2005 LEXUS ES300 Repair Manual

A79473
A79476
A79474
Pinch
PinchRetainer
Pull Out
A81596
Retainer
Pipe
O-ring Quick Connector
Nylon Tube
- FUELFUEL TANK ASSY (3MZ-FE)
11-29
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. DISCONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Remove the bolt and nut, then disconnect the parking
brake cable No. 3.
11. REMOVE FUEL TANK PROTECTOR LOWER CENTER
(a) Remove the 4 bolts, then remove the fuel tank protector
lower center.
12. REMOVE FUEL TANK ASSY
(a) Disconnect the fuel pump tube.
(1) Pinch the projection of the retainer to remove the
lock claws, then pull it down as shown in the illustra-
tion.
(2) Pull out the fuel pump tube.
NOTICE:

Check around the quick connector for dirt or mud be-
fore this operation. Remove the dirt if necessary.

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

Do not use any tools in this operation.

Do not bend or twist the nylon tube. Protect the quick
connector by covering it with a vinyl or plastic bag.

When the pipe and quick connector are stuck, push
and pull the quick connector to release. Pull out the
quick connector from the pipe.

A86275
PinchPinch
Pull Out
A75650
Tube Connector
Pipe O-ring Nylon Tube
Quick Connector
A86276
A
A
Push
Pinch
Pinch(d)(d)
(e)
A79478
11-30
- FUELFUEL TANK ASSY (3MZ-FE)
2058 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Disconnect the fuel tube No. 1.
(1) Pinch the tube connector, then pull out the fuel tube
No. 1.
NOTICE:

Check around the quick connector for dirt or mud be-
fore this operation. Remove the dirt if necessary.

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

Do not use any tools in this operation.

Do not bend or twist the nylon tube. Protect the quick
connector by covering it with a vinyl or plastic bag.

When the pipe and quick connector are stuck, push
and pull the quick connector to release. Pull out the
quick connector carefully.
(c) Set up a transmission jack underneath the fuel tank.
(d) Remove the 2 bolts which hold the fuel tank bands.
(e) Loosen the clamp bolt.
(f) Operate the transmission jack, then disconnect the fuel
tank inlet pipe.
(g) Disconnect the fuel tank vent hose from the charcoal can-
ister.
(1) Deeply push the quick connector to release the lock
pin.
(2) Pinch portion A.
(3) Pull out the fuel tank vent hose.
(h) Operate the transmission jack, then remove the fuel tank.
(i) Remove the 2 pins, then remove the 2 fuel tank bands as
shown in the illustration.

A79482
(j)(j)
(j)(j)
A86277Pinch
PinchPushAA
A79480
A79481
A79484
- FUELFUEL TANK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(j) Remove the 4 clip nuts.
13. REMOVE FUEL TANK VENT HOSE
(a) Deeply push the quick connector to release the lock pin.
(b) Pinch portion A.
(c) Pull out the fuel tank vent hose.
14. REMOVE FUEL PUMP TUBE SUB-ASSY
(a) Remove the fuel pump tube from the fuel main tube sup-
port.
15. REMOVE FUEL MAIN TUBE SUPPORT
(a) Remove the bolt, then remove the fuel main tube support.
16. REMOVE FUEL TANK CUSHION NO.2
(a) Remove the 7 fuel tank cushions from the fuel tank.

A86279
Push
A86339
Push
A86280
Push 11-32
- FUELFUEL TANK ASSY (3MZ-FE)
2060 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. INSTALL FUEL TANK CUSHION NO.2
(a) Install 7 new fuel tank cushions to the fuel tank.
18. INSTALL FUEL MAIN TUBE SUPPORT
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
19. INSTALL FUEL PUMP TUBE SUB-ASSY
20. INSTALL FUEL TANK VENT HOSE
(a) Push in the quick connector to the pipe until the quick con-
nector 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.
21. INSTALL FUEL TANK ASSY
(a) Install the 4 clip nuts.
(b) Install the 2 fuel tank bands with the 2 pins.
(c) Set up the fuel tank to the transmission jack.
(d) Connect the fuel tank vent hose to the charcoal canister.
(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 connector and pipe are
securely connected by pulling on them.
(e) Operate the transmission jack, then connect the fuel tank
filler pipe.
(f) Tighten the clamp bolt.
(g) Tighten the 2 bolts which hold the fuel tank bands.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
(h) Connect the fuel tube No. 1.
(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.

