torque spec LEXUS ES300 2005 Workshop Manual

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
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS

F16916
Push Rod Pin
Brake Pedal Support Assy Stop Lamp Switch Connector
Stop Lamp Switch Assy
Accelerator Pedal Assy
Accel Position
Sensor Connector
Accelerator Pedal Pad Brake Pedal Pad Brake Pedal
Return Spring Stop Lamp
Switch CushionClip
NVm (kgfVcm, ftVlbf) : Specified torque
Lithium soap base glycol grease
19.1 (194, 14)
13 (130, 9)
12 (122, 8.8)
26 (265, 19)
- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)32-15
2449 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

C69097
F40004
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-23
2457 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. INSPECT MASTER CYLINDER BODY
(a) Check the cylinder bore for rust or scoring.
11. INSTALL BRAKE MASTER CYLINDER KIT (W/O VSC)
(a) Place master cylinder in vise.
(b) Apply the lithium soap base glycol grease on new No.1
and No.2 piston sub-assy.
(c) Install the No.2 and No.1 piston sub-assy.
NOTICE:

If the piston is inserted at an angle, there is a possibil-
ity that the cylinder bore could be damaged.

Be careful not to damage the rubber lips on the pis-
tons.
(d) Push in the piston and install a new gasket and a new pis-
ton stopper bolt.
Torque: 10 NVm (100 kgfVcm, 7 ftVlbf)
(e) Push in the piston and install the snap ring with snap ring
pliers.
(f) Apply the lithium soap base glycol grease on a new O-
ring and install the O-ring to the master cylinder.
12. INSTALL BRAKE MASTER CYLINDER KIT (W/ VSC)
(a) Place master cylinder in vise.
(b) Apply the lithium soap base glycol grease on new No.1
and No.2 piston sub-assy.
(c) Install the No.2 and No.1 piston sub-assy.
NOTICE:

If the piston is inserted at an angle, there is a possibil-
ity that the cylinder bore could be damaged.

Be careful not to damage the rubber lips on the pis-
tons.

320DZ-05
F46404
Vacuum Hose Assy
Clip
Brake Master
Cylinder Sub-AssyGasket
Push Rod Pin
Push Rod Clevis
Clip
Brake Booster
Front Brake
Tube No.5Front Brake Tube Frame No.1

Non-reusable part
NVm (kgfVcm, ftVlbf): Specified torque
15 (155, 11)
13 (130, 9)
5.4 (55, 48 in.Vlbf)
13 (130, 9)
15 (155, 11)
13 (130, 9)
Vacuum Hose Bracket
15 (155, 11)
2-W ay
15 (155, 11)
Front Brake
Tube No.2
15 (155, 11)
Front Brake
Tube No.3
- BRAKEBRAKE BOOSTER ASSY
32-27
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS

BR3753
F40996
F40995
- BRAKEBRAKE BOOSTER ASSY
32-29
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. REMOVE BRAKE BOOSTER GASKET
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster.
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster with the 4 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
16. INSTALL FRONT BRAKE TUBE NO.5
(a) Using SST and install the front brake tube No.5.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
17. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the push rod clevis and lock nut.
18. INSTALL PUSH ROD PIN
(a) Install the push rod pin and clip.
HINT:
Apply the lithium soap base glycol grease to the part indicate by arrow (see page 32-27).
19. INSTALL BRAKE PEDAL RETURN SPRING
20. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
21. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
22. INSTALL FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
23. INSTALL VACUUM HOSE ASSY
(a) Install the vacuum hose and vacuum hose bracket to the
body with a bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(b) Connect the vacuum hose to the brake booster with the
clip.
24. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE PAGE 32-21)
SST 09737-00013, 09737-00020
25. INSTALL BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
26. FILL RESERVOIR WITH BRAKE FLUID

320E5-02
F41863
Front Disc
Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt

Gasket
Front Disc Brake
Bleeder Plug Cap
Disc Brake
Cylinder Assy LH

Set Ring

Cylinder BootFront Disc
Brake Piston

Piston Seal
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Disc brake grease Lithium soap base glycol grease
Non-reusable part


NVm (kgfVcm, ftVlbf)
: Specified torque Single Piston Type:






