LEXUS ES300 2005 Repair Manual

51069-02
F41598
F41599
- POWER STEERINGVANE PUMP ASSY
51-9
2584 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
NOTICE:

When using a vise, do not over tighten.

When installing, coat the parts indicated by the arrows with power steering fluid
(See page 51-7).
1. REMOVE FRONT WHEEL RH
2. DRAIN POWER STEERING FLUID
3. REMOVE FRONT FENDER LINER RH
4. REMOVE FRONT FENDER APRON SEAL RH
5. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Remove the clip and disconnect the oil reservoir to pump hose No.1.
NOTICE:
Take care not to spill fluid on the V belt.
6. REMOVE POWER STEERING OIL PRESSURE SWITCH
(a) Disconnect the connector.
(b) Remove the oil power steering pressure switch from the union bolt.
NOTICE:
Be careful not to drop the oil power steering pressure switch.
If the oil power steering pressure switch is dropped or strongly damaged, replace it with a new one.
7. DISCONNECT PRESSURE FEED HOSE
(a) Using a spanner (22 mm) to hold the pressure port union,
remove the union bolt and gasket.
8. REMOVE VANE PUMP V BELT
(a) Loosen the 2 bolts and remove the vane pump V belt.
9. REMOVE VANE PUMP ASSY
(a) Remove the 2 bolts and vane pump assy.

F41600
SST
C65312
51-10
- POWER STEERINGVANE PUMP ASSY
2585 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. REMOVE VANE PUMP PULLEY(TYPE A VANE PUMP)
(a) Using SST, stop the vane pump pulley rotation and loosen
the nut.
SST 09960-10010 (09962-01000, 09963-01000)
(b) Remove the nut and vane pump pulley from the vane
pump shaft.
11. REMOVE POWER STEERING SUCTION PORT UNION
(a) Remove the bolt and power steering suction port union.
(b) Remove the O-ring from the power steering suction port union.
12. REMOVE PRESSURE PORT UNION
(a) Remove the pressure port union.
(b) Remove the O-ring from the pressure port union.
13. REMOVE FLOW CONTROL VALVE
14. REMOVE FLOW CONTROL VALVE COMPRESSION SPRING
15. REMOVE VANE PUMP BRACKET REAR(TYPE A VANE PUMP)
(a) Remove the 2 bolts and vane pump bracket rear from the vane pump assy.
16. REMOVE VANE PUMP BRACKET REAR(TYPE B VANE PUMP)
(a) Remove the 2 bolts, 2 nuts and vane pump bracket rear from the vane pump assy.
17. REMOVE VANE PUMP HOUSING REAR
(a) Remove the 4 bolts and vane pump housing rear from the vane pump housing front.
(b) Remove the gasket.
(c) Remove the 2 O-rings from the vane pump housing rear.
18. REMOVE VANE PUMP SIDE PLATE REAR
(a) Remove the wave washer from the vane pump side plate rear.
(b) Remove the vane pump side plate rear.
19. REMOVE VANE PUMP CAM RING
20. REMOVE VANE PUMP ROTOR
(a) Remove the 10 vane pump plates from the vane pump ro-
tor.
(b) Using a screwdriver, remove the vane pump shaft snap
ring.
(c) Remove the vane pump rotor.
21. REMOVE VANE PUMP SHAFT(TYPE A VANE PUMP)
22. REMOVE W/PULLEY SHAFT SUB-ASSY(TYPE B VANE PUMP)

F41486
SST
F41618
Caliper Gauge
Micrometer
Vane Pump
Shaft
Bushing
Vane Pump Housing Front
Vane Pump
Housing FrontBushing
TYPE A VANE PUMP
TYPE B VANE PUMP
W/Pulley Shaft
Sub-assy
- POWER STEERINGVANE PUMP ASSY
51-1 1
2586 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
23. REMOVE PUMP BRACKET FRONT
(a) Remove the bolt and pump bracket front from the vane pump housing front.
24. REMOVE VANE PUMP HOUSING OIL SEAL
(a) Using SST and a hammer, tap out the vane pump housing
oil seal from the vane pump housing front.
SST 09631-10030
NOTICE:
Be careful not to damage the bushing of the vane pump
housing front.
25. INSPECT OIL CLEARANCE
(a) Using a micrometer and a caliper gauge, measure the oil
clearance.
Standard clearance:
0.027 - 0.054 mm (0.00106 - 0.00213 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the vane pump assy.

