gas type LEXUS ES300 2005 Repair Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 92 of 969
C91925
C86316
Magnet
AT0103
Magnet
C91927
Temperature
Sensor
D03547
Transmission Wire
40-20
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
44 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
(b) Remove the 2 magnets from the oil pan.
10. INSPECT TRANSMISSION OIL CLEANER MAGNET
(a) Remove the magnets and use them to collect any steel
chips. Examine the chips and particles in the pan and on
the magnet to determine what type of wear has occurred
in the transaxle:
Steel (magnetic).... bearing, gear and plate wear
Brass (non-magnetic).... bushing wear
11. DISCONNECT TRANSMISSION WIRE
(a) Remove the 7 connectors from the shift solenoid valves.
(b) Remove the bolt, lock plate and ATF temperature sensor.
12. REMOVE TRANSMISSION WIRE
(a) Remove the bolt and transmission wire from the transaxle
case.
Page 220 of 969
4010V-04
C91925
D30865
AT0103
C91927
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U151E)
40-21
2536 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
TRANSMISSION WIRE (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER NO.1
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket, and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all the pan
bolts, and carefully remove the oil pan assembly.
(b) Remove the 2 magnets from the oil pan.
(c) Examine particles in pan.
(1) Use the removed magnets to collect steel chips.
Look carefully at the chips and particles in the pan
and the magnet to anticipate the type of wear you
will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.
Page 223 of 969
4010W-04
C91925
D30865
AT0103
C91927
40-24
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
2539 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
TRANSMISSION VALVE BODY ASSY (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER NO.1
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket, and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all the pan
bolts, and carefully remove the oil pan assembly.
(b) Remove the 2 magnets from the oil pan.
(c) Examine particles in pan.
(1) Use the removed magnets to collect steel chips.
Look carefully at the chips and particles in the pan
and the magnet to anticipate the type of wear you
will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.
Page 276 of 969
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
2465 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT BRAKE
COMPONENTS
Page 277 of 969
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
2466 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 284 of 969
F41866
Anti Squeal
Shim
Wear Indicator
- BRAKEFRONT BRAKE
32-39
2473 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(2) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
(b) Install the anti squeal shim kit front (Twin piston Type).
(1) Apply the anti squeal shim with pad grease, and
install the anti squeal shim to each pad.
(2) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
must be replaced together with the pads.
Install the shims and pad wear indicator correctly of
which positions and directions.
38. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing upward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.
39. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder with the 2 bolts.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
40. CONNECT FRONT FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 NVm (300 kgfVcm, 22 ftVlbf)
HINT:
Install the flexible hose lock securely in the lock hold of the disc brake cylinder.
41. FILL RESERVOIR WITH BRAKE FLUID
42. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
43. BLEED BRAKE LINE (SEE PAGE 32-4)
44. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
45. CHECK BRAKE FLUID LEAKAGE
46. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
Page 286 of 969
320E8-04
F41547
F41548
F41550
- BRAKEREAR BRAKE
32-41
2475 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
HINT:
Overhaul the RH side by the same procedures with LH side.
Two types of brake pad exist; one is with slit and the other without slit.
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surfaces.
3. DISCONNECT REAR LH FLEXIBLE HOSE
(a) Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose
from the disc brake cylinder.
4. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the rear disc brake cylinder slide pin.
5. REMOVE DISC BRAKE CYLINDER ASSY REAR LH
(a) Lift up the disc brake cylinder and remove the disc brake
cylinder.
6. REMOVE REAR DISC BRAKE CYLINDER SLIDE
BUSH
(a) Remove the cylinder slide bush from the disc brake cylin-
der.
