lock LEXUS ES300 2005 Workshop Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 240 of 969
400FV-02
C93015
C92370
C93152
- AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT PARKING LOCK CABLE ASSY
40-41
2556 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FLOOR SHIFT PARKING LOCK CABLE ASSY
REPLACEMENT
1. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
2. REMOVE FRONT DOOR SCUFF PLATE RH (SEE PAGE 71-1 1)
3. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE PAGE 71-1 1)
4. REMOVE INSTRUMENT PANEL SUB-ASSY LOWER (SEE PAGE 71-1 1)
5. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
6. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
7. REMOVE CONSOLE PANEL UPPER REAR (SEE PAGE 71-1 1)
8. REMOVE CONSOLE BOX CARPET
9. REMOVE CONSOLE BOX ASSY (SEE PAGE 71-1 1)
10. REMOVE INSTRUMENT PANEL FINISH PANEL END LH (SEE PAGE 71-1 1)
11. REMOVE INSTRUMENT PANEL FINISH PANEL END RH (SEE PAGE 71-1 1)
12. REMOVE AIR DUCT REAR NO.1 (SEE PAGE 55-17)
13. REMOVE AIR DUCT REAR NO.2 (SEE PAGE 55-17)
14. REMOVE CONSOLE BOX DUCT NO.1 (SEE PAGE 55-17)
15. REMOVE FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Disconnect the parking lock cable end from the lever pin
of the floor shift assembly.
(b) Using a screwdriver, disconnect the parking lock cable
from the floor shift assembly and clamp.
(c) Disconnect the cable clamp.
(d) Turn the ignition switch to ACC or ON.
(e) Using a screwdriver, remove the cable from the upper
bracket.
Page 241 of 969
C93152
C93323
Lock Key
C92370
C93015
C93325
40-42
- AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT PARKING LOCK CABLE ASSY
2557 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
16. INSTALL FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Turn the ignition switch to ACC or ON.
(b) Connect the cable to the upper bracket.
(c) Connect the cable clamp.
(d) Shift the shift lever to P range and turn the ignition switch
to LOCK.
(e) Using a screwdriver, unlock the claw of the lock key of au-
tomatic adjustment part.
(f) Insert the slide cap into the through hole and install.
(g) Insert the lever pin into the hole of the parking lock cable.
(h) Lock the lock key.
Page 242 of 969
- AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT PARKING LOCK CABLE ASSY
40-43
2558 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. INSPECT CHECK KEY INTERLOCK OPERATION(See page 40-31)
18. INSTALL CONSOLE BOX DUCT NO.1
19. INSTALL AIR DUCT REAR NO.2
20. INSTALL AIR DUCT REAR NO.1
21. INSTALL INSTRUMENT PANEL FINISH PANEL END RH
22. INSTALL INSTRUMENT PANEL FINISH PANEL END LH
23. INSTALL CONSOLE BOX ASSY
24. INSTALL CONSOLE BOX CARPET
25. INSTALL CONSOLE PANEL UPPER REAR
26. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
27. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
28. INSTALL INSTRUMENT PANEL SUB-ASSY LOWER
29. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1
30. INSTALL FRONT DOOR SCUFF PLATE RH
31. INSTALL FRONT DOOR SCUFF PLATE LH
Page 249 of 969
3211W-03
F41694
F41695
F41696
C80826
32-4
- BRAKEBRAKE FLUID
2438 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE FLUID (From July, 2003)
BLEEDING
HINT:
If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system.
NOTICE:
Wash off the brake fluied immediately if it comes into contact with a painted surface.
1. FILL RESERVOIR WITH BRAKE FLUID
Fluid: SAE J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air from the master cylinder.
(a) Remove the air cleaner assembly with hose.
(b) Disconnect the brake lines from the master cylinder.
SST 09023-00101
(c) Slowly depress the brake pedal and hold it.
(d) Block off the outer holes with your fingers, and release the
brake pedal.
(e) Repeat (c) and (d) 3 or 4 times.
