Page 620 of 969
A86387
Pressure Gauge
A86386
Pressure Gauge
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-7
2068 Author: Date:
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.
Page 630 of 969
A87557
A86389
Push
- EMISSION CONTROLCHARCOAL CANISTER ASSY (3MZ-FE)
12-17
2078 Author: Date:
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)
Page 631 of 969
120BW-01
A86357
A A
Push
Pinch
Pinch
PushPinch
Pinch
(b)
A86388
Push
Push 12-18
- EMISSION CONTROLCHARCOAL CANISTER FILTER SUB-ASSY (3MZ-FE)
2079 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CHARCOAL CANISTER FILTER SUB-ASSY (3MZ-FE)
REPLACEMENT
1. REMOVE CHARCOAL CANISTER FILTER SUB-ASSY
(a) Disconnect the 2 fuel tank vent hoses.
(1) Deeply push the quick connector to release the lock
pin.
(2) Pinch portion A.
(3) Pull out the 2 fuel tank vent hoses.
(b) Remove the bolt, then remove the charcoal canister filter.
2. INSTALL CHARCOAL CANISTER FILTER SUB-ASSY
(a) Install the charcoal canister filter with the bolt.
Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf)
(b) Connect the 2 fuel tank vent hoses.
(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.
Page 634 of 969
A86272
Cover
Tube Joint Clip
A79489Mark
A81595
Tube Joint ClipCollar
- EMISSION CONTROLVAPOR PRESSURE SENSOR ASSY (3MZ-FE)
12-21
2082 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
8. 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.
9. INSTALL FUEL TANK VENT TUBE SET PLATE
(a) Align the mark of the fuel tank vent tube set plate with the
fuel suction tube w/ pump & gauge.
(b) Install the fuel tank vent tube set plate with the 8 bolts.
Torque: 5.9 NVm (60 kgfVcm, 52 in.Vlbf)
10. CONNECT FUEL PUMP TUBE SUB-ASSY
(a) 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.
11. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
12. CHECK FOR FUEL LEAKS (See page 11-5)
13. INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20)
14. INSTALL REAR SEAT CUSHION ASSY
15. SYSTEM INITIALIZATION (See page 19-15)
Page 686 of 969
A78827Adjusting Bar Bracket
(b)
(a)
(a)
(b)
(b)
A36749
A60523
A86600
17-10
- LUBRICATIONOIL PUMP ASSY (3MZ-FE)
2315 Author: Date:
30. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
(a) Remove the bolt and nut, then remove the adjusting bar
bracket.
(b) Remove the 3 bolts and compressor.
HINT:
Secure the hoses off to the side instead of detaching.
31. REMOVE COMPRESSOR MOUNTING BRACKET
NO.1
(a) Remove the 2 bolts and compressor mounting bracket.
32. SEPARATE ENGINE MOUNTING INSULATOR FR
(a) Remove the 3 nuts and bolt, then separate the engine
mounting insulator FR.
NOTICE:
Do not remove the engine mounting insulator FR.
33. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the bolt, then disconnect the power steering re-
turn hose clamp from the frame.
(b) Remove the 4 nuts.
(c) Place a wooden block on a jack underneath the engine.
(d) Jack up the engine, then remove the engine mounting in-
sulator RH.
NOTICE:
Be careful not to damage the oil pan.
Page 697 of 969
1809A-01
- IGNITIONIGNITION SYSTEM (3MZ-FE)
18-1
2326 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
IGNITION SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in this section mean temperature of the coils themselves. ºColdº is from -10C
(14F) to 50C (122F) and ºHotº is from 50C (122F) to 100C (212F).
1. INSPECT IGNITION COIL AND SPARK TEST
(a) Check the DTCs.
NOTICE:
If a DTC is present, perform troubleshooting in accordance with a procedure for that DTC.
(b) Check that a spark occurs.
(1) Remove the 6 ignition coils (see page 18-7).
(2) Using a spark plug wrench 16 mm, remove the 6 spark plugs.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(3) Install the spark plugs to each ignition coil, then connect the ignition coil connectors.
(4) Disconnect the 6 fuel injector connectors.
(5) Ground the spark plugs.
(6) Check that the spark plug occurs at each spark plug while the engine is being cranked.
NOTICE:
Be sure to ground the spark plugs when checking.
Replace the ignition coil if physical impact is felt.
Do not crank the engine for more than 2 seconds.
If a spark does not occur, perform the following test.
1 SPARK TEST
NG
2 CHECK CONNECTION OF IGNITION COIL CONNECTOR
NG CONNECT SECURELY
OK
3 REPLACE IT WITH NORMAL IGNITION COIL AND PERFORM SPARK TEST AGAIN
OK REPLACE IGNITION COIL ASSY
(See page 18-7)
NG
4 CHECK POWER SUPPLY TO IGNITION COIL
(a) Turn the ignition switch ON.
(b) Check that there is battery voltage at the ignition coil positive (+) terminal.
NG CHECK WIRE HARNESS (BETWEEN IGNITION
(START) SWITCH ASSY AND IGNITION COIL
ASSY)
OK
Page 712 of 969
C65925
C93871
F40140
F03956
SST
SST
- FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
26-9
2372 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Remove the bolt, disconnect the front flexible hose No. 1
and speed sensor front LH.
(d) Remove the 2 nuts and 2 bolts on the lower side of front
shock absorber with coil spring.
NOTICE:
When removing bolt, stop the bolt from rotating and loosen
the nut.
(e) Remove the 3 nuts on the upper side of the front shock
absorber with coil spring.
(f) Remove the front shock absorber with the coil spring.
NOTICE:
Be careful not to drop the 2 washers in the case that there
is front suspension upper brace center.
5. FIX FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower side of
the front shock absorber with coil spring and secure it in
a vise.
6. REMOVE SHOCK ABSORBER ASSY FRONT LH
(a) Using SST, compress the front coil spring LH.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
HINT:
Use 2 of the same type of SST.
(b) Remove the front suspension support sub-assy LH, front suspension support bearing LH, front coil
spring seat upper LH, front coil spring insulator upper LH, front coil spring LH, front spring bumper LH
and front coil spring insulator upper LH.
Page 746 of 969
F41497
SST
F41498
SST
F40050
Matchmarks
ZK8184
51-24
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2599 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. REMOVE STEERING LEFT TURN PRESSURE TUBE
(a) Using SST, remove the steering left turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the steering left turn pressure
tube.
18. REMOVE STEERING RIGHT TURN PRESSURE TUBE
(a) Using SST, remove the steering right turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the steering right turn pres-
sure tube.
19. FIX RACK & PINION POWER STEERING GEAR ASSY
(a) Using SST, secure the rack & pinion power steering gear
assy.
SST 09612-00012
HINT:
Tape the SST before use.
20. REMOVE TIE ROD ASSY LH
(a) Place matchmarks on the tie rod assy LH and steering
rack end sub-assy.
(b) Loosen the lock nut, and remove the tie rod assy LH and
lock nut.
21. REMOVE TIE ROD ASSY RH
HINT:
Remove the RH side by the same procedures with LH side.
22. INSPECT TIE ROD ASSY LH
(a) Secure the tie rod assy LH in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torque wrench, turn the nut continuously at a rate
of 2 - 4 seconds per 1 turn and take the torque reading
of the 5th turn.
Turning torque:
0.83 - 3.43 NVm (8.5 - 35.0 kgfVcm, 7.3 - 30.4 in.Vlbf)
23. INSPECT TIE ROD ASSY RH
HINT:
Remove the RH side by the same procedures with LH side.
