LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 601 of 969
A79490
A79491
Cover
Tube Joint Clip
A77832Tape
A79492
A79494
Tape
(a)
Slide
- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)11-21
2049 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Remove the fuel suction tube w/ pump & gauge from the
fuel tank.
NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gauge.
(d) Remove the gasket from the fuel suction tube w/ pump &
gauge.
6. REMOVE VAPOR PRESSURE SENSOR ASSY
(a) Remove the cover.
(b) Remove the tube joint clip, then pull out the vapor pres-
sure sensor.
7. REMOVE FUEL SUCTION SUPPORT NO.2
(a) Using a screwdriver with the tip wrapped in tape, unfasten
the 5 claws. Then remove the fuel suction support No. 2.
NOTICE:
Do not damage the fuel suction support No. 2.
8. REMOVE FUEL PUMP CUSHION RUBBER
9. REMOVE FUEL SENDER GAUGE ASSY
(a) Disconnect the fuel sender gauge connector.
(b) Using a screwdriver with the tip wrapped in tape, unfasten
the clamp to release the fuel sender gauge. Then slide the
fuel sender gauge to remove it from the fuel pump.
Page 602 of 969
A79493
Tape
(a)
A79495
(a)
(b)
(b)
A79496
A79497
A65037
11-22- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
2050 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. REMOVE FUEL SUCTION PLATE SUB-ASSY
(a) Disconnect the fuel pump connector.
(b) Using a screwdriver with the tip wrapped in tape, unfasten
the 4 claws. Then pull out the fuel suction plate.
NOTICE:
Do not damage the fuel suction plate.
11. REMOVE FUEL PUMP HARNESS
(a) Disconnect the connector.
(b) Using a small screwdriver, pry out the fuel pump harness.
12. REMOVE FUEL PUMP
(a) Pull out the fuel pump from the fuel tank fuel filter.
13. REMOVE FUEL PUMP FILTER
(a) Using a small screwdriver, pry out the clip.
(b) Pull out the fuel pump filter from the fuel pump.
14. REMOVE FUEL PRESSURE REGULATOR ASSY
(a) Pull out the fuel pressure regulator from the fuel tank fuel
filter.
(b) Remove the O-ring from the fuel pressure regulator.
Page 603 of 969
A65038
New O-ring
A65040
O-ring
A86272
Cover
Tube Joint Clip
- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)11-23
2051 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
15. INSTALL FUEL PRESSURE REGULATOR ASSY
(a) Apply a light coat of spindle oil or gasoline to a new O-
ring, then install it to the fuel pressure regulator.
(b) Push in the fuel pressure regulator to the fuel tank fuel fil-
ter.
16. INSTALL FUEL PUMP FILTER
(a) Install the fuel pump filter with a new clip.
17. INSTALL FUEL PUMP
(a) Apply a light coat of gasoline or spindle oil to the O-ring
on the fuel pump.
(b) Push in the fuel pump to the fuel tank fuel filter.
18. INSTALL FUEL PUMP HARNESS
19. INSTALL FUEL SUCTION PLATE SUB-ASSY
20. INSTALL FUEL SENDER GAUGE ASSY
21. INSTALL FUEL PUMP CUSHION RUBBER
22. INSTALL FUEL SUCTION SUPPORT NO.2
23. INSTALL VAPOR PRESSURE SENSOR ASSY
(a) Install the vapor pressure sensor with the tube joint clip.
NOTICE:
Check the connected part for scratch or foreign ob-
jects.
Check that the vapor pressure sensor is inserted se-
curely.
Check that the tube joint clip is on the collar of the va-
por pressure sensor.
After installing the tube joint clip, check that the vapor
pressure sensor has not been pulled off.
(b) Install the cover.
Page 604 of 969
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)
Page 605 of 969
110XY-01
A79485 A79485 Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
5.9 (60, 52 in.Vlbf)
x8Fuel Pump Tube Sub-assy
Tube Joint Clip Fuel Tank Bent Tube Set Plate
Fuel Suction
w/ Pump & Gauge Tube Assy
Fuel Suction Tube Set Gasket Vapor Pressure Sensor Connector Fuel Pump ConnectorRear Floor Service Hole Cover Rear Seat Cushion Assy
- FUELFUEL TANK ASSY (3MZ-FE)
11-25
2053 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FUEL TANK ASSY (3MZ-FE)
COMPONENTS
Page 606 of 969
A86273 Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
20 (199, 14)
56 (571, 41)
5.4 (55, 48 in.Vlbf)
5.4 (55, 48 in.Vlbf)
5.4 (55, 48 in.Vlbf)
5.4 (55, 48 in.Vlbf)
5.4 (55, 48 in.Vlbf)
39 (400, 29)
Fuel Tube No. 1
Fuel Tank Inlet Pipe
Sub-assy
Fuel Tank Assy
Fuel Tank Protector Lower Center
Fuel Tank Band Sub-assy No. 1 LH Fuel Tank Band Sub-assy No. 1 RH
Parking Brake Cable Assy No. 2
Parking Brake Cable Assy No. 3 Exhaust Pipe Gasket Pin
x4
39 (400, 29)
Pin
Floor Panel Brace Rear
Exhaust Pipe Gasket
56 (571, 41)
Exhaust Pipe Assy Center
x2x2
x2
11-26
- FUELFUEL TANK ASSY (3MZ-FE)
2054 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 607 of 969
A79483 Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torqueFuel Tank Vent Hose Fuel Pump Tube Sub-assy
Fuel Tank Cushion
No. 2
Clip Nut
Fuel Main Tube SupportFuel Tank Assy
x7
5.4 (55, 48 in.Vlbf)
x4
- FUELFUEL TANK ASSY (3MZ-FE)
11-27
2055 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 608 of 969
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.
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.