Page 729 of 969
51068-01
F41597
TYPE A VANE PUMP:
Pressure Port Union
Flow Control Valve
O-Ring
Flow Control Valve
Compression Spring
Power Steering
Suction Port Union
43 (438, 32)
Pump Bracket
Front
Vane Pump
Housing Front
O-Ring Gasket
O-Ring
24 (245, 18)24 (245, 18)
Vane Pump
Bracket Rear Vane Pump
Housing Rear
44 (449, 32)
Vane Pump Pulley
Vane Pump Shaft
Vane Pump Shaft Snap Ring
Vane Pump Housing Oil Seal
Vane Pump Plate
Vane Pump Rotor
Vane Pump Cam Ring
Vane Pump
Side Plate RearWave Washer
Non-reusable part
NVm (kgfVcm, ftVlbf) : Specified torque
Power steering fluid
X10
83 (846, 61)
13 (133, 10)
43 (438, 32)
- POWER STEERINGVANE PUMP ASSY
51-7
2582 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
VANE PUMP ASSY
COMPONENTS
Page 730 of 969
F41589
TYPE B VANE PUMP:
Pressure Port Union
O-Ring
Flow Control Valve
Flow Control Valve
Compression Spring
Gasket
Power Steering
Suction Port Union
O-Ring
Pump Bracket
Front
Vane Pump
Housing Front
O-Ring
24 (245, 18)
24 (245, 18)
Vane Pump
Housing Rear
Wave Washer
Vane Pump
Side Plate Rear
Vane Pump Cam Ring
Vane Pump Plate
Vane Pump Shaft Snap Ring W/Pulley Shaft
Sub-assy Vane Pump Housing
Oil Seal
Non-reusable part
NVm (kgfVcm, ftVlbf) : Specified torque
Power steering fluid
Vane Pump
Bracket Rear
X10
Vane Pump Rotor
83 (846, 61)
13 (133, 10)
44 (449, 32)
44 (449, 32)
51-8
- POWER STEERINGVANE PUMP ASSY
2583 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 732 of 969
F41600
SST
C65312
51-10
- POWER STEERINGVANE PUMP ASSY
2585 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. REMOVE VANE PUMP PULLEY(TYPE A VANE PUMP)
(a) Using SST, stop the vane pump pulley rotation and loosen
the nut.
SST 09960-10010 (09962-01000, 09963-01000)
(b) Remove the nut and vane pump pulley from the vane
pump shaft.
11. REMOVE POWER STEERING SUCTION PORT UNION
(a) Remove the bolt and power steering suction port union.
(b) Remove the O-ring from the power steering suction port union.
12. REMOVE PRESSURE PORT UNION
(a) Remove the pressure port union.
(b) Remove the O-ring from the pressure port union.
13. REMOVE FLOW CONTROL VALVE
14. REMOVE FLOW CONTROL VALVE COMPRESSION SPRING
15. REMOVE VANE PUMP BRACKET REAR(TYPE A VANE PUMP)
(a) Remove the 2 bolts and vane pump bracket rear from the vane pump assy.
16. REMOVE VANE PUMP BRACKET REAR(TYPE B VANE PUMP)
(a) Remove the 2 bolts, 2 nuts and vane pump bracket rear from the vane pump assy.
17. REMOVE VANE PUMP HOUSING REAR
(a) Remove the 4 bolts and vane pump housing rear from the vane pump housing front.
(b) Remove the gasket.
(c) Remove the 2 O-rings from the vane pump housing rear.
18. REMOVE VANE PUMP SIDE PLATE REAR
(a) Remove the wave washer from the vane pump side plate rear.
(b) Remove the vane pump side plate rear.
19. REMOVE VANE PUMP CAM RING
20. REMOVE VANE PUMP ROTOR
(a) Remove the 10 vane pump plates from the vane pump ro-
tor.
(b) Using a screwdriver, remove the vane pump shaft snap
ring.
(c) Remove the vane pump rotor.
21. REMOVE VANE PUMP SHAFT(TYPE A VANE PUMP)
22. REMOVE W/PULLEY SHAFT SUB-ASSY(TYPE B VANE PUMP)