parts of the fuel system pres-
sure until you have discharging the fuel system pres-
sure.

Even after discharge the fuel pressure, place a shop
rag over fittings as you separate them in order to re-
duce risk of fuel spray on yourself or in the engine
compartment.
(a) Disconnect the engine wire No. 3 (battery negative termi-
nal).
(b) Remove the circuit opening relay from the engine room
relay block.
(c) Connect the engine wire No. 3 (battery negative terminal).
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(d) Start the engine. After the engine has stopped on its own,
turn the ignition switch OFF.
HINT:
There is a case that DTC P0171 (system to lean) is output.
(e) Check that the engine does not start.
(f) Remove the fuel tank cap, then let the air out of the fuel
tank.
(g) Disconnect battery negative terminal.
(h) Reinstall the circuit opening relay.
3. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out. So observe these proce-
dures.
(1) Work in order to prevent gasoline from spilling out.
(2) Disconnect the fuel pump tube (see page 11-20).
(3) Drain the fuel remaining inside the fuel pump tube.

A71359
SSTSST
(T-joint)
SST
(Hose)
Fuel Tube
Connector
Fuel Inlet Tube
SST
(Hose)
A86347DLC3
Hand-held Tester
11-6
- FUELFUEL SYSTEM (3MZ-FE)
2034 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(g) Install SST (a pressure gauge) and fuel tube connector
using SST as shown in the illustration.
SST 09268-41047 (95336-08070), 09268-45014
(09268-41250, 09268-41200, 09268-41220)
(h) Wipe up any gasoline.
(i) Reconnect the engine wire No. 3 (battery negative termi-
nal).
(j) Connect the hand-hand tester to the DLC3.
(k) Measure the fuel pressure.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
If the pressure is high, replace the fuel pressure regulator.
If the pressure is low, check the fuel hose connections, fuel
pump, fuel filter and fuel pressure regulator.
(l) Disconnect the hand-held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/cm
2, 21 psi) or more
If the pressure is not as specified, check the fuel pump, pres-
sure regulator and/or fuel injectors.
(q) After checking the fuel pressure, disconnect the battery
negative terminal and carefully remove SST and the fuel
tube connector to prevent gasoline splash.
(r) Reconnect the No. 1 fuel pipe (the fuel tube connector).
CAUTION:
After taking the precautions, connect the quick connector.

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.

170FZ-02
A66623

C -29 -18 -7 4 16 27 38Recommended Viscosity (SAE)

F -20 0 20 40 60 80 1005W-30
A90353
Oil Pressure
Switch
A90354
Oil Pressure Gauge
- LUBRICATIONLUBRICATION SYSTEM (3MZ-FE)
17-1
2306 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
LUBRICATION SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) Warm up the engine, then stop the engine and wait for 5 minutes.
(b) Check that the engine oil level is between the low and full level marks on the level gage.
If low, check for leakage and add oil up to the full level mark.
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, water intrusion, discoloring
or thinning.
If the quality is visibly poor, replace the oil.
Oil grade:
Use API grade SL ºEnergy-Conservingº, or ILSAC
multigrade engine oil.
SAE 5W-30 is the best choice for good fuel economy,
and good starting in cold weather.
If SAE 5W-30 is not available, SAE 10W-30 may be
used.
However, it should be replaced with SAE 5W-30 at the
next oil replacement.
3. INSPECT OIL PRESSURE
(a) Disconnect the oil pressure switch connector.
(b) Using a deep socket wrench 24 mm, remove the oil pres-
sure switch.
(c) Install the oil pressure gauge.
(d) Warm up the engine.
(e) Inspect the oil pressure.
Oil pressure:
At idle29 kPa (0.3 kgf/cm2, 4.3 psi) or more
At 3,000 rpm245 to 539 kPa (2.5 to 5.5 kgf/cm2, 36 to 78 psi)

51018-15
F40449
F40897
Normal
Abnormal
F40898
- POWER STEERINGPOWER STEERING SYSTEM
51-3
2578 Author
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ON-VEHICLE INSPECTION
1. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords,
etc.
If any defect is found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the
missing chunks from the ribs are found on the belt, it should be
replaced.
2. BLEED POWER STEERING SYSTEM
(a) Check the fluid level.
(b) Jack up the front of the vehicle and support it with the
stands.
(c) Turn the steering wheel.
(1) With the engine stopped, turn the wheel slowly from
lock to lock several times.
(d) Lower the vehicle.
(e) Start the engine.
(1) Run the engine at idle for a few minutes.
(f) Turn the steering wheel.
(1) With the engine idling, turn the wheel to left or right
full lock position and keep it there for 2 - 3 seconds,
then turn the wheel to the opposite full lock position
and keep it there for 2 - 3 seconds.
(2) Repeat (1) several times.
(g) Stop the engine.
(h) Check for forming or emulsification.
Especially, if the system has to be bled twice because of foam-
ing or emulsification, check for fluid leaks in the system.
(i) Check the fluid level.
3. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir cap. If the fluid is cold, check that it is within the COLD
LEVEL range.

F40897
NormalAbnormal
R11786Engine Idling Engine Stopped5 mm (0.20 in.)
or less 51-4
- POWER STEERINGPOWER STEERING SYSTEM
2579 Author
: Date
:
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
raise fluid temperature.
Fluid temperature: 75 - 80°C (167 - 176°F)
(e) Check for foaming or emulsification.
If foaming or emulsification is identified, bleed the power steer-
ing system.
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed the power steering system.
(i) Check the fluid level.
4. CHECK STEERING FLUID PRESSURE
(a) Disconnect the pressure feed tube assy from the rack &
pinion power steering gear assy (See page 51-21).
(b) Connect SST, as shown in the illustration.
SST 09640-10010 (09641-01010, 09641-01020,
09641-01030)
NOTICE:
Check that the valve of the SST is in the open position.
(c) Bleed the power steering system.
(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to
raise fluid temperature.
Fluid temperature: 75 - 80 °C (167 - 176 °F)