LEXUS ES300 2005 Repair Manual

PASSENGER AIRBAG INDICATOR LAMP ± EL002-05 February 22, 2005
Page 2 of 2
MODELPLANTDRIVETRAINPRODUCTION CHANGE EFFECTIVE VIN
ES 330Tsutsumi2WDJTHBA30G#50024130ES 330Kanto2WDJTHBA30G#55068000
TMK2WDJTJGA3#U#50046500
RX 330
TMK4WDJTJHA3#U#50076003RX 330
TMMC2WD2T2GA3#U#5C021700TMMC4WD2T2HA3#U#5C046800
PREVIOUS PART NUMBERCURRENT PART NUMBERPART NAMEQTY
89952±3301089952±33011
Occupant Detection Computer
1
89952±4801089952±48011Occupant Detection Computer1
SPECIAL SERVICE TOOLS (SSTs)PART NUMBERQUANTITY
Lexus Diagnostic Tester Kit*010012701
12 Megabyte Diagnostic Tester Program Card
with version 12.01a Software (or later)*01002593-0051
Occupant Seat Weight Set*
00002±09077±011
* Essential SSTs.
NOTE:
Additional Diagnostic Tester Kits, Program Cards, or other SSTs may be ordered by
calling SPX/OTC at 1-800-933-8335.
1. Unfasten passenger seat and rock the assembly back providing access to the
underside of the seat. For information to unfasten the passenger seat, refer to the
Technical Information System (TIS): 2004 ± 2005 model year ES 330 or RX 330
Repair Manual:
Seat: Front Seat Assembly LH: Overhaul.
2. Disconnect the negative terminal of the vehicle battery.
3. Disconnect electrical connectors from Occupant Detection ECU.
4. Remove and replace the Occupant Detection ECU.
5. Reinstall the seat assembly. For more information, refer to TIS: 2004 ± 2005 model
year ES 330 or RX 330 Repair Manual:
Seat: Front Seat Assembly LH: Overhaul.
Torque: 36.8 Nm (375 kgfcm, 27 ftlbf)
6. Reconnect the negative terminal of the vehicle battery.
7. Perform Zero Point Calibration and Sensitivity Check following prompts in the
Diagnostic tool found under the Occupant Detect menu item (refer to
TSIB No. EL007±03, ª
Occupancy Classification System Calibration
(DTC B1150 & B1650)
.º
8. Reinitialize systems affected by the disconnection of the vehicle battery.
Production
Change
Information
Parts
Information
Required
SSTs
Repair
Procedure

Page 1 of 2Lexus Supports ASE Certification
Title:
PAINT STAINS UNDER RAPGARDE
Models:
'02 ± '06 All Models
Technical Service
Information Bulletin
January 31, 2003
PA001-03
TSIB REVISION NOTICE:
May 11, 2005: Applicable Vehicles has been updated to include 2004 ± 2006
model years.
The previous TSB should be discarded.
On some vehicles, when Rapgard is removed, the paint may have a stained
appearance under the clear coat. These stains should not be considered a defect in the
paint (clear coat or color coat). Wrinkles in the Rapgard sometimes trap water and
cause the paint to stain from the trapped moisture, especially on horizontal surfaces,
such as the hood, roof, and trunk. Stains can be removed by heating the stained surface
to remove the trapped moisture.
Stains
2002 ± 2006 model year vehicles, all models.
OP CODEDESCRIPTIONTIMEOFPT1T2
BD1055Remove Paint Stain Under Rapgard0.653301±#####6799
Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in
effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
PAINT
Introduction
Applicable
Vehicles
Warranty
Information

PAINT STAINS UNDER RAPGARD ± PA001-03 Revised January 31, 2003
Page 2 of 2
TOOLS & MATERIALSQUANTITY
Infrared Lamp or Heat Gun1
Aluminum Foil or Damp Cloth1
Thermometer1
1. Use the aluminum foil or damp cloth to cover plastic/rubber parts that are near
the stain.
2. Apply heat to the stain using an infrared lamp or heat gun.
NOTE:
Apply heat for 5 ± 10 minutes at 158
F ± 176
F (70
C ± 80
C). Do NOT allow the surface
to become hotter than 176
F (80
C). Measure the temperature with a thermometer.
3. After applying heat for 5 minutes, examine the area to determine if the stain has been
removed. If the stain still exists, continue to apply heat and re±examine the stain 5
minutes later.
Required
Tools &
Material
Repair
Procedure

