LEXUS ES300 2005 Repair Manual

A86230
Air
E
BatteryF
A86231
AC
B 13-4
- INTAKEINTAKE AIR CONTROL SYSTEM (3MZ-FE)
2089 Author
: Date
:
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.
4. INSPECT AIR CLEANER CAP SUB-ASSY
(a) Check the operation.
(1) Cover port C with your finger, then check that the air
flow from port B to A.
(2) Cover port C with your finger, then check that the air
does not flow from port A to B.
(3) Cover ports A and C with your fingers, then apply 60
kPa (450 mmHg, 18 in.Hg) of vacuum to port B.
Check that there is no vacuum change after 1 min-
ute.
If the operation is not as specified, replace the air cleaner cap.

1307X-01
A79700
(a)
A79701
(b)
A79702
Lever(c)
(c)
(c)
(c)
- INTAKEINTAKE AIR CONTROL VALVE ASSY NO.2 (3MZ-FE)
13-5
2090 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INTAKE AIR CONTROL VALVE ASSY NO.2 (3MZ-FE)
REPLACEMENT
1. REMOVE INTAKE AIR CONTROL VALVE ASSY NO.2
(a) Remove the wire harness clamp.
(b) Disconnect the vacuum hose.
(c) Remove the 3 bolts and nut.
(d) Rotate the lever to the closed position as shown in the il-
lustration, then pull out the intake air control valve No. 2.
(e) Remove the gasket from the intake air surge tank.
2. INSTALL INTAKE AIR CONTROL VALVE ASSY NO.2
(a) Install a new gasket to the intake air surge tank.
(b) Install the intake air control valve No. 2 with the 3 bolts and nut.
Torque: 10 NVm (102 kgfVcm, 7 ftVlbf)
(c) Connect the vacuum hose.
(d) Install the wire harness clamp.

1307Y-01
A86220
(a)
(b)(d)
(d)
(c)
(b)
(b)
(b)
A86221
(a)
(b)
(c)
(c) 13-6
- INTAKEINTAKE AIR CONTROL VALVE ASSY NO.3 (3MZ-FE)
2091 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INTAKE AIR CONTROL VALVE ASSY NO.3 (3MZ-FE)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5)
3. REMOVE AIR CLEANER INLET ASSY (See page 19-5)
4. REMOVE AIR CLEANER CAP SUB-ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the 4 vacuum hoses.
(c) Loosen the hose clamp bolt.
(d) Loosen the 2 bolts, then remove the air cleaner cap.
(e) Remove the air cleaner filter element.
5. REMOVE INTAKE AIR CONTROL VALVE ASSY NO.3
(a) Disconnect the VSV connector.
(b) Disconnect the vacuum hose.
(c) Unfasten the 2 claws, then remove the intake air control
valve No. 3.
6. INSTALL INTAKE AIR CONTROL VALVE ASSY NO.3
7. INSTALL AIR CLEANER CAP SUB-ASSY
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
8. INSTALL AIR CLEANER INLET ASSY (See page 19-5)
9. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
10. INSTALL RADIATOR LOWER AIR DEFLECTOR
11. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
12. SYSTEM INITIALIZATION (See page 19-15)

1307Z-01
A86218
(a)
(a)
A86219
(b)(c)
(d)
- INTAKEVACUUM SWITCHING VALVE ASSY NO.1 (3MZ-FE)
13-7
2092 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
VACUUM SWITCHING VALVE ASSY NO.1 (3MZ-FE)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
3. REMOVE EMISSION CONTROL VALVE SET (See page 12-19)
4. REMOVE VACUUM SWITCHING VALVE ASSY NO.1
(a) Remove the 2 screws, then remove the vacuum surge
tank.
(b) Disconnect the vacuum hose.
(c) Remove the vacuum hose.
(d) Remove the screw, then remove the vacuum switching
valve No. 1.
5. INSTALL VACUUM SWITCHING VALVE ASSY NO.1
6. INSTALL EMISSION CONTROL VALVE SET (See page 12-19)
7. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
8. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
9. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
10. SYSTEM INITIALIZATION (See page 19-15)

150B7-01
A86208
N´m (kgf´cm, ft´lbf)
: Specified torque

Non-reusable part
Exhaust Pipe
Gasket
44 (450, 33)
Heated Oxygen Sensor
44 (450, 33)
Heated Oxygen Sensor




62 (633, 46)
Exhaust Pipe No. 1
Support Bracket Front
33 (337, 24)
Exhaust Pipe No. 1
Support Bracket Rear
33 (337, 24)
x2
x2
x2
Exhaust Pipe Assy Tail
Tail Pipe Baffle
Exhaust Pipe Assy Center
x2
x2
x2
20 (199, 14)
x2
56 (574, 41)
Floor Panel Brace Rear

