air control system LEXUS ES300 2005 Owner's Guide

100J8-01
A86338
(a)
(b)
(b)
- ENGINE CONTROL SYSTEMACCELERATOR PEDAL ASSY (3MZ-FE (NORMAL
PEDAL))10-21
2026 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ACCELERATOR PEDAL ASSY (3MZ-FE (NORMAL PEDAL))
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE ACCELERATOR PEDAL ASSY
(a) Disconnect the accelerator position sensor connector.
(b) Remove the 2 bolts, then remove the accelerator pedal
rod.
3. INSTALL ACCELERATOR PEDAL ASSY
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
4. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
5. SYSTEM INITIALIZATION (See page 19-15)

100J9-02
A86255
(a)
(b)
(a)
(b)(a)
A86256
(b)
(a)
(b)
(b)
(b)
(b)
(c)
(c)
A86257
(a)
(a)
A86258
(a)
(a) 10-22
- ENGINE CONTROL SYSTEMECM (3MZ-FE)
2027 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ECM (3MZ-FE)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE FRONT DOOR SCUFF PLATE RH (See page 71-1 1)
3. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (See page 71-1 1)
4. REMOVE INSTRUMENT PANEL SUB-ASSY LOWER (See page 71-1 1)
5. REMOVE STEREO COMPONENT AMPLIFIER ASSY
(a) Disconnect the 3 stereo component amplifier connectors.
(b) Remove the 2 nuts, then remove the stereo component
amplifier.
6. REMOVE ECM
(a) Remove the wire harness clamp.
(b) Disconnect the 5 ECM connectors.
(c) Remove the 2 nuts, then remove the ECM.
7. REMOVE ECM BRACKET
(a) Remove the 2 screws, then remove the ECM bracket.
8. REMOVE ECM BRACKET NO.2
(a) Remove the 2 screws, then remove the ECM bracket No.
2.

A86259
(a)
(a)
- ENGINE CONTROL SYSTEMECM (3MZ-FE)
10-23
2028 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. REMOVE ECM BRACKET NO.3
(a) Remove the 2 screws, then remove the ECM bracket No
3.
10. INSTALL ECM BRACKET NO.3
11. INSTALL ECM BRACKET NO.2
12. INSTALL ECM BRACKET
13. INSTALL ECM
Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf)
14. INSTALL STEREO COMPONENT AMPLIFIER ASSY
Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf)
15. INSTALL INSTRUMENT PANEL SUB-ASSY LOWER
16. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1
17. INSTALL FRONT DOOR SCUFF PLATE RH
18. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
19. RESET MEMORY (See page 05-604)
20. SYSTEM INITIALIZATION (See page 19-15)

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.

120C0-01
A86341
Ventilation Valve Sub-assy
EVAP Service Port
Heated Oxygen Sensor
(Bank 1 Sensor 2)
Air Fuel Ratio Sensor
(Bank 1 Sensor 1) Vacuum Surge Tank
VSV for EVAP
Heated Oxygen Sensor
(Bank 2 Sensor 2)
Air Fuel Ratio Sensor
(Bank 2 Sensor 1)
Fuel Tank Cap Assy
Charcoal Canister Filter
Sub-assy Charcoal Canister Assy
Vapor Pressure Sensor Assy
VSV for CCV
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-1
2062 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
EMISSION CONTROL SYSTEM (3MZ-FE)
LOCATION

A86342
EVAP
Service Port Vacuum
Surge TankVSV
for EVAP
Fuel Tank Cap
Assy
Vapor Pressure Sensor
Assy
Fuel Tank Assy
Charcoal Canister Assy
VSV for CCVCharcoal Canister Filter
Sub-assyAir Fuel Ratio Sensor
(Bank 1 Sensor 1)
Heated Oxygen Sensor
(Bank 1 Sensor 2)
Heated Oxygen Sensor
(Bank 2 Sensor 2)
Air Fuel Ratio Sensor
(Bank 2 Sensor 1) Air Cleaner Assy
Ventilation Valve Assy
Vent Line
Air Inlet Line Purge Line
12-2
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2063 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

