suspension LEXUS ES300 2005 Service Manual

SA0028
AB
FrontA B
A: Inside
B: Outside
Z03382
Alignment
TesterGauge
C93871
26-6
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
2369 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully left and right, and measure
the turning angle.
Wheel turning angle:
Inside wheel36°39' ± 2° (36.65° ± 2°)
Outside wheel: Reference32°11' (32.18°)
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.
6. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
(a) Put the front wheel on the center of the alignment tester.
(b) Set the camber - caster - kingpin gauge at the center of
the axle hub or drive shaft.
Camber, caster and steering axis inclination:
Camber
Left-right error-0°43' ± 45' (-0.72° ± 0.75°)
45' (0.75°) or less
Caster
Left-right error2°46' ± 45' (2.77° ± 0.75°)
45' (0.75°) or less
Steering axis inclination11°27' (11.45°)
If the caster and steering axis inclination are not within the spec-
ification, after the camber has been correctly adjusted, recheck
the suspension parts for damage and/or worn out parts.
7. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheel.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
HINT:
When removing nuts, stop the bolt from rotating and loosen the
nut.
(c) Clean the installation surfaces of the shock absorber and
the steering knuckle.
(d) Temporarily install the 2 nuts.

C93869
1
2
Bolt
Adjusting
ValueSet BoltAdjusting Bolt90105-17008 90105-17009 90105-17010 90105-17011
121212121 Dot
2 Dots3 Dots
15'
30'
45'
100'
115'
130'
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
26-7
2370 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
(f) Tighten the nuts.
Torque: 210 NVm (2,141 kgfVcm, 155 ftVlbf)
NOTICE:
When installing the nuts, keep the bolts from rotating and
then torque the nut.
(g) Install the front wheel.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
HINT:

Try to adjust the camber to the center of the specified val-
ue.

Adjusting value for the set bolts is 6' to 30' (0.1° to 0.5°).
If the camber is not within the specified valve, estimate how
much additional camber adjustment will be required, and select
the camber adjusting bolt.
NOTICE:
Tighten the adjusting bolt with a new nut.
(i) Do the steps mentioned above again. At step (b), replace
1 or 2 selected bolts.
HINT:
When replacing the 2 bolts, replace 1 bolt for each time.

2606S-02
F40136
C91030
C93102
SST
26-8
- FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
2371 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT SHOCK ABSORBER WITH COIL SPRING
OVERHAUL
HINT:
COMPONENTS: See page 26-3.
1. REMOVE FRONT WHEEL
2. DISCONNECT FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the front stabilizer link
assy LH from the shock absorber assy front LH.
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
3. REMOVE FRONT SHOCK ABSORBER CAP LH
(H-TEMS SUSPENSION)
(a) Disconnect the connector.
(b) Remove the 3 nuts, harness clamp and the front shock
absorber cap LH.
4. REMOVE FRONT SHOCK ABSORBER WITH COIL
SPRING
(a) w/ H-TEMS:
Using SST, loosen the lock nut.
SST 09817-33190
(b) w/o H-TEMS:
Loosen the lock nut.
NOTICE:

Do not loosen except for the case with disassembling
the shock absorber assy front LH with coil spring.

Do not remove the lock nut.

C65925
C93871
F40140
F03956
SST
SST
- FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
26-9
2372 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Remove the bolt, disconnect the front flexible hose No. 1
and speed sensor front LH.
(d) Remove the 2 nuts and 2 bolts on the lower side of front
shock absorber with coil spring.
NOTICE:
When removing bolt, stop the bolt from rotating and loosen
the nut.
(e) Remove the 3 nuts on the upper side of the front shock
absorber with coil spring.
(f) Remove the front shock absorber with the coil spring.
NOTICE:
Be careful not to drop the 2 washers in the case that there
is front suspension upper brace center.
5. FIX FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower side of
the front shock absorber with coil spring and secure it in
a vise.
6. REMOVE SHOCK ABSORBER ASSY FRONT LH
(a) Using SST, compress the front coil spring LH.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
HINT:
Use 2 of the same type of SST.
(b) Remove the front suspension support sub-assy LH, front suspension support bearing LH, front coil
spring seat upper LH, front coil spring insulator upper LH, front coil spring LH, front spring bumper LH
and front coil spring insulator upper LH.

