tail LEXUS ES300 2005 Repair Manual

Illustration:
what to do and whereTask heading: what to do
Detailed text:
how to do task
Set part No.Component part No.
87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09316-60011 (09316-00011)
Illustration:
what to do and whereTask heading: what to do
Detailed text:
how to do task
Set part No.Component part No.
87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09316-60011 (09316-00011)
D26831
01-2- INTRODUCTIONHOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL
2 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Tightening torque, oil applying position, and non-reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc are described in the illustration.
(e) Installing procedure of operation item is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTIONIndicate the possibility of injury to you or other people.
NOTICEIndicate the possibility of damage to the components being repaired.
HINTProvide additional information to help you perform the repair efficiently.

G23361DLC3
Hand-held Tester
C80826
- BRAKEBRAKE FLUID
32-5
2439 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Repeat the above procedure to bleed the air out of the
brake line for each wheel.
4. BLEED BRAKE ACTUATOR ASSY (W/ VSC)
NOTICE:
After performing the usual air bleeding in the brake system,
if the height or feel of the brake pedal cannot be obtained,
perform air bleeding in the brake actuator assy with a
hand-held tester by following procedures below.
(a) Depress the brake pedal more than 20 times with the en-
gine off.
(b) Connect the hand-held tester to the DLC3, then turn the
ignition switch to the ON position.
NOTICE:
Do not start the engine.
(c) Select ºAIR BLEEDINGº on the hand-held tester.
HINT:
Please refer to the Hand-Held Tester Operator's Manual for fur-
ther details.
(d) Bleed the air out of the regular brake line in ºStep1: In-
creaseº on the hand-held tester display.
NOTICE:

Perform the air bleeding by following the steps dis-
played on the hand-held tester.

Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect the vinyl tube to either one of the bleeder
plugs.
(2) Depress the brake pedal several times, then loosen
the bleeder plug of one of the above wheels with the
pedal depressed.
(3) When fluid stops coming out, tighten the bleeder
plug, then release the brake pedal.
(4) Repeat (2) and (3) until all air in the fluid is complete-
ly bled out.
(5) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) Repeat the above procedure to bleed the air out of
the brake line for each wheel.
(e) Bleed the air out of the suction line in ºStep2: Inhalationº
on the hand-held tester display.
NOTICE:

Perform the air bleeding by following the steps dis-
played on the hand-held tester.

Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.

320E1-02
- BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32-47
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE ACTUATOR ASSY (W/O VSC)
ON-VEHICLE INSPECTION
1. CONNECT HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operator's manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay ON, check that the pedal does not pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR

3203J-09
32-50
- BRAKEBRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
2484 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
ON-VEHICLE INSPECTION
1. CONNECT HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operator's manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay ON, check that the pedal does not pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR

A85669
TC
CG
A82935
Tester TerminalEngine Wire 14-2
- ENGINE MECHANICALENGINE (3MZ-FE)
2094 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) When not using the hand-held tester or OBD II scan tool:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)
of the DLC3.
SST 09843-18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connecting wrong terminals can damage the
engine.

Turn OFF all electrical systems before connecting the
terminals.

Perform this inspection after the cooling fan motor is
turned OFF.
(2) Remove the V-bank cover.
(3) Pull out the engine wire colored by black and red as
shown in the illustration.
(4) Connect the tester terminal of the timing light to the
engine.
NOTICE:
Use a timing light which detects the first signal.
(5) Inspect the ignition timing at idle.
Ignition timing: 8 to 12 BTDC
NOTICE:
When checking the ignition timing, the transmission is in
the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, then check
that the engine speed returns to the idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Inspect the ignition timing at idle.
Ignition timing: 7 to 24 BTDC
(8) Confirm that the ignition timing advances when the
engine speed is increased.
(9) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the hand-held tester or OBD II scan tool:
(1) Connect the hand-held tester or OBD II scan tool to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester or OBD II scan tool.
Idle speed: 630 to 730 rpm
NOTICE:

When checking the idle speed, the transmission is in the neutral position.

Check the idle speed with the cooling fan OFF.

Switch OFF all accessories and air conditioning before connecting the hand-held tester or OBD
II scan tool.
HINT:
Refer to the hand-held tester or OBD II scan tool operator's manual for further details.

