air suspension LEXUS ES300 2005 Workshop Manual

2601I-09
ZX1712
26-16
- FRONT SUSPENSIONLOWER BALL JOINT ASSY FRONT LH
2379 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
LOWER BALL JOINT ASSY FRONT LH
REPLACEMENT
HINT:
CONPONENTS: See page 26-3.
1. REMOVE FRONT WHEEL
2. REMOVE FRONT AXLE HUB LH NUT (See page 30-8)
SST 09930-00010
3. DISCONNECT SPEED SENSOR FRONT LH (See page 30-8)
4. DISCONNECT FRONT DISC BRAKE CALIPER ASSY LH (See page 30-19)
5. REMOVE FRONT DISC
6. DISCONNECT TIE ROD ASSY LH (See page 30-8)
SST 09628-6201 1
7. DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-8)
8. REMOVE FRONT AXLE ASSY LH (See page 30-19)
9. REMOVE LOWER BALL JOINT ASSY FRONT LH (See page 30-19)
SST 09628-6201 1
10. INSPECT LOWER BALL JOINT ASSY FRONT LH
(a) As shown in the illustration, flip the ball joint stud back and
forth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate
of 3 - 5 seconds per 1 turn and take the torque reading
on the 5th turn.
Turning torque:
0.98 - 3.43 N´m (10 - 35 kgf´cm, 8.7 - 30 in.´lbf)
11. INSTALL LOWER BALL JOINT ASSY FRONT LH (See page 30-19)
12. INSTALL FRONT AXLE ASSY LH (See page 30-19)
13. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-8)
14. INSTALL TIE ROD ASSY LH (See page 30-8)
15. INSTALL FRONT DISC
16. INSTALL FRONT DISC BRAKE CALIPER ASSY LH (See page 30-19)
17. INSTALL SPEED SENSOR FRONT LH (See page 30-8)
18. INSTALL FRONT AXLE HUB LH NUT (See page 30-8)
19. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
20. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-5)
21. CHECK ABS SPEED SENSOR SIGNAL
w/ VSC (See page 05-471)
w/o VSC (See page 05-420)

2601J-17
F40143
C91607
- FRONT SUSPENSIONSTABILIZER BAR FRONT
26-17
2380 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
STABILIZER BAR FRONT
REPLACEMENT
HINT:
COMPONENTS: See page 26-3.
1. REMOVE FRONT WHEEL
2. REMOVE FRONT STABILIZER LINK ASSY LH
(a) Remove the 2 nuts and front stabilizer link assy LH.
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
3. REMOVE FRONT STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures with the LH side.
4. REMOVE FRONT STABILIZER BRACKET NO.1 LH
(a) Remove the 2 bolts and 2 front stabilizer brackets No. 1
LH.
5. REMOVE FRONT STABILIZER BRACKET NO.1 RH
HINT:
Remove the RH side by the same procedures with the LH side.
6. DISCONNECT TIE ROD ASSY LH (See page 30-8)
SST 09628-6201 1
7. DISCONNECT TIE ROD ASSY RH
SST 09628-6201 1
HINT:
Separate the RH side by the same procedures with the LH side.
8. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51-21)
SST 09023-00101
9. DISCONNECT PRESSURE FEED TUBE ASSY (See page 51-21)
SST 09023-00101
10. DISCONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY (See page 51-21)
11. REMOVE RACK & PINION POWER STEERING GEAR ASSY (See page 51-21)

C66721
C81547F40197
Inner side
Rear
side
C91607
26-18
- FRONT SUSPENSIONSTABILIZER BAR FRONT
2381 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
12. REMOVE STABILIZER BAR FRONT
13. REMOVE FRONT STABILIZER BAR BUSH NO.1
14. INSPECT FRONT STABILIZER LINK ASSY LH
(a) As shown in the illustration, flip the ball joint stud back and
forth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate
of 2 - 4 seconds per 1 turn and take the torque reading
on the 5th turn.
Turning torque:
0.05 - 1.96 N´m (0.5 - 20 kgf´cm, 0.4 - 17.4 in.´lbf)
15. INSTALL FRONT STABILIZER BAR BUSH NO.1
HINT:
Install the bushing to the inner side of the bushing stopper on
the stabilizer bar.
16. INSTALL STABILIZER BAR FRONT
17. INSTALL RACK & PINION POWER STEERING GEAR ASSY (See page 51-21)
18. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSY (See page 51-21)
19. INSTALL PRESSURE FEED TUBE ASSY (See page 51-21)
SST 09023-00101
20. INSTALL STEERING GEAR OUTLET RETURN TUBE (See page 51-21)
SST 09023-00101
21. INSTALL TIE ROD ASSY LH (See page 30-8)
22. INSTALL TIE ROD ASSY RH
HINT:
Install the RH side by the same procedures with the LH side.
23. INSTALL FRONT STABILIZER BRACKET NO.1 LH
(a) Install the 2 front stabilizer brackets No. 1 LH with the 2
bolts.
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)

F40143
- FRONT SUSPENSIONSTABILIZER BAR FRONT
26-19
2382 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
24. INSTALL FRONT STABILIZER BRACKET NO.1 RH
HINT:
Install the RH side by the same procedures with the LH side.
25. INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the 2 nuts.
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.
26. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures with the LH side.
27. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
28. BLEED POWER STEERING FLUID (See page 51-3)
29. CHECK POWER STEERING FLUID LEAKAGE
30. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-5)

