2005 LEXUS ES300 Repair Manual

A86346
A59499
Vacuum Gauge
A86347DLC3
Hand-held Tester
12-4
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2065 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
2. INSPECT FUEL CUT OFF RPM
(a) Check the operation.
(1) Increase the engine speed to at least 3,500 rpm.
(2) Use a sound scope to check the fuel injector operating noise.
(3) Check that when the throttle lever is released, the fuel injector operation noise stops momentarily
at 2,500 rpm and then resumes at 1,200 rpm.
2,500 rpm: Fuel cut off rpm
1,200 rpm: Fuel return rpm
3. VISUALLY INSPECT HOSES, CONNECTIONS AND
GASKETS
(a) Check the appearance.
(1) Check the engine assembly to see if the indicated
portions by the arrows have cracks, leaks or dam-
age.
HINT:
Separation of the engine oil level gauge, oil filler cap, PCV
hose, etc. may cause the engine to run improperly. Disconnec-
tion, looseness or cracks in the parts of the air induction system
between the throttle body and cylinder head will allow air suc-
tion and cause the engine to run improperly.
If necessary, repair the engine assembly.
4. INSPECT EVAP SYSTEM LINE
(a) Warm up the engine to the normal operating temperature.
(b) Connect the vacuum gauge (EVAP control system test
equipment vacuum gauge) to the EVAP service port on
the purge line. Then stop the engine.
(c) If you have the hand-held tester:
Force the VSV for EVAP to operate.
(1) Connect the hand-held tester to the DLC3.
(2) Start the engine.
(3) Turn the hand-held tester ON.
(4) Use the ACTIVE TEST mode on the hand-held tes-
ter to operate the VSV for EVAP.

A86348Battery
A59500
Vacuum Gauge
A72589
Pressure Gauge
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-5
2066 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) If you have no hand-held tester:
Force the VSV for EVAP to operate.
(1) Disconnect the VSV for EVAP connector.
(2) Connect the positive (+) and negative (-) leads of
the battery to the VSV for EVAP terminals.
(3) Start the engine.
(e) Check the vacuum at idle.
Vacuum:
Maintain at 0.368 to 19.713 in.Hg (5 to 268 in.Aq) for
over 5 seconds.
HINT:
If the vacuum does not change, it can be concluded that the
hose which connects the VSV to the service port is loose or
blocked, or the VSV is malfunctioning.
(f) If you have the hand-held tester:
Return to the normal VSV for EVAP.
(1) Stop the engine.
(2) Disconnect the hand-held tester from the DLC3.
(g) If you have no hand-held tester:
Return to the normal VSV for EVAP.
(1) Stop the engine.
(2) Disconnect the positive (+) and negative (-) leads
of the battery from the VSV for EVAP terminals.
(3) Reconnect the VSV for EVAP connector.
(h) Disconnect the vacuum gauge from the EVAP service
port on the purge line.
(i) Connect a pressure gauge to the EVAP service port on
the purge line.

A86347DLC3
Hand-held Tester
A86349Battery
A59501
Pressure Gauge
Pressure
A52634
Fuel Tank CapPressure Gauge
12-6
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2067 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(j) If you have the hand-held tester:
Force the VSV for CCV to operate.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Turn the hand-held tester ON.
(4) Use the ACTIVE TEST mode on the hand-held tes-
ter to operate the VSV for CCV.
NOTICE:
Do not start the engine during this operation.
HINT:
If the check is not completed within 10 minutes, the forced close
of the VSV for CCV will be tested.
(k) If you have no hand-held tester:
Force the VSV for CCV to operate.
(1) Disconnect the VSV for CCV connector.
(2) Connect the positive (+) and negative (-) leads of
the battery to the VSV for CCV terminals.
(l) Check the pressure.
(1) Add the pressure (13.5 to 15.5 in.Aq) from the
EVAP service port.
Pressure:
2 minutes after the pressure is added, the gauge
should be over 7.7 to 8.8 in.Aq.
HINT:
If you cannot add the pressure, it can be concluded that the
hose which connects the VSV for EVAP canister fuel tank is
slipped off or the VSV is open.
(2) Check if the pressure decreases when the fuel tank
cap is removed while adding the pressure.
HINT:
If the pressure does not decrease when the filler cap is re-
moved, it can be concluded that the hose which connects the
service port to the fuel tank is blocked, etc.
(m) If you have the hand-held tester:
Return to the normal VSV for CCV operation.
(1) Turn the ignition switch ON.
(2) Disconnect the hand-held tester from the DLC3.
(n) If you have no hand-held tester:
Return to the normal VSV for CCV operation.
(1) Disconnect the positive (+) and negative (-) leads
of the battery to the VSV for CCV terminals.
(2) Reconnect the VSV for CCV connector.

