length LEXUS ES300 2005 Service Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 737 of 969
F41573
F41492
- POWER STEERINGVANE PUMP ASSY
51-15
2590 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
37. INSTALL VANE PUMP HOUSING REAR
(a) Coat a new O-ring with power steering fluid and install it to the vane pump housing rear.
(b) Install the vane pump housing rear with the 4 bolts.
Torque: 24 NVm (245 kgfVcm, 18 ftVlbf)
38. MEASURE VANE PUMP ROTATION TORQUE(TYPE A
VANE PUMP)
(a) Check that the vane pump rotates smoothly without ab-
normal noise.
(b) Temporarily install the pulley set nut.
(c) Using a torque wrench, check the vane pump rotating
torque.
Rotating torque:
0.27 NVm (2.8 kgfVcm, 2.4 in.Vlbf) or less
39. MEASURE VANE PUMP ROTATION TORQUE(TYPE B
VANE PUMP)
(a) Check that the vane pump rotates smoothly without ab-
normal noise.
(b) Temporarily install the service bolt.
Recommended service bolt:
Thread diameter: 10 mm (0.39 in.)
Thread pitch: 1.25 mm (0.0492 in.)
Bolt length: 50 mm (1.97 in.)
(c) Using a torque wrench, check the vane pump rotating
torque.
Rotating torque:
0.27 NVm (2.8 kgfVcm, 2.4 in.Vlbf) or less
40. INSTALL VANE PUMP BRACKET REAR(TYPE A VANE PUMP)
(a) Install the vane pump bracket rear with the 2 bolts.
Torque: 43 NVm (438 kgfVcm, 32 ftVlbf)
41. INSTALL VANE PUMP BRACKET REAR(TYPE B VANE PUMP)
(a) Install the vane pump bracket rear with the 2 bolts and 2 nuts.
Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)
42. INSTALL FLOW CONTROL VALVE COMPRESSION SPRING
(a) Coat the flow control valve compression spring with power steering fluid and install it.
(b) Install the flow control valve compression spring.
43. INSTALL FLOW CONTROL VALVE
(a) Coat the flow control valve with power steering fluid.
(b) Install the flow control valve.
44. INSTALL PRESSURE PORT UNION
(a) Coat a new O-ring with power steering fluid and install it to the pressure port union.
(b) Install the pressure port union.
Torque: 83 NVm (846 kgfVcm, 61 ftVlbf)
Page 756 of 969
F41515SST
F41516
SST
F41517
SST
SST
Rack Guide
Spring Cap
F41518SSTFulcrum Length Rack Guide Spring
Cap Nut
SST
51-34
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2609 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Using SST, loosen the rack guide spring cap.
SST 09631-10021
(d) Using SST, turn the control valve to the right and left 1 or
2 times.
SST 09616-0001 1
(e) Using SST, loosen the rack guide spring cap until the
compression spring is not functioning.
SST 09631-10021
(f) Using SST and a torque wrench, tighten the rack guide
spring cap until the preload is within specification.
SST 09616-0001 1, 09631-10021
Preload (turning):
1.2 - 1.5 NVm (12.2 - 15.3 kgfVcm, 10.6 - 13.3 in.Vlbf)
(g) Apply sealant to 2 or 3 threads of the rack guide spring
cap nut.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(h) Temporarily install the rack guide spring cap nut.
(i) Using SST, hold the rack guide spring cap and using
another SST, tighten the rack guide spring cap nut.
SST 09616-0001 1, 09922-10010
Torque: 48 NVm (489 kgfVcm, 35 ftVlbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(j) Precheck the total preload.
Preload (turning):
1.2 - 1.5 NVm (12.2 - 15.3 kgfVcm, 10.6 - 13.3 in.Vlbf)
(k) Remove the RH and LH steering rack ends sub-assy.
Page 757 of 969
F40555
MP Grease
F40538F43004
Vinyl Tape
F41576
SST
SST Fulcrum
Length
C35928
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-35
2610 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(l) Apply MP grease into the control valve, as shown in the
illustration.
(m) Wind vinyl tape around the serration part of the control
valve.
(n) Install the dust cover to the control valve housing.
