Below you will find brief information for 2005 ES330 Automotive Air Conditioning and Heater System. This comprehensive repair manual details essential precautions for handling refrigerants, methods for inspecting refrigerant volume and pressure, and a detailed troubleshooting guide for common system malfunctions like insufficient cooling or overcharging. It also provides step-by-step instructions for discharging and charging refrigerant, as well as procedures for the replacement and overhaul of key components such as refrigerant lines, V-belts, the Air Conditioner Control Assembly, Air Conditioning Radiator Assembly, Blower Assembly, and Cooler Compressor Assembly. Torque specifications and inspection tips for various parts are included to ensure proper maintenance.
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55-1
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
PRECAUTION
550BQ-01
1.
DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2.
ALWAYS WEAR EYE PROTECTION
AC2810
AC2811
3.
BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional treatment.
4.
NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5.
BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
Wrong Okay
LO HI LO HI
N11084
6.
DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM
If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so take care to avoid this, necessary care should be taken.
7.
DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE
WHILE COMPRESSOR IS OPERATING
If the high pressure valves opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve.
8.
BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2616
55-2
HEATER & AIR CONDITIONER REFRIGERANT
ON-VEHICLE INSPECTION
550D4-02
Sight Glass
I31521
1.
INSPECT REFRIGERANT VOLUME
(a) Observe the sight glass on the cooler refrigerant liquid pipe A.
Test conditions:
Running engine at 1,500 rpm
Blower speed control switch at ”HI”
A/C switch ON
Temperature control dial at ”MAX. COOL”
Fully open the doors
Item
1 Bubbles present
Symptom
2 No bubbles present
3
No temperature difference between compressor inlet and outlet
Insufficient*
Amount of refrigerant
None, insufficient or too much
Empty or nearly empty
Corrective Actions
(1) Check for gas leakage and repair if necessary
(2) Add refrigerant until bubbles disappear
Refer 3 and 4
(1) Check for gas leakage with gas leak detector and repair if necessary
(2) Add refrigerant until bubbles disappear
4
Considerable temperature difference between compressor inlet and outlet.
Correct or too much Refer to 5 and 6
5
Immediately after air conditioning is turned off, refrigerant clear
Too much
(1) Discharge refrigerant
(2) Remove air and supply proper amount or purified refrigerant
6
Immediately after air conditioning is turned off, refrigerant foams and then becomes clear
Correct -
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2617
55-3
HEATER & AIR CONDITIONER REFRIGERANT
2.
INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
(a) This is a method in witch the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the these conditions are established.
Test conditions:
Temperature at the air inlet with the switch set at RECIRC is 30 - 35
°
C (86 - 95
°
F)
Engine running at 1,500 rpm
Blower speed control switch at ”HI” position
Temperature control dial at ”COOL” position
A/C switch ON
Fully open doors
(1) Normally functioning refrigeration system.
Gauge reading:
Low pressure side:
0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm 2 )
High pressure side:
1.37 - 1.57 MPa (14 - 16 kgf/cm
2)
E50573
Condition : Periodically cools and then fails to cool
(2) Moisture present in refrigeration system.
I22117
Symptom
During operation, pressure on low pressure side sometimes become a vacuum and sometime normal
Probable cause
Moisture in refrigerating system freezes at expansion valve orifice causing a temporary stop of cycle, however, when it melts, normal state is restored.
Diagnosis
Drier in oversaturected state
Moisture in refrigerating system freezes at expansion valve orifice and blocks circulation of refrigerant
Remedy
(1) Replace condenser
(2) Remove moisture in cycle by repeatedly evacuating air
(3) Supply proper amount of new refrigerant
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2618
55-4
HEATER & AIR CONDITIONER REFRIGERANT
(3) Insufficient cooling
Condition: Cooling system does not function effectively.
I22118
Symptom Probable cause Diagnosis
Pressure low on both low and high pressure sides
Bubbles seen thought sight glass continuously
Insufficient cooling performance
Gas leakage in refrigeration system
Insufficient refrigerant
Refrigerant leaking
Corrective Actions
(1) Check for gas leakage and repair if necessary
(2) Supply proper amount of new refrigerant
(3) If indicated pressure value is close to a 0 when connected to gauge, create the vacuum after inspecting and repairing location of leak
(4) Poor circulation of refrigerant
Condition: Cooling system close not function effectively.
Symptom
Pressure low on both low and high pressure sides
Frost on pipe from condenser to unit
Probable cause Diagnosis
Refrigerant flow obstructed by dirt in receiver
Receiver clogged
Corrective Action
Replace condenser
I22119
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2619
HEATER & AIR CONDITIONER REFRIGERANT
(5) Refrigerant does not circulate
Condition: Cooling system does not function. (Sometimes it way function)
55-5
I22120
Symptom Probable cause Diagnosis
Vacuum indicated on low pressure side, very low pressure indicated on high pressure side
Frost or dew seen on piping before and after receiver/ drier or expansion valve
Refrigerant flow obstructed by moisture or dirt in refrigerating system
Refrigerant flow obstructed by gas leaked from expansion valve
Refrigerant does not circulate
Corrective Actions
(1) Check expansion valve
(2) Clean out dirt in expansion valve by air blowing
(3) Replace condenser
(4) Evaporate air and supply proper amount of new refrigerant.
(5) For gas leakage from expansion valve, replace expansion valve
(6) Refrigerant overcharged or insufficient cooling of condenser
Condition: Cooling system does not function effectively.
I22121
Symptom Probable cause Diagnosis
Pressure too high on both low and high pressure sides
No sir bubbles seen through the sight glass even when the engine rpm is lowered
Unable to develop sufficient performance due to excessive use of refrigerating system
Insufficient cooling of condenser
Excessive refrigerant in cycle
→ too much refrigerant supplied
Condenser cooling insufficient
→ condenser fins clogged at cooling fan
Remedy
(1) Clean condenser
(2) Check cooling fan with cooling fan motor operation
(3) If (1) and (2) are in normal state, check amount of refrigerant and supply proper amount of refrigerant
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2620
55-6
HEATER & AIR CONDITIONER REFRIGERANT
(7) Air present in refrigeration system
Condition: Cooling system does not function.
