Torque LEXUS ES300 2005 Repair Manual
Page 264 of 969
F16909
F16907
F16910
F16906
F16908
- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)32-19
2453 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
31. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch assy with a nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
32. INSTALL ACCELERATOR & BRAKE PEDAL ASSY
(a) Install the accelerator & brake pedal assy with the 4 nuts
and bolts.
Torque:
Nut: 13 NVm (130 kgfVcm, 9 ftVlbf)
Bolt: 19.1 NVm (194 kgfVcm, 14 ftVlbf)
(b) Connect the accel position sensor connector.
(c) Connect the stop lamp switch connector.
33. INSTALL PUSH ROD PIN
(a) Install the push rod pin and clip.
HINT:
Apply the lithium soap base glycol grease to the parts indicates
by arrows (see page 32-14).
Page 268 of 969
C69097
F40004
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-23
2457 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. INSPECT MASTER CYLINDER BODY
(a) Check the cylinder bore for rust or scoring.
11. INSTALL BRAKE MASTER CYLINDER KIT (W/O VSC)
(a) Place master cylinder in vise.
(b) Apply the lithium soap base glycol grease on new No.1
and No.2 piston sub-assy.
(c) Install the No.2 and No.1 piston sub-assy.
NOTICE:
If the piston is inserted at an angle, there is a possibil-
ity that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pis-
tons.
(d) Push in the piston and install a new gasket and a new pis-
ton stopper bolt.
Torque: 10 NVm (100 kgfVcm, 7 ftVlbf)
(e) Push in the piston and install the snap ring with snap ring
pliers.
(f) Apply the lithium soap base glycol grease on a new O-
ring and install the O-ring to the master cylinder.
12. INSTALL BRAKE MASTER CYLINDER KIT (W/ VSC)
(a) Place master cylinder in vise.
(b) Apply the lithium soap base glycol grease on new No.1
and No.2 piston sub-assy.
(c) Install the No.2 and No.1 piston sub-assy.
NOTICE:
If the piston is inserted at an angle, there is a possibil-
ity that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pis-
tons.
Page 270 of 969
F40006
SST
F40992
F40991
Front Brake Tube
Frame No. 1
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-25
2459 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737-00020
18. INSTALL BRAKE MASTER CYLINDER SUB-ASSY
(a) Install the master cylinder sub-assy and 2-way with the
2 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
(b) Using SST and connect the 4 front brake tubes to the
master cylinder sub-assy.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
(c) Using SST and install the front brake tube frame No.1 to
the master cylinder.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
(d) Connect the level warnig switch connector.
19. FILL RESERVOIR WITH BRAKE FLUID
20. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
21. BLEED BRAKE LINE (SEE PAGE 32-4)
22. INSTALL AIR CLEANER ASSY
23. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
24. CHECK BRAKE FLUID LEAKAGE
Page 272 of 969
320DZ-05
F46404
Vacuum Hose Assy
Clip
Brake Master
Cylinder Sub-AssyGasket Push Rod Pin
Push Rod Clevis
Clip
Brake Booster
Front Brake
Tube No.5Front Brake Tube Frame No.1
Non-reusable part
NVm (kgfVcm, ftVlbf): Specified torque
15 (155, 11)
13 (130, 9)
5.4 (55, 48 in.Vlbf)
13 (130, 9)
15 (155, 11)
13 (130, 9)
Vacuum Hose Bracket
15 (155, 11)
2-W ay
15 (155, 11)
Front Brake
Tube No.2
15 (155, 11)
Front Brake
Tube No.3
- BRAKEBRAKE BOOSTER ASSY
32-27
2461 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS
Page 274 of 969
BR3753
F40996
F40995
- BRAKEBRAKE BOOSTER ASSY
32-29
2463 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. REMOVE BRAKE BOOSTER GASKET
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster.
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster with the 4 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
16. INSTALL FRONT BRAKE TUBE NO.5
(a) Using SST and install the front brake tube No.5.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
17. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the push rod clevis and lock nut.
18. INSTALL PUSH ROD PIN
(a) Install the push rod pin and clip.
HINT:
Apply the lithium soap base glycol grease to the part indicate by arrow (see page 32-27).
19. INSTALL BRAKE PEDAL RETURN SPRING
20. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
21. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
22. INSTALL FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
23. INSTALL VACUUM HOSE ASSY
(a) Install the vacuum hose and vacuum hose bracket to the
body with a bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(b) Connect the vacuum hose to the brake booster with the
clip.
24. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE PAGE 32-21)
SST 09737-00013, 09737-00020
25. INSTALL BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
26. FILL RESERVOIR WITH BRAKE FLUID
Page 276 of 969
320E5-02
F41863
Front Disc
Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt
Gasket
Front Disc Brake
Bleeder Plug Cap
Disc Brake
Cylinder Assy LH
Set Ring
Cylinder BootFront Disc
Brake Piston
Piston Seal
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Disc brake grease Lithium soap base glycol grease
Non-reusable part
NVm (kgfVcm, ftVlbf)
: Specified torque Single Piston Type:
Anti Squeal
Shim No.1
Disc Brake
Pad Kit Front Anti Squeal
Shim No.1
Anti Squeal
Shim No.2
Anti Squeal
Shim No.2
Wear Indicator
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)34.3 (350, 25)
34.3 (350, 25)
106.9 (1,090, 79)
106.9 (1,090, 79)
- BRAKEFRONT BRAKE
32-31
2465 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT BRAKE
COMPONENTS
Page 277 of 969
F41533Disc brake grease Lithium soap base glycol grease
Non-reusable part
NVm (kgfVcm, ftVlbf)
: Specified torque Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt
Gasket
Front Disc Brake
Bleeder Plug Cap
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Front Disc
Anti Squeal
Shim
Disc Brake
Pad Kit Front
Twin Piston Type:
Set Ring
Cylinder Boot Front Disc
Brake Piston
Piston Seal
Disc Brake
Cylinder Assy LH
Anti Squeal
ShimWear Indicator
106.9 (1,090, 79)
106.9 (1,090, 79)
34.3 (350, 25)
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)
34.3 (350, 25)
32-32
- BRAKEFRONT BRAKE
2466 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 282 of 969
F41544
F41565
- BRAKEFRONT BRAKE
32-37
2471 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
(b) Using a dial indicator, measure the disc runout 10 mm
(0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
(c) If the disc runout is greater than the maximum value,
check the bearing play in the axial direction and check the
axle hub runout (see page 30-2). If the bearing play and
axle hub runout are normal, adjust the disc runout or grind
it on a ºOn-carº brake lathe.
26. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder.
27. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
28. INSTALL PISTON SEAL
(a) Install the piston seal (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new piston seal.
(2) Install the piston seal to the disc brake cylinder.
(b) Install the 2 piston seals (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 new piston seals.
(2) Install the 2 piston seals to the disc brake cylinder.
29. INSTALL FRONT DISC BRAKE PISTON
(a) Install the front disc brake piston (Single piston Type).
(1) Apply the lithium soap base glycol grease to the piston.
(2) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
(b) Install the 2 front disc brake pistons (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 pistons.
(2) Install the 2 pistons to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
30. INSTALL CYLINDER BOOT
(a) Install the cylinder boot (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new
cylinder boot.
(2) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.
Page 283 of 969
F41566
C68792
F41703
Anti squeal
Shim No.1
Anti squeal
Shim No.2
Anti squeal
Shim No.1
Wear Indicator
32-38
- BRAKEFRONT BRAKE
2472 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the 2 cylinder boots (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2
new cylinder boots.
(2) Install the 2 cylinder boots to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install the 2 new set rings.
NOTICE:
Do not damage the cylinder boot.
31. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Apply the lithium soap base glycol grease to seal surface
of 2 new bush dust boots.
(c) Using a socket wrench (19 mm) and hammer, drive the 2
brake bush dust boots into the brake cylinder mounting.
32. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 106.9 NVm (1,090 kgfVcm, 79 ftVlbf)
33. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylinder slide bush.
(b) Install the cylinder slide bush to the cylinder slide pin.
34. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide
pins.
(b) Install the 2 cylinder slide pins to the disc brake cylinder mounting.
HINT:
Install the cylinder slide pin with cylinder slide bush into the bottom side.
35. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side front disc brake pad support plate.
36. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side front disc brake pad support plate.
37. INSTALL ANTI SQUEAL SHIM KIT FRONT
(a) Install the anti squeal shim kit front (Single piston Type).
(1) Apply the both sides of anti squeal shim No.1 with
pad grease, and install the shim together with anti
squeal shim No.2 to each pad.
Page 284 of 969
F41866
Anti Squeal
Shim
Wear Indicator
- BRAKEFRONT BRAKE
32-39
2473 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(2) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
(b) Install the anti squeal shim kit front (Twin piston Type).
(1) Apply the anti squeal shim with pad grease, and
install the anti squeal shim to each pad.
(2) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
38. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing upward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.
39. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder with the 2 bolts.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
40. CONNECT FRONT FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 NVm (300 kgfVcm, 22 ftVlbf)
HINT:
Install the flexible hose lock securely in the lock hold of the disc brake cylinder.
41. FILL RESERVOIR WITH BRAKE FLUID
42. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
43. BLEED BRAKE LINE (SEE PAGE 32-4)
44. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
45. CHECK BRAKE FLUID LEAKAGE
46. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)