turn signal 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 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
Page 265 of 969
F16914
F16911
32-20- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2454 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
34. INSTALL BRAKE PEDAL RETURN SPRING
35. INSTALL DRIVER SIDE JUNCTION BLOCK ASSY
(a) Install the junction block assy with the 3 nuts, then con-
nect the each connector.
36. INSTALL STEERING COLUMN ASSY (SEE PAGE 50-8)
37. CONNECT STEERING SLIDING YOKE SUB-ASSY (SEE PAGE 50-8)
38. CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (SEE PAGE 50-8)
39. INSPECT CHECK KEY INTERLOCK OPERATION (SEE PAGE 50-8)
40. INSTALL TURN SIGNAL SWITCH ASSY (SEE PAGE 50-8)
41. INSPECT SPIRAL CABLE SUB-ASSY (SEE PAGE 60-31)
42. INSTALL STEERING COLUMN COVER (SEE PAGE 50-8)
43. INSTALL STEERING COLUMN COVER LWR NO.2 (SEE PAGE 50-8)
44. INSTALL HEATER TO FOOT DUCT NO.3 (SEE PAGE 32-14)
45. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
46. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
47. INSTALL FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
48. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
49. INSTALL STEERING WHEEL ASSY (SEE PAGE 50-8)
50. INSPECT HORN BUTTON ASSY (SEE PAGE 60-22)
51. INSTALL HORN BUTTON ASSY (SEE PAGE 60-22)
52. INSTALL STEERING PAD SWITCH (SEE PAGE 82-1)
53. INSTALL CONNECTOR COVER (SEE PAGE 82-1)
54. INSTALL STEERING WHEEL COVER LOWER NO.2
55. INSPECT SRS WARNING LIGHT (SEE PAGE 05-818)
Page 322 of 969
C90470
Turn
Buckle
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.4
33-15
2511 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Tighten the turn buckle, connect the parking brake cable
assy No.4 to the parking brake cable assy No.1.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
8. INSTALL YAWRATE SENSOR (W/ VSC)(See page 32-59)
9. INSTALL CONSOLE BOX MOUNTING BRACKET NO.2
(a) Install the console box mounting bracket No.2 with the 2 bolts.
Torque: 12.5 NVm (128 kgfVcm, 9 ftVlbf)
10. INSTALL RR CONSOLE BOX
11. INSTALL CONSOLE BOX CARPET
12. INSTALL CONSOLE PANEL UPPER REAR
13. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL
14. CHECK VSC SENSOR SIGNAL (W/ VSC)(See page 05-471)
Page 341 of 969
C90470
Turn
Buckle
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.4
33-15
2511 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Tighten the turn buckle, connect the parking brake cable
assy No.4 to the parking brake cable assy No.1.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
8. INSTALL YAWRATE SENSOR (W/ VSC)(See page 32-59)
9. INSTALL CONSOLE BOX MOUNTING BRACKET NO.2
(a) Install the console box mounting bracket No.2 with the 2 bolts.
Torque: 12.5 NVm (128 kgfVcm, 9 ftVlbf)
10. INSTALL RR CONSOLE BOX
11. INSTALL CONSOLE BOX CARPET
12. INSTALL CONSOLE PANEL UPPER REAR
13. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL
14. CHECK VSC SENSOR SIGNAL (W/ VSC)(See page 05-471)
Page 363 of 969
F40147
F40136
F40152
30-18
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
2421 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the speed sensor to the steering knuckle with the
bolt.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
NOTICE:
Prevent foreign matter from adhering to the speed sensor.
42. 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.
43. INSTALL FRONT AXLE HUB LH NUT
(a) Using a socket wrench (30 mm), install a new axle hub LH
nut.
Torque: 294 NVm (2,998 kgfVcm, 217 ftVlbf)
(b) Using a chisel and hammer, stake the front axle hub LH
nut.
44. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
45. ADD AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-1)
46. INSPECT AUTOMATIC TRANSAXLE FLUID
47. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-5)
48. CHECK ABS SPEED SENSOR SIGNAL
w/ VSC (SEE PAGE 05-471)
w/o VSC (SEE PAGE 05-420)
Page 375 of 969
C83019
C83018
C83017
30-30
- DRIVE SHAFT / PROPELLER SHAFTREAR AXLE CARRIER SUB-ASSY LH
2433 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. INSTALL REAR AXLE CARRIER SUB-ASSY LH
(a) Install the rear axle carrier sub-assy LH with the 2 bolts
and nuts.
Torque: 255 NVm (2,600 kgfVcm, 188 ftVlbf)
NOTICE:
When installing bolt, stop the bolt from rotating and torque
the nut.
HINT:
Insert the bolt from the rear side of the vehicle and install the
nut.
11. TEMPORARILY TIGHTEN REAR SUSPENSION ARM
ASSY NO.1 LH
(a) Install the rear suspension arm assy No.1 LH to the rear
axle carrier sub-assy LH with the bolt and nut, temporarily
tighten the bolt.
