LEXUS ES300 2005 Repair Manual

A86352
Air
A86344
VoltmeterE10 12-8
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2069 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(8) Remove the vinyl or plastic bag from the fuel tank
to filler pipe port, then check that the pressure
drops.
If the pressure does not drop, replace the fuel tank.
(9) Drain fuel from the fuel tank.
(10) Reinstall the fuel tank vent hose to the fuel tank (see
page 11-28).
(11) Reinstall the fuel tank (see page 11-28).
7. CHECK AIR INLET LINE
(a) Disconnect the fuel tank vent hose (see page 12-18).
(b) Check that there is ventilation in fuel tank vent hose.
If necessary, replace the charcoal canister filter.
(c) Reconnect the fuel tank vent hose (see page 12-18).
8. INSPECT VAPOR PRESSURE SENSOR
(a) Inspect the voltage (power source).
(1) Turn the ignition switch ON.
(2) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Voltage:
Tester ConnectionSpecified Condition
VC (E10-18) - E2 (E10-28)4.5 to 5.5 V
CAUTION:
Connect the test leads from the back side of the ECM con-
nector to the terminals.
(3) Turn the ignition switch OFF.

G37993
Voltmeter E10 E6
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-9
2070 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Inspect the voltage (power output).
(1) Turn the ignition switch ON.
(2) Remove the fuel tank cap.
(3) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Voltage:
Tester ConnectionSpecified Condition
PTNK (E6-21) - E2 (E10-28)3.0 to 3.6 V
CAUTION:
Connect the test leads from the back side of the ECM con-
nector to the terminals.
(4) Reinstall the fuel tank cap.
(5) Turn the ignition switch OFF.

120C2-01
A59511
Cylinder Head Side:
Clean Hose
A59512
Intake Manifold Side:
Clean Hose
A76682
Gasket
A86329
12-10
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2071 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INSPECTION
1. INSPECT VENTILATION VALVE SUB-ASSY
(a) Check the operation.
(1) Install a clean hose as shown in the illustration.
(2) Blow air into the cylinder head side, then check that
air passes through easily.
CAUTION:
Do not suck air through the ventilation valve. Petroleum
substances inside the ventilation valve are harmful.
(3) Blow air into the intake manifold side, then check
that air passes through with difficulty.
If the operation is not as specified, replace the ventilation valve.
2. INSPECT FUEL TANK CAP ASSY
(a) Check the appearance.
(1) Visually check if the fuel tank cap and gasket are de-
formed or damaged.
If necessary, replace the fuel tank cap.
3. INSPECT CHARCOAL CANISTER ASSY
(a) Check the appearance.
(1) Visually check the charcoal canister to see if the in-
dicated portions by the arrows are cracked or dam-
aged.
If necessary, replace the charcoal canister.

A86330
Purge Port
Air Inlet Port
Vent Port
Air
A86331
Purge Port
Air Inlet Port
Vent Port
Air
A86332
Purge Port
Air Inlet Port
Vent Port
Vacuum
A86333
Purge PortAir Inlet Port
Vent PortVacuum
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-1 1
2072 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Check the operation.
(1) While holding the purge port closed, blow air (0.39
kPa (4.0 gf/cm
2, 0.06 psi)) into the vent port, then
check that the air flows from the air inlet port.
If the operation is not as specified, replace the charcoal canis-
ter.
(2) While holding the air inlet port closed, blow air (0.39
kPa (4.0 gf/cm
2, 0.06 psi)) into the vent port, then
check that the air flows from the purge port.
If the operation is not as specified, replace the charcoal canis-
ter.
(3) While holding the air inlet port closed, apply vacuum
(3.43 kPa (25.7 mm/Hg, 1.01 in.Hg)) to the vent
port, then check that the air is sucked from the
purge port.
If the operation is not as specified, replace the charcoal canis-
ter.
(c) Check the air tightness.
(1) While holding the vent and air inlet ports closed, ap-
ply vacuum (3.43 kPa (25.7 mmHg, 1.01 in.Hg)) to
the purge port, then check that the vacuum is main-
tained for 1 minute.
HINT:
In order to maintain air tightness, the check should be per-
formed with the VSV (for CCV) terminal port held closed by your
finger.
If the operation is not as specified, replace the charcoal canis-
ter.

A86334
A86335
Purge Port
Air Inlet Port
Vent Port
VacuumA
B
A86336
Purge Port
Air Inlet Port
Vent Port
VacuumA
B
A86337
(e)
(f)
(f)
A86286
Ohmmeter 12-12
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2073 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Inspect the diaphragm.
(1) Remove the air hose.
(2) While holding the vent, purge and air inlet ports
closed, apply vacuum (1.42 kPa (11 mmHg, 0.42
in.Hg)) into port A, then check that the air is sucked
from port B.
If the operation is not as specified, replace the charcoal canis-
ter.
(3) While holding the vent, purge and air inlet ports
closed, apply vacuum (1.42 kPa (11 mmHg, 0.42
in.Hg)) into port A, then measure how long it takes
for vacuum to drop.
Vacuum drop time: 10 seconds or longer
If the operation is not as specified, replace the charcoal canis-
ter.
(4) Reinstall the air hose.
(e) Disconnect the air hose.
(f) Remove the 2 bolts, then remove the VSV.
(g) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1 - 225 to 30 W at 20
C (68
F)
1 - 232 to 40 W at 100
C (212
F)
If the resistance is not as specified, replace the charcoal canis-
ter.