NOTE : These gauge indications are shown when the refrigerating system has been opens and the refrigerant charged without vacuum purging.
I22122
Symptom Probable cause Diagnosis Corrective Actions
Pressure too high on both low and high pressure sides
The low pressure piping too hot to the touch
Bubbles seen through sight glass
Air entered in refrigerating system
Air present in refrigerating system
Insufficient vacuum purging
(1) Check compressor oil to see if it is see if it is dirty or insufficient
(2) Evacuate air and supply new refrigerant
(8) Expansion valve improperly
Condition: Refrigerant functions insufficient.
Symptom
Pressure too high on both low and high pressure sides
Frost or large amount of dew on piping on low pressure side
Probable cause
Trouble in expansion valve
Diagnosis
Excessive refrigerant in low pressure piping
Expansion valve opened too wide
Corrective Actions
Check expansion valve
I22123
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2621
HEATER & AIR CONDITIONER REFRIGERANT
(9) Defective compression compressor
55-7
Condition : Refrigerant is not effective.
Symptom Probable cause
Pressure too high on low high pressure sides
Pressure too low to on high pressure side
Internal leak in compressor
Gauge readings (Reference)
Pressure on low pressure side
MPa (kgf/cm
2
)
0.5 (5.0)
Blower HI Zone
Diagnosis Corrective Actions
Compression failure
Leakage from valve damaged or broken sliding parts
Repair or replace compressor
I22124
0.4 (4.0)
1.06 (10.9)
0.3 (3.0)
0.27 (2.85)
0.2 (2.0)
0.22 (2.25)
0.2 (2.1)
0.14 (1.5)
0.5 (5.0)
1.2 (12.3)
1.25 (12.8)
1.32 (13.5)
1.0 (10.0) 1.5 (15.0)
Blower LO Zone
2.0 (20.0)
Pressure on HI pressure side
MPa (kgf/cm
2
)
I30081
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2622
55-8
HEATER & AIR CONDITIONER REFRIGERANT
550D5-02
REPLACEMENT
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
(a) Turn the A/C switch ON.
(b) Operating the cooler compressor at the engine rpm of approx. 1,000 for 5 to 6 min., circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.
(c) Stop the engine.
(d) Let the refrigerant gas out.
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070,
07117-88080)
2.
CHARGE REFRIGERANT
(a) Using a vacuum pump, perform a vacuum pumping.
(b) Charge refrigerant, HFC-134a (R134a).
Standard: 550 50 g (19.37 1. 76 oz.)
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080)
High
Pressure
Amount to be charged
Add. 100g
Mean value in proper range
50 g ( 1. 76 oz.)
Over charged
Point where bubbles disappear
Sub-cool system
Refrigerant Amount
3.
WARM UP ENGINE
4.
INSPECT LEAKAGE OF REFRIGERANT
I30082
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2623
HEATER & AIR CONDITIONER REFRIGERANT LINE
COMPONENTS
55-9
550D6-02
Cooler Refrigerant Liquid Pipe A
5.4 (55, 49 in.
⋅ lbf)
9.8 (100, 87 in.
⋅ lbf)
9.8 (100, 87 in.
⋅ lbf)
Cooler Refrigerant Suction Hose No. 1
5.4 (55, 49 in.
⋅ lbf)
9.8 (100, 87 in.
⋅ lbf)
Cooler Refrigerant Discharge Hose No. 1
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
I31620
2624
55-10
HEATER & AIR CONDITIONER V (COOLER COMPRESSOR TO CRANKSHAFT
PULLEY) BELT NO.1
REPLACEMENT
Bolt C
Bolt B
550D7-02
1.
REMOVE V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Loosen the bolt C.
(b) Loosen the bolt A.
(c) Loosen the bolt B and remove the cooler V belt No. 1.
Bolt A
I30370
2.
INSTALL V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Temporarily install the cooler V belt No. 1 as illustrated.
I30370
DENSO
Measuring
Position
Bolt B
Boroughs
I30370
3.
ADJUST V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Apply drive belt tension by turning the bolt B.
Drive belt tension:
New Belt: 165 27 lbf
Used belt: 88 22 lbf
HINT:
”New belt” refers to a belt which has been used less than
5 minutes on a running engine.
”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more.
After installing the drive belt, check that it fits properly in the ribbed grooves.
N01881
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2625
HEATER & AIR CONDITIONER V (COOLER COMPRESSOR TO CRANKSHAFT
PULLEY) BELT NO.1
55-1 1
Check that the drive belt fits properly in the ribbed grooves.
Wrong Correct
Bolt C
Bolt A
CH0086
4.
FULLY TIGHTEN V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Tighten the bolt A.
Torque: 17.5 N
⋅ m (178 kgf
⋅ cm, 12 ft
⋅ lbf)
(b) Tighten the bolt C.
Torque: 58 N
⋅ m (591 kgf
⋅ cm, 43 ft
⋅ lbf)
I30370
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2626
55-12
HEATER & AIR CONDITIONER AIR CONDITIONER CONTROL ASSEMBLY
COMPONENTS
550D8-02
Heater Control Housing Sub-assy
Air Conditioning Control Bulb
Heater Control Housing
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
I31621
2627
55-13
HEATER & AIR CONDITIONER AIR CONDITIONER CONTROL ASSEMBLY
OVERHAUL
HINT:
COMPONENTS: See page 55-12
1.
REMOVE AIR CONDITIONER CONTROL ASSEMBLY (See page 71-1 1 )
550D9-02
2.
REMOVE HEATER CONTROL HOUSING SUB-ASSY
(a) Remove the 4 screws.
(b) Release the 4 fitting claws, disconnect the heater control housing sub-assy.
4 Claws
I31622
(c) Disconnect the connect, remove the heater control housing sub-assy.