HINT:
Insert the bolt from the front side of the vehicle and while fixing
the nut, turn and install the bolt.
12. TEMPORARILY TIGHTEN REAR SUSPENSION ARM
ASSY NO.2 LH
(a) Install the rear suspension arm No.2 to the rear axle carri-
er sub-assy LH with the bolt and nut, temporarily tighten
the bolt.
HINT:
Insert the bolt from the rear side of the vehicle and while fixing
the nut, turn and install the bolt.
13. INSTALL REAR AXLE HUB & BEARING ASSY LH (SEE PAGE 30-26)
14. INSTALL SKID CONTROL SENSOR WIRE
15. INSTALL REAR DISC
16. INSTALL REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-26)
17. TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-18)
18. STABILIZE SUSPENSION (SEE PAGE 27-18)
19. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-10)
20. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-14)
21. FULLY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-18)
22. INSTALL REAR WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
23. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (SEE PAGE 27-3)
24. CHECK ABS SPEED SENSOR SIGNAL
w/ VSC (SEE PAGE 05-471)
w/o VSC (SEE PAGE 05-420)
Page 378 of 969
A85669
TC
CG
A82935
Tester TerminalEngine Wire 14-2
- ENGINE MECHANICALENGINE (3MZ-FE)
2094 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) When not using the hand-held tester or OBD II scan tool:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)
of the DLC3.
SST 09843-18040
NOTICE:
Make sure of the terminal numbers before connecting
them. Connecting wrong terminals can damage the
engine.
Turn OFF all electrical systems before connecting the
terminals.
Perform this inspection after the cooling fan motor is
turned OFF.
(2) Remove the V-bank cover.
(3) Pull out the engine wire colored by black and red as
shown in the illustration.
(4) Connect the tester terminal of the timing light to the
engine.
NOTICE:
Use a timing light which detects the first signal.
(5) Inspect the ignition timing at idle.
Ignition timing: 8 to 12 BTDC
NOTICE:
When checking the ignition timing, the transmission is in
the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, then check
that the engine speed returns to the idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Inspect the ignition timing at idle.
Ignition timing: 7 to 24 BTDC
(8) Confirm that the ignition timing advances when the
engine speed is increased.
(9) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the hand-held tester or OBD II scan tool:
(1) Connect the hand-held tester or OBD II scan tool to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester or OBD II scan tool.
Idle speed: 630 to 730 rpm
NOTICE:
When checking the idle speed, the transmission is in the neutral position.
Check the idle speed with the cooling fan OFF.
Switch OFF all accessories and air conditioning before connecting the hand-held tester or OBD
II scan tool.
HINT:
Refer to the hand-held tester or OBD II scan tool operator's manual for further details.
Page 719 of 969
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)
Page 815 of 969
5002H-02
C90698
Steering Column
CoverHorn Button Assy
Steering Wheel Assy
Steering Pad SwitchConnector
Cover
Turn Signal Switch Assy
50 (510, 37)
Steering Column Cover
Lower No.2Instrument Panel
Finish Plate
NVm (kgfVcm, ftVlbf) : Specified torque
21 (214, 15)
8.8 (90, 78 in.Vlbf)
Steering Wheel
Cover Lower No. 2
Instrument Panel Sub-assy Upper
Steering Column Assy
Steering Column Hole
Cover Sub-assy No. 2
Hose Clamp
Heater to Foot
Duct No. 3
Steering Intermediate
Shaft Sub-assyInstrument Panel Insert
Sub-assy Lower LH
Front Door Scuff Plate LH
35 (360, 26)
35 (360, 26)
21 (214, 15)
50-6
- STEERING COLUMNSTEERING COLUMN ASSY
2567 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
STEERING COLUMN ASSY
COMPONENTS
Page 818 of 969
C90687
C90688Matchmarks
- STEERING COLUMNSTEERING COLUMN ASSY
50-9
2570 Author: Date:
15. REMOVE TURN SIGNAL SWITCH ASSY
(a) Disconnect the 3 connectors.
(b) Disconnect the airbag connector.
(c) Remove the 3 screws and turn signal switch assy.
16. REMOVE INSTRUMENT PANEL FINISH PLATE(See page 71-1 1)
17. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Place the ignition switch lock cylinder assy at the key ACC
position.
(b) Remove the cable cap claw from the key interlock and pull
out the floor shift parking lock cable assy.
18. DISCONNECT STEERING SLIDING YOKE SUB-ASSY
(a) Place the matchmarks on the steering sliding yoke sub-
assy and intermediate shaft sub-assy.
(b) Remove the bolt and disconnect the steering sliding yoke
sub-assy .
19. REMOVE STEERING COLUMN HOLE COVER SUB-ASSY NO.2
(a) Remove the hose clamp.
(b) Remove the steering column hole cover sub-assy No.2.
20. REMOVE STEERING COLUMN ASSY
(a) Disconnect the connectors and wire harness clamps.
(b) Disconnect the driver side junction block.