P19471
Compression Gauge
- ENGINE MECHANICALENGINE (3MZ-FE)
14-3
2095 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the intake air surge tank (see page 11-13).
(c) Disconnect the injector connectors.
(d) Remove the ignition coils.
(e) Remove the spark plugs.
(f) Inspect the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
SST 09992-00500
(2) Fully open the throttle.
(3) While cranking the engine, measure the compres-
sion pressure.
Compression pressure:
1.5 MPa (15.3 kgf/cm
2, 218 psi)
Minimum pressure:
1.0 MPa (10.2 kgf/cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 15 psi)
NOTICE:

Always use a fully-charged battery to obtain engine
speed of 250 rpm or more.

Check the other cylinder's compression pressure in
the same way.

This measurement must be done as quickly as pos-
sible.
(4) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
spark plug hole, then inspect again.
HINT:

If adding oil increases the compression, the piston rings
and/or cylinder bore may be worn or damaged.

If pressure stays low, the valve may be sticking or seated
improperly, or there may be leakage past the gasket.
10. INSPECT CO/HC
HINT:
The ECM properly controls the CO/HC concentration in the emission gas.
(a) Start the engine.
(b) Run the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Check the CO/HC concentration at idle and/or at 2,500 rpm.
HINT:
When doing the 2 mode (with the engine is at idle and at 2,500 rpm) tests, these measuring order are pre-
scribed by the applicable local regulations.
If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.
(1) Check the heated oxygen sensor operation (see page 05-126).

150B7-01
A86208
N´m (kgf´cm, ft´lbf)
: Specified torque

Non-reusable part
Exhaust Pipe
Gasket
44 (450, 33)
Heated Oxygen Sensor
44 (450, 33)
Heated Oxygen Sensor




62 (633, 46)
Exhaust Pipe No. 1
Support Bracket Front
33 (337, 24)
Exhaust Pipe No. 1
Support Bracket Rear
33 (337, 24)
x2
x2
x2
Exhaust Pipe Assy Tail
Tail Pipe Baffle
Exhaust Pipe Assy Center
x2
x2
x2
20 (199, 14)
x2
56 (574, 41)
Floor Panel Brace Rear

Exhaust Pipe Gasket
Exhaust Pipe Gasket

Exhaust Pipe
Gasket
Exhaust Pipe Assy Front

56 (574, 41)
62 (633, 46)
- EXHAUSTEXHAUST PIPE ASSY (3MZ-FE)
15-1
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
EXHAUST PIPE ASSY (3MZ-FE)
COMPONENTS

150B8-01
A86209
A86210
(a)
(b)
(a)
(b)
(b)
A86211
Plastic-faced Hammer
15-2
- EXHAUSTEXHAUST PIPE ASSY (3MZ-FE)
2275 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Removal & Installation and Disassembly & Reassembly
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE HEATED OXYGEN SENSOR (See page 12-24)
SST 09224-00010
3. REMOVE FLOOR PANEL BRACE REAR
(a) Remove the 2 bolts, then remove the floor panel brace
rear.
4. REMOVE EXHAUST PIPE ASSY TAIL
(a) Remove the 2 nuts.
(b) Remove the exhaust pipe tail and gasket from the 3 ex-
haust pipe supports.
5. REMOVE TAIL PIPE BAFFLE
(a) Using a plastic-faced hammer, uniformly tap the tail pipe
baffle to remove.

A86216
Keyway
KeyPlastic-faced
Hammer
- EXHAUSTEXHAUST PIPE ASSY (3MZ-FE)
15-5
2278 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. INSTALL TAIL PIPE BAFFLE
(a) Align the keyway of the tail pipe baffle with the key on the
exhaust pipe tail.
(b) Using a plastic-faced hammer, tap the tail pipe baffle to
install.
15. INSTALL EXHAUST PIPE ASSY TAIL
(a) Install a new gasket and the exhaust pipe tail to the 3 exhaust pipe supports.
(b) Tighten the 2 new nuts.
Torque: 56 NVm (574 kgfVcm, 41 ftVlbf)
16. INSTALL HEATED OXYGEN SENSOR (See page 12-24)
SST 09224-00010
17. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
18. CHECK FOR EXHAUST GAS LEAKS
19. INSTALL FLOOR PANEL BRACE REAR
Torque: 20 NVm (199 kgfVcm, 14 ftVlbf)
20. SYSTEM INITIALIZATION (See page 19-15)

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.