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.

A86352
Air
A86344
VoltmeterE10 12-8
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2069 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(8) Remove the vinyl or plastic bag from the fuel tank
to filler pipe port, then check that the pressure
drops.
If the pressure does not drop, replace the fuel tank.
(9) Drain fuel from the fuel tank.
(10) Reinstall the fuel tank vent hose to the fuel tank (see
page 11-28).
(11) Reinstall the fuel tank (see page 11-28).
7. CHECK AIR INLET LINE
(a) Disconnect the fuel tank vent hose (see page 12-18).
(b) Check that there is ventilation in fuel tank vent hose.
If necessary, replace the charcoal canister filter.
(c) Reconnect the fuel tank vent hose (see page 12-18).
8. INSPECT VAPOR PRESSURE SENSOR
(a) Inspect the voltage (power source).
(1) Turn the ignition switch ON.
(2) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Voltage:
Tester ConnectionSpecified Condition
VC (E10-18) - E2 (E10-28)4.5 to 5.5 V
CAUTION:
Connect the test leads from the back side of the ECM con-
nector to the terminals.
(3) Turn the ignition switch OFF.

G37993
Voltmeter E10 E6
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-9
2070 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Inspect the voltage (power output).
(1) Turn the ignition switch ON.
(2) Remove the fuel tank cap.
(3) Using a voltmeter, measure the voltage between
the terminals of the ECM.
Voltage:
Tester ConnectionSpecified Condition
PTNK (E6-21) - E2 (E10-28)3.0 to 3.6 V
CAUTION:
Connect the test leads from the back side of the ECM con-
nector to the terminals.
(4) Reinstall the fuel tank cap.
(5) Turn the ignition switch OFF.

120C2-01
A59511
Cylinder Head Side:
Clean Hose
A59512
Intake Manifold Side:
Clean Hose
A76682
Gasket
A86329
12-10
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2071 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INSPECTION
1. INSPECT VENTILATION VALVE SUB-ASSY
(a) Check the operation.
(1) Install a clean hose as shown in the illustration.
(2) Blow air into the cylinder head side, then check that
air passes through easily.
CAUTION:
Do not suck air through the ventilation valve. Petroleum
substances inside the ventilation valve are harmful.
(3) Blow air into the intake manifold side, then check
that air passes through with difficulty.
If the operation is not as specified, replace the ventilation valve.
2. INSPECT FUEL TANK CAP ASSY
(a) Check the appearance.
(1) Visually check if the fuel tank cap and gasket are de-
formed or damaged.
If necessary, replace the fuel tank cap.
3. INSPECT CHARCOAL CANISTER ASSY
(a) Check the appearance.
(1) Visually check the charcoal canister to see if the in-
dicated portions by the arrows are cracked or dam-
aged.
If necessary, replace the charcoal canister.

A86330
Purge Port
Air Inlet Port
Vent Port
Air
A86331
Purge Port
Air Inlet Port
Vent Port
Air
A86332
Purge Port
Air Inlet Port
Vent Port
Vacuum
A86333
Purge PortAir Inlet Port
Vent PortVacuum
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
12-1 1
2072 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Check the operation.
(1) While holding the purge port closed, blow air (0.39
kPa (4.0 gf/cm
2, 0.06 psi)) into the vent port, then
check that the air flows from the air inlet port.
If the operation is not as specified, replace the charcoal canis-
ter.
(2) While holding the air inlet port closed, blow air (0.39
kPa (4.0 gf/cm
2, 0.06 psi)) into the vent port, then
check that the air flows from the purge port.
If the operation is not as specified, replace the charcoal canis-
ter.
(3) While holding the air inlet port closed, apply vacuum
(3.43 kPa (25.7 mm/Hg, 1.01 in.Hg)) to the vent
port, then check that the air is sucked from the
purge port.
If the operation is not as specified, replace the charcoal canis-
ter.
(c) Check the air tightness.
(1) While holding the vent and air inlet ports closed, ap-
ply vacuum (3.43 kPa (25.7 mmHg, 1.01 in.Hg)) to
the purge port, then check that the vacuum is main-
tained for 1 minute.
HINT:
In order to maintain air tightness, the check should be per-
formed with the VSV (for CCV) terminal port held closed by your
finger.
If the operation is not as specified, replace the charcoal canis-
ter.