W03646
F40160
SST
SST
F40168
OutsideOutside
55
F40161
55 Outside 26-10
- FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
2373 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
7. INSPECT SHOCK ABSORBER ASSY FRONT LH
(a) Compress and extend the shock absorber rod and check
that there is no abnormal resistance or unusual sound
during operation.
If there is any abnormality, replace the shock absorber assy
front LH with a new one.
NOTICE:
When disposing of the shock absorber assy front LH, see
DISPOSAL on page 26-13.
8. INSTALL SHOCK ABSORBER ASSY FRONT LH
(a) Install the front coil spring insulator lower LH onto the
shock absorber assy front LH.
(b) Install the front spring bumper LH to the piston rod.
(c) Using SST, compress the front coil spring LH.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
HINT:
Use 2 of the same type of SST.
(d) Install the front coil spring LH to the shock absorber assy
front LH.
HINT:
Fit the lower end of the front coil spring LH into the gap of the
spring lower seat.
(e) Install the front coil spring insulator upper LH as shown in
the illustration.
(f) Install the front coil spring seat upper LH to the shock ab-
sorber assy front LH with the mark facing to the outside
of the vehicle.

F40162
F40169
OutsideOutside
F40140
C93871
C93102
SST
- FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
26-1 1
2374 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(g) Install a new front suspension support bearing LH.
(h) Install the front suspension support sub-assy LH with the
mark facing to the outside of the vehicle.
(i) Temporarily tighten the new lock nut.
9. INSTALL FRONT SHOCK ABSORBER WITH COIL
SPRING
(a) Install the front shock absorber with coil spring as shown
in the illustration.
(b) Install the 3 nuts to the upper side of front shock absorber
with coil spring.
Torque: 80 NVm (816 kgfVcm, 59 ftVlbf)
NOTICE:
Be careful not to drop the 2 washers in the case that there
is front suspension upper brace center.
(c) Install the 2 bolts and 2 nuts to the lower side of front
shock absorber with coil spring.
Torque: 210 NVm (2,141 kgfVcm, 155 ftVlbf)
NOTICE:
When installing bolt, stop the bolt from rotating and torque
the nut.
(d) w/ H-TEMS:
Using SST, fully tighten the lock nut.
SST 09817-33190
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
(e) w/o H-TEMS:
Fully tighten the lock nut.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)

C65925
C91030
F40136
26-12
- FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
2375 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Install the front flexible hose No. 1 and speed sensor front
LH with the bolt.
Torque: 18.8 NVm (192 kgfVcm, 14 ftVlbf)
10. INSTALL FRONT SHOCK ABSORBER CAP LH
(H-TEMS SUSPENSION)
(a) Install the front shock absorber cap LH with the 3 nuts.
Torque: 14 NVm (143 kgfVcm, 10 ftVlbf)
(b) Disconnect the connector, install the harness clamp.
11. INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the nut.
Torque: 74 NVm (755 kgfVcm, 55 ftVlbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
12. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
13. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-5)

2601G-1 1
N00204
- FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
26-13
2376 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
DISPOSAL
HINT:
Dispose the RH side by the same procedures with the LH side.
1. DISPOSE OF SHOCK ABSORBER ASSY FRONT LH
(a) Fully extend the shock absorber rod.
(b) Using a drill, make a hole in the cylinder as shown in the
illustration to discharge the gas inside.
CAUTION:

When drilling, chips may fly out, work carefully.

The gas is colorless, odorless and non-poisonous.

2601H-09
C83387
C91606
F02227
26-14- FRONT SUSPENSIONFRONT SUSPENSION ARM SUB-ASSY LOWER NO.1
LH (From July, 2003)
2377 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1
LH (From July, 2003)
REPLACEMENT
HINT:
COMPONENTS: See page 26-3.
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See page 14-29)
2. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 3 nuts and the transverse engine engine
mounting insulator.
3. REMOVE FRONT SUSPENSION ARM SUB- ASSY
LOWER NO.1 LH
(a) Remove the 2 bolts on the front side of the front suspen-
sion arm sub-assy lower No. 1 LH.
(b) Remove the bolt and nut on the rear side of the front sus-
pension arm sub-assy lower No. 1 LH.
(c) Remove the front suspension arm sub-assy lower No. 1
LH.
(d) Remove the front lower arm bush stopper from the front
suspension arm sub-assy lower No. 1 LH.

C91606
F02227
C83387
- FRONT SUSPENSIONFRONT SUSPENSION ARM SUB-ASSY LOWER NO.1
LH (From July, 2003)26-15
2378 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
4. INSTALL FRONT SUSPENSION ARM SUB- ASSY
LOWER NO.1 LH
(a) Install the front lower arm bush stopper to the front sus-
pension arm sub-assy lower No. 1 LH.
(b) Install the front suspension arm sub-assy lower No. 1 LH
with the 2 bolts to the front side.
Torque: 200 NVm (2,039 kgfVcm, 148 ftVlbf)
(c) Install the front suspension arm sub-assy lower No. 1 LH
with the bolt and nut to the rear side.
Torque: 206 NVm (2,101 kgfVcm, 152 ftVlbf)
5. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
INSULATOR
(a) Install the transverse engine engine mounting insulator
with the 3 nuts.
Torque: 87 NVm (887 kgfVcm, 64 ftVlbf)
6. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See page 14-29)