engine 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 56 of 969
01-8- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
8 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U) ISC
Idle Speed Control-
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CC0
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass-
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
TCMTransmission Control ModuleTransmission ECU (Electronic Control Unit)
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic ConverterThree-W ay Catalytic (TWC)
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCO
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor (Read Switch Type)
WOTWide Open ThrottleFull Throttle
Page 200 of 969
4005R-08
D25120
Add if hotOK if hot
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE FLUID
40-1
2516 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AUTOMATIC TRANSAXLE FLUID
ON-VEHICLE INSPECTION
1. CHECK THE FLUID LEVEL
HINT:
Drive the vehicle so that the engine and transaxle are at normal
operating temperature.
Fluid temperature: 70 - 80 °C (158 - 176 °F)
(a) Park the vehicle on a level surface and set the parking
brake.
(b) With the engine idling and the brake pedal depressed,
shift the shift lever into all positions from P to L position,
and return to P position.
(c) take out the dipstick and wipe it clean.
(d) Put it back fully into the pipe.
(e) take it out and check that the fluid level is in the HOT posi-
tion.
If there are leaks, it is necessary to repair or replace O-rings,
FIPGs, oil seals, plugs and/or other parts.
Page 202 of 969
4010O-05
D30614
D25415
C99458
- AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (U151E)
40-3
2518 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PARK/NEUTRAL POSITION SWITCH ASSY (U151E)
REPLACEMENT
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSY
3. REMOVE AIR CLEANER HOSE NO.1
4. REMOVE AIR CLEANER BRACKET
5. REMOVE AIR CLEANER INLET NO.1
6. REMOVE INTAKE AIR RESONATOR SUB-ASSY
7. REMOVE ENGINE UNDER COVER NO.1
8. DISCONNECT TRANSMISSION CONTROL CABLE
ASSY
(a) Remove the nut from the control shaft lever.
(b) Disconnect the control cable from the control shaft lever.
(c) Remove the clip and disconnect the control cable from
the control cable bracket.
9. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY
(a) Disconnect the park/neutral position switch connector.
(b) Remove the nut, washer and control shaft lever.
Page 205 of 969
40-6
- AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (U151E)
2521 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
12. ADJUST SHIFT LEVER POSITION (SEE PAGE 40-40)
13. INSPECT SHIFT LEVER POSITION (SEE PAGE 40-40)
14. INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (SEE PAGE 40-7)
15. INSTALL ENGINE UNDER COVER NO.1
16. INSTALL INTAKE AIR RESONATOR SUB-ASSY
17. INSTALL AIR CLEANER INLET NO.1
18. INSTALL AIR CLEANER BRACKET
19. INSTALL AIR CLEANER HOSE NO.1
20. INSTALL AIR CLEANER ASSY
21. INSTALL BATTERY
Page 206 of 969
4010P-03
C99453
Groove
Neutral
Basic Line
- AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (U151E)
40-7
2522 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSY
(a) Apply the parking brake and turn the ignition switch to ON.
(b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P posi-
tion.
(c) Check that the back-up light is lit and the reverse warning buzzer sounds only when the shift lever is
set in R position.
If a failure is found, check the continuity of the park/neutral position switch.
2. ADJUST PARK/NEUTRAL POSITION SWITCH ASSY
(a) Loosen the 2 bolts of park/neutral position switch and set
the shift lever to the N position.
(b) Align the groove with neutral basic line.
(c) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(d) After adjustment, perform the inspection described in
step 1.
Page 207 of 969
4010Q-02
D31337
Bearing Bracket Hole Snap Ring
32 (326, 24)
12 (122, 9)
64 (653, 47)
46 (470, 34)
Front Drive Shaft Assy RH
Transmission Control
Cable Bracket No.2
41 (418, 30)
12 (122, 9)
37 (377, 27)
5.5 (56, 49 in.Vlbf)
9.8 (100, 87 in.Vlbf)
Wire Harness
Automatic
Transmission Case
Cover
Front Drive
ShaftLH Hole
Snap Ring
Front Drive Shaft
Assy LH
Starter Assy
O-ring
Transimission Oil
Filler Tube Sub-assy
ATF Level
Gauge Oil Cooler
Outlet Tube No.1 Oil Cooler Inlet
Tube No.1Oil Cooler Tube ClampTransmission Control
Cable Bracket No.1 Flywheel Housing
Under CoverTorque Converter ClutchEngine
Mounting
Bracket FR
X6
N´m (kgf´cm, ft´lbf): Specified torque
Non-reusable partWire Harness Clamp
12 (122, 9)
12 (122, 9)
34 (350, 25)
8.4 (86, 74 in.Vlbf)
64 (653, 47)
5.4 (55, 48 in.Vlbf)
7.8 (80, 69 in.Vlbf)
13 (130, 9)
Exhaust Pipe Support Bracket
37 (377, 27)
34 (350, 25)
x 5 40-8
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
2523 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AUTOMATIC TRANSAXLE ASSY (U151E)
COMPONENTS
Page 208 of 969
4010R-03
C91731
D31338
D30466
D30464
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
40-9
2524 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-29)
2. REMOVE FRONT DRIVE SHAFT ASSY RH
(SEE PAGE 30-8)
3. REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-8)
4. REMOVE TRANSMISSION CONTROL CABLE
BRACKET NO.2
(a) Remove the bolt and transmission control cable bracket
No.2.