I31623
3.
REMOVE AIR CONDITIONING CONTROL BULB
(a) Remove the air conditioning control bulb.
8 Claws
I31626
4.
REMOVE HEATER CONTROL HOUSING
(a) Release the 8 fitting claws, remove the heater control housing.
I31627
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2628
55-14
B
A
B
HEATER & AIR CONDITIONER AIR CONDITIONER CONTROL ASSEMBLY
B
5.
INSTALL AIR CONDITIONING CONTROL BULB
(a) Install the air conditioning control bulb to the air conditioner panel sub-assy.
Bulb position:
Position
A
B
Part No.
90010 - 03048
90010 - 03049
I31626
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2629
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
COMPONENTS
Instrument Panel Reinforcement
55-15
550DA-02
Instrument Panel
Brace Sub-assy No. 2
Instrument Finish Panel Retainer Lower
20 (203, 14)
Instrument Panel
Brace Sub-assy
9.8 (100, 87 in.
⋅ lbf)
Air Duct Rear No. 1
Console Box Duct No. 1
Air Duct Rear No. 2
1.5 (15, 12 in.
⋅ lbf)
Defroster Nozzle
Assy Lower
1.5 (15, 12 in.
⋅ lbf)
O-ring
Piping Clamp
O-ring
Blower Assy
1.5 (15, 12 in.
⋅ lbf)
Heater To Foot Duct No. 3
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Compressor Oil ND-OIL 8 or equivalent
Non-reusable part
Heater To Foot Duct No. 1
1.5 (15, 12 in.
⋅ lbf)
Air Conditioning Radiator Assy
I31632
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2630
55-16
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
Air Conditioning Tube Assy
Cooler Expansion Valve
Packing
3.5 (35, 30 in.
⋅ lbf)
Cooler Evaporator Sub-assy No. 1
O-ring
Cooler Thermistor No. 1
Mode Damper Servo Sub-assy
Air Mix Damper Servo
Sub-assy
Air Mix Damper Servo
Sub-assy
Piping Clamp
Heater Radiator Unit Sub-assy
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Compressor Oil ND-OIL 8 or equivalent
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
I31633
2631
55-17
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
550DB-02
OVERHAUL
HINT:
COMPONENTS: See page 55-15
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55-8 )
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070,
07117-88080)
2.
DISCONNECT COOLER REFRIGERANT SUCTION
HOSE NO.1
(a) Install SST to piping clamp.
SST 09870-00015
HINT:
Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label.
Push Pull
(b) Push down SST and release the clamp lock.
NOTICE:
Be careful not to deform the tube, when pushing SST.
(c) Pull SST slightly and push the release lever, then remove the piping clamp with SST.
Disconnect the tube using hand
SST
Release
Lever
Screw
Driver
I03839
(d) Disconnect the cooler refrigerant suction hose No. 1.
NOTICE:
Do not use tools like screwdriver to remove the tube.
Cap the open fittings immediately to keep moisture or dirt out of the system.
I06919
3.
DISCONNECT COOLER REFRIGERANT LIQUID PIPE A
SST 09870-00025
HINT:
Disconnect cooler refrigerant liquid pipe A in the same way as the cooler refrigerant suction hose No. 1.
4.
DISCONNECT HEATER OUTLET WATER HOSE
(a) Using pliers, grip the claws of clip and slide the clip and disconnect the heater outlet water hose.
I31522
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2632
55-18
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
5.
DISCONNECT HEATER INLET WATER HOSE
HINT:
Disconnect in the same way as the heater outlet water hose.
6.
REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1 )
HINT:
Refer to the instructions for removal of the instrument panel safety pad sub-assy.
7.
REMOVE AIR DUCT REAR NO.1
(a) Remove the 2 screws, bolt and nut.
(b) Remove the air duct rear No. 1.
I31636
8.
REMOVE AIR DUCT REAR NO.2
(a) Remove the 2 screws, bolt and nut.
(b) Remove the air duct rear No. 2.
I31637
9.
REMOVE CONSOLE BOX DUCT NO.1
(a) Remove the clip and console box duct No. 1.
I31497
10.
DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY
11.
REMOVE WINDSHIELD WIPER RELAY ASSY
12.
REMOVE HEADLAMP LEVELING ECU ASSY
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2633
55-19
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
13.
REMOVE INSTRUMENT PANEL BRACE SUB-ASSY
NO.1
(a) Remove the bolt and earth wire.
I31766
(b) Release the 2 clamps.
2 Clamps
I31581
(c) Remove the bolt and screw.
(d) Remove the nut and instrument panel brace sub-assy
No. 1.
I31501
14.
REMOVE INSTRUMENT FINISH PANEL RETAINER
LOWER
(a) Remove the 2 bolts and instrument finish retainer lower.
I31502
15.
REMOVE INSTRUMENT PANEL BRACE SUB-ASSY
NO.2
(a) Remove the 2 clamps, nut and passenger side junction block.
2 Clamps
I31768
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2634
55-20
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
(b) Remove the 2 bolts and 2 earth wires.
I31767
(c) Remove the 2 nuts, bolt and instrument panel brace subassy No. 2.
I31504
16.
REMOVE HEATER TO FOOT DUCT NO.3
(a) Remove the clip and heater to foot duct No. 3.
I31499
17.
REMOVE HEATER TO FOOT DUCT NO.1
(a) Remove the clip and heater to foot duct No. 1.
I31500
18.
DISCONNECT STEERING COLUMN ASSY
(a) Remove the 3 nuts and driver side junction block.
I31505
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2635
2 Clamps
55-21
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
(b) Remove the 2 nuts and steering side connector block.
I31577
(c) Release the 2 clamps.
(d) Remove the 3 bolts, disconnect the steering column assy.
I31506
19.
REMOVE INSTRUMENT PANEL REINFORCEMENT
(a) Disconnect the 10 clamps and the wire harness.
10 Clamps
I31769
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2636
55-22
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
(b) Remove the 3 nuts, disconnect the 3 earth wires.
I31770
(c) Remove the 3 caps, 7 bolts and instrument panel reinforcement.
Clamp
I31563
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
I31771
20.
REMOVE BLOWER ASSY
(a) Disconnect the connectors.
(b) Remove the screw, clamp and blower connector holder.
Author: Date: 2637
6 Clamps
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
(c) Disconnect the 6 clamps and the wire harness.
55-23
I31772
(d) Remove the 2 screws, 2 nuts and blower assy.
4 Claws
I31509
21.
REMOVE DEFROSTER NOZZLE ASSY LOWER
(a) Release the 4 fitting claws, remove the defroster nozzle assy lower.
I31510
22.
REMOVE AIR CONDITIONING RADIATOR ASSY
(a) Remove the 2 nuts and air conditioning radiator assy.
I31511
23.
REMOVE MODE DAMPER SERVO SUB-ASSY
(a) Remove the 3 screws and mode damper servo sub-assy.
I31512
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2638
55-24
2 Claws
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
24.
REMOVE AIRMIX DAMPER SERVO SUB-ASSY
(a) LH side:
Remove the 3 screws and air mix damper servo subassy.
I31514
(b) RH side:
Remove the 3 screws and air mix damper servo subassy.
I31638
25.
REMOVE HEATER RADIATOR UNIT SUB-ASSY
(a) Release the 2 fitting claws, remove the piping clamp.
(b) Remove the heater radiator unit sub-assy.
NOTICE:
Prepare a support plate and waste to catch the leaked coolant.
I31513
26.
REMOVE AIR CONDITIONING TUBE ASSY
(a) Remove the packing.
I31515
(b) Using a hexagon wrench 4 mm (0.16 in.), remove the 2 hexagon bolts and air conditioning tube assy.
(c) Remove the 2 O-rings from the air conditioning tube assy.
I31516
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2639
55-25
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
27.
REMOVE COOLER EXPANSION VALVE
(a) Remove the cooler expansion valve from the cooler evaporator sub-assy No. 1.
I31517
28.
REMOVE COOLER THERMISTOR NO.1
29.
REMOVE COOLER EVAPORATOR SUB-ASSY NO.1
(a) Release the fitting claw, remove the 3 screws and air duct sub-assy .
Claw
I31518
(b) Release the 4 fitting claws, remove the air duct sub-assy.
4 Claws
I31639
(c) Remove the 11 screws and heater case LH.
(d) Remove the cooler evaporator sub-assy No. 1 from the heater case RH.
I31640
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2640
55-26
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
(e) Remove the 2 O-rings from the cooler evaporator subassy No. 1.
I31520
30.
INSTALL COOLER EVAPORATOR SUB-ASSY NO.1
(a) Apply compressor oil to the contact surfaces of 2 new Orings and the cooler expansion valve and install them.
Compressor oil: ND-OIL 8 or equivalent
I31520
(b) Install the cooler evaporator sub-assy No. 1 to the heater case RH.
(c) Install the heater case LH with the 11 screws.
I31640
(d) Install the air duct sub-assy.
4 Claws
I31639
(e) Install the air duct sub-assy with the 3 screws.
Claw
I31518
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2641
55-27
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
31.
INSTALL COOLER EXPANSION VALVE
(a) Install the cooler expansion valve to the cooler evaporator
No. 1.
I31517
I31516
32.
INSTALL AIR CONDITIONING TUBE ASSY
(a) Apply compressor oil to the contact surfaces of 2 new Orings and the air conditioning tube assy and install them.
Compressor oil: ND-OIL 8 or equivalent
(b) Using a hexagon wrench 4 mm (0.16 in.), install the air conditioner tube assy and 2 hexagon bolts to the cooler evaporator sub-assy No. 1.
Torque: 3.5 N
⋅ m (35 kgf
⋅ cm, 30 in.
⋅ lbf)
(c) Install the packing.
HINT:
Securely attach so that the gap in the packing will not be mode.
I31515
33.
INSTALL AIR CONDITIONING RADIATOR ASSY
(a) Install the air conditioning radiator assy with the 2 nuts.
Torque: 1.5 N
⋅ m (15 kgf
⋅ cm, 12 in.
⋅ lbf)
I31511
(2)
(1)
(2)
(3) (3)
I31552
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
34.
INSTALL DEFROSTER NOZZLE ASSY LOWER
(a) Install the defroster nozzle assy lower.
NOTICE:
After locating the pin (1) in the illustration, install (2), then
(3).
Author: Date:
2642
55-28
6 Clamps
Clamp
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
35.
INSTALL BLOWER ASSY
(a) Install the blower assy with the 2 screws and 2 nuts.
Torque: 1.5 N
⋅ m (15 kgf
⋅ cm, 12 in.
⋅ lbf)
I31509
(b) Install the 6 clamps, connect the wire harness.
I31772
(c) Install the blower connector holder with the screw.
(d) Connect the connectors.
I31563
36.
INSTALL INSTRUMENT PANEL REINFORCEMENT
(a) Install the instrument panel reinforcement with the 7 bolts and 3 caps.
Torque: 20 N
⋅ m (203 kgf
⋅ cm, 14 ft
⋅ lbf) (Bolt A)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(A)
I31771
Author: Date: 2643
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
(b) Install the 3 earth wires with the 3 nuts.
Torque: 8.4 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
55-29
(c) Install the 10 clamps, connect the wire harness.
I31770
10 Clamps
2 Clamps
I31506
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
37.
INSTALL STEERING COLUMN ASSY
(a) Install the steering column assy with the 3 bolts.
(b) Install the 2 clamps.
I31769
Author: Date:
2644
55-30
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
(c) Install the steering side connector block with the 2 nuts.
I31577
(d) Install the driver side junction block with the 3 nuts.
Torque: 8.4 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
I31505
38.
INSTALL INSTRUMENT PANEL BRACE SUB-ASSY
NO.2
(a) Install the instrument panel brace sub-assy No. 2 with the
2 nuts and bolt.
