2005 LEXUS ES300 Repair Manual

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.

A86298
(f)
(f)
A86299
(g)
(g)
(i)
(h)
(h)
(i)
A86301
(l)
(k)(k)
(k)(l)
(k)
(i)
A79710
(a)
(b)(c)
A86302
(a)(a)
(a)
(a)
(a)
(a) 11-14
- FUELFUEL INJECTOR ASSY (3MZ-FE)
2042 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Remove the 2 nuts, then remove the pressure feed tube.
(g) Remove the 2 bolts, then remove the engine hunger No.
1.
(h) Remove the 2 bolts, then remove the surge tank stay No.
1.
(i) Remove the 2 bolts, then remove the surge tank stay No.
2.
(j) Disconnect the bond cable No. 1 connector.
(k) Using a socket hexagon wrench 8, remove the 4 bolts.
(l) Remove the 2 nuts, then remove the emission control
valve bracket and intake air surge tank.
(m) Remove the gasket from the intake air surge tank.
9. SEPARATE FUEL PIPE SUB-ASSY NO.1
(a) Remove the fuel pressure pulsation damper and 2 gas-
kets.
(b) Remove the fuel pipe No. 2 union bolt and 2 gaskets.
(c) Remove the bolt, then separate the fuel pipe No. 1.
10. REMOVE FUEL INJECTOR ASSY
(a) Disconnect the 6 fuel injector connectors.

A86303
(b)
(b)
(b)
(b)
A86304
(c)
(d)(c)
(c)
(c)(d)
(d)
(d)
(d)
(d)
A81137
A79762
New O-ring
New Grommet
A81139
Turn
Push
- FUELFUEL INJECTOR ASSY (3MZ-FE)
11-15
2043 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Remove the 4 bolts, then remove the 2 fuel delivery pipes
together with the 6 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when removing the
fuel delivery pipe.
(c) Remove the 4 delivery pipe No. 1 spacers from the intake
manifold.
(d) Remove the 6 insulators from the intake manifold.
(e) Pull out the fuel injector from the fuel delivery pipe.
11. INSTALL FUEL INJECTOR ASSY
(a) Install new grommets to each fuel injector.
(b) Apply a light coat of spindle oil or gasoline to new O-rings,
then install them to each fuel injector.
(c) Apply a light coat of spindle oil or gasoline to the place
where the fuel delivery pipe contacts the O-ring.
(d) Push the fuel injector while twisting it back and forth to
install it in the fuel delivery pipe.
NOTICE:

Be careful not to twist the O-ring.

After installing the fuel injectors, check that they turn
smoothly. If not, replace O-ring with a new O-ring.

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)

- FUELFUEL INJECTOR ASSY (3MZ-FE)
11-17
2045 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
18. ADD ENGINE COOLANT (See page 16-9)
19. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
20. CHECK FOR FUEL LEAKS (See page 11-5)
21. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)
22. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
23. SYSTEM INITIALIZATION (See page 19-15)

110XW-02
A79485 A79485
Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
5.9 (60, 52 in.Vlbf)
x8Fuel Pump Tube Sub-assy
Tube Joint Clip Fuel Tank Bent Tube Set Plate
Fuel Suction
w/ Pump & Gauge Tube Assy

Fuel Suction Tube Set Gasket Vapor Pressure Sensor Connector Fuel Pump ConnectorRear Floor Service Hole Cover Rear Seat Cushion Assy
11-18- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
2046 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (3MZ-FE)
COMPONENTS

A79486 A79486
Non-reusable part
Vapor Pressure Sensor Assy
Tube Joint Clip Fuel Suction Plate Sub-assy
Fuel Pump Harness
Fuel Tank Fuel Filter Fuel Sender Gauge Assy

Fuel Pressure Regulator
O-ring
Fuel Pressure Regulator AssyFuel Pump Assy
Fuel Pump Filter

Fuel Pump Filter Clip
Fuel Pump Cushion Rubber
Fuel Suction Support No. 2
- FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)11-19
2047 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

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.