(f) Install the air cleaner assembly with hose.
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
Page 253 of 969
320DV-02
F41697
Stop Lamp
Switch
Push Rod
Pedal Height
32-8
- BRAKEBRAKE PEDAL SUPPORT ASSY
2442 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE PEDAL SUPPORT ASSY
ADJUSTMENT
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Inspect brake pedal height.
Pedal height from asphalt sheet:
144.1 - 154.1 mm (5.673 - 6.067 in.)
(b) Adjust brake pedal height.
(1) Remove the instrument panel finish panel sub-
assy lower and instrument panel insert sub-assy
lower LH.
(2) Disconnect the connector from the stop lamp
switch.
(3) Loosen the stop lamp switch lock nut and remove
the stop lamp switch.
(4) Loosen the clevis lock nut.
(5) Adjust the pedal height by turning the pedal push
rod.
(6) Tighten the push rod lock nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
(7) Install the stop lamp switch.
(8) Connect the connector to the stop lamp switch.
(9) Push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.),
turn the stop lamp switch to lock the nut in the posi-
tion where the stop lamp goes off.
(10) After installation, push the brake pedal in 5 - 10 mm
(0.20 - 0.39 in.), check that stop lamp lights up.
(11) Install the instrument panel insert sub-assy lower
LH and instrument panel finish panel sub-assy low-
er.
Page 255 of 969
320DW-02
F42132
Brake Pedal Support
Stop Lamp
Switch Assy
Lock Nut
Brake Pedal Bush
Brake Pedal Bush Stop Light Switch Cushion
Brake Pedal
Push Rod Pin Brake Pedal Return Spring
Clip
Brake Pedal Pad
Non-reusable part
NVm (kgfVcm, ftVlbf) : Specified torque
Lithium soap base glycol grease
26 (265, 19)
37 (375, 27)
13 (130, 9)
13 (130, 9)
20 (204, 15)
32-10
- BRAKEBRAKE PEDAL SUPPORT ASSY
2444 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS
Page 256 of 969
320DX-02
- BRAKEBRAKE PEDAL SUPPORT ASSY
32-1 1
2445 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1)
2. REMOVE INSTRUMENT PANEL REINFORCEMENT (SEE PAGE 71-1 1)
3. REMOVE BRAKE PEDAL RETURN SPRING
4. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
5. REMOVE BRAKE PEDAL SUPPORT ASSY
(a) Disconnect the stop lamp switch connector.
(b) Remove the bolt, 4 nuts and brake pedal support assy.
6. REMOVE STOP LAMP SWITCH ASSY
(a) Loosen the lock nut and remove the stop lamp switch.
7. REMOVE BRAKE PEDAL SUB-ASSY
(a) Remove the nut, bolt and brake pedal sub-assy from brake pedal support assy.
8. REMOVE BRAKE PEDAL PAD
9. REMOVE BRAKE PEDAL BUSH
(a) Remove the 2 brake pedal bushes from brake pedal.
10. REMOVE STOP LAMP SWITCH CUSHION
11. INSTALL STOP LAMP SWITCH CUSHION
12. INSTALL BRAKE PEDAL BUSH
(a) Install the new 2 brake pedal bushes to brake pedal.
HINT:
Apply the lithium soap base glycol grease to the parts indicates by arrows (see page 32-10).
13. INSTALL BRAKE PEDAL PAD
14. INSTALL BRAKE PEDAL SUB-ASSY
(a) Install the brake pedal sub-assy with the bolt and nut.
Torque: 37 NVm (375 kgfVcm, 27 ftVlbf)
15. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch with the lock nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
16. INSTALL BRAKE PEDAL SUPPORT ASSY
(a) Install the brake pedal support assy with the bolt and 4 nuts.
Torque:
Bolt: 20 NVm (204 kgfVcm, 15 ftVlbf)
Nut: 13 NVm (130 kgfVcm, 9 ftVlbf)
17. INSTALL PUSH ROD PIN
(a) Install the push rod pin and clip.
