fuel system LEXUS ES300 2005 User Guide
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 571 of 969
A86260 Non-reusable part
: Specified torque VSV Connector
8.0 (82, 71 in.Vlbf)x2
Emission
Control Valve Set
Emission Control Valve Bracket
Intake Air Surge Tank
Air Surge Tank
to Intake Manifold
Gasket
Throttle Motor Connector
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N´m (kgf´cm, ft´lbf)
Union to Check Valve Hose
Fuel Vapor Feed Hose
x2 x3
Engine Hunger No. 1Surge Tank Stay
No. 1
Surge Tank Stay
No. 2
20 (204, 14)
20 (204, 14)
20 (204, 14)
7.8 (80, 69 in.Vlbf)
x2
x2 Pressure Feed
Tube Assy
28 (286, 21)
x2
x2
Bond Cable No. 1
Connector
28 (286, 21)
10-14
- ENGINE CONTROL SYSTEMKNOCK SENSOR (3MZ-FE)
2019 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 572 of 969
A86261 Non-reusable part
: Specified torqueN´m (kgf´cm, ft´lbf)Knock Sensor
Knock Sensor Connector
20 (204, 14)
Intake Manifold
to Head Gasket No. 2 Intake Manifold
to Head Gasket No. 1
Radiator Hose InletWater Outlet
Heater Inlet
Water Hose Intake Manifold Ground Cable
Washer
8.4 (86, 74 in.Vlbf)
x2x9
x2
Washer
15 (153, 11)
15 (153, 11)
Fuel Pipe
Clamp
Engine Moving
Control Rod
23 (235, 17)
15 (153, 11)
x2
Fuel Injector
Connector
Clamp
Fuel Injector Connector
64 (653, 47)
x2
Engine Coolant
Temperature Sensor
Connector
Radio Setting
Condenser
64 (653, 47)
Bond Cable No. 1
Connector
Pipe
- ENGINE CONTROL SYSTEMKNOCK SENSOR (3MZ-FE)
10-15
2020 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 573 of 969
100J7-02
A86262
(a)
(b)
(b)
(b)
(b)
A86263
Fuel Pipe
Clamp
Pinch
Pinch
Pull Out
A75650
Tube Connector
Pipe O-ring Nylon Tube
Quick Connector
A86264
(b) 10-16
- ENGINE CONTROL SYSTEMKNOCK SENSOR (3MZ-FE)
2021 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3. DRAIN ENGINE COOLANT (See page 16-9)
4. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
5. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
6. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
7. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
8. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
9. REMOVE ENGINE MOVING CONTROL ROD
(a) Remove the pipe from the clamp.
(b) Remove the 4 bolts, then remove the engine moving con-
trol rod and radio setting condenser.
10. REMOVE INTAKE MANIFOLD
(a) Disconnect the fuel pipe No. 1.
(1) Remove the fuel pipe clamp.
(2) Pinch the tube connector, then pull out the fuel pipe
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 and pull the
quick connector out carefully.
(b) Disconnect the heater inlet water hose.
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 576 of 969
A8626611 10
9 8
5
7
64
3 2
1
A86269
Push
Fuel Pipe
Clamp
A86262
A
B
B
B
- ENGINE CONTROL SYSTEMKNOCK SENSOR (3MZ-FE)
10-19
2024 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
15. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold with the 9 bolts, 2 nuts and 2
washers. Using several steps, tighten the 9 bolts and 2
nuts uniformly in the sequence shown in the illustration.
Torque: 15 NVm (153 kgfVcm, 11 ftVlbf)
(b) Retighten the 9 water outlet mounting bolts and 2 nuts.
Torque: 15 NVm (153 kgfVcm, 11 ftVlbf)
(c) Install the ground cable with the nut.
Torque: 8.4 NVm (86 kgfVcm, 74 in.Vlbf)
(d) Connect the heater inlet water hose.
(e) Connect the fuel pipe No. 1.
(1) Push in the quick connector to the pipe until it
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 them.
(2) Install the fuel pipe clamp.
