light 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 255 of 969
320DW-02
F42132
Brake Pedal Support
Stop Lamp
Switch Assy
Lock Nut
Brake Pedal Bush
Brake Pedal Bush Stop Light Switch Cushion
Brake Pedal
Push Rod Pin Brake Pedal Return Spring
Clip
Brake Pedal Pad
Non-reusable part
NVm (kgfVcm, ftVlbf) : Specified torque
Lithium soap base glycol grease
26 (265, 19)
37 (375, 27)
13 (130, 9)
13 (130, 9)
20 (204, 15)
32-10
- BRAKEBRAKE PEDAL SUPPORT ASSY
2444 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS
Page 257 of 969
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.
Page 265 of 969
F16914
F16911
32-20- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2454 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
34. INSTALL BRAKE PEDAL RETURN SPRING
35. INSTALL DRIVER SIDE JUNCTION BLOCK ASSY
(a) Install the junction block assy with the 3 nuts, then con-
nect the each connector.
36. INSTALL STEERING COLUMN ASSY (SEE PAGE 50-8)
37. CONNECT STEERING SLIDING YOKE SUB-ASSY (SEE PAGE 50-8)
38. CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (SEE PAGE 50-8)
39. INSPECT CHECK KEY INTERLOCK OPERATION (SEE PAGE 50-8)
40. INSTALL TURN SIGNAL SWITCH ASSY (SEE PAGE 50-8)
41. INSPECT SPIRAL CABLE SUB-ASSY (SEE PAGE 60-31)
42. INSTALL STEERING COLUMN COVER (SEE PAGE 50-8)
43. INSTALL STEERING COLUMN COVER LWR NO.2 (SEE PAGE 50-8)
44. INSTALL HEATER TO FOOT DUCT NO.3 (SEE PAGE 32-14)
45. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
46. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
47. INSTALL FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
48. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
49. INSTALL STEERING WHEEL ASSY (SEE PAGE 50-8)
50. INSPECT HORN BUTTON ASSY (SEE PAGE 60-22)
51. INSTALL HORN BUTTON ASSY (SEE PAGE 60-22)
52. INSTALL STEERING PAD SWITCH (SEE PAGE 82-1)
53. INSTALL CONNECTOR COVER (SEE PAGE 82-1)
54. INSTALL STEERING WHEEL COVER LOWER NO.2
55. INSPECT SRS WARNING LIGHT (SEE PAGE 05-818)
Page 267 of 969
C69097
R12236
(A)
F41707
F09717
R12236
(A) 32-22
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
2456 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Push in the piston and remove the piston stopper bolt and
gasket.
(e) Remove the No.1 piston sub-assy, pulling straight out not
at an angle.
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
(f) Place a waste cloth and 2 wooden blocks on the work
table and lightly edges until the No.2 piston sub-assy
drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag the top of the blocks
is at least 100 mm (3.94 in.).
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
9. REMOVE BRAKE MASTER CYLINDER KIT (W/ VSC)
(a) Place master cylinder in vise.
(b) Remove the O-ring.
(c) Push in the piston and remove the snap ring with snap
ring pliers.
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
(d) Push in the piston with a screwdriver, and remove the
straight pin by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(e) Remove the No.1 piston sub-assy, pulling straight out not
at an angle.
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
(f) Place a waste cloth and 2 wooden blocks on the work
table and lightly edges until the No.2 piston sub-assy
drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag the top of the blocks
is at least 100 mm (3.94 in.).
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
Page 269 of 969
F09718
F41707
F42650
SST 32-24
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
2458 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Install a straight pin.
HINT:
Insert the No.2 piston with the groove positioning horizontally.
(e) Push in the piston and install the snap ring with snap ring
pliers.
(f) Apply the lithium soap base glycol grease on a new O-
ring and install the O-ring to the master cylinder.
13. INSTALL MASTER CYLINDER RESERVOIR GROMMET
(a) Apply the lithium soap base glycol grease on the 2 master cylinder reservoir grommets.
(b) Install the 2 master cylinder reservoir grommets to the master cylinder reservoir sub-assy.
14. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
(a) Install the master cylinder reservoir sub-assy to the master cylinder with the screw.
15. INSTALL BRAKE MASTER CYLINDER RESERVOIR STRAINER
(a) Install the brake master cylinder reservoir strainer.
16. INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY
(a) Install the brake master cylinder reservoir filler cap assy.
17. INSPECT AND ADJUST BRAKE BOOSTER PUSH
ROD
(a) Apply SST to the master cylinder.
SST 09737-00013
(b) Set SST, on the master cylinder, lower the pin of the SST
until it slightly touches the piston.
(c) Apply the chalk to the flat surfaced tip of the SST pin.
(d) Turn SST upside down and place it clearance between
the brake booster and SST.
Clearance: 0 mm (0 in.)
HINT:
If there is a clearance between the SST main body and
the booster shell. It means that the specified value, and
no chalk attachment on the booster push rod means that
it is more than the specified value.