49. INSTALL STEERING RACK END SUB-ASSY
(a) Install a new 2 claw washers, and temporarily install the
2 steering rack ends sub-assy.
HINT:
Align the claws of the claw washer with the power steering rack
grooves.
(b) Using 2 SSTs, install the 2 steering rack ends sub-assy.
SST 09922-10010
Torque: 58.5 NVm (597 kgfVcm, 43 ftVlbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Using SST, hold the power steering rack and install the
steering rack end sub-assy.
Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).
(c) Using a brass bar and a hammer, stake the claw washer.
NOTICE:
Avoid any impact to the power steering rack.
Page 759 of 969
F41519
Fulcrum
Length
SST
F41613
Fulcrum
Length
SST
F41496
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-37
2612 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
58. INSTALL STEERING LEFT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install
them to the steering left turn pressure tube.
(b) Using SST, install the steering left turn pressure tube to
the rack & pinion power steering gear assy.
SST 09023-38201
Torque: 11.5 NVm (117 kgfVcm, 8 ftVlbf)
HINT:
Use a torque wrench with a fulcrum length of 345 mm
(9.84 in.).
This torque value is effective in the case that SST is paral-
lel to a torque wrench.
59. INSTALL STEERING RIGHT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install
them to the steering right turn pressure tube.
(b) Using SST, install the steering right turn pressure tube to
the rack & pinion power steering gear assy.
SST 09023-38201
Torque: 11.5 NVm (117 kgfVcm, 8 ftVlbf)
HINT:
Use a torque wrench with a fulcrum length of 345 mm
(11.81 in.).
This torque value is effective in the case that SST is paral-
lel to a torque wrench.
60. INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR
(a) Install the power steering rack housing heat insulator.
HINT:
Install nut when installing the return clamp.
61. INSTALL RACK & PINION POWER STEERING GEAR
ASSY
(a) Install the rack & pinion power steering gear assy with the
2 bolts and 2 nuts.
Torque: 70 NVm (714 kgfVcm, 52 ftVlbf)
Page 760 of 969
F41568
F41587
Fulcrum
Length
SST
F41586
Fulcrum
Length
SST
F41602
51-38
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2613 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Connect the tube clamp with the bolt.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
62. CONNECT PRESSURE FEED TUBE ASSY
(a) Using SST, connect the pressure feed tube assy to the
rack & pinion power steering gear assy.
SST 09023-12701
Torque: 22.5 NVm (229 kgfVcm, 17 ftVlbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in the case that SST is paral-
lel to a torque wrench.
(b) Using SST, connect the return tube assy to the rack & pin-
ion power steering gear assy.
SST 09023-12701
Torque: 22.5 NVm (229 kgfVcm, 17 ftVlbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in the case that SST is paral-
lel to a torque wrench.
(c) Install the return tube assy clamp with the nut.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
Page 765 of 969
2704P-06
SA3213
A
DB
Front
C
C91810
C91811
- REAR SUSPENSIONREAR WHEEL ALIGNMENT
27-3
2385 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR WHEEL ALIGNMENT
ADJUSTMENT
1. INSPECT TIRE (See page 28-1)
2. MEASURE VEHICLE HEIGHT (See page 26-5)
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle height to the specified value.
3. INSPECT TOE-IN
Toe-in:
Toe-in
(total)A + B: 0°22' ± 11' (0.4° ± 0.2°)
C - D: 4 ± 2 mm (0.16 ± 0.08 in.)
If the toe-in is not within the specified value, inspect and re-
place the suspension parts if necessary.
4. ADJUST TOE-IN
(a) Measure the lengths of the right and left No. 2 lower sus-
pension arms.
No. 2 lower suspension arm length difference:
1.0 mm (0.039 in.) or less
If the left-right difference is larger than 1.0 mm (0.039 in.), ad-
just it by following the procedures below.
(b) Loosen the lock nuts.
(c) Turn the right and left adjusting tube by an equal amount
to adjust toe-in.
HINT:
Try to adjust the toe-in to the center value.
One turn of the each adjusting tube will adjust the toe-in
by approximately 67' (112', 10.8 mm, 0.425 in.).
