LEXUS ES300 2005 Repair Manual

A79482
(j)(j)
(j)(j)
A86277Pinch
PinchPushAA
A79480
A79481
A79484
- FUELFUEL TANK ASSY (3MZ-FE)
11-31
2059 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(j) Remove the 4 clip nuts.
13. REMOVE FUEL TANK VENT HOSE
(a) Deeply push the quick connector to release the lock pin.
(b) Pinch portion A.
(c) Pull out the fuel tank vent hose.
14. REMOVE FUEL PUMP TUBE SUB-ASSY
(a) Remove the fuel pump tube from the fuel main tube sup-
port.
15. REMOVE FUEL MAIN TUBE SUPPORT
(a) Remove the bolt, then remove the fuel main tube support.
16. REMOVE FUEL TANK CUSHION NO.2
(a) Remove the 7 fuel tank cushions from the fuel tank.

A86279
Push
A86339
Push
A86280
Push 11-32
- FUELFUEL TANK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. INSTALL FUEL TANK CUSHION NO.2
(a) Install 7 new fuel tank cushions to the fuel tank.
18. INSTALL FUEL MAIN TUBE SUPPORT
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
19. INSTALL FUEL PUMP TUBE SUB-ASSY
20. INSTALL FUEL TANK VENT HOSE
(a) Push in the quick connector to the pipe until the quick con-
nector 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 on them.
21. INSTALL FUEL TANK ASSY
(a) Install the 4 clip nuts.
(b) Install the 2 fuel tank bands with the 2 pins.
(c) Set up the fuel tank to the transmission jack.
(d) Connect the fuel tank vent hose to the charcoal canister.
(1) Push in the quick connector to the pipe until the
quick connector makes a ºclickº sound.
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.
(e) Operate the transmission jack, then connect the fuel tank
filler pipe.
(f) Tighten the clamp bolt.
(g) Tighten the 2 bolts which hold the fuel tank bands.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
(h) Connect the fuel tube No. 1.
(1) Push in the quick connector to the pipe until the
quick connector 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 on them.

A81598
Retainer
Push
- FUELFUEL TANK ASSY (3MZ-FE)
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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)

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)
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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)
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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)
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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)
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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)
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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
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- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
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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.

A86387
Pressure Gauge
A86386
Pressure Gauge
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(o) Disconnect the pressure gauge from the EVAP service
port on the purge line.
5. CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER
PIPE
(a) Check the operation.
(1) Remove the fuel tank (see page 11-28).
(2) Remove the fuel tank vent hose from the fuel tank
(see page 11-28).
(3) Connect the pressure gauge to the fuel tank vent
hose port of the fuel tank.
(4) Apply pressure to the fuel tank, so that the internal
pressure of the fuel tank is 4 kPa (41 gf/cm
2, 0.58
psi).
(5) Check that the internal fuel tank pressure is main-
tained for 1 minute.
(6) Check the connected portions of each hose and
pipe.
(7) Check the installed parts on the fuel tank.
If there is no abnormality, replace the fuel tank and fuel tank filler
pipe.
(8) Reinstall the fuel tank vent hose to the fuel tank (see
page 11-28).
(9) Reinstall fuel tank (see page 11-28).
6. INSPECT FUEL CUT OFF VALVE AND FILL CHECK
VA LV E
(a) Check the operation.
(1) Remove the fuel tank (see page 11-28).
(2) Remove the fuel tank vent hose from the fuel tank
(see page 11-28).
(3) Connect the pressure gauge to the fuel tank vent
hose port of the fuel tank.
(4) Fully fill the fuel tank with fuel.
HINT:
In the condition that the fuel is full, there is no ventilation as the
float valve of the fill check valve is closed.
(5) Install the fuel suction w/ pump & gauge tube (see
page 11-20).
(6) Securely cover the fuel pump tube, fuel tube No. 1
port and fuel tank to filler pipe port with vinyl or plas-
tic bags to perform the accurate pressure test.
(7) Apply 4 kPa (41 gf/cm
2, 0.58 psi) of pressure to the
fuel tank vent hose port of the fuel tank.