instrument panel LEXUS ES300 2005 User Guide

550DD-02
I31523Clamp
I31524
I315282 Clamps
I31525
55-34
- HEATER & AIR CONDITIONERBLOWER ASSY
2649 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
HINT:
COMPONENTS: See page 55-33
1. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)
2. REMOVE HEATER TO FOOT DUCT NO.1 (See page 55-17)
3. REMOVE BLOWER ASSY (See page 55-17)
4. REMOVE AIR REFINER ELEMENT
5. REMOVE COWL WIRE NO.2
(a) Remove the clamp and cowl wire No. 2.
6. REMOVE RECIRCULATION DAMPER SERVO
SUB-ASSY
(a) Remove the 3 screws and recirculation damper servo
sub-assy .
7. REMOVE INSTRUMENT PANEL NO.3 WIRE
(a) Disconnect the connectors, remove the 2 clamps and
instrument panel No. 3 wire.
8. REMOVE BLOWER MOTOR CONTROL
(a) Remove the 2 screws and blower motor control.

I31527
- HEATER & AIR CONDITIONERBLOWER ASSY
55-35
2650 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. REMOVE BLOWER W/FAN MOTOR SUB-ASSY
(a) Remove the 3 screws and blower w/fan motor sub-assy.
10. INSTALL BLOWER ASSY (See page 55-17)
11. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)

400FU-02
C93015
C92370
- AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT ASSY
40-33
2548 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FLOOR SHIFT ASSY
OVERHAUL
1. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
2. REMOVE FRONT DOOR SCUFF PLATE RH (SEE PAGE 71-1 1)
3. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE PAGE 71-1 1)
4. REMOVE INSTRUMENT PANEL SUB-ASSY LOWER (SEE PAGE 71-1 1)
5. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
6. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
7. REMOVE CONSOLE BOX ASSY (SEE PAGE 71-1 1)
8. REMOVE CONSOLE BOX CARPET
9. REMOVE CONSOLE BOX ASSY (SEE PAGE 71-1 1)
10. REMOVE INSTRUMENT PANEL FINISH PANEL END RH (SEE PAGE 71-1 1)
11. REMOVE INSTRUMENT PANEL FINISH PANEL END LH (SEE PAGE 71-1 1)
12. REMOVE AIR DUCT REAR NO.1 (SEE PAGE 55-17)
13. REMOVE AIR DUCT REAR NO.2 (SEE PAGE 55-17)
14. REMOVE CONSOLE BOX DUCT NO.1 (SEE PAGE 55-17)
15. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Disconnect the parking lock cable end from the lever pin
of the floor shift assembly.
(b) Using a screwdriver, disconnect the parking lock cable
from the floor shift assembly and clamp.
(c) Disconnect the cable clamp.

400FV-02
C93015
C92370
C93152
- AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT PARKING LOCK CABLE ASSY
40-41
2556 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FLOOR SHIFT PARKING LOCK CABLE ASSY
REPLACEMENT
1. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
2. REMOVE FRONT DOOR SCUFF PLATE RH (SEE PAGE 71-1 1)
3. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE PAGE 71-1 1)
4. REMOVE INSTRUMENT PANEL SUB-ASSY LOWER (SEE PAGE 71-1 1)
5. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
6. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
7. REMOVE CONSOLE PANEL UPPER REAR (SEE PAGE 71-1 1)
8. REMOVE CONSOLE BOX CARPET
9. REMOVE CONSOLE BOX ASSY (SEE PAGE 71-1 1)
10. REMOVE INSTRUMENT PANEL FINISH PANEL END LH (SEE PAGE 71-1 1)
11. REMOVE INSTRUMENT PANEL FINISH PANEL END RH (SEE PAGE 71-1 1)
12. REMOVE AIR DUCT REAR NO.1 (SEE PAGE 55-17)
13. REMOVE AIR DUCT REAR NO.2 (SEE PAGE 55-17)
14. REMOVE CONSOLE BOX DUCT NO.1 (SEE PAGE 55-17)
15. REMOVE FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Disconnect the parking lock cable end from the lever pin
of the floor shift assembly.
(b) Using a screwdriver, disconnect the parking lock cable
from the floor shift assembly and clamp.
(c) Disconnect the cable clamp.
(d) Turn the ignition switch to ACC or ON.
(e) Using a screwdriver, remove the cable from the upper
bracket.

- AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT PARKING LOCK CABLE ASSY
40-43
2558 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. INSPECT CHECK KEY INTERLOCK OPERATION(See page 40-31)
18. INSTALL CONSOLE BOX DUCT NO.1
19. INSTALL AIR DUCT REAR NO.2
20. INSTALL AIR DUCT REAR NO.1
21. INSTALL INSTRUMENT PANEL FINISH PANEL END RH
22. INSTALL INSTRUMENT PANEL FINISH PANEL END LH
23. INSTALL CONSOLE BOX ASSY
24. INSTALL CONSOLE BOX CARPET
25. INSTALL CONSOLE PANEL UPPER REAR
26. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
27. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
28. INSTALL INSTRUMENT PANEL SUB-ASSY LOWER
29. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1
30. INSTALL FRONT DOOR SCUFF PLATE RH
31. INSTALL FRONT DOOR SCUFF PLATE LH

400FW-02
D25414
D25415
C93327
40-44
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION CONTROL CABLE ASSY
2559 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
TRANSMISSION CONTROL CABLE ASSY
REPLACEMENT
1. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1)
2. REMOVE AIR CONDITIONING RADIATOR ASSY (SEE PAGE 55-17)
3. REMOVE AIR BAG SENSOR ASSY CENTER (SEE PAGE60-55)
4. REMOVE BATTERY
5. REMOVE AIR CLEANER ASSY
6. REMOVE AIR CLEANER HOSE NO.1
7. REMOVE INTAKE AIR RESONATOR SUB-ASSY
8. REMOVE 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.
(d) Disconnect the control cable from the control cable
clamp.

C90581
C93327
D25414
D25415
40-46
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION CONTROL CABLE ASSY
2561 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Install the shift cable grommet retainer No.2 with the 2
bolts.
Torque: 4.9 NVm (50 kgfVcm, 43 in.Vlbf)
(e) Connect the control cable to the control cable clamp.
(f) Temporarily install the control cable to the control shaft le-
ver with nuts.
(g) Install the control cable and a new clip to the bracket.
10. INSTALL INTAKE AIR RESONATOR SUB-ASSY
11. INSTALL AIR CLEANER HOSE NO.1
12. INSTALL AIR CLEANER ASSY
13. INSTALL AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-55)
14. INSTALL AIR CONDITIONING RADIATOR ASSY (SEE PAGE 55-17)
15. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1)
16. INSTALL BATTERY
17. ADJUST SHIFT LEVER POSITION (SEE PAGE40-40)
18. INSPECT SHIFT LEVER POSITION (SEE PAGE40-40)

320DV-02
F41697
Stop Lamp
Switch
Push Rod
Pedal Height
32-8
- BRAKEBRAKE PEDAL SUPPORT ASSY
2442 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE PEDAL SUPPORT ASSY
ADJUSTMENT
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Inspect brake pedal height.
Pedal height from asphalt sheet:
144.1 - 154.1 mm (5.673 - 6.067 in.)
(b) Adjust brake pedal height.
(1) Remove the instrument panel finish panel sub-
assy lower and instrument panel insert sub-assy
lower LH.
(2) Disconnect the connector from the stop lamp
switch.
(3) Loosen the stop lamp switch lock nut and remove
the stop lamp switch.
(4) Loosen the clevis lock nut.
(5) Adjust the pedal height by turning the pedal push
rod.
(6) Tighten the push rod lock nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
(7) Install the stop lamp switch.
(8) Connect the connector to the stop lamp switch.
(9) Push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.),
turn the stop lamp switch to lock the nut in the posi-
tion where the stop lamp goes off.
(10) After installation, push the brake pedal in 5 - 10 mm
(0.20 - 0.39 in.), check that stop lamp lights up.
(11) Install the instrument panel insert sub-assy lower
LH and instrument panel finish panel sub-assy low-
er.