N00372
HeightThickness
Length
R10282
Feeler Gauge
F41490
F41491F41622
Compressed Air
R08702
Vernier Calipers
51-12
- POWER STEERINGVANE PUMP ASSY
2587 Author
: Date
:
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.

W03541F41624
Press
SST
Oil Seal
F40339
Power Steering Fluid
F40339
Power Steering Fluid
- POWER STEERINGVANE PUMP ASSY
51-13
2588 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
29. INSPECT PRESSURE PORT UNION
If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage, replace
the vane pump assy.
30. INSTALL VANE PUMP HOUSING OIL SEAL
(a) Coat a new vane pump housing oil seal lip with power
steering fluid.
(b) Using SST and a press, install the new vane pump hous-
ing oil seal.
SST 09950-60010 (09951-00330),
09950-70010 (09951-07100)
NOTICE:
Make sure that the vane pump housing oil seal is installed
facing the correct direction.
31. INSTALL PUMP BRACKET FRONT
(a) Install the pump bracket front with the bolt.
Torque:
Type A Vane Pump: 43 NVm (438 kgfVcm, 32 ftVlbf)
Type B Vane Pump: 44 NVm (449 kgfVcm, 32 ftVlbf)
32. INSTALL VANE PUMP SHAFT(TYPE A VANE PUMP)
(a) Coat inside bushing surface of the vane pump housing
front with power steering fluid.
(b) Gradually insert the vane pump shaft from the pulley side.
NOTICE:
Do not damage the vane pump housing oil seal lip in the
vane pump housing front.
33. INSTALL W/PULLEY SHAFT SUB- ASSY(TYPE B
VANE PUMP)
(a) Coat inside bushing surface of the vane pump housing
front with power steering fluid.
(b) Gradually insert the w/pulley shaft sub-assy from the
pulley side.
NOTICE:
Do not damage the vane pump housing oil seal lip in the
vane pump housing front.

F40340
F40341
Inscribed
Mark
F04644
Round End
Gasket
F41480
Set
R11292
51-14
- POWER STEERINGVANE PUMP ASSY
2589 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
34. INSTALL VANE PUMP ROTOR
(a) Install the vane pump rotor.
(b) Using a snap ring expander, install a new vane pump
shaft snap ring.
35. INSTALL VANE PUMP CAM RING
(a) Align the holes of the vane pump cam ring with 2 straight
pins, and install the vane pump cam ring with inscribed
mark facing outward.
(b) Coat 10 vane pump plates with power steering fluid.
(c) Install the vane pump plates with the round end facing
outward.
(d) Install a new gasket.
36. INSTALL VANE PUMP SIDE PLATE REAR
(a) Coat a new O-ring with power steering fluid and install it
to the vane pump side plate rear.
(b) Align the groove of the vane pump cam ring with that of
the vane pump side plate rear, install the vane pump side
plate rear.
(c) Install the wave washer so that its protrusions fit into the
slots in the vane pump side plate rear.

F41573
F41492
- POWER STEERINGVANE PUMP ASSY
51-15
2590 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
37. INSTALL VANE PUMP HOUSING REAR
(a) Coat a new O-ring with power steering fluid and install it to the vane pump housing rear.
(b) Install the vane pump housing rear with the 4 bolts.
Torque: 24 NVm (245 kgfVcm, 18 ftVlbf)
38. MEASURE VANE PUMP ROTATION TORQUE(TYPE A
VANE PUMP)
(a) Check that the vane pump rotates smoothly without ab-
normal noise.
(b) Temporarily install the pulley set nut.
(c) Using a torque wrench, check the vane pump rotating
torque.
Rotating torque:
0.27 NVm (2.8 kgfVcm, 2.4 in.Vlbf) or less
39. MEASURE VANE PUMP ROTATION TORQUE(TYPE B
VANE PUMP)
(a) Check that the vane pump rotates smoothly without ab-
normal noise.
(b) Temporarily install the service bolt.
Recommended service bolt:
Thread diameter: 10 mm (0.39 in.)
Thread pitch: 1.25 mm (0.0492 in.)
Bolt length: 50 mm (1.97 in.)
(c) Using a torque wrench, check the vane pump rotating
torque.
Rotating torque:
0.27 NVm (2.8 kgfVcm, 2.4 in.Vlbf) or less
40. INSTALL VANE PUMP BRACKET REAR(TYPE A VANE PUMP)
(a) Install the vane pump bracket rear with the 2 bolts.
Torque: 43 NVm (438 kgfVcm, 32 ftVlbf)
41. INSTALL VANE PUMP BRACKET REAR(TYPE B VANE PUMP)
(a) Install the vane pump bracket rear with the 2 bolts and 2 nuts.
Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)
42. INSTALL FLOW CONTROL VALVE COMPRESSION SPRING
(a) Coat the flow control valve compression spring with power steering fluid and install it.
(b) Install the flow control valve compression spring.
43. INSTALL FLOW CONTROL VALVE
(a) Coat the flow control valve with power steering fluid.
(b) Install the flow control valve.
44. INSTALL PRESSURE PORT UNION
(a) Coat a new O-ring with power steering fluid and install it to the pressure port union.
(b) Install the pressure port union.
Torque: 83 NVm (846 kgfVcm, 61 ftVlbf)

