torque spec LEXUS ES300 2005 Repair Manual

190SM-01
A81658
SST 1-A
SST 1-B
Turn
Hold
A81659
SST 2
Insert
SST 1
A81660
TurnSST1-A
A81661
SST 1-A
SST 1-B
Turn
Hold
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
19-23
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE GENERATOR PULLEY
SST 09820-6301 1 (09820-06010, 09820-06020)
HINT:
SST 1-A and B09820 - 06010
SST 209820 - 06020
(a) Hold SST 1-A with a torque wrench, then tighten SST
1-B clockwise with the specified torque.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
NOTICE:
Check that SST is secured to the rotor shaft.
(b) Clamp SST 2 in a vise.
(c) Insert SST 1-A and B into SST 2, then attach the pulley
nut to SST 2.
(d) To loosen the pulley nut, turn SST 1-A in the direction
shown in the illustration.
NOTICE:
To prevent damage to the rotor shaft, do not loosen the
pulley nut more than a half turn.
(e) Remove the generator from SST 2.
(f) Turn SST 1-B, then remove SST 1-A and B.
(g) Remove the pulley nut, then remove the generator pulley.

A75676
Diameter
A81670
Generator
PulleyGenerator Washer
A81671
Deep Socket
Wrench 21
A81148
A79315
Pin (f1.0 mm (0.039 in.))
19-26
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
2358 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Inspect the diameter.
(1) Using vernier calipers, measure the slip ring diame-
ter.
Standard diameter:
14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)
If the diameter is less than minimum, replace the generator ro-
tor.
7. INSTALL GENERATOR ROTOR ASSY
(a) Place the generator drive end frame on the generator
pulley.
(b) Install the generator rotor and generator washer.
8. INSTALL GENERATOR COIL ASSY
(a) Using a deep socket wrench 21 and press, press in the
generator coil carefully.
(b) Tighten the 4 bolts.
Torque: 5.8 NVm (59 kgfVcm, 51 in.Vlbf)
9. INSTALL GENERATOR BRUSH HOLDER ASSY
(a) While pushing the 2 brushes to inside the brush holder,
insert a pin (f1.0 mm (0.039 in.)) into the brush holder
hole.

A81672
Pin (f1.0 mm (0.039 in.)
A81146
A81164
A81658
SST 1-A
SST 1-B
Turn
Hold
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
19-27
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the generator brush holder with the 2 screws.
Torque: 1.8 NVm (18 kgfVcm, 16 in.Vlbf)
(c) Pull out the pin (f1.0 mm (0.039 in.)) from the generator
brush holder.
(d) Install the terminal insulator.
NOTICE:
Pay attention to the mounting orientation of the terminal in-
sulator.
(e) Install the generator rear end cover with the 3 nuts.
Torque: 4.6 NVm (47 kgfVcm, 41 in.Vlbf)
10. INSTALL GENERATOR PULLEY
SST 09820-6301 1 (09820-06010, 09820-06020)
HINT:
SST 1-A and B09820 - 06010
SST 209820 - 06020
(a) Install the generator pulley to the rotor shaft by tightening
the generator pulley nut by hand.
(b) Hold SST 1-A with a torque wrench, then tighten SST
1-B clockwise with the specified torque.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
NOTICE:
Check that SST is secured to the rotor shaft.

5002H-02
C90698
Steering Column
CoverHorn Button Assy
Steering Wheel Assy
Steering Pad SwitchConnector
Cover
Turn Signal Switch Assy
50 (510, 37)
Steering Column Cover
Lower No.2Instrument Panel
Finish Plate
NVm (kgfVcm, ftVlbf) : Specified torque
21 (214, 15)
8.8 (90, 78 in.Vlbf)
Steering Wheel
Cover Lower No. 2
Instrument Panel Sub-assy Upper
Steering Column Assy
Steering Column Hole
Cover Sub-assy No. 2
Hose Clamp
Heater to Foot
Duct No. 3
Steering Intermediate
Shaft Sub-assyInstrument Panel Insert
Sub-assy Lower LH
Front Door Scuff Plate LH
35 (360, 26)
35 (360, 26)
21 (214, 15)
50-6
- STEERING COLUMNSTEERING COLUMN ASSY
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
STEERING COLUMN ASSY
COMPONENTS