320DX-02
- BRAKEBRAKE PEDAL SUPPORT ASSY
32-1 1
2445 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1)
2. REMOVE INSTRUMENT PANEL REINFORCEMENT (SEE PAGE 71-1 1)
3. REMOVE BRAKE PEDAL RETURN SPRING
4. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
5. REMOVE BRAKE PEDAL SUPPORT ASSY
(a) Disconnect the stop lamp switch connector.
(b) Remove the bolt, 4 nuts and brake pedal support assy.
6. REMOVE STOP LAMP SWITCH ASSY
(a) Loosen the lock nut and remove the stop lamp switch.
7. REMOVE BRAKE PEDAL SUB-ASSY
(a) Remove the nut, bolt and brake pedal sub-assy from brake pedal support assy.
8. REMOVE BRAKE PEDAL PAD
9. REMOVE BRAKE PEDAL BUSH
(a) Remove the 2 brake pedal bushes from brake pedal.
10. REMOVE STOP LAMP SWITCH CUSHION
11. INSTALL STOP LAMP SWITCH CUSHION
12. INSTALL BRAKE PEDAL BUSH
(a) Install the new 2 brake pedal bushes to brake pedal.
HINT:
Apply the lithium soap base glycol grease to the parts indicates by arrows (see page 32-10).
13. INSTALL BRAKE PEDAL PAD
14. INSTALL BRAKE PEDAL SUB-ASSY
(a) Install the brake pedal sub-assy with the bolt and nut.
Torque: 37 NVm (375 kgfVcm, 27 ftVlbf)
15. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch with the lock nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
16. INSTALL BRAKE PEDAL SUPPORT ASSY
(a) Install the brake pedal support assy with the bolt and 4 nuts.
Torque:
Bolt: 20 NVm (204 kgfVcm, 15 ftVlbf)
Nut: 13 NVm (130 kgfVcm, 9 ftVlbf)
17. INSTALL PUSH ROD PIN
(a) Install the push rod pin and clip.
HINT:
Apply the lithium soap base glycol grease to the parts indicates by arrows (see page 32-10).
18. INSTALL BRAKE PEDAL RETURN SPRING
19. INSTALL INSTRUMENT PANEL REINFORCEMENT (SEE PAGE 71-1 1)
20. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1)
21. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8)
22. CHECK PEDAL FREE PLAY (SEE PAGE 32-8)
23. CHECK PEDAL RESERVE DISTANCE (SEE PAGE 32-8)

320OF-03
F42717
Stop Lamp
Switch Assy
Push Rod
Pedal Height
32-12- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2446 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
ADJUSTMENT
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Inspect brake pedal height.
Pedal height from asphalt sheet:
144.1 - 154.1 mm (5.673 - 6.067 in.)
(b) Adjust brake pedal height.
(1) Remove the instrument panel finish panel sub-
assy lower and instrument panel insert sub-assy
lower LH.
(2) Disconnect the connector from the stop lamp switch
assy.
(3) Loosen the stop lamp switch lock nut and remove
the stop lamp switch assy.
(4) Loosen the clevis lock nut.
(5) Adjust the pedal height by turning the pedal push
rod.
(6) Tighten the push rod lock nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
(7) Install the stop lamp switch assy.
(8) Connect the connector to the stop lamp switch assy.
(9) Push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.),
turn the stop lamp switch assy to lock the nut in the
position where the stop lamp goes off.
(10) After installation, push the brake pedal in 5 - 10 mm
(0.20 - 0.39 in.), check that stop lamp lights up.
(11) Install the instrument panel insert sub-assy lower
LH and instrument panel finish panel sub-assy low-
er.