F41600
SST
F41599
A
B
W03441
Pressure
Feed
Hose
Stopper 51-16
- POWER STEERINGVANE PUMP ASSY
2591 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
45. INSTALL POWER STEERING SUCTION PORT UNION
(a) Coat a new O-ring with power steering fluid and install it to the power steering suction port union.
(b) Install the power steering suction port union with the bolt.
Torque: 13 NVm (133 kgfVcm, 10 ftVlbf)
46. INSTALL VANE PUMP PULLEY(TYPE A VANE PUMP)
(a) Install the vane pump pulley to the vane pump shaft.
(b) Using SST, stop the vane pump pulley rotation and install
the nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)
47. INSTALL VANE PUMP ASSY
(a) Temporarily install the vane pump assy with the 2 (A and
B) bolts.
48. INSTALL VANE PUMP V BELT
(a) Install the vane pump V belt and adjust the V belt tension
(See page 14-1).
(b) Torque the bolt A.
Torque: 43 NVm (438 kgfVcm, 32 ftVlbf)
(c) Torque the bolt B.
Torque: 43 NVm (438 kgfVcm, 32 ftVlbf)
49. CONNECT PRESSURE FEED HOSE
(a) Using a spanner (22 mm) to hold the pressure port union,
connect the pressure feed hose with the union bolt and
a new gasket.
Torque: 51.5 NVm (525 kgfVcm, 38 ftVlbf)
HINT:
Make sure the stopper of the pressure feed hose touches the
pump bracket front as shown in the illustration, then install the
union bolt.
50. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Install the power steering oil pressure switch to the union bolt.
Torque: 21 NVm (214 kgfVcm, 15 ftVlbf)
NOTICE:
Be careful not to allow oil from being attached to the connector.
(b) Connect the connector.

- POWER STEERINGVANE PUMP ASSY
51-17
2592 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
51. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Connect the oil reservoir to pump hose No.1.
(b) Install the clip.
52. INSTALL FRONT FENDER APRON SEAL RH
53. INSTALL FRONT FENDER LINER RH
54. INSTALL FRONT WHEEL RH
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
55. BLEED POWER STEERING FLUID (See page 51-3)
56. INSPECT FLUID LEAK

5106A-01
F41605
Rack & Pinion Power
Steering Gear Assy
 Cotter Pin Return Tube
Assy Clamp
Power Steering Rack
Housing Heat InsulatorPressure
Feed Tube
Return Tube
Assy
Front Stabilizer
Bracket No.1 LH Front Stabilizer
Bracket No.1 RH
Front Stabilizer Bar
Front
Stabilizer Bar
Bush No.1
Front Stabilizer Bar
Bush No.1
* For use with SST
NVm (kgfVcm, ftVlbf) : Specified torque
 Non-reusable part
24.5 (250, 18)
*22.5 (229, 17)
19 (194, 14)
 Cotter Pin
O-Ring
9.8 (100, 87 in.Vlbf)9.8 (100, 87 in.Vlbf)
24.5 (250, 18)
*22.5 (229, 17)
35.3 (360, 26)
70 (714, 52)
49 (500, 36)
19 (194, 14)
74 (755, 55)
74 (755, 55)
49 (500, 36)
Steering Intermediate
Shaft Sub-assy
51-18
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2593 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
RACK & PINION POWER STEERING GEAR ASSY
COMPONENTS