2005 LEXUS ES300 battery

110XR-01
A62391
Circuit Opening Relay
- FUELFUEL SYSTEM (3MZ-FE)
11-1
2029 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FUEL SYSTEM (3MZ-FE)
PRECAUTION
1. PRECAUTION
(a) Before working on the fuel system, disconnect the engine wire No. 3 (battery negative terminal) from
battery.
(b) Do not smoke or work near open flame when working on the fuel system.
(c) Keep gasoline away from the rubber or leather parts.
2. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any parts of the fuel system pres-
sure until you have discharging the fuel system pres-
sure.

Even after discharge the fuel pressure, place a shop
rag over fittings as you separate them in order to re-
duce risk of fuel spray on yourself or in the engine
compartment.
(a) Disconnect the engine wire No. 3 (battery negative termi-
nal).
(b) Remove the circuit opening relay from the engine room
relay block.
(c) Connect the engine wire No. 3 (battery negative terminal).
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(d) Start the engine. After the engine has stopped on its own,
turn the ignition switch OFF.
HINT:
There is a case that DTC P0171 (system to lean) is output.
(e) Check that the engine does not start.
(f) Remove the fuel tank cap, then let the air out of the fuel
tank.
(g) Disconnect battery negative terminal.
(h) Reinstall the circuit opening relay.
3. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out. So observe these proce-
dures.
(1) Work in order to prevent gasoline from spilling out.
(2) Disconnect the fuel pump tube (see page 11-20).
(3) Drain the fuel remaining inside the fuel pump tube.

110XS-01
Fuel Tube Connector
A50710
A60083
Fuel Pipe
Clamp
A
A
B12941
- FUELFUEL SYSTEM (3MZ-FE)
11-5
2033 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ON-VEHICLE INSPECTION
1. CHECK FUEL PRESSURE
(a) Discharge the fuel pressure and take precautions against
possible fuel spillage (see page 11-1).
(b) Check that tha battery voltage is above 12 V.
(c) Disconnect the engine wire No. 3 (battery negative termi-
nal).
(d) Pull out the fuel tube connector from a new fuel tube.
HINT:
Part No. 23801-20190
(e) Remove the fuel pipe clamp.
(f) Disconnect the quick connector from the fuel pipe by
pinching portion A with your fingers as shown in the il-
lustration.
CAUTION:

After taking the precautions, disconnect the quick
connector.

As pressure remains in the fuel line, prevent it from
splashing inside the engine compartment.

A71359
SSTSST
(T-joint)
SST
(Hose)
Fuel Tube
Connector
Fuel Inlet Tube
SST
(Hose)
A86347DLC3
Hand-held Tester
11-6
- FUELFUEL SYSTEM (3MZ-FE)
2034 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(g) Install SST (a pressure gauge) and fuel tube connector
using SST as shown in the illustration.
SST 09268-41047 (95336-08070), 09268-45014
(09268-41250, 09268-41200, 09268-41220)
(h) Wipe up any gasoline.
(i) Reconnect the engine wire No. 3 (battery negative termi-
nal).
(j) Connect the hand-hand tester to the DLC3.
(k) Measure the fuel pressure.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
If the pressure is high, replace the fuel pressure regulator.
If the pressure is low, check the fuel hose connections, fuel
pump, fuel filter and fuel pressure regulator.
(l) Disconnect the hand-held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/cm
2, 21 psi) or more
If the pressure is not as specified, check the fuel pump, pres-
sure regulator and/or fuel injectors.
(q) After checking the fuel pressure, disconnect the battery
negative terminal and carefully remove SST and the fuel
tube connector to prevent gasoline splash.
(r) Reconnect the No. 1 fuel pipe (the fuel tube connector).
CAUTION:
After taking the precautions, connect the quick connector.

A86390
SST
B05331
A84685
Ohmmeter
A84686Battery
- FUELFUEL SYSTEM (3MZ-FE)
11-9
2037 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(6) Operate the fuel pump (see page 11-5).
(7) Connect SST (a wire) to the
fuel injector and battery
for 15 seconds, then measure the injection volume
with the graduated cylinder. Test each fuel injector
2 or 3 times.
SST 09842-30070
Standard:
Injection VolumeDifference between Cylenders
60 to 73 cm3
(3.7 to 4.5 cu in.)
per 15 seconds13 cm3 (0.8 cu in.) or less
NOTICE:
Always do the switching at the battery side.
If the injection volume is not as specified, replace the fuel injec-
tor.
(c) Inspect the leakage.
(1) In the condition of step (7), disconnect the test
probes of SST (a wire) from the battery, then check
the fuel leakage from the fuel injector.
Fuel drop: 1 drop or less per 12 minutes
If the fuel drop is not as specified, replace the fuel injector.
2. INSPECT FUEL PUMP
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1 - 20.2 to 3.0 W at 20C (68F)
If the resistance is not as specified, replace the fuel pump.
(b) Check the operation.
(1) Apply battery positive voltage across the terminals.
(2) Check that the fuel pump operates.
NOTICE:

These tests must be performed quickly (within 10 se-
conds) to prevent burnout of the coil.