A81598
Retainer
Push
- FUELFUEL TANK ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(i) Connect the fuel pump tube.
(1) Push in the quick connector to the pipe until the
quick connector makes a ºclickº sound, then push
up the retainer until the claws lock.
NOTICE:

Check the connected part for damage or foreign ob-
jects.

After connecting, check if the connector and pipe are
securely connected by pulling on them.
22. INSTALL FUEL TANK PROTECTOR LOWER CENTER
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
23. INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
24. INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
25. INSTALL EXHAUST PIPE ASSY CENTER
(a) Install 2 new gaskets and the exhaust pipe center to the 2 exhaust pipe supports.
(b) Tighten the 2 bolts and 4 new nuts.
Torque: 56 NVm (571 kgfVcm, 41 ftVlbf)
26. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20)
27. ADD FUEL
28. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
29. CHECK FOR FUEL LEAKS (See page 11-5)
30. CHECK FOR EXHAUST GAS LEAKS
31. INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20)
32. INSTALL REAR SEAT CUSHION ASSY
33. INSTALL FLOOR PANEL BRACE REAR (See page 15-2)
34. SYSTEM INITIALIZATION (See page 19-15)

120C0-01
A86341
Ventilation Valve Sub-assy
EVAP Service Port
Heated Oxygen Sensor
(Bank 1 Sensor 2)
Air Fuel Ratio Sensor
(Bank 1 Sensor 1) Vacuum Surge Tank
VSV for EVAP
Heated Oxygen Sensor
(Bank 2 Sensor 2)
Air Fuel Ratio Sensor
(Bank 2 Sensor 1)
Fuel Tank Cap Assy
Charcoal Canister Filter
Sub-assy Charcoal Canister Assy
Vapor Pressure Sensor Assy
VSV for CCV
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
EMISSION CONTROL SYSTEM (3MZ-FE)
LOCATION

A86342
EVAP
Service Port Vacuum
Surge TankVSV
for EVAP
Fuel Tank Cap
Assy
Vapor Pressure Sensor
Assy
Fuel Tank Assy
Charcoal Canister Assy
VSV for CCVCharcoal Canister Filter
Sub-assyAir Fuel Ratio Sensor
(Bank 1 Sensor 1)
Heated Oxygen Sensor
(Bank 1 Sensor 2)
Heated Oxygen Sensor
(Bank 2 Sensor 2)
Air Fuel Ratio Sensor
(Bank 2 Sensor 1) Air Cleaner Assy
Ventilation Valve Assy
Vent Line
Air Inlet Line Purge Line
12-2
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2063 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

120C1-02
G37992
Voltmeter E9 E8
A86347DLC3
Hand-held Tester
A86385
Lean
14.7 3.3 V
RichAir
Fuel
Ratio
Time Keep the engine speed
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-3
2064 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ON-VEHICLE INSPECTION
1. INSPECT AIR FUEL RATIO COMPENSATION SYSTEM
(a) Inspect the voltage.
(1) Turn the ignition switch ON.
(2) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Standard:
Tester ConnectionSpecified Condition
A1A+ (E9-22) - E1 (E8-1)3.3 V
A1A- (E9-30) - E1 (E8-1)3.0 V
A2A+ (E9-23) - E1 (E8-1)3.3 V
A2A- (E9-31) - E1 (E8-1)3.0 V
CAUTION:
Connect the test leads from the back side of the ECM con-
nector to the terminals.
HINT:
The voltage between the terminals of the ECM is constant re-
gardless of the voltage output from the air fuel ratio sensor (A/F
sensor).
(b) Check the operation.
(1) Connect the hand-held tester to the DLC3.
(2) Enter ºDIAGNOSIS/ENHANCED OBD II/DATA
LISTº, then select ºAFS B1 S1º and ºAFS B2 S1º to
display the monitor.
(3) Warm up the A/F sensor with the engine speed at
2,500 rpm for approximately 2 minutes.
(4) Keep the engine speed at 2,500 rpm, then confirm
that the waveform of ºAFS B1 S1º and ºAFS B2 S1º
are similar as shown in the illustration.
HINT:

The waveform in the illustration is a sample.

Only the hand-held tester displays the waveform of the
A/F sensor.
(c) Confirm that the display of ºDATA LISTº - ºO2S B1 S2º
and ºO2S B2 S2º fluctuates up and down between 0 V
and 1 V with the engine speed at 2,500 rpm.