LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 291 of 969
F41551
F41562
Cylinder Slide Pin
Cylinder Mounting
Lithium soap base glycol grease
F41558Lithium soap base glycol grease
32-46
- BRAKEREAR BRAKE
2480 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
40. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), install the cylinder slide
pin.
Torque: 39.2 NVm (400 kgfVcm, 29 ftVlbf)
41. INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a) Apply the lithium soap base glycol grease to seal surface
of a new bush dust boot.
(b) Install the bush dust boot to the cylinder slide pin.
42. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylin-
der slide bush.
(b) Install the cylinder slide bush to the disc brake cylinder.
43. INSTALL DISC BRAKE CYLINDER ASSY REAR LH
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the disc brake cylinder to the cylinder slide pin.
44. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the cylinder slide pin to the disc brake cylinder.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
45. CONNECT REAR LH 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 hole of the disc brake cylinder.
46. FILL RESERVOIR WITH BRAKE FLUID
47. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
48. BLEED BRAKE LINE (SEE PAGE 32-4)
49. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
50. CHECK BRAKE FLUID LEAKAGE
51. INSTALL REAR WHEEL
Torque: 103 NVm (1050 kgfVcm, 76 ftVlbf)
Page 292 of 969
320E1-02
- BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32-47
2481 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE ACTUATOR ASSY (W/O VSC)
ON-VEHICLE INSPECTION
1. CONNECT HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operator's manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay ON, check that the pedal does not pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
Page 293 of 969
320E2-04
F40998
C84798
To RL W/C
To FR W/C
To FL W/C
To RR W/C From M/C 2nd
From M/C 1st
F40998
32-48
- BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
2482 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluid immediately if it comes into contact with a painted surface.
2. REMOVE BRAKE ACTUATOR WITH BRACKET
(a) Using SST, disconnect the 6 brake lines from the actuator.
SST 09023-00101
(b) Use tags or make a memo to identify the place to recon-
nect.
(c) Disconnect the brake actuator connector.
(d) Remove the 3 nuts and brake actuator with bracket.
3. REMOVE BRAKE ACTUATOR ASSY
(a) Remove the 2 nuts and brake actuator from the bracket.
(b) Remove the 2 holders and 3 cushions from the brake actuator.
4. INSTALL BRAKE ACTUATOR ASSY
(a) Install the 3 cushions and 2 holders to the brake actuator.
(b) Install the brake actuator to the bracket with the 2 nuts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
5. INSTALL BRAKE ACTUATOR WITH BRACKET
(a) Install the brake actuator with the 3 nuts.
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
(b) Connect the brake actuator connector.
Page 294 of 969
C84798
To RL W/C
To FR W/C
To FL W/C
To RR W/C From M/C 2nd
From M/C 1st
- BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32-49
2483 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Using SST, connect the each brake line to the correct
position of brake actuator, as shown in the illustration.
SST 09023-00101
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
6. FILL RESERVOIR WITH BRAKE FLUID
7. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
8. BLEED BRAKE LINE (SEE PAGE 32-4)
9. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
10. CHECK BRAKE FLUID LEAKAGE
11. CHECK OPERATION OF BRAKE ACTUATOR (SEE PAGE 32-47)
Page 295 of 969
3203J-09
32-50
- BRAKEBRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
2484 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
ON-VEHICLE INSPECTION
1. CONNECT HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operator's manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay ON, check that the pedal does not pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
Page 296 of 969
3211Y-04
F45680
F45681
From M/C 1st
To FL W/CFrom M/C 2nd
To RR W/C
To RL W/CTo FR W/C
F45682
- BRAKEBRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
32-51
2485 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluid immediately if it comes into contact with a painted surface.
2. REMOVE BRAKE ACTUATOR WITH BRACKET
(a) Using SST, disconnect the 6 brake lines from the actuator.
SST 09023-00101
(b) Use tags or make a memo to identify the place to recon-
nect.
(c) Disconnect the actuator connector.
Page 297 of 969
F45683
F40999
C86250
From M/C 2nd
To FL W/CFrom M/C 1st
To RR W/C
To RL W/CTo FR W/C
32-52
- BRAKEBRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
2486 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Remove the 3 nuts and brake actuator with bracket.
3. REMOVE BRAKE ACTUATOR ASSY
(a) Remove the 2 nuts and brake actuator from the bracket.
4. INSTALL BRAKE ACTUATOR ASSY
(a) Install the brake actuator to the bracket with the 2 nuts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
5. INSTALL BRAKE ACTUATOR WITH BRACKET
(a) Install the brake actuator with the 3 nuts.
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
(b) Connect the brake actuator connector.
(c) Using SST, connect the each brake line to the correct
position of brake actuator, as shown in the illustration.
SST 09023-00101
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
6. FILL RESERVOIR WITH BRAKE FLUID
7. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
8. BLEED BRAKE LINE (SEE PAGE 32-4)
Page 298 of 969
- BRAKEBRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
32-53
2487 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. BLEED BRAKE ACTUATOR ASSY (W/ VSC) (SEE PAGE 32-4)
SST 09992-00242, 09992-00350
10. CHECK FLUID LEVEL IN RESERVOIR(SEE PAGE 32-4)
11. CHECK BRAKE FLUID LEAKAGE
12. CHECK OPERATION OF BRAKE ACTUATOR (SEE PAGE 32-47)
Page 299 of 969
3203N-09
F41016
F41018F41017
C84803
32-54
- BRAKESPEED SENSOR FRONT LH
2488 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
SPEED SENSOR FRONT LH
REPLACEMENT
HINT:
Replace the RH side by the same procedures with LH side.
1. REMOVE FRONT WHEEL
2. REMOVE FRONT FENDER LINER LH
3. REMOVE SPEED SENSOR FRONT LH
(a) Disconnect the speed sensor connector and clamp.
(b) Remove the 2 clamp bolts holding the sensor harness
and clamp from the body and shock absorber.
(c) Remove the bolt and speed sensor FR LH.
NOTICE:
Do not stick and foreign matter on the sensor tip.
Page 300 of 969
C84803
F41018F41017
A
B
F41016
- BRAKESPEED SENSOR FRONT LH
32-55
2489 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
4. INSTALL SPEED SENSOR FRONT LH
(a) Install the speed sensor FR LH with the bolt.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
NOTICE:
Make sure the sensor tip is clean.
(b) Install the sensor harness clamps with the 2 bolts ºAº and
ºBº to the body and shock absorber.
Torque:
Bolt A: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
Bolt B: 18.8 NVm (192 kgfVcm, 14 ftVlbf)
(c) Connect the clamp to the knuckle.
(d) Connect the speed sensor connector and clamp.
5. INSTALL FRONT FENDER LINER LH
6. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
7. CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-420 or 05-471)