I31504
(b) Install the 2 earth wires with the 2 bolts.
Torque: 8.4 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
I31767
(c) Install the passenger side junction block with the nut and
2 clamps.
Torque: 8.4 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
2 Clamps
I31768
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2645
55-31
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
39.
INSTALL INSTRUMENT FINISH PANEL RETAINER
LOWER
(a) Install the instrument finish panel retainer lower with the
2 bolts.
I31502
40.
INSTALL INSTRUMENT PANEL BRACE SUB-ASSY
NO.1
(a) Install the instrument panel brace sub-assy No. 1 with the nut.
(b) Install the bolt and screw.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 87 in.
⋅ lbf) (Screw)
I31501
(c) Install the 2 clamps.
2 Clamps
I31581
(d) Install the earth wire with the bolt.
Torque: 8.4 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
I31766
41.
INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2646
55-32
Connect
Gap
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
Wrong
I06878
42.
INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
(a) Lubricate new O-ring with compressor oil and install them to the hose.
Compressor oil: ND-OIL 8 or equivalent
(b) Install the cooler refrigerant suction hose No.1 and piping clamp.
HINT:
After connection, check the fitting for claw of the piping clamp.
43.
INSTALL COOLER REFRIGERANT LIQUID PIPE A
HINT:
Install in the same way as the cooler refrigerant suction hose No. 1.
44.
ADD COOLANT (See page 16-9 )
45.
CHARGE REFRIGERANT (See page 55-8 )
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080)
Specified amount: 550 50 g (19.37 1.76 oz.)
46.
WARM UP ENGINE
47.
CHECK ENGINE COOLANT LEAK (See page 16-9 )
48.
INSPECT LEAKAGE OF REFRIGERANT (See page 55-8 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2647
COMPONENTS
HEATER & AIR CONDITIONER BLOWER ASSY
1.5 (15, 12 in.
⋅ lbf)
Blower Assy
1.5 (15, 12 in.
⋅ lbf)
Heater To Foot Duct No. 1
Recirculation Damper Servo Sub-assy
Cowl Wire No. 2
Air Refiner Element
55-33
550DC-02
Blower Motor Control
Blower w/ fan Motor Sub-assy
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Instrument Panel No. 3 Wire
Author: Date:
I31634
2648
55-34
HEATER & AIR CONDITIONER BLOWER ASSY
OVERHAUL
HINT:
COMPONENTS: See page 55-33
1.
REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1 )
2.
REMOVE HEATER TO FOOT DUCT NO.1 (See page 55-17 )
3.
REMOVE BLOWER ASSY (See page 55-17 )
4.
REMOVE AIR REFINER ELEMENT
5.
REMOVE COWL WIRE NO.2
(a) Remove the clamp and cowl wire No. 2.
550DD-02
Clamp
2 Clamps
I31523
6.
REMOVE RECIRCULATION DAMPER SERVO
SUB-ASSY
(a) Remove the 3 screws and recirculation damper servo sub-assy .
I31524
7.
REMOVE INSTRUMENT PANEL NO.3 WIRE
(a) Disconnect the connectors, remove the 2 clamps and instrument panel No. 3 wire.
I31528
8.
REMOVE BLOWER MOTOR CONTROL
(a) Remove the 2 screws and blower motor control.
I31525
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2649
55-35
HEATER & AIR CONDITIONER BLOWER ASSY
9.
REMOVE BLOWER W/FAN MOTOR SUB-ASSY
(a) Remove the 3 screws and blower w/fan motor sub-assy.
I31527
10.
INSTALL BLOWER ASSY (See page 55-17 )
11.
INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2650
55-36
HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY
COMPONENTS
550DE-02
Cooler Compressor Bracket
Magnet Clutch Assy
18 (184, 13)
Snap Ring
Magnet Clutch Washer
Snap Ring
Cooler Compressor Assy
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
I31774
2651
55-37
HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY
550DF-02
REPLACEMENT
HINT:
COMPONENTS: See page 55-36
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55-8 )
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070,
07117-88080)
2.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55-10 )
3.
REMOVE GENERATOR ASSY (See page 19-21 )
I31543
4.
DISCONNECT COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the nut and disconnect the cooler refrigerant discharge hose No. 1.
(b) Remove the O-ring from the cooler refrigerant discharge hose No. 1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
I31542
5.
DISCONNECT COOLER REFRIGERANT SUCTION
HOSE NO.1
(a) Remove the nut and disconnect the cooler refrigerant suction hose No. 1.
(b) Remove the O-ring from the cooler refrigerant suction hose No. 1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
6.
REMOVE COMPRESSOR AND MAGNETIC CLUTCH
(a) Disconnect the connector and clamp.
(b) Remove the 2 bolts, nut and cooler compressor bracket.
I31544
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2652
55-38
HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY
(c) Remove the 3 bolts and compressor and magnetic clutch.
I31546
7.
REMOVE COOLER COMPRESSOR BRACKET
(a) Remove the screw, earth wire and cooler compressor bracket.
E58517
8.
REMOVE MAGNET CLUTCH ASSY
(a) Remove the bolt and bracket.
(b) Place the compressor and magnetic clutch in vise.
I30363
(c) Using a vise pliers, hold the magnet clutch hub.
(d) Remove the bolt, magnet clutch hub and magnet clutch washer.
I31547
(e) Using a snap ring expander, remove the snap ring and magnet clutch rotor.
(f) Disconnect the connector.
E37091
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2653
55-39
HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY
(g) Using a snap ring expander, remove the snap ring and magnet clutch starter.
I30400
9.
REMOVE COOLER COMPRESSOR ASSY
10.
INSTALL MAGNET CLUTCH ASSY
(a) Matching the parts shown in the illustration, install the magnet clutch starter.
I30631
(b) Using a snap ring expander, install a new snap ring with the chamfered side facing up.
(c) Connect the connector.
I30400
(d) Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up.
(e) Install the magnet clutch washer and magnet clutch hub.