Keep the fuel pump as far away from the battery as
possible.

Always do the switching at the battery side.
If the operation is not as specified, replace the fuel pump.

110XV-01
A79751
(b)(a)
(a)
A86300(c)
(e)
(e)(f)
(d)
(g)
(g)
A86297
(b)
(a)
(c)
(d)
A79706
(e)
- FUELFUEL INJECTOR ASSY (3MZ-FE)
11-13
2041 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3. DRAIN ENGINE COOLANT (See page 16-9)
4. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
5. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
6. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
7. REMOVE EMISSION CONTROL VALVE SET
(a) Disconnect the 2 VSV connectors.
(b) Remove the wire harness clamp.
(c) Disconnect the fuel vapor feed hose No. 1.
(d) Disconnect the fuel vapor feed hose No. 2.
(e) Disconnect the 2 vacuum hoses.
(f) Remove the clamp.
(g) Remove the 2 nuts, then remove the emission control
valve set.
8. REMOVE INTAKE AIR SURGE TANK
(a) Disconnect the throttle motor connector.
(b) Disconnect the water by-pass hose No. 3.
(c) Disconnect the water by-pass hose No. 2.
(d) Disconnect the union to check valve hose.
(e) Disconnect the ventilation hose.

A86305Turn 11-16
- FUELFUEL INJECTOR ASSY (3MZ-FE)
2044 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Install 6 new insulators and the 4 delivery pipe No. 1
spacers to the intake manifold.
(f) Place the 2 fuel delivery pipes together with the 6 fuel in-
jectors to the intake manifold.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(g) Temporarily install the 4 bolts which attach the fuel deliv-
ery pipe to the intake manifold.
(h) Check that the fuel injectors rotate smoothly.
If the fuel injectors do not rotate smoothly, the probable cause
is incorrect installation of the O-ring. Replace it with a new one.
(i) Tighten the 4 bolts.
Torque: 10 NVm (102 kgfVcm, 7 ftVlbf)
(j) Connect the 6 fuel injector connectors.
12. INSTALL FUEL PIPE SUB-ASSY NO.1
(a) Install 2 new gaskets and fuel pipe No. 2 union bolt.
Torque: 33 NVm (331 kgfVcm, 24 ftVlbf)
(b) Install 2 new gaskets and fuel pressure pulsation damper.
Torque: 33 NVm (331 kgfVcm, 24 ftVlbf)
(c) Install the fuel pipe No. 1 with the bolt.
Torque: 20 NVm (199 kgfVcm, 14 ftVlbf)
13. INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket to the intake air surge tank.
(b) Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
(c) Using a socket hexagon wrench 8, tighten the 4 bolts.
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
(d) Install the surge tank stay No. 2 with the 2 bolts.
Torque: 20 NVm (199 kgfVcm, 14 ftVlbf)
(e) Install the surge tank stay No. 1 with the 2 bolts.
Torque: 20 NVm (199 kgfVcm, 14 ftVlbf)
(f) Install the engine hunger No. 1 with the 2 bolts.
Torque: 20 NVm (199 kgfVcm, 14 ftVlbf)
(g) Install the pressure feed tube with the 2 nuts.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
(h) Connect the ventilation hose.
(i) Connect the union to check valve hose.
(j) Connect the water by-pass hose No. 2.
(k) Connect the water by-pass hose No. 3.
(l) Connect the throttle motor connector.
14. INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
15. INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
16. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
17. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)

110XX-02
A79487
(b)
(c)
A91017
Nylon Tube Fuel Tube Joint
O-ring
Tube Joint Clip Fuel Suction Plate
A79488
Tube Joint Clip
A79489
(b)
(b)
(b)(b)(b)
(b)
(b)
(b) 11-20
- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
2048 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
(a) Remove the rear floor service hole cover.
(b) Disconnect the vapor pressure sensor connector.
(c) Disconnect the fuel pump connector.
5. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY
(a) Remove the tube joint clip, then pull out the fuel pump
tube.
NOTICE:

Check around the connector for dirt or mud before
this operation. Remove the dirt if necessary.

Be careful of mud because the fuel tube joint has an
O-ring which seals the pipe and connector that can
be contaminated.

Do not use any tools in this operation.

Do not bend or twist the nylon tube. Protect the con-
nector by covering it with a vinyl or plastic bag.

When the pipe and connector are stuck, push and pull
the connector to release. Pull the connector carefully.
(b) Remove the 8 bolts, then remove the fuel tank vent tube
set plate.

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)