LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
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Matchmarks
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- BRAKEFRONT BRAKE
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
19. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
Single piston type:
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Twin piston type:
Standard thickness: 10.6 mm (0.417 in.)
Minimum thickness: 1.0 mm (0.039 in.)
20. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are
cleaned off.
21. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are
cleaned off.
22. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 in.)
Minimum thickness: 26.0 mm (1.024 in.)
23. REMOVE FRONT DISC
(a) Put matchmarks on the disc and the axle hub.
(b) Remove the disc.
24. INSTALL FRONT DISC
(a) Aligning the matchmarks, install the front disc.
HINT:
When replacing the disc with a new one, select the installation position where the disc has the minimum run-
out.
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
(b) Using a dial indicator, measure the disc runout 10 mm
(0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
(c) If the disc runout is greater than the maximum value,
check the bearing play in the axial direction and check the
axle hub runout (see page 30-2). If the bearing play and
axle hub runout are normal, adjust the disc runout or grind
it on a ºOn-carº brake lathe.
26. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder.
27. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
28. INSTALL PISTON SEAL
(a) Install the piston seal (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new piston seal.
(2) Install the piston seal to the disc brake cylinder.
(b) Install the 2 piston seals (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 new piston seals.
(2) Install the 2 piston seals to the disc brake cylinder.
29. INSTALL FRONT DISC BRAKE PISTON
(a) Install the front disc brake piston (Single piston Type).
(1) Apply the lithium soap base glycol grease to the piston.
(2) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
(b) Install the 2 front disc brake pistons (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 pistons.
(2) Install the 2 pistons to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
30. INSTALL CYLINDER BOOT
(a) Install the cylinder boot (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new
cylinder boot.
(2) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.
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C68792
F41703
Anti squeal
Shim No.1
Anti squeal
Shim No.2
Anti squeal
Shim No.1
Wear Indicator
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the 2 cylinder boots (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2
new cylinder boots.
(2) Install the 2 cylinder boots to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install the 2 new set rings.
NOTICE:
Do not damage the cylinder boot.
31. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Apply the lithium soap base glycol grease to seal surface
of 2 new bush dust boots.
(c) Using a socket wrench (19 mm) and hammer, drive the 2
brake bush dust boots into the brake cylinder mounting.
32. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 106.9 NVm (1,090 kgfVcm, 79 ftVlbf)
33. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylinder slide bush.
(b) Install the cylinder slide bush to the cylinder slide pin.
34. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide
pins.
(b) Install the 2 cylinder slide pins to the disc brake cylinder mounting.
HINT:
Install the cylinder slide pin with cylinder slide bush into the bottom side.
35. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side front disc brake pad support plate.
36. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side front disc brake pad support plate.
37. INSTALL ANTI SQUEAL SHIM KIT FRONT
(a) Install the anti squeal shim kit front (Single piston Type).
(1) Apply the both sides of anti squeal shim No.1 with
pad grease, and install the shim together with anti
squeal shim No.2 to each pad.
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Anti Squeal
Shim
Wear Indicator
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(2) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
(b) Install the anti squeal shim kit front (Twin piston Type).
(1) Apply the anti squeal shim with pad grease, and
install the anti squeal shim to each pad.
(2) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
38. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing upward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.
39. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder with the 2 bolts.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
40. CONNECT FRONT FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 NVm (300 kgfVcm, 22 ftVlbf)
HINT:
Install the flexible hose lock securely in the lock hold of the disc brake cylinder.
41. FILL RESERVOIR WITH BRAKE FLUID
42. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
43. BLEED BRAKE LINE (SEE PAGE 32-4)
44. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
45. CHECK BRAKE FLUID LEAKAGE
46. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
Page 285 of 969
320E7-03
F41864Disc brake grease Lithium soap base glycol grease
Non-reusable part
NVm (kgfVcm, ftVlbf)
: Specified torque Rear LH
Flexible Hose Union Bolt
Gasket
Rear Disc Brake
Cylinder Slide Pin
Rear Disc Brake
Cylinder Slide Bush
Rear Disc Brake
Bleeder Plug
Rear Disc Brake
Bleeder Plug Cap
Disc Brake Cylinder
Assy Rear LH
Piston Seal
Rear Disc Brake
Disc Brake Piston
Cylinder Boot
Set Ring
Rear Disc Brake
Bush Dust Boot
Rear Disc Brake
Cylinder Slide Pin
Rear Disc Brake
Pad Support Plate
Rear Disc Brake
Cylinder Mounting LH
Anti Squeal
Shim No.1
Disc Brake
Pad Kit Rear Disc Brake
Pad Kit Rear
Parking Brake Shoe
Adjusting Hole Plug
Rear DiscAnti Squeal
Shim No.2 Wear Indicator Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Wear Indicator
61.8 (630, 46)
61.8 (630, 46)
39.2 (400, 29)
29.4 (300, 22)
34.3 (350, 25)
8.3 (85, 74 in.Vlbf)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR BRAKE
COMPONENTS
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320E8-04
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
HINT:
Overhaul the RH side by the same procedures with LH side.