NOTICE:
Do not change the combination of the magnet clutch washers used before disassembly.
I31582
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2654
55-40
HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY
(f) Using a vise pliers, hold the magnet clutch hub and install the bolt.
Torque: 18 N
⋅ m (184 kgf
⋅ cm, 13 ft
⋅ lbf)
I31548
I30369
11.
INSPECT MAGNETIC CLUTCH CLEARANCE
(a) Set the dial indicator to the magnet clutch hub.
(b) Connect the battery positive lead to the terminal 3 of magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance.
Standard clearance:
0.35 - 0.60 mm (0.014 - 0.024 in.)
If the measured value is out of the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers.
NOTICE:
Adjustment shall be performed with 3 or less magnet clutch washers.
(c) Remove the compressor and magnetic clutch from the vise.
(d) Install the bolt and bracket.
I30363
12.
INSTALL COOLER COMPRESSOR BRACKET
(a) Install the earth wire and cooler compressor bracket with the screw.
E58517
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2655
55-41
HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY
13.
INSPECT COMPRESSOR OIL
(a) When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation.
Standard:
(Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.) ) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing)
NOTICE:
When checking the compressor oil level, observe the precautions on the cooler removal/installation.
Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage.
Be sure to use ND-OIL8 for compressor oil.
14.
TEMPORARY TIGHTEN COMPRESSOR AND
MAGNETIC CLUTCH
(a) Temporarily the compressor and magnetic clutch with the
3 bolts.
(A)
I31546
15.
FULLY TIGHTEN COMPRESSOR AND MAGNETIC
CLUTCH
(a) Tighten the compressor and magnetic clutch with the bolt
(A) and bolt (B).
Torque: 25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
(E)
(D)
(B)
I31561
(b) Install the cooler compressor bracket with the 2 bolts and nut.
Torque:
25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf) (Bolt (C))
25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf) (Nut (D))
18 N
⋅ m (184 kgf
⋅ cm, 13 ft
⋅ lbf) (Bolt (E))
(C)
I31544
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2656
55-42
(F)
HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY
(c) Tighten the compressor and magnetic clutch with the bolt
(F).
Torque: 25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
(d) Connect the connector.
I31562
16.
INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent
(c) Install a O-ring to the cooler refrigerant suction hose
No. 1.
(d) Install the cooler refrigerant suction hose No. 1 to the compressor and magnetic clutch with the nut.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 87 in.
⋅ lbf)
I31542
17.
INSTALL COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent
(c) Install a O-ring to the cooler refrigerant discharge hose
No. 1.
(d) Install the cooler refrigerant discharge hose No. 1 to the compressor and magnetic clutch with the nut.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 87 in.
⋅ lbf)
I31543
18.
INSTALL GENERATOR ASSY (See page 19-21 )
19.
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55-10 )
20.
CHARGE REFRIGERANT (See page 55-8 )
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080)
Specified amount: 550 50 g (19.37 1.76 oz.)
21.
WARM UP ENGINE
22.
INSPECT LEAKAGE OF REFRIGERANT (See page 55-8 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2657
55-43
HEATER & AIR CONDITIONER COOLER CONDENSER ASSY
ON-VEHICLE INSPECTION
1.
INSPECT COOLER CONDENSER ASSY
(a) If a fin of the cooler condenser assy is dirty, clean it with water and dry it with compressor air.
NOTICE:
Do not damage the fin of the condenser assy.
(b) If a fin of the condenser assy is bent, make it straight using a screwdriver or pliers.
2.
INSPECT CONDENSER FOR LEAKAGE OF REFRIGERANT
(a) Using a halogen leak detector, check pipe joints for gas leakage.
(b) If gas leakage is detected in a joint, check the torque of the joint.
550DG-02
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2658
55-44
COMPONENTS
HEATER & AIR CONDITIONER COOLER CONDENSER ASSY
Air Cleaner Inlet No. 1
Air Cleaner Inlet Assy
550DH-02
Radiator Support Upper
9.8 (100, 85 in.
⋅ lbf)
O-ring
Radiator Lower Air Deflector
Hood Lock Release Lever
Protector
9.8 (100, 85 in.
⋅ lbf)
5.4 (55, 47 in.
⋅ lbf)
O-ring
Cooler Condenser Assy
Cooler Dryer
Filter
O-ring
Cap
12 (125, 9)
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf)
: Specified torque
Compressor oil ND-OIL 8 or equivalent
Non-reusable parts
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
I31635
2659
55-45
HEATER & AIR CONDITIONER COOLER CONDENSER ASSY
550DI-02
OVERHAUL
HINT:
COMPONENTS: See page 55-44
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55-8 )
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070,
07117-88080)
I31538
2.
REMOVE COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant discharge hose No. 1 from the cooler condenser assy.
(b) Remove the O-ring from the cooler refrigerant discharge hose No. 1.
NOTICE:
Seat the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
I31539
3.
DISCONNECT COOLER REFRIGERANT LIQUID PIPE
A
(a) Remove the bolt and disconnect the cooler refrigerant liquid pipe A from the cooler condenser assy.
(b) Remove the O-ring from the cooler refrigerant liquid pipe
A.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
4.
REMOVE AIR CLEANER INLET ASSY (See page 16-21 )
5.
REMOVE RADIATOR SUPPORT UPPER (See page 16-21 )
6.
REMOVE COOLER CONDENSER ASSY
(a) Remove the 2 nuts and cooler condenser assy.
I31540
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2660
55-46
10 mm
(0.39 in.)
Hexagon
Wrench
Modulator
HEATER & AIR CONDITIONER COOLER CONDENSER ASSY
7.
REMOVE COOLER DRYER
(a) Using hexagon wrench 10 mm (0.39 in.), remove the cap and filter from the modulator.
I30086
(b) Remove the 2 O-rings from the cap.
E50132
E57114
(c) Using a needle nose pliers, remove the cooler dryer.
8.
INSTALL COOLER DRYER
(a) Using a needle nose pliers, install the cooler dryer.
