LEXUS ES300 2005 Repair Manual

3203F-08
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
C16481
Ventilation
No Ventilation 32-26
- BRAKEBRAKE BOOSTER ASSY
2460 Author
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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.

320DZ-05
F46404
Vacuum Hose Assy
Clip
Brake Master
Cylinder Sub-AssyGasket
Push Rod Pin
Push Rod Clevis
Clip
Brake Booster
Front Brake
Tube No.5Front Brake Tube Frame No.1

Non-reusable part
NVm (kgfVcm, ftVlbf): Specified torque
15 (155, 11)
13 (130, 9)
5.4 (55, 48 in.Vlbf)
13 (130, 9)
15 (155, 11)
13 (130, 9)
Vacuum Hose Bracket
15 (155, 11)
2-W ay
15 (155, 11)
Front Brake
Tube No.2
15 (155, 11)
Front Brake
Tube No.3
- BRAKEBRAKE BOOSTER ASSY
32-27
2461 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS

3211X-04
F40995
F40996
BR3753
32-28
- BRAKEBRAKE BOOSTER ASSY
2462 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. REMOVE AIR CLEANER ASSY
2. DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluid immediately if it comes into contact with a painted surface.
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
4. REMOVE VACUUM HOSE ASSY
(a) Remove the bolt and separate the vacuum hose from the
vacuum hose bracket.
(b) Slide the clip and disconnect the vacuum hose from the
brake booster.
5. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
6. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
7. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
8. REMOVE BRAKE PEDAL RETURN SPRING
9. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
10. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Loosen the lock nut and remove the push rod clevis.
11. REMOVE FRONT BRAKE TUBE NO.5
(a) Using SST and remove the front brake tube No.5.
SST 09023-00101
12. REMOVE BRAKE BOOSTER ASSY
(a) Remove the 4 nuts.
(b) Pull out the brake booster assy.

BR3753
F40996
F40995
- BRAKEBRAKE BOOSTER ASSY
32-29
2463 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. REMOVE BRAKE BOOSTER GASKET
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster.
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster with the 4 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
16. INSTALL FRONT BRAKE TUBE NO.5
(a) Using SST and install the front brake tube No.5.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
17. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the push rod clevis and lock nut.
18. INSTALL PUSH ROD PIN
(a) Install the push rod pin and clip.
HINT:
Apply the lithium soap base glycol grease to the part indicate by arrow (see page 32-27).
19. INSTALL BRAKE PEDAL RETURN SPRING
20. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
21. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
22. INSTALL FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
23. INSTALL VACUUM HOSE ASSY
(a) Install the vacuum hose and vacuum hose bracket to the
body with a bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(b) Connect the vacuum hose to the brake booster with the
clip.
24. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE PAGE 32-21)
SST 09737-00013, 09737-00020
25. INSTALL BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
26. FILL RESERVOIR WITH BRAKE FLUID

32-30
- BRAKEBRAKE BOOSTER ASSY
2464 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
27. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
28. BLEED BRAKE LINE (SEE PAGE 32-4)
29. INSTALL AIR CLEANER ASSY
30. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
31. CHECK BRAKE FLUID LEAKAGE
32. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8 or 32-12)

320E5-02
F41863
Front Disc
Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt

Gasket
Front Disc Brake
Bleeder Plug Cap
Disc Brake
Cylinder Assy LH

Set Ring

Cylinder BootFront Disc
Brake Piston

Piston Seal
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Disc brake grease Lithium soap base glycol grease
Non-reusable part


NVm (kgfVcm, ftVlbf)
: Specified torque Single Piston Type:






Anti Squeal
Shim No.1
Disc Brake
Pad Kit Front Anti Squeal
Shim No.1
Anti Squeal
Shim No.2
Anti Squeal
Shim No.2
Wear Indicator
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)34.3 (350, 25)
34.3 (350, 25)
106.9 (1,090, 79)
106.9 (1,090, 79)
- BRAKEFRONT BRAKE
32-31
2465 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT BRAKE
COMPONENTS

F41533Disc brake grease Lithium soap base glycol grease
Non-reusable part


NVm (kgfVcm, ftVlbf)
: Specified torque Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt

Gasket
Front Disc Brake
Bleeder Plug Cap
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Front Disc
Anti Squeal
Shim
Disc Brake
Pad Kit Front
Twin Piston Type:

Set Ring

Cylinder Boot Front Disc
Brake Piston

Piston Seal




Disc Brake
Cylinder Assy LH
Anti Squeal
ShimWear Indicator
106.9 (1,090, 79)
106.9 (1,090, 79)
34.3 (350, 25)
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)
34.3 (350, 25)
32-32
- BRAKEFRONT BRAKE
2466 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

320E6-04
F41534
F41535
F41536
- BRAKEFRONT BRAKE
32-33
2467 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
HINT:
Overhaul the RH side by the same procedures with LH side.
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surfaces.
3. DISCONNECT FRONT FLEXIBLE HOSE
(a) Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose
from the disc brake cylinder.
4. REMOVE DISC BRAKE CYLINDER ASSY LH
(a) Remove the 2 bolts and disc brake cylinder.
5. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Remove the 2 brake pads with anti
squeal shims.
6. REMOVE ANTI SQUEAL SHIM KIT FRONT
(a) Remove the 2 anti squeal shims from 2 brake pads.
(b) Using a screwdriver, remove the wear indicator from 2
brake pads.
7. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the upper side front disc brake pad support plate.
8. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the bottom side front disc brake pad support plate.
9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the 2 cylinder slide pins from the disc brake cylin-
der mounting.

F41537
F41561
C68791
F41563
F41564
32-34
- BRAKEFRONT BRAKE
2468 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. REMOVE FRONT DISC BRAKE CYLINDER SLIDE
BUSH
(a) Remove the cylinder slide bush from the cylinder slide
pin.
11. REMOVE FRONT DISC BRAKE CYLINDER
MOUNTING LH
(a) Remove the 2 bolts and disc brake cylinder mounting.
12. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Using a screwdriver and hammer, remove the 2 bush dust
boots from the disc brake cylinder mounting.
13. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder boot
from the disc brake cylinder (Single piston Type).
(b) Using a screwdriver, remove the 2 set rings and 2 cylinder
boots from the disc brake cylinder (Twin piston Type).

F41539
F41560
- BRAKEFRONT BRAKE
32-35
2469 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. REMOVE FRONT DISC BRAKE PISTON
(a) Remove the front disc brake piston (Single piston Type).
(1) Place a piece of cloth or like, between the piston
and the disc brake cylinder.
(2) Use compressed air to remove the piston from the
disc brake cylinder.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
NOTICE:
Do not spatter the brake fluid.
(b) Remove the 2 front disc brake pistons (Twin piston Type).
(1) Place a piece of cloth or like, between the piston
and the disc brake cylinder.
(2) Use compressed air to remove one of the piston
from the disc brake cylinder.
(3) Press the removed piston to the cylinder with a cer-
tain force that prevent the piston from flying out via
a chip of wood. Then blow into the air of compressor
again to remove the other piston.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
NOTICE:
Do not spatter the brake fluid.
15. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the disc brake cylinder (Single piston Type).
NOTICE:
Do not damage the inner cylinder and the cylinder groove.
(b) Using a screwdriver, remove the 2 piston seals from the disc brake cylinder (Twin piston Type).
NOTICE:
Do not damage the inner cylinder and the cylinder groove.
16. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
17. REMOVE FRONT DISC BRAKE BLEEDER PLUG
18. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the cylinder bore and piston for rust or scoring.