torque LEXUS ES300 2005 Repair Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 795 of 969
A79720
A79729
A79719
A79718
19-14
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2346 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the starter field frame with the 2 through bolts.
Torque: 6.0 NVm (61 kgfVcm, 53 in.Vlbf)
17. INSTALL STARTER MAGNETIC SWITCH ASSY
(a) Apply grease to the plunger and hook.
(b) Hook the plunger hook of the starter magnetic switch on
the drive lever.
(c) Install the plunger and return spring.
(d) Install the starter magnetic switch with the 2 screws.
Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf)
(e) Connect the lead wire to terminal C with the nut.
Torque: 10 NVm (102 kgfVcm, 7 ftVlbf)
Page 800 of 969
190SK-01
A87596N´m (kgf´cm, ft´lbf) : Specified torqueGenerator
Connector
Generator Assy
V-ribbed Belt No. 1
18 (184, 13)
Plate Washer
9.8 (100, 7)
58 (591, 43)
8.4 (86, 74 in.Vlbf)
Wiring Harness Clamp Bracket
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
19-19
2351 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
GENERATOR ASSY (3MZ-FE)
COMPONENTS
Page 801 of 969
A86392
Generator Pulley
Drive End Frame Assy
GeneratorGenerator Rotor AssyGenerator Washer
Generator Coil AssyTerminal Insulator
Generator
Brush Holder Assy
Generator
Rear End Cover
x4
Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
5.8 (59, 51 in.Vlbf)
1.8 (18, 16 in.Vlbf)
4.6 (47, 41 in.Vlbf)
111 (1,125, 81)
x2x3 19-20
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
2352 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 803 of 969
A87593
B
A
A87594
B
AC 19-22
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
2354 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
3. INSTALL GENERATOR ASSY
(a) Install the wiring harness clamp bracket with the bolt.
Torque: 8.4 NVm (86 kgfVcm, 74 in.Vlbf)
(b) Temporarily install the generator with bolts A and B.
(c) Adjust the V-ribbed belt No. 1 tension by tightening bolt
C (see page 14-1).
(d) Tighten bolts A and B.
Torque:
18 NVm (180 kgfVcm, 13 ftVlbf) for bolt A
58 NVm (591 kgfVcm, 43 ftVlbf) for bolt B
(e) Install the generator wire with the nut.
Torque: 9.8 NVm (100 kgfVcm, 7 ftVlbf)
(f) Connect the generator connector.
(g) Install the wire harness clamp.
4. INSPECT DRIVE BELT (See page 14-1)
5. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
6. SYSTEM INITIALIZATION (See page 19-15)
Page 804 of 969
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
2355 Author: Date:
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.
Page 807 of 969
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: Date:
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.
Page 808 of 969
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
2359 Author: Date:
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.
Page 809 of 969
A81659
SST 2
Insert
SST 1
A81673
TurnSST1-A
A81661
SST 1-A
SST 1-B
Turn
Hold 19-28
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
2360 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Clamp SST 2 in a vise.
(d) Insert SST 1-A and B into SST 2, then attach the genera-
tor pulley nut to SST 2.
(e) Tighten the generator pulley nut by turning SST 1-A in the
direction shown in the illustration.
Torque: 111 NVm (1,125 kgfVcm, 81 ftVlbf)
(f) Remove the generator from SST 2.
(g) Turn SST 1-B, then remove SST 1-A and B.
(h) Turn the generator pulley, then check that the generator
pulley moves smoothly.
Page 814 of 969
R00429
Marked Line
F16018
- STEERING COLUMNSTEERING
50-5
2566 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(1) Draw a line on the RH and LH tie rod and rack ends
where it can easily be seen.
(2) Using a paper gauge, measure the distance from
RH and LH tie rod ends to the rack end screws.
HINT:
Measure the RH side and LH side.
Make a note of the measured values.
(3) Remove the RH and LH boot clips from the rack
boots.
(4) Loosen the RH and LH lock nuts.
(5) Turn the RH and LH rack end by the same amount
(but in different directions) according to the steering
angle.
1 turn 360 deg. of rack end (1.5 mm (0.059 in.) horizon-
tal movement) - 12 deg. of steering angle.
(6) Tighten the RH and LH lock nuts.
Torque: 74 NVm (755 kgfVcm, 55 ftVlbf)
NOTICE:
Make sure that the difference in length between RH and LH
tie rod ends and rack end screws are within 1.5 mm (0.059
in.).
(7) Install the RH and LH boot clips.
Page 815 of 969
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
2567 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
STEERING COLUMN ASSY
COMPONENTS