E50386
(b) Install 2 new O-rings to the cap.
(c) Sufficiently apply compressor oil to the fit surfaces of the
O-ring and the cap.
Compressor oil: ND-OIL 8 or equivalent
E50132
10 mm
(0.39 in.)
Hexagon
Wrench
Modulator
I30086
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Using hexagon wrench 10 mm (0.39 in.), install the cap to the condenser assy.
Torque: 12 N
⋅ m (125 kgf
⋅ cm, 9 ft
⋅ lbf)
Author: Date: 2661
HEATER & AIR CONDITIONER COOLER CONDENSER ASSY
9.
INSTALL COOLER CONDENSER ASSY
(a) Install the cooler condenser assy with the 2 nuts.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 85 in.
⋅ lbf)
55-47
I31541
10.
INSTALL RADIATOR SUPPORT UPPER (See page 16-21 )
11.
INSTALL COOLER REFRIGERANT LIQUID PIPE A
(a) Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy.
(b) Sufficiently apply compressor oil to the new O-ring and tube joint.
Compressor oil: ND-OIL 8 or equivalent
(c) Install a O-ring to the cooler refrigerant liquid pipe A.
(d) Connect the cooler refrigerant liquid pipe A to the cooler condenser assy with the bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 47 in.
⋅ lbf)
I31539
12.
INSTALL COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy.
(b) Sufficiently apply compressor oil to the new O-ring and tube joint.
Compressor oil: ND-OIL 8 or equivalent
(c) Install a O-ring to the cooler refrigerant discharge hose
No. 1.
(d) Connect the cooler refrigerant discharge hose No. 1 to the cooler condenser assy with the bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 47 in.
⋅ lbf)
I31538
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2662
55-48
HEATER & AIR CONDITIONER COOLER CONDENSER ASSY
13.
CHARGE REFRIGERANT (See page 55-8 )
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080)
Specified amount: 550 50 g (19.37 1.76 oz.)
14.
WARM UP ENGINE
15.
INSPECT LEAKAGE OF REFRIGERANT (See page 55-8 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2663
AC–1
AIR CONDITIONING – AIR CONDITIONING SYSTEM
AC09C–01
PRECAUTION
1.
DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2.
ALWAYS WEAR EYE PROTECTION
AC2810
AC2811
3.
BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional treatment.
4.
NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5.
BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPL PHYSICAL SHOCKS TO IT
Wrong Okay
LO HI LO HI
N11084
6.
DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM
If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so that take care to avoid this, necessary care should be taken.
7.
DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE
WHILE COMPRESSOR IS OPERATING
If the high pressure valve is opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve.
8.
BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc.
1997 LEXUS ES300 (RM511U)
Author: Date:
1558
AC–2
AIR CONDITIONING – AIR CONDITIONING SYSTEM
9.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
The Lexus ES300 is equipped an SRS (Supplemental Restraint
System) such as the driver and passenger air bag. Failure to carry out service operations the correct sequence could cause the SRS to unexpectedly deployed during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following item carefully, then follow the correct procedure described in the repair manual.
1997 LEXUS ES300 (RM511U)
Author: Date: 1559
Item
AC–3
Sight Glass
AIR CONDITIONING
N20242
– AIR CONDITIONING SYSTEM
AC2SY–01
ON–VEHICLE INSPECTION
1.
INSPECT REFRIGERANT VOLUME
Observe the sight glass on the liquid tube.
Test conditions:
Running engine at 1,500 rpm
Blower speed control switch set at ”HI”
A/C switch ON
Temperature control set at ”MAX. COOL”
Fully open doors
Symptom Amount of refrigerant
1 Bubbles present in sight glass
2 No bubbles present i sight glass
3
No temperature difference between compressor inlet and outlet
*Insufficient
None, sufficient or too much
Empty or nearly empty
Remedy
(1) Check for gas leakage with gas leak detector and repair if necessary
(2) Add refrigerant until bubbles disappear
Refer to item 3 and 4
(1) Check for gas leakage with gas leak detector and repair if necessary
(2) Add refrigerant until bubbles disappear
4
Temperature between compressor inlet and outlet is noticeably different
Correct or too much Refer to items 5 and 6
5
Immediately after air conditioning is turned off, refrigerant in sight glass stays clear
Too much
(1) Discharge refrigerant
(2) Evacuate air and charge proper amount of new refrigerant
6
When air conditioning is turned off, refrigerant foams and then stays clear
Correct –
HINT:
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient.
2.
INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
This is a method in witch the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the these conditions are established.
Test conditions:
Temperature at the air inlet with the switch set at RECIRC is 30 – 35
°
C (86 – 95
°
F)
Engine running at 1,500 rpm
Blower speed control set at ”HI”
Temperature control set at ”MAX COOL”
(1) Normally functioning refrigeration system
Gauge reading:
Low pressure side: 0.15 – 0.25 MPa (1.5 – 2.5 kgf/cm 2 )
High pressure side: 0.15 – 0.25 MPa (1.5 – 2.5 kgf/cm
2
)
I01386
1997 LEXUS ES300 (RM511U)
Author: Date:
1560
AC–4
AIR CONDITIONING – AIR CONDITIONING SYSTEM
(2) Moisture present in refrigeration system.
