height LEXUS ES300 2005 User Guide

A78319
Front Side:
Upper Side:Right Side:
Lower Side:
Back Side: Back Side: Protrusion Height: 6 mm (0.24 in.)
Protrusion Height: 11 mm (0.43 in.) 4 mm
(0.16 in)
10 mm
(0.39 in.)
22 mm
(0.87 in.)12 mm
(0.47 in.) 12 mm
(0.47 in.)4 mm
(0.16 in)
4 mm
(0.16 in)
12 mm
(0.47 in.)4 mm
(0.16 in)
12 mm
(0.47 in.)
4 mm
(0.16 in)
12 mm
(0.47 in.) Protrusion Height: 6 mm (0.24 in.)
Protrusion Height: 6 mm (0.24 in.)Protrusion Height: 6 mm (0.24 in.) Protrusion Height: 6 mm (0.24 in.) 14-174
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
2266 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. INSTALL STRAIGHT PIN

A78816
Upper Side:
Protrusion Height: 10 mm (0.39 in.) Protrusion Height: 4 mm (0.16 in.)16 mm
(0.63 in.)
20 mm
(0.79 in.)11 mm
(0.43 in.)
8 mm
(0.31 in.)
P12418A32958
A78817
80C (176F)
A78376
Front Mark
Front Mark
(Mold Mark)
- ENGINE MECHANICALCYLINDER BLOCK ASSY (3MZ-FE)
14-175
2267 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
33. INSTALL RING PIN
34. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not aligned with the
pin hole cutout of the piston.
35. INSTALL W/PIN PISTON SUB-ASSY
(a) Gradually heat the piston up to approximately 80C
(176F).
(b) Coat the piston pin with engine oil.
(c) Align the front marks of the piston and connecting rod,
then push in the piston pin with your thumb until the pin
contacts the snap ring.

A86594
5
SST
Stopper
Bolt
Radiator
Tank
Core
Plate 1
6482 7 3
A86595
Rib
Bracket
A86596
A86597
H 16-26
- COOLINGRADIATOR ASSY (3MZ-FE)
2304 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
16. CAULK CORE PLATE
(a) Lightly press SST against the core plate in the order
shown in the illustration. After repeating this a few times,
fully caulk the core plate by gripping the handle until
stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01020)
HINT:

Do not tap the areas protruding around the pipes, brack-
ets or tank ribs.

The points shown in the illustration and oil cooler near
here cannot be tapped with the SST. Use pliers or a simi-
lar tool and be careful not to damage the core plate.
(b) Check the core plate height (H) after completing the
caulking.
Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.)
If the height is not as specified, adjust the stopper bolt of the
handle again, then caulk again.

2606R-02
START
Preliminary Check
Tire pressure
Vehicle height
Brake dragging ROAD TEST
Does the vehicle lead/pull?
Cross switch front tire & wheel
assemblies (left & right).
Does the vehicle lead/pull in
same direction as before?
Check front wheel alignment.
Is it within specification?
Adjust front wheel alignment.Reverse the front left side
tire and rebalance it.
Does the vehicle
lead/pull to the left?
COMPLETE
Are the tires uni-directional type?
Choose the position of front tire & wheel
assemblies where there is least amount of pull.
Increase left front camber and decrease
right front camber until lead/pull is eliminated.Increase right front camber and decrease
left front camber until lead/pull is eliminated.
NO
YES
YES
NO
YES
YES
NO
YES
NO COMPLETE
NONOYES NOIs there steering
off center?
Adjust front tie rods.
NO
YES
Is the lead/pull stronger
than before?
YES
NOTICE : Do not exceed 1° of cross camber.
Do not exceed adjustment range.
Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed
of 35mph. Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in
a straight line for 100 meters at a constant speed of 35mph without holding the steering wheel.
(1) The vehicle can keep straight but the steering wheel has some angle.
STEERING OFF CENTER (See page 50-4)
(2) The vehicle cannot keep straight.
STEERING PULL
YES NO
YES ROAD TEST
Does the vehicle still lead/pull?
NO ROAD TEST
Does the vehicle still lead/pull? ROAD TEST
Does the vehicle still lead/pull?
ROAD TEST
Does the vehicle still lead/pull?NO
Contact your local retail tire distributor.YES
*
*
26-2
- FRONT SUSPENSIONFRONT SUSPENSION SYSTEM
2365 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPAIR
HINT:
This is the repair procedure for vehicle pull.

