LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 261 of 969
320OG-05
F16911
F16914
32-16- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2450 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. PRECAUTION (SEE PAGE 60-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE STEERING WHEEL COVER LOWER NO.2
5. REMOVE CONNECTOR COVER (SEE PAGE 82-1)
6. REMOVE STEERING PAD SWITCH (SEE PAGE 82-1)
7. REMOVE HORN BUTTON ASSY (SEE PAGE 60-22)
8. REMOVE STEERING WHEEL ASSY (SEE PAGE 50-8)
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
9. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
10. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
11. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
12. REMOVE HEATER TO FOOT DUCT NO.3 (SEE PAGE 32-14)
13. REMOVE STEERING COLUMN COVER LWR NO.2 (SEE PAGE 50-8)
14. REMOVE STEERING COLUMN COVER (SEE PAGE 50-8)
15. REMOVE TURN SIGNAL SWITCH ASSY (SEE PAGE 50-8)
16. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (SEE PAGE 50-8)
17. DISCONNECT STEERING SLIDING YOKE SUB-ASSY (SEE PAGE 50-8)
18. REMOVE STEERING COLUMN HOLE COVER SUB-ASSY NO.2 (SEE PAGE 50-8)
19. REMOVE STEERING COLUMN ASSY (SEE PAGE 50-8)
20. REMOVE DRIVER SIDE JUNCTION BLOCK ASSY
(a) Remove the 3 nuts and junction bloke assy, then discon-
nect the connector.
21. REMOVE BRAKE PEDAL RETURN SPRING
Page 262 of 969
F16908
F16906
F16910
F16907
F16909
- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)32-17
2451 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
22. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
23. REMOVE ACCELERATOR & BRAKE PEDAL ASSY
(a) Disconnect the stop lamp switch connector.
(b) Disconnect the accel position sensor connector.
(c) Remove the 4 bolts, nuts and accelerator & brake pedal
assy.
24. REMOVE STOP LAMP SWITCH ASSY
(a) Loosen the nut and remove the stop lamp switch assy.
Page 263 of 969
F16905
F16904
F16904
F16905
32-18- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2452 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. REMOVE BRAKE PEDAL PAD
26. REMOVE STOP LAMP SWITCH CUSHION
27. REMOVE ACCELERATOR PEDAL ASSY
(a) Remove the bolt, nut and accelerator pedal assy.
28. INSTALL ACCELERATOR PEDAL ASSY
(a) Install the accelerator pedal assy with nut and bolt.
Torque: 12 NVm (122 kgfVcm, 8.8 ftVlbf)
29. INSTALL STOP LAMP SWITCH CUSHION
30. INSTALL BRAKE PEDAL PAD
Page 264 of 969
F16909
F16907
F16910
F16906
F16908
- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)32-19
2453 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
31. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch assy with a nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
32. INSTALL ACCELERATOR & BRAKE PEDAL ASSY
(a) Install the accelerator & brake pedal assy with the 4 nuts
and bolts.
Torque:
Nut: 13 NVm (130 kgfVcm, 9 ftVlbf)
Bolt: 19.1 NVm (194 kgfVcm, 14 ftVlbf)
(b) Connect the accel position sensor connector.
(c) Connect the stop lamp switch connector.
33. 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 32-14).
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 266 of 969
320DY-06
F40991
Front Brake Tube
Frame No.1
F40992
F40004
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-21
2455 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE MASTER CYLINDER SUB-ASSY (From August,
2002)
OVERHAUL
1. REMOVE AIR CLEANER ASSY
2. DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluied immediately if it comes into contact with a painted surface.
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSY
(a) Disconnect the level warning switch connector.
(b) Using SST, remove the front brake tube frame No.1.
SST 09023-00101
(c) Using SST, disconnect the 4 brake tubes from the master
cylinder.
SST 09023-00101
(d) Remove the 2 nuts, pull out the 2-way and brake master
cylinder sub-assy.
4. REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY
(a) Remove the master cylinder reservoir filler cap assy.
5. REMOVE BRAKE MASTER CYLINDER RESERVOIR STRAINER
(a) Remove the master cylinder reservoir strainer.
6. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
(a) Remove the screw and pull out the master cylinder reservoir sub-assy.
7. REMOVE MASTER CYLINDER RESERVOIR GROMMET
(a) Remove the 2 master cylinder reservoir grommets.
8. REMOVE BRAKE MASTER CYLINDER KIT (W/O 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.
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 268 of 969
C69097
F40004
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-23
2457 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. INSPECT MASTER CYLINDER BODY
(a) Check the cylinder bore for rust or scoring.
11. INSTALL BRAKE MASTER CYLINDER KIT (W/O VSC)
(a) Place master cylinder in vise.
(b) Apply the lithium soap base glycol grease on new No.1
and No.2 piston sub-assy.
(c) Install the No.2 and No.1 piston sub-assy.
NOTICE:
If the piston is inserted at an angle, there is a possibil-
ity that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pis-
tons.
(d) Push in the piston and install a new gasket and a new pis-
ton stopper bolt.
Torque: 10 NVm (100 kgfVcm, 7 ftVlbf)
(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.
12. INSTALL BRAKE MASTER CYLINDER KIT (W/ VSC)
(a) Place master cylinder in vise.
(b) Apply the lithium soap base glycol grease on new No.1
and No.2 piston sub-assy.
(c) Install the No.2 and No.1 piston sub-assy.
NOTICE:
If the piston is inserted at an angle, there is a possibil-
ity that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pis-
tons.
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