LEXUS ES300 2005 Repair Manual

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.

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.

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.

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).

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.

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.

110XU-01
A86358N´m (kgf´cm, ft´lbf) : Specified torque
7.9 (81, 70 in.Vlbf)x3
V-bank Cover Sub-assy
Mass Air Flow
Meter Connector Fuel Vapor Feed Hose
Assy
Vacuum Hose
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
5.0 (51, 44 in.Vlbf)
W/O TEMS:
Front Suspension Upper Brace Center
80 (816, 59)
Spacer
x2
Vacuum Hose
80 (816, 59)x2
Spacer
11-10
- FUELFUEL INJECTOR ASSY (3MZ-FE)
2038 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FUEL INJECTOR ASSY (3MZ-FE)
COMPONENTS