ECU LEXUS ES300 2005 User Guide
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 284 of 969
F41866
Anti Squeal
Shim
Wear Indicator
- BRAKEFRONT BRAKE
32-39
2473 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(2) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
(b) Install the anti squeal shim kit front (Twin piston Type).
(1) Apply the anti squeal shim with pad grease, and
install the anti squeal shim to each pad.
(2) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
38. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing upward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.
39. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder with the 2 bolts.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
40. CONNECT FRONT FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 NVm (300 kgfVcm, 22 ftVlbf)
HINT:
Install the flexible hose lock securely in the lock hold of the disc brake cylinder.
41. FILL RESERVOIR WITH BRAKE FLUID
42. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
43. BLEED BRAKE LINE (SEE PAGE 32-4)
44. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
45. CHECK BRAKE FLUID LEAKAGE
46. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
Page 290 of 969
F41559
F41865
Anti Squeal
Shim No.2 Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Anti Squeal
Shim No.1
Wear Indicator
- BRAKEREAR BRAKE
32-45
2479 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. INSTALL PISTON SEAL
(a) Apply the lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder.
33. INSTALL REAR DISC BRAKE PISTON
(a) Apply the lithium soap base glycol grease to the piston.
(b) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
34. INSTALL CYLINDER BOOT
(a) Apply the lithium soap base glycol grease to a new cylin-
der boot.
(b) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(c) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.
35. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 61.8 NVm (630 kgfVcm, 46 ftVlbf)
36. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side rear disc brake pad support plate.
37. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side rear disc brake pad support plate.
38. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT
(a) Apply the both sides of anti squeal shim No.1 with pad
grease, and install the shim together with anti squeal shim
No.2 to each pad.
(b) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
39. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing downward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.
Page 291 of 969
F41551
F41562
Cylinder Slide Pin
Cylinder Mounting
Lithium soap base glycol grease
F41558Lithium soap base glycol grease
32-46
- BRAKEREAR BRAKE
2480 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
40. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), install the cylinder slide
pin.
Torque: 39.2 NVm (400 kgfVcm, 29 ftVlbf)
41. INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a) Apply the lithium soap base glycol grease to seal surface
of a new bush dust boot.
(b) Install the bush dust boot to the cylinder slide pin.
42. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylin-
der slide bush.
(b) Install the cylinder slide bush to the disc brake cylinder.
43. INSTALL DISC BRAKE CYLINDER ASSY REAR LH
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the disc brake cylinder to the cylinder slide pin.
44. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the cylinder slide pin to the disc brake cylinder.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
45. CONNECT REAR LH FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 NVm (300 kgfVcm, 22 ftVlbf)
HINT:
Install the flexible hose lock securely in the lock hole of the disc brake cylinder.
46. FILL RESERVOIR WITH BRAKE FLUID
47. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
48. BLEED BRAKE LINE (SEE PAGE 32-4)
49. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
50. CHECK BRAKE FLUID LEAKAGE
51. INSTALL REAR WHEEL
Torque: 103 NVm (1050 kgfVcm, 76 ftVlbf)
Page 371 of 969
3006I-04
C83014
C83008
C83035
30-26
- DRIVE SHAFT / PROPELLER SHAFTREAR AXLE HUB & BEARING ASSY LH
2429 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR AXLE HUB & BEARING ASSY LH
REPLACEMENT
HINT:
COMPONENTS: See page 30-4
Replace the RH side by the same procedures with the LH side.
1. REMOVE REAR WHEEL
2. DISCONNECT REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the bolt and disconnect the rear flexible hose.
(b) Remove the 2 bolts and rear disc brake caliper assy LH.
(c) Support the rear disc brake caliper assy LH securely.
3. REMOVE REAR DISC
4. DISCONNECT SKID CONTROL SENSOR WIRE
5. REMOVE REAR AXLE HUB & BEARING ASSY LH
(a) Remove the 4 bolts and rear axle hub & bearing assy LH.
6. REMOVE SKID CONTROL SENSOR (SEE PAGE 32-56)
7. INSTALL SKID CONTROL SENSOR (SEE PAGE 32-56)
Page 419 of 969
A78535
A78706Align
A78707
Main GearSub Gear
Service Bolt
A78708
101
2
3
4
5
6
7
89
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-43
2135 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
26. REMOVE WATER PUMP ASSY
(a) Remove the 3 bolts and 3 nuts, then remove the water
pump and gasket.
27. REMOVE CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being removed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
(c) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 5 bearing caps and camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
Page 420 of 969
A78709
10
1
2
3
4
5
67
8
9
A78710Align
A78711Main GearSub Gear
Service Bolt 14-44
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2136 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
28. REMOVE NO.2 CAMSHAFT
(a) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 5 bearing caps and No. 2 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 2 camshaft.
29. REMOVE NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being removed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Align the timing marks (1 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
Page 470 of 969
A05077
Clamp
Clamp
Clamp
A78706Align
A78707
Main GearSub Gear
Service Bolt
A78708
101
2
3
4
5
6
7
89 14-94
- ENGINE MECHANICALCAMSHAFT (RH BANK) (3MZ-FE)
2186 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. REMOVE TIMING BELT NO.3 COVER
(a) Disconnect the 3 engine wire harness clamps from the
timing belt No. 3 cover.
