2005 LEXUS ES300 Repair Manual

110XS-01
Fuel Tube Connector
A50710
A60083
Fuel Pipe
Clamp
A
A
B12941
- FUELFUEL SYSTEM (3MZ-FE)
11-5
2033 Author
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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
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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.

A86347DLC3
Hand-held Tester
A62390
FP
+B
- FUELFUEL SYSTEM (3MZ-FE)
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2035 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand-held tester.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON and the hand-held tes-
ter ON.
NOTICE:
Do not start the engine.
(3) Select the ACTIVE TEST mode on the hand-held
tester.
(4) If you need help to select the ACTIVE TEST mode
on the hand-held tester, refer to the hand-held tes-
ter operator's manual.
(b) When not using the hand-held tester.
(1) Remove the circuit opening relay.
(2) Using a service wire, connect terminals FP and +B
of the engine room relay block.
NOTICE:
Pay due attention to the terminal connecting position to
avoid a malfunction.
(3) Turn the ignition switch ON, and check that the fuel
pump operates.
NOTICE:
Do not start the engine.
(c) Check that there are no fuel leaks after doing mainte-
nance anywhere on the fuel system.

110XT-02
Fuel Tube Connector
A50710
Fuel Tube Connector
SST
(Hose)
B12947
A86391
SST
(Hose)
SST
(Union)
O-ring
Vinyl TubeSST
(Clamp)
11-8
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2036 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INSPECTION
1. INSPECT FUEL INJECTOR ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1 - 213.4 to 14.2 W at 20C (68F)
If the resistance is not as specified, replace the fuel injector.
(b) Check the operation.
CAUTION:

This test involves high-pressure fuel and electricity.
Keep the injector free of sparks during the test.

Take every precaution regarding safe handling of
both the fuel and electricity.

Perform this test in a safe area, and avoid any sparks
or flame.

Do not smoke.
(1) Pull out the fuel tube connector from a new fuel
tube.
HINT:
Part No. 23801 - 20190
(2) Connect SST and the fuel tube connector to the fuel
pipe.
SST 09268-41047 (95336-08070)
CAUTION:
After taking the precautions, connect the quick connector.
(3) Install the grommet and O-ring to the fuel injector.
(4) Connect SST (a union and hose) to the fuel injector,
then hold the fuel injector and union with SST (a
clamp).
SST 09268- 41047 (09268- 41110, 09268- 41300,
95336-08070)
(5) Put the fuel injector into a graduated cylinder.
HINT:
Install a suitable vinyl tube to the fuel injector to contain the gas-
oline spray.

A86390
SST
B05331
A84685
Ohmmeter
A84686Battery
- FUELFUEL SYSTEM (3MZ-FE)
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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.

110XU-01
A86358N´m (kgf´cm, ft´lbf) : Specified torque
7.9 (81, 70 in.Vlbf)x3
V-bank Cover Sub-assy
Mass Air Flow
Meter Connector Fuel Vapor Feed Hose
Assy
Vacuum Hose
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
5.0 (51, 44 in.Vlbf)
W/O TEMS:
Front Suspension Upper Brace Center
80 (816, 59)
Spacer
x2
Vacuum Hose
80 (816, 59)x2
Spacer
11-10
- FUELFUEL INJECTOR ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FUEL INJECTOR ASSY (3MZ-FE)
COMPONENTS

A86260
Non-reusable part
: Specified torque VSV Connector
8.0 (82, 71 in.Vlbf)x2
Emission
Control Valve Set
Emission Control Valve Bracket
Intake Air Surge Tank

Air Surge Tank
to Intake Manifold
Gasket
Throttle Motor Connector
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N´m (kgf´cm, ft´lbf)
Union to Check Valve Hose
Fuel Vapor Feed Hose
x2 x3
Engine Hunger No. 1Surge Tank Stay
No. 1
Surge Tank Stay
No. 2
20 (199, 14)
20 (199, 14)
20 (199, 14)
7.8 (80, 69 in.Vlbf)
x2
x2 Pressure Feed
Tube Assy
28 (286, 21)
x2
x2
Bond Cable No. 1
Connector
28 (286, 21)
- FUELFUEL INJECTOR ASSY (3MZ-FE)
11-1 1
2039 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

A86296
Non-reusable part
: Specified torqueN´m (kgf´cm, ft´lbf)
Fuel Injector O-ring

Fuel Injector Grommet
Fuel Injector Assy
Fuel Delivery Pipe
Sub-assyFuel Injector
Connector

Injector Vibration Insulator
Fuel Pressure
Pulsation Damper Assy
Fuel Pump Hose Gasket

Fuel Pipe
No. 2 Gasket Delivery Pipe No. 1 Spacer
Delivery Pipe No. 1 Spacer Fuel Delivery Pipe No. 2
Fuel Injector
Connector
Injector
Vibration Insulator
Fuel Pipe Sub-assy No. 1
33 (331, 24)
20 (199, 14)
33 (331, 24)
10 (102, 7)
10 (102, 7)
Fuel Pipe No. 2 Union Bolt
11-12
- FUELFUEL INJECTOR ASSY (3MZ-FE)
2040 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)