lock LEXUS ES300 2005 Repair Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 557 of 969
A78323
10
45
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-181
2273 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) After applying the specified torque, rotate the drain cock
clockwise as shown in the illustration.
Torque: 39 NVm (398 kgfVcm, 29 ftVlbf)
NOTICE:
Install the drain cock within 3 minutes after applying
adhesive.
Do not expose the drain cock to coolant within 1 hour
after installing.
Do not rotate the drain cock by more than 1 revolution
(360) after tightening the drain cock with the speci-
fied torque.
Do not loosen the drain cock after setting it correctly.
Page 574 of 969
A86265
(c)
(d)
(d)
(d)
(d)
(d)(d)
A862661 2
3 4
75
68
9 10
11
A86267
(a)
(b)
(c)
- ENGINE CONTROL SYSTEMKNOCK SENSOR (3MZ-FE)
10-17
2022 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Remove the nut, then disconnect the ground cable.
(d) Disconnect the 6 fuel injector connectors.
(e) In order to remove the intake manifold, using several
steps, remove the 9 bolts and 2 nuts in the sequence
shown in the illustration.
11. REMOVE WATER OUTLET
(a) Disconnect the bond cable No. 1 connector.
(b) Disconnect the pipe of the radiator reserve tank.
(c) Lock the hose clamp as shown in the illustration, then dis-
connect the radiator hose inlet.
Page 575 of 969
A86268
(d)
(e)
(f)
(f)
(f)
(f)
(g)
A79749
(a)
(b)
(a)
(b)
A79750
Upper
Engine
Front0 to 5 10-18
- ENGINE CONTROL SYSTEMKNOCK SENSOR (3MZ-FE)
2023 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Disconnect the engine coolant temperature sensor con-
nector.
(e) Remove the clamp.
(f) Remove the 2 bolts, 2 nuts and 2 washers.
(g) Lock the hose clamp as shown in the illustration. Then re-
move the water outlet together with water by-pass hose
No. 1.
(h) Remove the 2 gaskets from the 2 cylinder heads.
12. REMOVE KNOCK SENSOR
(a) Disconnect the 2 knock sensor connectors.
(b) Remove the 2 nuts, then remove the 2 knock sensors.
13. INSTALL KNOCK SENSOR
(a) Install the 2 knock sensors with the 2 nuts as shown in the
illustration.
Torque: 20 NVm (204 kgfVcm, 14 ftVlbf)
(b) Connect the 2 knock sensor connectors.
14. INSTALL WATER OUTLET
(a) Install 2 new gaskets to the 2 cylinder heads.
(b) Install the water outlet together with water by-pass hose No. 1, then unlock the hose clamp.
(c) Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 NVm (153 kgfVcm, 11 ftVlbf)
(d) Install the clamp.
(e) Connect the engine coolant temperature sensor connector.
(f) Connect the bond cable No. 3 connector.
(g) Connect the pipe of the radiator reserve tank.
(h) Connect the radiator hose inlet, then unlock the hose clamp.
Page 581 of 969
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.
Page 587 of 969
A86347DLC3
Hand-held Tester
A62390
FP
+B
- FUELFUEL SYSTEM (3MZ-FE)
11-7
2035 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand-held tester.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON and the hand-held tes-
ter ON.
NOTICE:
Do not start the engine.
(3) Select the ACTIVE TEST mode on the hand-held
tester.
(4) If you need help to select the ACTIVE TEST mode
on the hand-held tester, refer to the hand-held tes-
ter operator's manual.
(b) When not using the hand-held tester.
(1) Remove the circuit opening relay.
(2) Using a service wire, connect terminals FP and +B
of the engine room relay block.
NOTICE:
Pay due attention to the terminal connecting position to
avoid a malfunction.
(3) Turn the ignition switch ON, and check that the fuel
pump operates.
NOTICE:
Do not start the engine.
(c) Check that there are no fuel leaks after doing mainte-
nance anywhere on the fuel system.
Page 609 of 969
A79473
A79476
A79474
Pinch
PinchRetainer
Pull Out
A81596
Retainer
Pipe
O-ring Quick Connector
Nylon Tube
- FUELFUEL TANK ASSY (3MZ-FE)
11-29
2057 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. DISCONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Remove the bolt and nut, then disconnect the parking
brake cable No. 3.
11. REMOVE FUEL TANK PROTECTOR LOWER CENTER
(a) Remove the 4 bolts, then remove the fuel tank protector
lower center.
12. REMOVE FUEL TANK ASSY
(a) Disconnect the fuel pump tube.
(1) Pinch the projection of the retainer to remove the
lock claws, then pull it down as shown in the illustra-
tion.
(2) 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 out the
quick connector from the pipe.
Page 610 of 969
A86275
PinchPinch
Pull Out
A75650
Tube Connector
Pipe O-ring Nylon Tube
Quick Connector
A86276
A
A
Push
Pinch
Pinch(d)(d)
(e)
A79478
11-30
- FUELFUEL TANK ASSY (3MZ-FE)
2058 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Disconnect the fuel tube No. 1.
(1) Pinch the tube connector, then pull out the fuel tube
No. 1.
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 out the
quick connector carefully.
(c) Set up a transmission jack underneath the fuel tank.
(d) Remove the 2 bolts which hold the fuel tank bands.
(e) Loosen the clamp bolt.
(f) Operate the transmission jack, then disconnect the fuel
tank inlet pipe.
(g) Disconnect the fuel tank vent hose from the charcoal can-
ister.
(1) Deeply push the quick connector to release the lock
pin.
(2) Pinch portion A.
(3) Pull out the fuel tank vent hose.
(h) Operate the transmission jack, then remove the fuel tank.
(i) Remove the 2 pins, then remove the 2 fuel tank bands as
shown in the illustration.
Page 611 of 969
A79482
(j)(j)
(j)(j)
A86277Pinch
PinchPushAA
A79480
A79481
A79484
- FUELFUEL TANK ASSY (3MZ-FE)
11-31
2059 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(j) Remove the 4 clip nuts.
13. REMOVE FUEL TANK VENT HOSE
(a) Deeply push the quick connector to release the lock pin.
(b) Pinch portion A.
(c) Pull out the fuel tank vent hose.
14. REMOVE FUEL PUMP TUBE SUB-ASSY
(a) Remove the fuel pump tube from the fuel main tube sup-
port.
15. REMOVE FUEL MAIN TUBE SUPPORT
(a) Remove the bolt, then remove the fuel main tube support.
16. REMOVE FUEL TANK CUSHION NO.2
(a) Remove the 7 fuel tank cushions from the fuel tank.
Page 613 of 969
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)
Page 618 of 969
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.