Exhaust Pipe Gasket
Exhaust Pipe Gasket

Exhaust Pipe
Gasket
Exhaust Pipe Assy Front

56 (574, 41)
62 (633, 46)
- EXHAUSTEXHAUST PIPE ASSY (3MZ-FE)
15-1
2274 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
EXHAUST PIPE ASSY (3MZ-FE)
COMPONENTS

150B8-01
A86209
A86210
(a)
(b)
(a)
(b)
(b)
A86211
Plastic-faced Hammer
15-2
- EXHAUSTEXHAUST PIPE ASSY (3MZ-FE)
2275 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Removal & Installation and Disassembly & Reassembly
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE HEATED OXYGEN SENSOR (See page 12-24)
SST 09224-00010
3. REMOVE FLOOR PANEL BRACE REAR
(a) Remove the 2 bolts, then remove the floor panel brace
rear.
4. REMOVE EXHAUST PIPE ASSY TAIL
(a) Remove the 2 nuts.
(b) Remove the exhaust pipe tail and gasket from the 3 ex-
haust pipe supports.
5. REMOVE TAIL PIPE BAFFLE
(a) Using a plastic-faced hammer, uniformly tap the tail pipe
baffle to remove.

A86212
(a)
(b)
(b)
(a)
A86213
A86214
(a)
(a)
(b)
- EXHAUSTEXHAUST PIPE ASSY (3MZ-FE)
15-3
2276 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
6. REMOVE EXHAUST PIPE ASSY CENTER
(a) Remove the 2 bolts and 2 nuts.
(b) Remove the exhaust pipe center and gasket from the 2
exhaust pipe supports.
7. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
FRONT
(a) Remove the 2 nuts, then remove the exhaust pipe No. 1
support bracket front.
8. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
REAR
(a) Remove the 2 bolts.
(b) Remove the exhaust pipe No. 1 support bracket rear from
the exhaust pipe front.

A86215
(a)
(a)
(a)
(a)
A60823
Exhaust Pipe
No. 1 Support Bracket
15-4
- EXHAUSTEXHAUST PIPE ASSY (3MZ-FE)
2277 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 nuts, then remove the exhaust
pipe front and 2 gaskets.
10. INSTALL EXHAUST PIPE ASSY FRONT
(a) Install 2 new gaskets and the exhaust pipe front with the 2 bolts.
Torque: 62 NVm (633 kgfVcm, 46 ftVlbf)
(b) Tighten 2 new nuts.
Torque: 62 NVm (633 kgfVcm, 46 ftVlbf)
11. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
REAR
Torque: 33 NVm (337 kgfVcm, 24 ftVlbf)
HINT:
Be careful not to install the exhaust pipe No. 1 support bracket
rear in the wrong direction.
12. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT
Torque: 33 NVm (337 kgfVcm, 24 ftVlbf)
13. INSTALL EXHAUST PIPE ASSY CENTER
(a) Install a new gasket and the exhaust pipe center to the 2 exhaust pipe supports.
(b) Tighten the 2 bolts and 2 new nuts.
Torque: 56 NVm (574 kgfVcm, 41 ftVlbf)

A86216
Keyway
KeyPlastic-faced
Hammer
- EXHAUSTEXHAUST PIPE ASSY (3MZ-FE)
15-5
2278 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. INSTALL TAIL PIPE BAFFLE
(a) Align the keyway of the tail pipe baffle with the key on the
exhaust pipe tail.
(b) Using a plastic-faced hammer, tap the tail pipe baffle to
install.
15. INSTALL EXHAUST PIPE ASSY TAIL
(a) Install a new gasket and the exhaust pipe tail to the 3 exhaust pipe supports.
(b) Tighten the 2 new nuts.
Torque: 56 NVm (574 kgfVcm, 41 ftVlbf)
16. INSTALL HEATED OXYGEN SENSOR (See page 12-24)
SST 09224-00010
17. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
18. CHECK FOR EXHAUST GAS LEAKS
19. INSTALL FLOOR PANEL BRACE REAR
Torque: 20 NVm (199 kgfVcm, 14 ftVlbf)
20. SYSTEM INITIALIZATION (See page 19-15)

160QB-01
A60522
Radiator Cap
Tester
- COOLINGCOOLING SYSTEM (3MZ-FE)
16-1
2279 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COOLING SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
(a) Remove the water outlet cap.
CAUTION:
To avoid the danger of being burned, do not remove the wa-
ter outlet cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and
steam to blow out from the radiator.
(b) Fill the radiator with coolant, then attach a radiator cap
tester.
(c) Warm up the engine.
(d) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), then check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(e) Reinstall the water outlet cap.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ºLOWº and ºFULLº lines when the engine is cold.
If low, check for leaks and add ºToyota Super Long Life Coolantº or similar high quality ethylene glycol based
non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology
up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the water outlet cap.
CAUTION:
To avoid the danger of being burned, do not remove the water outlet cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there are any excessive deposits of rust or scale around the water outlet cap and water outlet
filler hole; the coolant should free of oil.
If excessively dirty, replace the coolant.
(c) Reinstall the water outlet cap.