(b) Remove the 6 bolts and timing belt cover.
26. REMOVE CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being removed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following steps must
be carried out.
(a) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
(c) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 5 bearing caps and camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
Page 484 of 969
A78711Main GearSub Gear
Service Bolt
A78712
10
12
3
4
5
67
89
A78713
10
1
2
3
4
5
6
7
89 14-108
- ENGINE MECHANICALCAMSHAFT (LH BANK) (3MZ-FE)
2200 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional
spring force of the sub gear has been eliminated by installation
of the service bolt.
(c) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 5 bearing caps and No. 3 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
24. REMOVE NO.4 CAMSHAFT SUB-ASSY
(a) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 5 bearing caps and No. 4 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the
cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 4 camshaft.
25. REMOVE CAMSHAFT TIMING GEAR ASSY (See page 14-93)
26. REMOVE CAMSHAFT SUB GEAR NO.3 (See page 14-93)
SST 09960-10010 (09962-01000, 09963-00500)
27. INSTALL CAMSHAFT SUB GEAR NO.3 (See page 14-93)
SST 09960-10010 (09962-01000, 09963-00500)
28. INSTALL CAMSHAFT TIMING GEAR ASSY (See page 14-93)
Page 509 of 969
141JJ-01
A86574
- ENGINE MECHANICALCYLINDER HEAD GASKET NO.2 (3MZ-FE)
14-133
2225 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. DRAIN ENGINE COOLANT (See page 16-9)
4. DRAIN ENGINE OIL (See page 17-20)
5. REMOVE FRONT WHEEL RH
6. REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5)
7. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1)
8. REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1)
9. REMOVE AIR CLEANER INLET ASSY (See page 19-5)
10. REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
11. REMOVE AIR CLEANER CASE (See page 19-5)
12. REMOVE EMISSION CONTROL VALVE SET (See page 11-13)
13. REMOVE INTAKE AIR SURGE TANK (See page 11-13)
14. REMOVE INTAKE MANIFOLD (See page 10-16)
15. REMOVE WATER OUTLET (See page 10-16)
16. REMOVE FRONT FENDER APRON SEAL RH
17. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5)
18. REMOVE VANE PUMP V BELT (See page 14-5)
19. REMOVE ENGINE MOVING CONTROL ROD (See page 14-79)
20. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79)
21. REMOVE GENERATOR BRACKET NO.2 (See page 14-79)
22. REMOVE CRANKSHAFT PULLEY (See page 14-79)
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
23. REMOVE TIMING BELT NO.1 COVER
24. REMOVE TIMING BELT NO.2 COVER (See page 14-79)
25. REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79)
26. REMOVE TIMING BELT GUIDE NO.2
27. REMOVE TIMING BELT (See page 14-79)
28. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
29. REMOVE CAMSHAFT TIMING PULLEY (See page 14-93)
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
30. REMOVE TIMING BELT NO.3 COVER (See page 14-93)
31. REMOVE MANIFOLD STAY NO.2 (See page 14-29)
32. SEPARATE EXHAUST PIPE ASSY FRONT (See page 15-2)
33. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt which secures the oil level gage guide
from the cylinder head LH.
(b) Pull out the oil level gage guide and oil level gage together
from the cylinder block.
(c) Remove the O-ring from the oil level gage guide.
Page 576 of 969
A8626611 10
9 8
5
7
64
3 2
1
A86269
Push
Fuel Pipe
Clamp
A86262
A
B
B
B
- ENGINE CONTROL SYSTEMKNOCK SENSOR (3MZ-FE)
10-19
2024 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
15. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold with the 9 bolts, 2 nuts and 2
washers. Using several steps, tighten the 9 bolts and 2
nuts uniformly in the sequence shown in the illustration.
Torque: 15 NVm (153 kgfVcm, 11 ftVlbf)
(b) Retighten the 9 water outlet mounting bolts and 2 nuts.
Torque: 15 NVm (153 kgfVcm, 11 ftVlbf)
(c) Install the ground cable with the nut.
Torque: 8.4 NVm (86 kgfVcm, 74 in.Vlbf)
(d) Connect the heater inlet water hose.
(e) Connect the fuel pipe No. 1.
(1) Push in the quick connector to the pipe until it
makes a ºclickº sound.
NOTICE:
Check the connected part for damage or foreign ob-
jects.
After connecting, check if the quick connector and
pipe are securely connected by pulling them.
(2) Install the fuel pipe clamp.
16. INSTALL ENGINE MOVING CONTROL ROD
Torque:
23 NVm (235 kgfVcm, 17 ftVlbf) for bolt A
64 NVm (653 kgfVcm, 47 ftVlbf) for bolt B
17. INSTALL INTAKE AIR SURGE TANK (See page 11-13)
18. INSTALL EMISSION CONTROL VALVE SET (See page 11-13)
19. INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1)
20. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
21. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
22. ADD ENGINE COOLANT (See page 16-9)
23. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1)
24. CHECK FOR FUEL LEAKS (See page 11-5)
25. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1)