2605T-05
C91608
B Front:A
C91609
C Rear:
D
SA3213
A
DB
Front
C
F40165
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
26-5
2368 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT WHEEL ALIGNMENT (From July, 2003)
ADJUSTMENT
1. INSPECT TIRE (See page 26-5)
2. MEASURE VEHICLE HEIGHT
Vehicle height:
FrontA - B: 120 mm (4.72 in.)
RearD - C: 52 mm (2.05 in.)
Measuring points:
A: Ground clearance of front wheel center
B: Ground clearance of lower suspension arm No. 2 set bolt
center
C: Ground clearance of strut rod set bolt center
D: Ground clearance of rear wheel center
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specified value.
HINT:
Bounce the vehicle at the corners up and down to stabilize the
suspension and inspect the vehicle height.
3. INSPECT TOE-IN
Toe-in:
Toe-in
(total)A + B: 0° ± 12' (0° ± 0.2°)
C - D: 0 ± 2 mm (0 ± 0.08 in.)
If the toe-in is not within the specified value, adjust it at the rack
ends.
4. ADJUST TOE-IN
(a) Remove the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to
adjust the toe-in.
HINT:
Try to adjust the toe-in to the center of the specified value.
(d) Make sure that the lengths of the right and left rack ends
are the same.
(e) Torque the tie rod end lock nuts.
Torque: 74 N´m (755 kgf´cm, 55 ft´lbf)
(f) Place the boots on the seats and install the clips.
HINT:
Make sure that the boots are not twisted.
(g) Perform VSC system calibration. (See page 05-471)

N00372
HeightThickness
Length
R10282
Feeler Gauge
F41490
F41491F41622
Compressed Air
R08702
Vernier Calipers
51-12
- POWER STEERINGVANE PUMP ASSY
2587 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
26. INSPECT VANE PUMP ROTOR AND VANE PUMP
PLATES
(a) Using a micrometer, measure the height, thickness and
length of the vane pump plates.
Minimum height: 8.6 mm (0.339 in.)
Minimum thickness: 1.397 mm (0.05500 in.)
Minimum length: 14.991 mm (0.59020 in.)
(b) Using a feeler gauge, measure the clearance between
the vane pump rotor groove and vane pump plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the vane pump assy.
27. INSPECT FLOW CONTROL VALVE
(a) Coat the flow control valve with power steering fluid and
check that it falls smoothly into the flow control valve hole
by its own weight.
(b) Check the flow control valve for leakage. Close one of the
holes and apply compressed air of 392 - 490 kPa (4 - 5
kgf/cm
2, 57 - 71 psi) into the opposite side hole, and con-
firm that air does not come out from the end holes.
If necessary, replace the vane pump assy.
28. INSPECT FLOW CONTROL VALVE COMPRESSION
SPRING
(a) Using vernier calipers, measure the free length of the flow
control valve compression spring.
Minimum free length: 32.24 mm (1.2693 in.)
If it is not within the specification, replace the vane pump assy.

2704P-06
SA3213
A
DB
Front
C
C91810
C91811
- REAR SUSPENSIONREAR WHEEL ALIGNMENT
27-3
2385 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR WHEEL ALIGNMENT
ADJUSTMENT
1. INSPECT TIRE (See page 28-1)
2. MEASURE VEHICLE HEIGHT (See page 26-5)
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle height to the specified value.
3. INSPECT TOE-IN
Toe-in:
Toe-in
(total)A + B: 0°22' ± 11' (0.4° ± 0.2°)
C - D: 4 ± 2 mm (0.16 ± 0.08 in.)
If the toe-in is not within the specified value, inspect and re-
place the suspension parts if necessary.
4. ADJUST TOE-IN
(a) Measure the lengths of the right and left No. 2 lower sus-
pension arms.
No. 2 lower suspension arm length difference:
1.0 mm (0.039 in.) or less
If the left-right difference is larger than 1.0 mm (0.039 in.), ad-
just it by following the procedures below.
(b) Loosen the lock nuts.
(c) Turn the right and left adjusting tube by an equal amount
to adjust toe-in.
HINT:

Try to adjust the toe-in to the center value.

One turn of the each adjusting tube will adjust the toe-in
by approximately 67' (112', 10.8 mm, 0.425 in.).
(d) Torque the lock nut.
Torque: 56 NVm (570 kgfVcm, 41 ftVlbf)
5. INSPECT CAMBER
Camber
Right-left error-1°23' ± 45' (-1.38° ± 0.75°)
45' (0.75°) or less
HINT:
Camber is not adjustable. If the measurement is not within the specification, inspect the suspension parts
for damaged and/or worn-out parts and replace them if necessary.