A86287A B
C
Air
A86288Battery ClosedValve
A86289A B
C
Air
Battery
A86290
Ohmmeter
A86292
Air
E
F
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-13
2074 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(h) Check the operation.
(1) Check that air flows from port A to B and C.
(2) Apply battery voltage across the terminals.
(3) Check that the valve is closed.
(4) Check that air does not flow from port A to B.
(5) Check that air flows from port A to C.
If the operation is not as specified, replace the charcoal canis-
ter.
(i) Install the VSV with the 2 bolts.
(j) Connect the air hose.
4. INSPECT VACUUM SWITCHING VALVE ASSY NO.1
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1 - 226 to 30 W at 20
C (68
F)
If the resistance is not as specified, replace the vacuum switch-
ing valve No. 1.
(b) Check the operation.
(1) Check that air does not flow from port E to F.

A86293Battery Air
E
F
A86294
Ohmmeter
A86295
Ohmmeter
Bank 1 Sensor 2 Bank 2 Sensor 2 12-14
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2075 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to F.
If the operation is not as specified, replace the vacuum switch-
ing valve No. 1.
5. INSPECT AIR FUEL RATIO SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1 (HT) - 2 (+B)1.8 to 3.4 W at 20
C (68
F)
If the resistance is not as specified, replace the air fuel ratio sen-
sor.
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continu-
ity between terminals 2 (+B) and 4 (AF-).
If there is continuity, replace the air fuel ratio sensor.
6. INSPECT HEATED OXYGEN SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1 (HT) - 2 (+B)11 to 16 W at 20
C (68
F)
If the resistance is not as specified, replace the heated oxygen
sensor.
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continu-
ity between terminals 1 (HT) and 4 (E).
If there is continuity, replace the heated oxygen sensor.

A84683
OhmmeterBattery
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-15
2076 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
7. INSPECT AIR FUEL RATIO SENSOR HEATER RELAY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
3 - 510 kW or higher
3 - 5Below 1W
(Apply battery voltage to terminals 1 and 2
If the result is not as specified, replace the air fuel ratio sensor
heater relay.

120BT-01
A86270
(a)
(b)
(b)(c)
A86393
A A
PushPinch
Pinch
A86360
(e)
(e)
(f) 12-16
- EMISSION CONTROLCHARCOAL CANISTER ASSY (3MZ-FE)
2077 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CHARCOAL CANISTER ASSY (3MZ-FE)
REPLACEMENT
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 (See page 11-28)
9. DISCONNECT PARKING BRAKE CABLE ASSY NO.2 (See page 11-28)
10. DISCONNECT PARKING BRAKE CABLE ASSY NO.3 (See page 11-28)
11. REMOVE FUEL TANK PROTECTOR LOWER CENTER (See page 11-28)
12. REMOVE FUEL TANK ASSY (See page 11-28)
13. REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the VSV connector.
(b) Remove the 2 wire harness clamps.
(c) Disconnect the fuel hose No. 1.
(d) Disconnect the fuel tank vent hose.
(1) Deeply push the quick connector to release the lock
pin.
(2) Pinch portion A.
(3) Pull out the fuel tank vent hose.
(e) Remove the 2 bolts.
(f) Unfasten the claw, then remove the charcoal canister.

A87557
A86389
Push
- EMISSION CONTROLCHARCOAL CANISTER ASSY (3MZ-FE)
12-17
2078 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. REMOVE FUEL EMISSION TUBE FUEL HOSE
(a) Remove the fuel emission tube fuel hose.
15. INSTALL FUEL EMISSION TUBE FUEL HOSE
16. INSTALL CHARCOAL CANISTER ASSY
(a) Install the charcoal canister with the 2 bolts.
Torque: 40 NVm (400 kgfVcm, 29 ftVlbf)
(b) Connect the fuel tank vent hose.
(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.
(c) Connect the fuel hose No. 1.
(d) Install the 3 wire harness clamps.
(e) Connect the VSV connector.
17. INSTALL FUEL TANK ASSY (See page 11-28)
18. INSTALL FUEL TANK PROTECTOR LOWER CENTER (See page 11-28)
19. INSTALL PARKING BRAKE CABLE ASSY NO.3 (See page 11-28)
20. INSTALL PARKING BRAKE CABLE ASSY NO.2 (See page 11-28)
21. INSTALL EXHAUST PIPE ASSY CENTER (See page 11-28)
22. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20)
23. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
24. ADD FUEL
25. CHECK FOR FUEL LEAKS (See page 11-5)
26. CHECK FOR EXHAUST GAS LEAKS
27. INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20)
28. INSTALL REAR SEAT CUSHION ASSY
29. INSTALL FLOOR PANEL BRACE REAR (See page 15-2)
30. SYSTEM INITIALIZATION (See page 19-15)