C92308
NVm (kgfVcm, ftVlbf) : Specified torque
35 (360, 26)
Non-reusable partUn-lock Waring
Switch AssyTransponder Key Amplifier
Ignition Switch Lock
Cylinder Assy
Steering Column Upper
w/ Switch Bracket Assy
Steering Column Assy
Ignition or Starter
Switch Assy
Steering Sliding
Yoke Sub-assySteering Column
Clamp Upper
 Tapered-Head Bolt
- STEERING COLUMNSTEERING COLUMN ASSY
50-7
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

C90690
C90688
Matchmarks
- STEERING COLUMNSTEERING COLUMN ASSY
50-13
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37. INSTALL STEERING COLUMN ASSY
(a) Install the steering column assy with the 2 nuts and bolt.
Torque: 21 NVm (214 kgfVcm, 15 ftVlbf)
(b) Connect the driver side junction block.
(c) Connect the connectors and wire harness clamps.
38. CONNECT STEERING SLIDING YOKE SUB-ASSY
(a) Align the matchmarks on the steering sliding yoke sub-
assy and steering intermediate shaft sub-assy.
(b) Connect the steering sliding yoke sub-assy with the bolt.
Torque: 35 NVm (360 kgfVcm, 26 ftVlbf)
39. CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY
(a) Place the ignition switch lock cylinder assy at the key ACC position.
(b) Install the floor shift parking lock cable assy.
40. INSPECT CHECK KEY INTERLOCK OPERATION(See page 40-31)
41. INSTALL INSTRUMENT PANEL FINISH PLATE(See page 71-1 1)
42. INSTALL TURN SIGNAL SWITCH ASSY
(a) Install the turn signal switch assy with the 3 screws.
(b) Connect the airbag connector.
(c) Connect the 3 connectors.
43. INSPECT SPIRAL CABLE SUB-ASSY(See page 60-31)
44. INSTALL STEERING COLUMN COVER
(a) Install the steering column cover with the 3 screws.
45. INSTALL STEERING COLUMN COVER LWR NO.2
46. INSTALL HEATER TO FOOT DUCT NO.3(See page 71-1 1)
47. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
48. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
49. INSTALL FRONT DOOR SCUFF PLATE LH
50. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

50-14
- STEERING COLUMNSTEERING COLUMN ASSY
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51. INSTALL STEERING WHEEL ASSY
(a) Align the matchmarks on the steering wheel assy and steering main shaft assy.
(b) Install the steering wheel assy set nut.
Torque: 50 NVm (510 kgfVcm, 37 ftVlbf)
52. INSPECT HORN BUTTON ASSY(See page 60-22)
53. INSTALL HORN BUTTON ASSY(See page 60-22)
54. INSTALL STEERING PAD SWITCH
(a) Connect the connector.
(b) Install the steering pad switch with the 2 screws.
55. INSTALL CONNECTOR COVER
56. INSTALL STEERING WHEEL COVER LOWER NO.2
57. INSPECT SRS WARNING LIGHT(See page 05-818)

