fuel system LEXUS ES300 2005 Owner's Manual

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.

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.

110XT-02
Fuel Tube Connector
A50710
Fuel Tube Connector
SST
(Hose)
B12947
A86391
SST
(Hose)
SST
(Union)
O-ring
Vinyl TubeSST
(Clamp)
11-8
- FUELFUEL SYSTEM (3MZ-FE)
2036 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INSPECTION
1. INSPECT FUEL INJECTOR ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1 - 213.4 to 14.2 W at 20C (68F)
If the resistance is not as specified, replace the fuel injector.
(b) Check the operation.
CAUTION:

This test involves high-pressure fuel and electricity.
Keep the injector free of sparks during the test.

Take every precaution regarding safe handling of
both the fuel and electricity.

Perform this test in a safe area, and avoid any sparks
or flame.

Do not smoke.
(1) Pull out the fuel tube connector from a new fuel
tube.
HINT:
Part No. 23801 - 20190
(2) Connect SST and the fuel tube connector to the fuel
pipe.
SST 09268-41047 (95336-08070)
CAUTION:
After taking the precautions, connect the quick connector.
(3) Install the grommet and O-ring to the fuel injector.
(4) Connect SST (a union and hose) to the fuel injector,
then hold the fuel injector and union with SST (a
clamp).
SST 09268- 41047 (09268- 41110, 09268- 41300,
95336-08070)
(5) Put the fuel injector into a graduated cylinder.
HINT:
Install a suitable vinyl tube to the fuel injector to contain the gas-
oline spray.

A86390
SST
B05331
A84685
Ohmmeter
A84686Battery
- FUELFUEL SYSTEM (3MZ-FE)
11-9
2037 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(6) Operate the fuel pump (see page 11-5).
(7) Connect SST (a wire) to the
fuel injector and battery
for 15 seconds, then measure the injection volume
with the graduated cylinder. Test each fuel injector
2 or 3 times.
SST 09842-30070
Standard:
Injection VolumeDifference between Cylenders
60 to 73 cm3
(3.7 to 4.5 cu in.)
per 15 seconds13 cm3 (0.8 cu in.) or less
NOTICE:
Always do the switching at the battery side.
If the injection volume is not as specified, replace the fuel injec-
tor.
(c) Inspect the leakage.
(1) In the condition of step (7), disconnect the test
probes of SST (a wire) from the battery, then check
the fuel leakage from the fuel injector.
Fuel drop: 1 drop or less per 12 minutes
If the fuel drop is not as specified, replace the fuel injector.
2. INSPECT FUEL PUMP
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1 - 20.2 to 3.0 W at 20C (68F)
If the resistance is not as specified, replace the fuel pump.
(b) Check the operation.
(1) Apply battery positive voltage across the terminals.
(2) Check that the fuel pump operates.
NOTICE:

These tests must be performed quickly (within 10 se-
conds) to prevent burnout of the coil.

Keep the fuel pump as far away from the battery as
possible.

Always do the switching at the battery side.
If the operation is not as specified, replace the fuel pump.

110XV-01
A79751
(b)(a)
(a)
A86300(c)
(e)
(e)(f)
(d)
(g)
(g)
A86297
(b)
(a)
(c)
(d)
A79706
(e)
- FUELFUEL INJECTOR ASSY (3MZ-FE)
11-13
2041 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
(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 2 vacuum hoses.
(f) Remove the clamp.
(g) Remove the 2 nuts, then remove the emission control
valve set.
8. REMOVE INTAKE AIR SURGE TANK
(a) Disconnect the throttle motor connector.
(b) Disconnect the water by-pass hose No. 3.
(c) Disconnect the water by-pass hose No. 2.
(d) Disconnect the union to check valve hose.
(e) Disconnect the ventilation hose.

- FUELFUEL INJECTOR ASSY (3MZ-FE)
11-17
2045 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
18. ADD ENGINE COOLANT (See page 16-9)
19. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
20. CHECK FOR FUEL LEAKS (See page 11-5)
21. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
22. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
23. SYSTEM INITIALIZATION (See page 19-15)

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)