(d) Torque the lock nut.
Torque: 56 NVm (570 kgfVcm, 41 ftVlbf)
5. INSPECT CAMBER
Camber
Right-left error-1°23' ± 45' (-1.38° ± 0.75°)
45' (0.75°) or less
HINT:
Camber is not adjustable. If the measurement is not within the specification, inspect the suspension parts
for damaged and/or worn-out parts and replace them if necessary.
Page 793 of 969
A76677
Length
A88418
Ohmmeter
A81655
FreeLock
A81656
Apply Grease
A82440
Snap Ring
Pliers
19-12
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2344 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. INSPECT STARTER COMMUTATOR END FRAME
ASSY
(a) Inspect the length.
(1) Using vernier calipers, measure the brush length.
Standard length: 9.0 mm (0.354 in.)
Minimum length: 4.0 mm (0.158 in.)
If the length is less than minimum, replace the starter commuta-
tor end frame.
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continu-
ity between the positive (+) and negative (- )
brushes.
If there is continuity, repair or replace the starter commutator
end frame.
10. INSPECT STARTER DRIVE HOUSING ASSY (W/
CLUTCH & DRIVE LEVER & CENTER BEARING)
(a) Check the operation.
(1) Rotate the clutch pinion gear counterclockwise,
then check that it turns freely. Try to rotate the clutch
pinion gear clockwise and check that it locks.
If necessary, replace the starter drive housing.
11. INSTALL PLANETARY GEAR
(a) Apply grease to the planetary gears and pin parts of the
planetary shaft.
(b) Install the 3 planetary gears to the starter drive housing.
12. INSTALL STARTER ARMATURE ASSY
(a) Apply grease to the plate washer and armature shaft.
(b) Install the starter armature to the starter commutator end
frame.
(c) Using snap ring pliers, install the plate washer and a new
snap ring.
Page 794 of 969
A58810
Length
A81178
A73991
keyway
Key
A79727
Rubber
Cutout
A79728Key Keyway
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-13
2345 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Inspect the length.
(1) Using vernier calipers, measure the snap ring
length.
Maximum length: 5.0 mm (0.197 in.)
If the length is greater than maximum, replace it with a new snap
ring.
13. INSTALL STARTER COMMUTATOR END FRAME
COVER
(a) Install the starter commutator end frame cover to the
starter commutator end frame.
14. INSTALL STARTER ARMATURE PLATE
(a) Insert the starter armature plate to the starter field frame.
(b) Align the keyway of the starter plate with the key inside the
starter yoke, then install the starter plate.
15. INSTALL STARTER COMMUTATOR END FRAME
ASSY
(a) Align the rubber with the cutout of the starter field frame.
(b) Install the starter commutator end frame to the starter field
frame.
16. INSTALL STARTER FIELD FRAME ASSY
(a) Align the key of the starter field frame with the keyway of
the starter drive housing.
Page 806 of 969
A81664
Generator Washer
A79305
Length
A79306
A88420
Ohmmeter Slip Ring
A88421
Ohmmeter Slip RingRotor Core
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
19-25
2357 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
4. REMOVE GENERATOR ROTOR ASSY
(a) Remove the generator washer and generator rotor.
5. INSPECT GENERATOR BRUSH HOLDER ASSY
(a) Inspect the length.
(1) Using vernier calipers, measure the exposed brush
length.
Standard exposed brush length: 10.5 mm (0.413 in.)
Minimum exposed brush length: 4.5 mm (0.177 in.)
If the exposed brush length is less than minimum, replace the
generator brush holder.
6. INSPECT GENERATOR ROTOR ASSY
(a) Check that the bearing is not rough or worn.
If necessary, replace the generator rotor.
(b) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the slip rings.
Resistance: 2.3 to 2.7W at 20C (68F)
If the resistance is not as specified, replace the generator rotor.
(c) Check the continuity.
(1) Using an ohmmeter, check that there is no continu-
ity between the slip ring and rotor core.
If there is continuity, replace the generator rotor.
(d) Check the appearance.
(1) Check that the slip rings are not rough or scored.
If rough or scored, replace the generator rotor.
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.