Brake booster push rod clearance before shipment is ad-
justed to be 0.105 mm ( 0.004 in.).
Page 270 of 969
F40006
SST
F40992
F40991
Front Brake Tube
Frame No. 1
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-25
2459 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737-00020
18. INSTALL BRAKE MASTER CYLINDER SUB-ASSY
(a) Install the master cylinder sub-assy and 2-way with the
2 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
(b) Using SST and connect the 4 front brake tubes to the
master cylinder sub-assy.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
(c) Using SST and install the front brake tube frame No.1 to
the master cylinder.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
(d) Connect the level warnig switch connector.
19. FILL RESERVOIR WITH BRAKE FLUID
20. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
21. BLEED BRAKE LINE (SEE PAGE 32-4)
22. INSTALL AIR CLEANER ASSY
23. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
24. CHECK BRAKE FLUID LEAKAGE
Page 271 of 969
3203F-08
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
C16481
Ventilation
No Ventilation 32-26
- BRAKEBRAKE BOOSTER ASSY
2460 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE BOOSTER ASSY (From July, 2003)
ON-VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Air tightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press the brake pedal several times slowly.
HINT:
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is air tight.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion switch OFF and check that there is no change
in the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Check vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.
Page 305 of 969
3203S-1 1
32-60
- BRAKESTEERING SENSOR
2494 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
STEERING SENSOR
REPLACEMENT
1. PRECAUTION (SEE PAGE 60-1)
2. SEPARATE BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE HORN BUTTON ASSY (SEE PAGE 60-22)
5. REMOVE STEERING WHEEL ASSY (SEE PAGE 50-8)
6. REMOVE STEERING COLUMN LOWER COVER (SEE PAGE 50-8)
7. REMOVE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-31)
8. REMOVE WINDSHIELD WIPER SWITCH ASSY
9. REMOVE STEERING SENSOR
10. INSTALL STEERING SENSOR
11. INSPECT SPIRAL CABLE SUB-ASSY
(a) If the following condition is identified, replace the spiral cable sub-assy with new one.
Condition:
Scratches or cracks on the connector
Cracks, dents or chipping of the spiral cable sub-assy
12. INSTALL WINDSHIELD WIPER SWITCH ASSY
13. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
14. INSTALL SPIRAL CABLE SUB-ASSY (SEE PAGE 60-31)
15. INSTALL STEERING COLUMN LOWER COVER (SEE PAGE 50-8)
16. CENTER SPIRAL CABLE (SEE PAGE 60-31)
17. INSTALL STEERING WHEEL ASSY (SEE PAGE 50-8)
18. INSPECT STEERING WHEEL CENTER POINT (SEE PAGE 50-8)
19. INSTALL HORN BUTTON ASSY (SEE PAGE 60-22)
20. INSPECT SRS WARNING LIGHT (SEE PAGE 05-818)
Page 309 of 969
3305G-02
F41011
Adjusting Nut
Lock Nut 33-2
- PARKING BRAKEPARKING BRAKE SYSTEM
2498 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. REMOVE REAR WHEEL
2. ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16)
3. INSTALL REAR WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
4. INSPECT PARKING BRAKE PEDAL TRAVEL
(a) Slowly depress the parking brake pedal all the way, and count the number of clicks.
Parking brake pedal travel: 3 - 6 clicks at 300 N (31 kgf, 68.3 lbf)
5. ADJUST PARKING BRAKE PEDAL TRAVEL
(a) Depress the parking brake pedal 3 notches to make a
room for the procedure, and loosen the lock nut.
(b) Return the parking brake pedal to the original position.
(c) Turn the adjusting nut until the parking brake pedal travel
is correct.
(d) Depress the parking brake pedal 3 notches to make a
room for the procedure, and tighten the lock nut.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(e) Return the parking brake pedal to the original position.
(f) Check whether parking brake drags or not.
(g) When operating the parking brake pedal, check that the
parking brake pedal indicator light lights up.
Page 328 of 969
3305G-02
F41011
Adjusting Nut
Lock Nut 33-2
- PARKING BRAKEPARKING BRAKE SYSTEM
2498 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. REMOVE REAR WHEEL
2. ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16)
3. INSTALL REAR WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
4. INSPECT PARKING BRAKE PEDAL TRAVEL
(a) Slowly depress the parking brake pedal all the way, and count the number of clicks.
Parking brake pedal travel: 3 - 6 clicks at 300 N (31 kgf, 68.3 lbf)
5. ADJUST PARKING BRAKE PEDAL TRAVEL
(a) Depress the parking brake pedal 3 notches to make a
room for the procedure, and loosen the lock nut.
(b) Return the parking brake pedal to the original position.
(c) Turn the adjusting nut until the parking brake pedal travel
is correct.
(d) Depress the parking brake pedal 3 notches to make a
room for the procedure, and tighten the lock nut.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(e) Return the parking brake pedal to the original position.
(f) Check whether parking brake drags or not.
(g) When operating the parking brake pedal, check that the
parking brake pedal indicator light lights up.