Lexus Supports ASE CertificationPage 1 of 2
Title:
IRON PARTICLE RUST
CONTAMINATION REPAIR
Models:
'94 ± Current
Technical Service
Information Bulletin
January 12, 2005
PA001-05
The purpose of this bulletin is to provide information regarding the proper procedures to
clean vehicles that may have been subjected to contamination by airborne iron particles
such as rail dust.
1994 ± Current model year Lexus vehicles.
TOOLS & MATERIALSQUANTITY
Auto Magic
Special Cleaner Concentrate #713*1
Rubber Gloves, Aprons, Boots
Eye ProtectionAs NeededSponges or Wash MittsAs Needed
Pail or Bucket
* Contact the main office of Auto Wax Company Inc. (1±800±826±0828 or www.automagic.biz) to find a
local source for Auto Magic
Special Cleaner Concentrate.
During rail transportation or extended storage near industrial areas, vehicles may
occasionally be subjected to contamination by airborne iron particles shed from railroad
tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc.
This type of contamination can be identified by the presence of small red or brown
particles on the paint surface. These particles are often difficult to see on dark color
paints, but can be easily felt when brushing a hand across horizontal body surfaces such
as hood, roof, or deck lid.
CAUTION:
Because of the abrasiveness of these small iron particles, polishing or buffing
procedures should not be attempted to repair the paint surface of an affected vehicle.
This will result in further paint damage and detract from vehicle appearance.
Washing the affected paint surfaces with Auto Magic
Special Cleaner Concentrate is
the recommended method to dislodge embedded iron particles and remove the
surrounding rust stains. The correct usage of Auto Magic
Special Cleaner
Concentrate is described in this bulletin.
OP CODEDESCRIPTIONTIMEOFPT1T2
N/ANot Applicable to Warranty±±±±
PAINT
Introduction
Applicable
Vehicles
Required
Tools &
Materials
Condition
Inspection
Repair
Warranty
Information

IRON PARTICLE RUST CONTAMINATION REPAIR ± PA001-05 January 12, 2005
Page 2 of 2
WARNING:
Auto Magic

Special Cleaner Concentrate is a corrosive material. Appropriate
personal protection equipment must be worn to protect persons performing the
contamination removal procedure. Please refer to the precautions on the product prior
to use.
CAUTION:
Consult local or state regulations regarding the handling, use, and disposal of Auto
Magic

Special Cleaner Concentrate prior to use.
Under no circumstances should contamination removal be performed in direct
sunlight or contamination removal solution be allowed to dry on vehicle surfaces, as
staining of plastic, rubber, or painted parts may result.
1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid
car wash detergent. Rinse again thoroughly with fresh water.
2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution
ratio when applying to any other surface. Apply the diluted cleaner concentrate so
that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate
the surface.
3. Thoroughly rinse vehicle with fresh water.
4. Inspect vehicle carefully both visually and by feel to determine if all iron particles
have been removed. Repeat the wash several times if necessary to achieve
complete removal.
5. Dry vehicle with a soft terry cloth towel and apply a non±abrasive, non±silicone glaze
to obtain a high±gloss finish.
General
Precautions
Repair
Procedure

Lexus Supports ASE CertificationPage 1 of 2
Title:
WHEEL FILM FOR BRAKE ROTOR
RUST PREVENTION
Models:
All Models with Wheel Film
Technical Service
Information Bulletin
July 16, 2004
PD001-04
To prevent brake rotor rust from forming during transportation and storage, wheel film will
be adopted instead of using a cardboard type anti±rust cover.
The purpose of the wheel film is to protect the disc brake rotor from weather elements
and initial rust before the vehicle is delivered to the customer. Consequently, the film
should remain on the wheel as long as possible.
NOTE:
Retain the wheel film on the disc wheel during vehicle display and storage.
Do not remove the wheel film right away at Pre±Delivery Service (PDS) if the vehicle
will be stored after PDS.
Remove the wheel film just prior to delivery to customers.
Wheel FilmFeatures of Wheel Film:
Material: Polyethylene
Color: Transparent
All Models with wheel film.
OP CODEDESCRIPTIONTIMEOFPT1T2
N/ANot Applicable to Warranty±±±±
PRE±DELIVERY SERVICE
Introduction
Applicable
Vehicles
Warranty
Information