HINT:
Apply the lithium soap base glycol grease to the parts indicates by arrows (see page 32-10).
18. INSTALL BRAKE PEDAL RETURN SPRING
19. INSTALL INSTRUMENT PANEL REINFORCEMENT (SEE PAGE 71-1 1)
20. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1)
21. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8)
22. CHECK PEDAL FREE PLAY (SEE PAGE 32-8)
23. CHECK PEDAL RESERVE DISTANCE (SEE PAGE 32-8)
Page 257 of 969
320OF-03
F42717
Stop Lamp
Switch Assy
Push Rod
Pedal Height
32-12- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2446 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
ADJUSTMENT
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Inspect brake pedal height.
Pedal height from asphalt sheet:
144.1 - 154.1 mm (5.673 - 6.067 in.)
(b) Adjust brake pedal height.
(1) Remove the instrument panel finish panel sub-
assy lower and instrument panel insert sub-assy
lower LH.
(2) Disconnect the connector from the stop lamp switch
assy.
(3) Loosen the stop lamp switch lock nut and remove
the stop lamp switch assy.
(4) Loosen the clevis lock nut.
(5) Adjust the pedal height by turning the pedal push
rod.
(6) Tighten the push rod lock nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
(7) Install the stop lamp switch assy.
(8) Connect the connector to the stop lamp switch assy.
(9) Push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.),
turn the stop lamp switch assy to lock the nut in the
position where the stop lamp goes off.
(10) After installation, push the brake pedal in 5 - 10 mm
(0.20 - 0.39 in.), check that stop lamp lights up.
(11) Install the instrument panel insert sub-assy lower
LH and instrument panel finish panel sub-assy low-
er.
Page 259 of 969
320OJ-03
F16915
Instrument Panel Insert
Sub-assy Lower LH
Instrument Panel
Sub-assy Upper
Front Door Scuff Plate LH Driver Side
Junction Block AssyHeater to Foot Duct No.3Steering Column Cover LowerSteering Column Cover Upper Instrument Cluster Finish Panel
Steering Column Assy
Steering Intermediate
Shaft Sub-assyHorn Button Assy Steering Wheel Cover
No.2 Steerig Wheel Assy
20.6 (210, 15)
20.6 (210, 15)50 (510, 37)
8.8 (90, 78 in.Vlbf)
NVm (kgfVcm, ftVlbf) : Specified torqueSteering Wheel
Cover No.3
Connector Cover
Steering Column
Cover Lower No.2
32-14- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2448 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS
Page 261 of 969
320OG-05
F16911
F16914
32-16- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2450 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. PRECAUTION (SEE PAGE 60-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE STEERING WHEEL COVER LOWER NO.2
5. REMOVE CONNECTOR COVER (SEE PAGE 82-1)
6. REMOVE STEERING PAD SWITCH (SEE PAGE 82-1)
7. REMOVE HORN BUTTON ASSY (SEE PAGE 60-22)
8. REMOVE STEERING WHEEL ASSY (SEE PAGE 50-8)
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
9. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
10. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
11. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
12. REMOVE HEATER TO FOOT DUCT NO.3 (SEE PAGE 32-14)
13. REMOVE STEERING COLUMN COVER LWR NO.2 (SEE PAGE 50-8)
14. REMOVE STEERING COLUMN COVER (SEE PAGE 50-8)
15. REMOVE TURN SIGNAL SWITCH ASSY (SEE PAGE 50-8)
16. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (SEE PAGE 50-8)
17. DISCONNECT STEERING SLIDING YOKE SUB-ASSY (SEE PAGE 50-8)
18. REMOVE STEERING COLUMN HOLE COVER SUB-ASSY NO.2 (SEE PAGE 50-8)
19. REMOVE STEERING COLUMN ASSY (SEE PAGE 50-8)
20. REMOVE DRIVER SIDE JUNCTION BLOCK ASSY
(a) Remove the 3 nuts and junction bloke assy, then discon-
nect the connector.
21. REMOVE BRAKE PEDAL RETURN SPRING