120C1-02
G37992
Voltmeter E9 E8
A86347DLC3
Hand-held Tester
A86385
Lean
14.7 3.3 V
RichAir
Fuel
Ratio
Time Keep the engine speed
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-3
2064 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ON-VEHICLE INSPECTION
1. INSPECT AIR FUEL RATIO COMPENSATION SYSTEM
(a) Inspect the voltage.
(1) Turn the ignition switch ON.
(2) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Standard:
Tester ConnectionSpecified Condition
A1A+ (E9-22) - E1 (E8-1)3.3 V
A1A- (E9-30) - E1 (E8-1)3.0 V
A2A+ (E9-23) - E1 (E8-1)3.3 V
A2A- (E9-31) - E1 (E8-1)3.0 V
CAUTION:
Connect the test leads from the back side of the ECM con-
nector to the terminals.
HINT:
The voltage between the terminals of the ECM is constant re-
gardless of the voltage output from the air fuel ratio sensor (A/F
sensor).
(b) Check the operation.
(1) Connect the hand-held tester to the DLC3.
(2) Enter ºDIAGNOSIS/ENHANCED OBD II/DATA
LISTº, then select ºAFS B1 S1º and ºAFS B2 S1º to
display the monitor.
(3) Warm up the A/F sensor with the engine speed at
2,500 rpm for approximately 2 minutes.
(4) Keep the engine speed at 2,500 rpm, then confirm
that the waveform of ºAFS B1 S1º and ºAFS B2 S1º
are similar as shown in the illustration.
HINT:

The waveform in the illustration is a sample.

Only the hand-held tester displays the waveform of the
A/F sensor.
(c) Confirm that the display of ºDATA LISTº - ºO2S B1 S2º
and ºO2S B2 S2º fluctuates up and down between 0 V
and 1 V with the engine speed at 2,500 rpm.

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.

A86347DLC3
Hand-held Tester
A86349Battery
A59501
Pressure Gauge
Pressure
A52634
Fuel Tank CapPressure Gauge
12-6
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2067 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(j) If you have the hand-held tester:
Force the VSV for CCV to operate.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Turn the hand-held tester ON.
(4) Use the ACTIVE TEST mode on the hand-held tes-
ter to operate the VSV for CCV.
NOTICE:
Do not start the engine during this operation.
HINT:
If the check is not completed within 10 minutes, the forced close
of the VSV for CCV will be tested.
(k) If you have no hand-held tester:
Force the VSV for CCV to operate.
(1) Disconnect the VSV for CCV connector.
(2) Connect the positive (+) and negative (-) leads of
the battery to the VSV for CCV terminals.
(l) Check the pressure.
(1) Add the pressure (13.5 to 15.5 in.Aq) from the
EVAP service port.
Pressure:
2 minutes after the pressure is added, the gauge
should be over 7.7 to 8.8 in.Aq.
HINT:
If you cannot add the pressure, it can be concluded that the
hose which connects the VSV for EVAP canister fuel tank is
slipped off or the VSV is open.
(2) Check if the pressure decreases when the fuel tank
cap is removed while adding the pressure.
HINT:
If the pressure does not decrease when the filler cap is re-
moved, it can be concluded that the hose which connects the
service port to the fuel tank is blocked, etc.
(m) If you have the hand-held tester:
Return to the normal VSV for CCV operation.
(1) Turn the ignition switch ON.
(2) Disconnect the hand-held tester from the DLC3.
(n) If you have no hand-held tester:
Return to the normal VSV for CCV operation.
(1) Disconnect the positive (+) and negative (-) leads
of the battery to the VSV for CCV terminals.
(2) Reconnect the VSV for CCV connector.