WHEEL FILM FOR BRAKE ROTOR RUST PREVENTION ± PD001-04 July 16, 2004
Page 2 of 2
Firmly hold the outer end of the wheel film to pull it off.
NOTE:
If film adhesive residue is found on the disc wheel, remove it with a soft
cloth dipped in ethyl alcohol (ethanol). Do not use thinner to remove the
adhesive residue.
When the wheel film is removed below an ambient temperature of 0
C (32
F), it is
possible that the film may tear. For ease of film removal in cold conditions, please
warm the film above 0
C (32
F) using one of the following methods:
± Splash (hot) water on the wheel film.
± Warm wheel film with cotton cloth soaked in hot water.
± Warm wheel film with heat gun. Be sure not to overheat the film and wheel.
± Warm wheel film by infrared heater (lamp) for paint. Be sure not to overheat
the film and wheel.
± Warm wheel film by steam car wash.
± Park vehicle indoors (e.g. garage, etc.) for an extended period of time.
Please follow local laws for disposal. Polyethylene film will not generate harmful gasses
when it is burned.
MODEL(FRONT &PLANT20032004(FRONT &REAR)PLANT123456789101112123456789101112
GS 430/300Beginning January 2005
GX 470JAPANBeginning January 2005
LX 470Beginning January 2005
RX 330TMMCRX 330
JAPANSC 430JAPAN
This is a tentative schedule. There is a possibility that the introduction timing may be delayed on some models.
Removal
Procedure
Disposal
Procedure
Introduction
Schedule

Lexus Supports ASE CertificationPage 1 of 9
Title:
PRE-DELIVERY SERVICE (PDS)
INFORMATION FOR ES 330
Models:
'04 ES 330
Technical Service
Information Bulletin
August 26, 2003
PD002-03
The following items need to be performed during Pre±Delivery Service (PDS) on
2004 model year ES 330 vehicles.
2004 model year ES 330 vehicles.
ITEM NO.SUBJECTPAGE
1D.C.C. Fuse Installation During PDS2
2Removal of Front Emergency Towing Eyelet and Installation
of Towing Eyelet Hole Cover (Performed at Port)3
3Front License Plate Mounting Bracket Installation4
4Initialization of Moon Roof5
5Initial Calibration of Compass6
6Installation of Rubber Body Plugs9
OP CODEDESCRIPTIONTIMEOFPT1T2
N/ANot Applicable to Warranty±±±±
PRE±DELIVERY SERVICE
Introduction
Applicable
Vehicles
Contents
Warranty
Information

PRE±DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 ± PD002-03 August 26, 2003
Page 2 of 9
D.C.C. FUSE INSTALLATION DURING PDS
The D.C.C. fuse has been removed at the assembly plant to reduce parasitic current
draw in transit and storage.
The removed D.C.C. fuse (30 A) is stored in the blank space of the Junction Block in
the engine compartment. The D.C.C. fuse must be reinstalled during Pre±Delivery
Service (PDS) in the dealership as shown below.
Junction Block
Install D.C.C. Fuse (30 A)
Here (Original Location)Remove This Fuse
NOTE:
Removing the D.C.C. fuse cuts off power sources relating to the Dome, ECU±B and
RAD No. 1 fuses.
If the vehicle is stored in the dealership for a long period of time after PDS,
disconnect the negative battery terminal to prevent battery discharge. Refer to TSIB
PG009±02 for battery maintenance information.
ITEM NO. 1:
Introduction
Installation
Procedure

PRE±DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 ± PD002-03 August 26, 2003
Page 3 of 9
REMOVAL OF FRONT EMERGENCY TOWING EYELET AND INSTALLATION OF
TOWING EYELET HOLE COVER (PERFORMED AT PORT)
1. Remove the emergency towing eyelet
from the front bumper by turning
counterclockwise.
NOTE:
If it is hard to loosen the emergency
towing eyelet, use a steel bar.
2. Place the removed emergency
towing eyelet in the tool tray in the
luggage compartment.
3. Install the front towing eyelet hole
cover which is stored in the glove box
onto the front bumper as shown in
the diagram. ITEM NO. 2:
Emergency Towing Eyelet
Installation
Procedure