5. REMOVE WIRE HARNESS CLAMP
(a) Disconnect the wire harnesses from the clamps.
(b) Remove the 2 bolts and 2 clamps.
6. DISCONNECT WIRE HARNESS
(a) Remove the bolt and wire harness.
7. REMOVE STARTER ASSY
(a) Disconnect the connector.
(b) Remove the nut and disconnect the starter wire.
(c) Remove the 2 bolts and starter assy.
Page 210 of 969
D31339
D25420
D31340
D30472
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
40-1 1
2526 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Disconnect the breather hose from the wire harness
bracket.
12. REMOVE OIL COOLER OUTLET TUBE NO.1
(a) Using SST and spanner, disconnect the oil cooler outlet tube No.1.
SST 09023-12701
13. REMOVE ENGINE MOUNTING BRACKET FR
(a) Remove the 3 bolts and engine mounting bracket FR.
14. REMOVE AUTOMATIC TRANSAXLE ASSY
(a) Remove the 2 bolts and fryweel housing under cover.
(b) Turn the crankshaft to gain access and remove the 6 bolts
while holding the crankshaft pulley bolt with a wrench.
Page 212 of 969
C83051
D31341Dimension B
B
D30511D31482
AA
A
A
BA
CC
D30472
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
40-13
2528 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
19. INSTALL TORQUE CONVERTER CLUTCH ASSY
(a) Install the torque converter clutch to the automatic trans-
axle.
(b) Using vernier calipers, measure dimension ºAº between
the transaxle fitting part and the converter fitting part of
the drive plate.
(c) Using vernier calipers and a straight edge, measure di-
mension ºBº shown in the illustration and check that ºBº
is greater than ºAº measured in (b).
Standard: A + 1 mm or more
NOTICE:
Do not add the thickness of the straight edge.
20. INSTALL AUTOMATIC TRANSAXLE ASSY
(a) Install the automatic transaxle and 8 bolts to the engine.
Torque:
Bolt A: 64 NVm (653 kgfVcm, 47 ftVlbf)
Bolt B: 46 NVm (470 kgfVcm, 34 ftVlbf)
Bolt C: 37 NVm (377 kgfVcm, 27 ftVlbf)
(b) Apply a few drops of adhesive to each 2 threads on the
tip of the 6 torque converter clutch mounting bolts.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent
(c) Install the 6 torque converter clutch mounting bolts.
Torque: 41 NVm (418 kgfVcm, 30 ftVlbf)
HINT:
First install green colored bolt, and then install the other 5 bolts.
Page 213 of 969
D31340
D25420
C88135
D31339
Breather Hose
C88278
40-14
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
2529 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
21. INSTALL ENGINE MOUNTING BRACKET FR
(a) Install the engine mounting bracket FR with the 3 bolts to
the automatic transaxle.
Torque: 64 NVm (653 kgfVcm, 47 ftVlbf)
22. INSTALL TRANSMISSION OIL FILLER TUBE
SUB-ASSY
(a) Coat a new O-ring with ATF, and install it to the oil filler
tube.
(b) Install the oil filler tube with the bolt to the automatic trans-
axle.
Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf)
(c) Install the ATF level gauge.
(d) Connect the breather hose to the wire harness bracket.
23. INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Install the control cable bracket No.1 with the 2 bolts.
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
24. INSTALL OIL COOLER INLET TUBE NO.1
(a) Temporarily install the oil cooler outlet tube No.1.
(b) Temporarily install the oil cooler inlet tube No.1.