16. INSTALL ENGINE MOVING CONTROL ROD
Torque:
23 NVm (235 kgfVcm, 17 ftVlbf) for bolt A
64 NVm (653 kgfVcm, 47 ftVlbf) for bolt B
17. INSTALL INTAKE AIR SURGE TANK (See page 11-13)
18. INSTALL EMISSION CONTROL VALVE SET (See page 11-13)
19. INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
20. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
21. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
22. ADD ENGINE COOLANT (See page 16-9)
23. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
24. CHECK FOR FUEL LEAKS (See page 11-5)
25. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
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 582 of 969
B00679
B00347
New O-ring
Delivery Pipe
InjectorCORRECT
WRONG
Grommet
FI6372
A62371
Delivery Pipe
Spacer
InsulatorO-ring
Grommet
A60083
Fuel Pipe
Clamp
11-2
- FUELFUEL SYSTEM (3MZ-FE)
2030 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(4) In order to prevent the disconnected fuel pump tube
from being damaged and foreign objects from being
introduced, cover the disconnected fuel pump tube
with a vinyl or plastic bag.
(5) Place a tray under the vehicle or point of disconnec-
tion to catch any fuel that may spill.
(6) Put a container under the connection.
(b) Take the following precautions when removing and instal-
ling the fuel injectors.
NOTICE:
Never reuse the O-ring.
(1) When installing a new O-ring on the fuel injector, be
careful not to damage it.
(2) Coat a new O-ring with spindle oil or gasoline be-
fore installing. Never use engine oil, gear oil or
brake oil.
(c) Install the fuel injector to the fuel delivery pipe and intake
manifold as shown in the illustration. Before installing the
fuel injector, be sure to apply spindle oil or gasoline to the
place where the fuel delivery pipe or intake manifold
touches the O-ring of the fuel injector.
(d) Take the following precautions when disconnecting the
quick connector.
(1) Remove the fuel pipe clamp.
(2) Check the pipe and around the quick connector for
dirt or mud before disconnecting them. Remove the
dirt if necessary.
Page 583 of 969
A
A
B12941
B12944
Vinyl Bag
A52581
A71366
Push
A71366
Pull
- FUELFUEL SYSTEM (3MZ-FE)
11-3
2031 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(3) Disconnect the quick connector from the pipe while
pinching portion A with your fingers as shown in the
illustration.
(4) If the quick connector and pipe are stuck, pinch the
pipe, then push and pull the quick connector to re-
lease and pull it out.
NOTICE:
Do not use any tools.
(5) If there is dirt or any other substances on the sealing
surface that might interfere with the seal, clean the
area thoroughly before assembling.
(6) In order to prevent the disconnected pipe and quick
connector from damage or dirt, cover them with a vi-
nyl or plastic bag.
(e) Take the following precautions when connecting the quick
connector.
(1) Check the connected part of the pipe for damage or
foreign objects.
(2) Align the axis of the quick connector with the axis of
the pipe, then push into the quick connector until the
quick connector makes a ºclickº sound. In case that
the connection is tight, apply a little amount of fresh
engine oil to the tip of the pipe.
(3) After connecting, check if the pipe and quick con-
nector are securely connected by pulling on them.
(4) Install the fuel pipe clamp.
(5) Check if there is any leakage.
Page 584 of 969
11-4
- FUELFUEL SYSTEM (3MZ-FE)
2032 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
4. CHECK FOR FUEL LEAKS
(a) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system (see page
11-5).
Page 585 of 969
110XS-01
Fuel Tube Connector
A50710
A60083
Fuel Pipe
Clamp
A
A
B12941
- FUELFUEL SYSTEM (3MZ-FE)
11-5
2033 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ON-VEHICLE INSPECTION
1. CHECK FUEL PRESSURE
(a) Discharge the fuel pressure and take precautions against
possible fuel spillage (see page 11-1).
(b) Check that tha battery voltage is above 12 V.
(c) Disconnect the engine wire No. 3 (battery negative termi-
nal).
(d) Pull out the fuel tube connector from a new fuel tube.
HINT:
Part No. 23801-20190
(e) Remove the fuel pipe clamp.
(f) Disconnect the quick connector from the fuel pipe by
pinching portion A with your fingers as shown in the il-
lustration.
CAUTION:
After taking the precautions, disconnect the quick
connector.
As pressure remains in the fuel line, prevent it from
splashing inside the engine compartment.