2706H-02
B53735
B53736
27-10
- REAR SUSPENSIONREAR SUSPENSION ARM ASSY NO.1 LH
2392 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR SUSPENSION ARM ASSY NO.1 LH
REPLACEMENT
HINT:
COMPONENTS: See page 27-2
1. REMOVE REAR WHEEL
2. REMOVE EXHAUST PIPE ASSY CENTER (See page 15-2)
3. REMOVE STABILIZER BAR REAR (See page 27-16)
4. SEPARATE STRUT ROD ASSY REAR (See page 27-18)
5. SEPARATE HEIGHT CONTROL SENSOR SUB-ASSY REAR RH (See page 65-33)
6. SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH
(a) Remove the bolt, nut and rear suspension arm No. 2 (out-
er side) from the rear carrier.
HINT:
Keep the nut fixed while loosening and removing the bolt.
7. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH
HINT:
Separate the RH side by the procedures with the LH side.
8. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH
(a) Remove the bolt, nut and rear suspension arm No. 1 (out-
er side) from rear axle carrier.
HINT:
Keep the nut fixed while loosening and removing the bolt.
9. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH
HINT:
Separate the RH side by the procedures with the LH side.

B53742
B53736
B53735
27-12
- REAR SUSPENSIONREAR SUSPENSION ARM ASSY NO.1 LH
2394 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. INSTALL REAR SUSPENSION MEMBER SUB-ASSY
(a) Support the rear suspension member with a jack.
(b) Install the rear suspension member with the 4 nuts, 2 bolts
and 4 retainers.
Torque:
A, B: 55 NVm (561 kgfVcm, 41 ftVlbf)
C: 38 NVm (387 kgfVcm, 28 ftVlbf)
14. TEMPORARILY TIGHTEN REAR SUSPENSION ARM
ASSY NO.1 LH
(a) Connect the rear suspension arm No. 1 (outer side) to the
rear axle carrier with the bolt and nut, and temporarily
tighten the bolt and nut.
HINT:
Insert the bolt from the front side of the vehicle and temporarily
install the bolt.
15. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH
HINT:
Temporarily tighten the RH side by the procedures with the LH side.
16. TEMPORARILY TIGHTEN REAR SUSPENSION ARM
ASSY NO.2 LH
(a) Connect the rear suspension arm No. 2 (outer side) to the
rear axle carrier with the bolt and nut, and temporarily
tighten the bolt.
HINT:
Insert the bolt from the rear side of the vehicle and temporarily
install the bolt.
17. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH
HINT:
Temporarily tighten the RH side by the procedures with the LH side.
18. CONNECT HEIGHT CONTROL SENSOR SUB-ASSY REAR RH (See page 65-33)
19. TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (See page 27-18)

2706I-02
C82992
C82993
C82992
27-14
- REAR SUSPENSIONREAR SUSPENSION ARM ASSY NO.2 LH
2396 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR SUSPENSION ARM ASSY NO.2 LH
REPLACEMENT
HINT:
COMPONENTS: See page 27-2
1. REMOVE REAR WHEEL
2. REMOVE EXHAUST PIPE ASSY CENTER (See page 15-2)
3. REMOVE STABILIZER BAR REAR (See page 27-16)
4. SEPARATE STRUT ROD ASSY REAR (See page 27-18)
5. SEPARATE HEIGHT CONTROL SENSOR SUB-ASSY REAR RH (See page 65-33)
6. SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH (See page 27-10)
7. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH
HINT:
Separate the RH side by the procedures with the LH side.
8. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH (See page 27-10)
9. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH
HINT:
Separate the RH side by the procedures with the LH side.
10. REMOVE REAR SUSPENSION MEMBER SUB-ASSY (See page 27-10)
11. REMOVE REAR SUSPENSION ARM ASSY NO.2 LH
(a) Remove the bolt and rear suspension arm No. 2 (inner
side).
(b) Remove the bolt, nut and disconnect the rear suspension
arm No. 2 (outer side) from rear axle carrier.
HINT:
Keep the nut fixed while loosening and removing the bolt.
12. INSTALL REAR SUSPENSION ARM ASSY NO.2 LH
(a) Install the rear suspension arm No. 2 (inner side) with the
bolt and temporarily tighten the bolt.