Anti Squeal
Shim No.1
Disc Brake
Pad Kit Front Anti Squeal
Shim No.1
Anti Squeal
Shim No.2
Anti Squeal
Shim No.2
Wear Indicator
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)34.3 (350, 25)
34.3 (350, 25)
106.9 (1,090, 79)
106.9 (1,090, 79)
- BRAKEFRONT BRAKE
32-31
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT BRAKE
COMPONENTS

F41533Disc brake grease Lithium soap base glycol grease
Non-reusable part


NVm (kgfVcm, ftVlbf)
: Specified torque Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt

Gasket
Front Disc Brake
Bleeder Plug Cap
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Front Disc
Anti Squeal
Shim
Disc Brake
Pad Kit Front
Twin Piston Type:

Set Ring

Cylinder Boot Front Disc
Brake Piston

Piston Seal




Disc Brake
Cylinder Assy LH
Anti Squeal
ShimWear Indicator
106.9 (1,090, 79)
106.9 (1,090, 79)
34.3 (350, 25)
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)
34.3 (350, 25)
32-32
- BRAKEFRONT BRAKE
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

F41544
F41565
- BRAKEFRONT BRAKE
32-37
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
(b) Using a dial indicator, measure the disc runout 10 mm
(0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
(c) If the disc runout is greater than the maximum value,
check the bearing play in the axial direction and check the
axle hub runout (see page 30-2). If the bearing play and
axle hub runout are normal, adjust the disc runout or grind
it on a ºOn-carº brake lathe.
26. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder.
27. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
28. INSTALL PISTON SEAL
(a) Install the piston seal (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new piston seal.
(2) Install the piston seal to the disc brake cylinder.
(b) Install the 2 piston seals (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 new piston seals.
(2) Install the 2 piston seals to the disc brake cylinder.
29. INSTALL FRONT DISC BRAKE PISTON
(a) Install the front disc brake piston (Single piston Type).
(1) Apply the lithium soap base glycol grease to the piston.
(2) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
(b) Install the 2 front disc brake pistons (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 pistons.
(2) Install the 2 pistons to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
30. INSTALL CYLINDER BOOT
(a) Install the cylinder boot (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new
cylinder boot.
(2) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.

320E7-03
F41864Disc brake grease Lithium soap base glycol grease
Non-reusable part


NVm (kgfVcm, ftVlbf)
: Specified torque Rear LH
Flexible Hose Union Bolt

Gasket
Rear Disc Brake
Cylinder Slide Pin
Rear Disc Brake
Cylinder Slide Bush
Rear Disc Brake
Bleeder Plug
Rear Disc Brake
Bleeder Plug Cap
Disc Brake Cylinder
Assy Rear LH

Piston Seal
Rear Disc Brake
Disc Brake Piston

Cylinder Boot

Set Ring
Rear Disc Brake
Bush Dust Boot
Rear Disc Brake
Cylinder Slide Pin
Rear Disc Brake
Pad Support Plate
Rear Disc Brake
Cylinder Mounting LH
Anti Squeal
Shim No.1
Disc Brake
Pad Kit Rear Disc Brake
Pad Kit Rear
Parking Brake Shoe
Adjusting Hole Plug
Rear DiscAnti Squeal
Shim No.2 Wear Indicator Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Wear Indicator



61.8 (630, 46)
61.8 (630, 46)
39.2 (400, 29)
29.4 (300, 22)
34.3 (350, 25)
8.3 (85, 74 in.Vlbf)
32-40
- BRAKEREAR BRAKE
2474 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR BRAKE
COMPONENTS

F41554
F41555
Matchmarks
F41556
32-44
- BRAKEREAR BRAKE
2478 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
23. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
USA, Canada models:
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 10.5 mm (0.413 in.)
Brazil models:
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 8.5 mm (0.335 in.)
24. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
25. REMOVE REAR DISC
(a) Put matchmarks on the disc and the axle hub.
(b) Remove the disc.
26. INSTALL REAR DISC
(a) Aligning the matchmarks, install the rear disc.
HINT:
When replacing the disc with a new one, select the installation position where the disc has the minimum run-
out.
27. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
28. INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
(b) Using a dial indicator, measure the disc runout 10 mm
(0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.15 mm (0.0059 in.)
(c) If the disc runout is greater than the maximum value,
check the bearing play in the axial direction and check the
axle hub runout (see page 30-2). If the bearing play and
axle hub runout are normal, adjust the disc runout or grind
it on a ºOn-carº brake lathe.
29. ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-16)
30. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder.
31. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP