LEXUS ES300 2005 Repair Manual

1809C-01
A79541
RH Bank:
(a)
(b)
A78529
LH Bank:
(a)
(b)
- IGNITIONVVT SENSOR (3MZ-FE)
18-5
2330 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
VVT SENSOR (3MZ-FE)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5)
3. REMOVE AIR CLEANER INLET ASSY (See page 19-5)
4. REMOVE AIR CLEANER ASSY (See page 19-5)
5. REMOVE VVT SENSOR
(a) Remove the 2 VVT sensor connectors.
(b) Remove the 2 bolts, then remove the 2 VVT sensors.
HINT:
The VVT sensor is installed with the bolt.
6. INSTALL VVT SENSOR
(a) Apply a light coat of engine oil to the O-ring on each VVT sensor.
(b) Install the 2 VVT sensors with the 2 bolts.
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
NOTICE:
Be careful not to twist the O-ring.
(c) Connect the 2 VVT sensor connectors.
7. INSTALL AIR CLEANER ASSY (See page 19-5)
8. INSTALL AIR CLEANER INLET ASSY (See page 19-5)
9. INSTALL RADIATOR LOWER AIR DEFLECTOR
10. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
11. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
12. CHECK FOR ENGINE OIL LEAKS
13. SYSTEM INITIALIZATION (See page 19-15)

1809D-01
A86232
A86233
A79763
(a)
(b) 18-6
- IGNITIONCRANKSHAFT POSITION SENSOR (3MZ-FE)
2331 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CRANKSHAFT POSITION SENSOR (3MZ-FE)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE ENGINE UNDER COVER NO.1
(a) Remove the 3 clips and 5 screws, then remove the engine
under cover No. 1.
3. REMOVE FRONT FENDER APRON SEAL RH
(a) Remove the clip and 2 bolts, then remove the front fender
apron seal.
4. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the crankshaft position sensor connector.
(b) Remove the bolt, then remove the crankshaft position
sensor.
5. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
6. INSTALL FRONT FENDER APRON SEAL RH
7. INSTALL ENGINE UNDER COVER NO.1
8. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
9. SYSTEM INITIALIZATION (See page 19-15)

1809E-02
A86234
(a)(b)
(b)
(b)(a)
(a)
RH Bank:
A86235
(a)
(b)(b)
(b)
(a)
(a)LH Bank:
- IGNITIONIGNITION COIL ASSY (3MZ-FE)
18-7
2332 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
IGNITION COIL ASSY (3MZ-FE)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. DRAIN ENGINE COOLANT (RH BANK) (See page 10-1 1)
3. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS, RH BANK)
(See page 16-9)
4. REMOVE V-BANK COVER SUB-ASSY (See page 16-9)
5. REMOVE AIR CLEANER CAP SUB-ASSY (RH BANK) (See page 16-9)
6. REMOVE EMISSION CONTROL VALVE SET (RH BANK) (See page 11-13)
7. REMOVE INTAKE AIR SURGE TANK (RH BANK) (See page 11-13)
8. REMOVE IGNITION COIL ASSY
(a) Disconnect the 6 connectors.
(b) Remove the 6 bolts, then remove the 6 ignition coils.
HINT:
The ignition coil is installed with the bolt.
9. INSTALL IGNITION COIL ASSY
Torque: 8.0 NVm (80 kgfVcm, 71 in.Vlbf)
10. INSTALL INTAKE AIR SURGE TANK (RH BANK) (See page 11-13)
11. INSTALL EMISSION CONTROL VALVE SET (RH BANK) (See page 11-13)
12. INSTALL AIR CLEANER CAP SUB-ASSY (RH BANK) (See page 16-9)
13. CHECK CONNECTION OF VACUUM HOSE (RH BANK) (See page 14-29)
14. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
15. ADD ENGINE COOLANT (RH BANK) (See page 10-1 1)
16. CHECK FOR ENGINE COOLANT LEAKS (RH BANK) (See page 16-1)
17. INSTALL V-BANK COVER SUB-ASSY (See page 16-9)
18. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS, RH BANK)
(See page 16-9)
19. SYSTEM INITIALIZATION (See page 19-15)

2601D-09
- FRONT SUSPENSIONFRONT SUSPENSION SYSTEM
26-1
2364 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT SUSPENSION SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of
the likely cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)-
26-8
26-8
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)28-1
26-8
26-8
Front wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Ball joint (Worn)
6. Hub bearing (Worn)
7. Steering linkage (Loose or worn)28-1
28-1
26-8
26-5
27-3
26-16
30-2
-
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)28-1
26-5
27-3
26-8
-

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
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPAIR
HINT:
This is the repair procedure for vehicle pull.

2601C-06
C93850
N´m (kgf´cm, ft´lbf): Specified torque

Non-reusable part

Front Suspension
Support Sub-assy LH
Front Suspension
Support Bearing LH
Front Coil Spring
Seat Upper LH
Front Coil Spring
Insulator Upper
LH
Front Coil Spring LH
Front Spring Bumper LH
Front Coil Spring
Insulator Lower LH
Shock Absorber Assy
Front LH Front Stabilizer
Link Assy LH
Front Flexible Hose
No. 1
74 (755, 55)
Speed Sensor
Front LH
Front Axle Assy LH
49 (500, 36)
18.8 (192, 14)
14 (143, 10)
80 (816, 59)
w/ H-TEMS: w/ H-TEMS:
Front Shock Absorber
Cap LH
80 (816, 59)
80 (816, 59)
Front Suspension
Upper Brace CenterWasher
210 (2,141, 155)
- FRONT SUSPENSIONFRONT SUSPENSION (From July, 2003)
26-3
2366 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT SUSPENSION (From July, 2003)
COMPONENTS

C93097
74 (755, 55)
Front Stabilizer
Link Assy RH
Stabilizer Bar FrontFront Stabilizer Bracket No. 1 RH
Front Stabilizer Bar Bush No. 1
Front Stabilizer Bracket No. 1 LH
Front Stabilizer Link Assy LH
Rack & Pinion Power
Steering Gear Assy
Speed Sensor
Front LH
Front Frame Assy
Front Lower Arm
Bush Stopper
Lower Ball Joint
Assy Front LH
Front Suspension
Arm Sub-assy
Lower No. 1 LHFront Brake
Caliper Assy
Front Axle Assy LH
Cotter Pin
19 (194, 14)

Cotter Pin
N´m (kgf´cm, ft´lbf): Specified torque

Non-reusable part
Front Disc
74 (755, 55)
74 (755, 55)
206 (2,101, 152)
294 (2,998, 217)
49 (500, 36)
87 (887, 64)
123 (1,254 91)
200 (2,039, 148)
200 (2,039, 148)
75 (765, 55)
70 (714, 52)
70 (714, 52)
8.0 (82, 71 in.Vlbf)
106.9 (1,090, 79)
106.9 (1,090, 79)
19 (194, 14)


210 (2,141, 155)
95 (969, 70)
Transverse Engine
Engine Mounting
Insulator
26-4
- FRONT SUSPENSIONFRONT SUSPENSION (From July, 2003)
2367 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

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
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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)

SA0028
AB
FrontA B
A: Inside
B: Outside
Z03382
Alignment
TesterGauge
C93871
26-6
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
2369 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully left and right, and measure
the turning angle.
Wheel turning angle:
Inside wheel36°39' ± 2° (36.65° ± 2°)
Outside wheel: Reference32°11' (32.18°)
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.
6. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
(a) Put the front wheel on the center of the alignment tester.
(b) Set the camber - caster - kingpin gauge at the center of
the axle hub or drive shaft.
Camber, caster and steering axis inclination:
Camber
Left-right error-0°43' ± 45' (-0.72° ± 0.75°)
45' (0.75°) or less
Caster
Left-right error2°46' ± 45' (2.77° ± 0.75°)
45' (0.75°) or less
Steering axis inclination11°27' (11.45°)
If the caster and steering axis inclination are not within the spec-
ification, after the camber has been correctly adjusted, recheck
the suspension parts for damage and/or worn out parts.
7. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheel.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
HINT:
When removing nuts, stop the bolt from rotating and loosen the
nut.
(c) Clean the installation surfaces of the shock absorber and
the steering knuckle.
(d) Temporarily install the 2 nuts.

C93869
1
2
Bolt
Adjusting
ValueSet BoltAdjusting Bolt90105-17008 90105-17009 90105-17010 90105-17011
121212121 Dot
2 Dots3 Dots
15'
30'
45'
100'
115'
130'
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
(f) Tighten the nuts.
Torque: 210 NVm (2,141 kgfVcm, 155 ftVlbf)
NOTICE:
When installing the nuts, keep the bolts from rotating and
then torque the nut.
(g) Install the front wheel.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
HINT:

Try to adjust the camber to the center of the specified val-
ue.

Adjusting value for the set bolts is 6' to 30' (0.1° to 0.5°).
If the camber is not within the specified valve, estimate how
much additional camber adjustment will be required, and select
the camber adjusting bolt.
NOTICE:
Tighten the adjusting bolt with a new nut.
(i) Do the steps mentioned above again. At step (b), replace
1 or 2 selected bolts.
HINT:
When replacing the 2 bolts, replace 1 bolt for each time.