51017-12
51-2
- POWER STEERINGPOWER STEERING SYSTEM
2577 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
SymptomSuspect AreaSee page
Hard steering
1. Tires (Improperly inflated)
2. Power steering fluid level (Low)
3. Drive belt (Loose)
4. Front wheel alignment (Incorrect)
5. Steering system joints (Worn)
6. Suspension arm ball joints (Worn)
7. Steering column (Binding)
8. Vane pump assy
9. Rack & pinion power steering gear assy28-1
51-3
14-1
26-5
-
26-16
-
51-9
51-21
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Rack & pinion power steering gear assy28-1
26-5
-
51-21
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Steering intermediate shaft sub-assy (Worn)
4. Sliding yoke (Worn)
5. Front wheel bearing (Worn)
6. Rack & pinion power steering gear assy-
26-16
-
-
30-2
51-21
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Vane pump assy
4. Rack & pinion power steering gear assy51-3
-
51-9
51-21

2701I-09
- REAR SUSPENSIONREAR SUSPENSION SYSTEM
27-1
2383 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR SUSPENSION SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)-
27-4
27-4
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)28-1
27-16
27-4
Rear wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Hub bearing (Worn)28-1
28-1
27-4
26-5
27-3
30-2
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)28-1
26-5
27-3
27-4
-

2704V-06
C92643
Rear Suspension Member
Sub-Assy
Rear Suspension Support
No. 1 Cover LH
Collar
Suspension Support
Spring Bumper
Coil Spring
Lower Insulator Rear Suspension
Arm Assy No. 2 LH
Rear Suspension
Arm Assy No. 1 LH
Strut Rod Assy Rear
Bracket
Bushing
Shock Absorber
Assy Rear LH Rear Stabilizer
Link Assy LH Stabilizer Bar Rear Parking Brake Cable
NVm (kgfVcm, ftVlbf) : Specified torque
49 (500, 36)
39 (400, 29)
55 (561, 41)
100 (1,020, 74)
100 (1,020, 74)
113 (1,150, 83)
39 (400, 29)
19 (195, 14)
5.4 (55, 48 in.Vlbf)
255 (2,600, 188)
113 (1,150, 83)
100 (1,020, 74)
100 (1,020, 74)
55 (561, 41)
38 (387, 28)
RH Side:
w/TEMS:
19 (195, 14)



Non-reusable partw/o TEMS:5.4 (55, 48 in.Vlbf)
27-2
- REAR SUSPENSIONREAR SUSPENSION
2384 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR SUSPENSION
COMPONENTS

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.

2706G-03
C66631
F41030
27-4
- REAR SUSPENSIONSHOCK ABSORBER ASSY REAR LH
2386 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
SHOCK ABSORBER ASSY REAR LH
REPLACEMENT
HINT:
COMPONENTS: See page 27-2
1. REMOVE REAR WHEEL
2. REMOVE REAR SEAT CUSHION ASSY (See page 72-39)
3. REMOVE REAR SEATBACK ASSY (See page 72-39)
4. REMOVE ROOF SIDE GARNISH INNER RH (See page 76-25)
5. REMOVE ROOF SIDE GARNISH INNER LH
HINT:
Remove the LH side by the same procedures with the RH side.
6. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page 72-39)
7. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
HINT:
Remove the LH side by the same procedures with the RH side.
8. REMOVE CENTER STOP LAMP ASSY (W/O SUN SHADE) (See page 65-31)
9. REMOVE REAR SEAT SHOULDER BELT COVER (See page 61-15)
10. REMOVE PACKAGE TRAY TRIM PANEL ASSY (W/ SUN SHADE) (See page 61-15)
11. REMOVE PACKAGE TRAY TRIM PANEL ASSY (W/O SUN SHADE) (See page 61-15)
12. REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER (See page 61-15)
13. SEPARATE REAR STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the stabilizer bar link from
the shock absorber.
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm)
wrench to hold the stud.
14. REMOVE REAR SUSPENSION SUPOPORT NO.1 COVER LH (W/O H-TEMS SUSPENSION)
15. REMOVE REAR SHOCK ABSORBER WITH COIL
SPRING
(a) Remove the 2 bolts, disconnect the flexible hose and ABS
speed sensor wire harness from shock absorber.

C66634
C92644
w/o TEMS
w/ TEMSSST
C92184
F40121
28mm(1.1 in)
- REAR SUSPENSIONSHOCK ABSORBER ASSY REAR LH
27-5
2387 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Loosen the 2 bolts on the lower side of the shock absorb-
er.
HINT:
Do not remove the 2 bolts.
(c) Support the rear axle carrier with a jack.
(d) w/o TEMS:
Loosen the suspension support center nut.
(e) w/ TEMS:
Loosen the suspension support center nut.
SST 09817-33190
NOTICE:
Do not remove the nut.
HINT:
If not disassembling the rear shock absorber, it is not necessary
to loosen the nut.
(f) Remove the 3 nuts of the suspension support.
(g) Lower the rear axle carrier and remove the 2 nuts and
bolts on the lower side of the shock absorber.
(h) Remove the shock absorber with the coil spring.
16. FIX REAR SHOCK ABSORBER WITH COIL SPRING
17. REMOVE SHOCK ABSORBER ASSY REAR LH
(a) Install 2 nuts and a bolt to the bracket at the lower part of
the shock absorber, and secure it in a vise.