PASSENGER AIRBAG INDICATOR LAMP ± EL002-05 February 22, 2005
Page 2 of 2
MODELPLANTDRIVETRAINPRODUCTION CHANGE EFFECTIVE VIN
ES 330Tsutsumi2WDJTHBA30G#50024130ES 330Kanto2WDJTHBA30G#55068000
TMK2WDJTJGA3#U#50046500
RX 330
TMK4WDJTJHA3#U#50076003RX 330
TMMC2WD2T2GA3#U#5C021700TMMC4WD2T2HA3#U#5C046800
PREVIOUS PART NUMBERCURRENT PART NUMBERPART NAMEQTY
89952±3301089952±33011
Occupant Detection Computer
1
89952±4801089952±48011Occupant Detection Computer1
SPECIAL SERVICE TOOLS (SSTs)PART NUMBERQUANTITY
Lexus Diagnostic Tester Kit*010012701
12 Megabyte Diagnostic Tester Program Card
with version 12.01a Software (or later)*01002593-0051
Occupant Seat Weight Set*
00002±09077±011
* Essential SSTs.
NOTE:
Additional Diagnostic Tester Kits, Program Cards, or other SSTs may be ordered by
calling SPX/OTC at 1-800-933-8335.
1. Unfasten passenger seat and rock the assembly back providing access to the
underside of the seat. For information to unfasten the passenger seat, refer to the
Technical Information System (TIS): 2004 ± 2005 model year ES 330 or RX 330
Repair Manual:
Seat: Front Seat Assembly LH: Overhaul.
2. Disconnect the negative terminal of the vehicle battery.
3. Disconnect electrical connectors from Occupant Detection ECU.
4. Remove and replace the Occupant Detection ECU.
5. Reinstall the seat assembly. For more information, refer to TIS: 2004 ± 2005 model
year ES 330 or RX 330 Repair Manual:
Seat: Front Seat Assembly LH: Overhaul.
Torque: 36.8 Nm (375 kgfcm, 27 ftlbf)
6. Reconnect the negative terminal of the vehicle battery.
7. Perform Zero Point Calibration and Sensitivity Check following prompts in the
Diagnostic tool found under the Occupant Detect menu item (refer to
TSIB No. EL007±03, ª
Occupancy Classification System Calibration
(DTC B1150 & B1650)
.º
8. Reinitialize systems affected by the disconnection of the vehicle battery.
Production
Change
Information
Parts
Information
Required
SSTs
Repair
Procedure

REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE ± ST004-01 RevisedDecember 21, 2001
Page 10 of 11
STEP 3:
Adjust cross camber to eliminate vehicle pulling.
HINT:
If the tires are placed in the positions they were in during tire rotation when the least
amount of vehicle pulling occurred, wheel alignment can be performed with a minimal
amount of adjustment.
WHEN VEHICLE PULLS TO LEFTWHEN VEHICLE PULLS TO RIGHT
Increase right front camber and decrease left
front camber until vehicle pulling is eliminatedIncrease left front camber and decrease right
front camber until vehicle pulling is eliminated
NOTE:
Keep the cross camber within 1
or less.
Keep the camber of each wheel within specifications (+/±45' of center value).
If adjustment exceeds the specifications, uneven tire wear will result.
5. Camber Adjustment Method
NOTE:
After the camber has been adjusted,
inspect the toe±in.
NOTE:
The method of camber adjustment
differs for different models, so please
refer to the repair manual of the
vehicle involved. (This is a sample
from the RX 300 Repair Manual).
A. Remove the front wheels and
ABS speed sensor clamp.
B. Remove the two nuts on the lower
side of the shock absorber.
C. Coat the threads of the nuts with
engine oil.
D. Temporarily install the two nuts.
E. Adjust the camber by pushing or
pulling the lower side of the shock
absorber in the direction in which
the camber adjustment is
required.
F. Tighten the nuts.
Torque: 210 Nm
(2,150 kgfcm, 155 ftlbf)
Repair
Procedures
(Continued)
1
2

REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE ± ST004-01 RevisedDecember 21, 2001
Page 11 of 11
G. Install the front wheels.
Torque: 103 Nm (1,050 kgfcm, 76 ftlbf)
H. Check the camber.
NOTE:
Adjusting value for the set bolts
is
6' ± 30' (0.1
± 0.5
).
When making an adjustment of more
than 45', replace the upper and lower
steering knuckle set bolts with the
adjusting bolts
. If the camber is not
within the specification, use the table
shown to estimate how much
additional camber adjustment will be
required, and select the appropriate
camber adjusting bolt.
I. Follow steps 5±a through 5±h
again. Between steps 5±b and
5±c, exchange one or two
selected bolts.
HINT:
When exchanging the two bolts,
exchange one bolt each time.
If Vehicle Pull Is Eliminated: Repair Is Now Complete.
If Vehicle Is Still Pulling: Contact Your Regional Office For Further Assistance.
Repair
Procedures
(Continued)