Two types of brake pad exist; one is with slit and the other without slit.
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surfaces.
3. DISCONNECT REAR LH 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 REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the rear disc brake cylinder slide pin.
5. REMOVE DISC BRAKE CYLINDER ASSY REAR LH
(a) Lift up the disc brake cylinder and remove the disc brake
cylinder.
6. REMOVE REAR DISC BRAKE CYLINDER SLIDE
BUSH
(a) Remove the cylinder slide bush from the disc brake cylin-
der.
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
7. REMOVE REAR DISC BRAKE BUSH DUST BOOT
(a) Remove the bush dust boot from the cylinder slide pin.
8. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), remove the cylinder
slide pin.
9. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Remove the 2 brake pads with anti squeal shims.
10. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT
(a) Remove the 2 anti squeal shims from 2 brake pads.
(b) Using a screwdriver, remove the wear indicator from 2
brake pads.
11. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the upper side rear disc brake pad support plate.
12. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the bottom side rear disc brake pad support plate.
13. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
LH
(a) Remove the 2 bolts and disc brake cylinder mounting.
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder boot
from the disc brake cylinder.
15. REMOVE REAR DISC BRAKE PISTON
(a) Place a piece of cloth or like, between the piston and the
disc brake cylinder.
(b) 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.
16. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the disc brake cylinder.
NOTICE:
Do not damage the inner cylinder and the cylinder groove.
17. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
18. REMOVE REAR DISC BRAKE BLEEDER PLUG
19. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the cylinder bore and piston for rust or scoring.
20. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
USA, Canada models:
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Brazil models:
Standard thickness: 11.0 mm (0.433 in.)
Minimum thickness: 1.0 mm (0.039 in.)
21. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are
cleaned off.
22. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are
cleaned off.
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Matchmarks
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
23. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
USA, Canada models:
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 10.5 mm (0.413 in.)
Brazil models:
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 8.5 mm (0.335 in.)
24. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
25. REMOVE REAR DISC
(a) Put matchmarks on the disc and the axle hub.
(b) Remove the disc.
26. INSTALL REAR DISC
(a) Aligning the matchmarks, install the rear disc.
HINT:
When replacing the disc with a new one, select the installation position where the disc has the minimum run-
out.
27. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
28. INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
(b) Using a dial indicator, measure the disc runout 10 mm
(0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.15 mm (0.0059 in.)
(c) If the disc runout is greater than the maximum value,
check the bearing play in the axial direction and check the
axle hub runout (see page 30-2). If the bearing play and
axle hub runout are normal, adjust the disc runout or grind
it on a ºOn-carº brake lathe.
29. ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-16)
30. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder.
31. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
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Anti Squeal
Shim No.2 Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Anti Squeal
Shim No.1
Wear Indicator
- BRAKEREAR BRAKE
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. INSTALL PISTON SEAL
(a) Apply the lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder.
33. INSTALL REAR DISC BRAKE PISTON
(a) Apply the lithium soap base glycol grease to the piston.
(b) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
34. INSTALL CYLINDER BOOT
(a) Apply the lithium soap base glycol grease to a new cylin-
der boot.
(b) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(c) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.
35. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 61.8 NVm (630 kgfVcm, 46 ftVlbf)
36. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side rear disc brake pad support plate.
37. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side rear disc brake pad support plate.
38. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT
(a) Apply the both sides of anti squeal shim No.1 with pad
grease, and install the shim together with anti squeal shim
No.2 to each pad.
(b) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
39. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing downward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.