Condition : Periodically cools and then fails to cool
I01387
Symptom seen in refrigeration system
Probable cause Diagnosis
During operation, pressure on low pressure side sometimes become a vacuum and sometime normal
Moisture entered in refrigeration system freezes at expansion valve orifice and temporarily stops cycle, but normal state is restored after a time when the ice melts
Drier in oversaturated state
Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant
Remedy
(1) Replace receiver
(2) Remove moisture in cycle through repeatedly evacuating air
(3) Charge proper amount of new refrigerant
(3) Insufficient cooling
Condition: Insufficient cooling
I01388
Symptom seen in refrigeration system
Probable cause Diagnosis
Pressure low on both low and high pressure sides
Bubbles seen in sight glass continuously
Insufficient cooling performance
Gas leakage at some place in refrigeration system
Insufficient refrigerant in system
Refrigerant leaking
Remedy
(1) Check for gas leakage with gas leak detector and repair if necessary
(2) Charge proper amount of refrigerant
(3) If indicated pressure value is near 0 when connected to gauge, create the vacuum after inspecting and repairing the location of the leak
1997 LEXUS ES300 (RM511U)
Author: Date: 1561
Condition: Insufficient cooling
AIR CONDITIONING – AIR CONDITIONING SYSTEM
(4) Poor circulation of refrigerant
AC–5
Symptom seen in refrigeration system
Pressure low in both low and high pressure sides
Frost on tube from receiver to unit
Probable cause Diagnosis
Refrigerant flow obstructed by dirt in receiver
Receiver clogged
Remedy
Replace receiver
I01389
(5) Refrigerant does not circulate
Condition: Does not cool (Cools from time to time in some cases)
I01449
Symptom seen in refrigeration system
Probable cause Diagnosis
Vacuum indicated on low pressure side, very low pressure indicated on high pressure side
Frost or dew seen on piping before and after receiver/ drier or expansion valve
Refrigerant flow obstructed by moisture or dirt in refrigeration system
Refrigerant flow obstructed by gas leakage from expansion valve
Refrigerant does not circulate
Remedy
(1) Check expansion valve
(2) Clean out dirt in expansion valve by blowing with air
(3) Replace receiver
(4) Evacuate air and charge new refrigerant to proper amount
(5) For gas leakage from expansion valve, replace expansion valve
1997 LEXUS ES300 (RM511U)
Author: Date:
1562
AC–6
Condition: Insufficient cooling
AIR CONDITIONING – AIR CONDITIONING SYSTEM
(6) Refrigerant overcharged or insufficient cooling of condenser
I01390
Symptom seen in refrigeration system
Probable cause Diagnosis Remedy
Pressure too high on both low and high pressure sides
No air bubbles seen through the sight glass even when the engine rpm is lowered
Unable to develop sufficient performance due to excessive refrigeration system
Insufficient cooling of condenser
Excessive refrigerant in cycle
→
refrigerant over charged
Condenser cooling
→
condenser fins clogged of condenser fan faulty
(1) Clean condenser
(2) Check condenser fan motor operation
(3) If (1) and (2) are in normal state, check amount of refrigerant
Charge proper amount of refrigerant
(7) Air present in refrigeration system
Condition: Insufficient cooling
NOTE : These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without vacuum purging.
I01392
Symptom seen in refrigeration system
Pressure too high on both low and high pressure sides
The low pressure piping hot to touch
Bubbles seen in sight glass
Probable cause Diagnosis
Air entered in refrigeration system
Air present in refrigeration system
Insufficient vacuum purging
Remedy
(1) Check compressor oil to see if it is dirty or insufficient
(2) Evacuate air and charge new refrigerant
1997 LEXUS ES300 (RM511U)
Author: Date: 1563
Condition: Insufficient cooling
AIR CONDITIONING – AIR CONDITIONING SYSTEM
(8) Expansion valve improperly
AC–7
Symptom seen in refrigeration system
Pressure too high on both low and high pressure sides
Frost or large amount of dew on piping on low pressure side
Probable cause
Trouble in expansion valve
Diagnosis
Excessive refrigerant in low pressure piping
Expansion valve opened too wide
Remedy
Check expansion valve
Replace if defective
I01450
(9) Defective compression compressor
Condition : Does not cool
Symptom seen in refrigeration system
Pressure too high on low and high pressure sides
Pressure too low on high pressure side
Probable cause
Internal leak in compressor
Diagnosis Remedy
Compression defective
Valve leaking or broken sliding parts
Repair or replace compressor
I01393
1997 LEXUS ES300 (RM511U)
Author: Date:
1564
AC–8
Drain Hose
AIR CONDITIONING – AIR CONDITIONING SYSTEM
3.
INSPECT IDLE–UP SPEED
(a) Warm up engine
(b) Inspect idle–up speed when the these conditions are established.
Test conditions:
Blower speed control set at ”HI”
Temperature control set at ”MAX COOL”
A/C switch ON
Put gear shift in neutral
Magnetic clutch condition Idle speed
Magnetic clutch not engaged 700
±
50 rpm
Magnetic clutch engaged 700
±
50 rpm
If idle speed is not as specified, check IAC valve and air intake system.
4.
INSPECT FOR LEAKAGE OF REFRIGERANT
(a) Perform under these conditions:
Stop engine
Secure good ventilation (If not, the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline or exhaust gas.)
Repeat the test 2 or 3 times
Make sure that there is some refrigerant remaining in the refrigeration system.
When compressor is OFF: Approx. 392 – 588 kPa
(4 – 6 kgf/cm
2
, 57 – 85 psi)
N14519
(b) Bring the gas leak detector close to the drain hose before performing the test.
HINT:
After the blower motor is stopped, leave the A/C unit for more than 15 minutes.
Expose the gas leak detector sensor the under the drain hose.
When bring the gas leak detector close to the drain hose, make sure that the gas leak detector does not reach to the volatile gases.
If such reaction is unavoidable, the vehicle must be lifted up.
(c) If gas leak is not detected through the drain hose, remove the blower linear controller from the A/C unit. Then insert the gas leak detector sensor into the unit and perform the test.
1997 LEXUS ES300 (RM511U)
Author: Date: 1565
AC–9
AIR CONDITIONING – AIR CONDITIONING SYSTEM
(d) Disconnect the connector and leave the pressure switch for approx. 20 minutes. Then bring the gas leak detector close to the pressure switch and perform the test.
Gas Leak
Detector
Pressure
Switch
(e) Bring the gas leak detector close to the refrigerant lines and perform the test.
HINT:
Make sure that there is no dirt on joints.
N14517
1997 LEXUS ES300 (RM511U)
Author: Date:
1566
AC–10
Quick Disconnect
adapter
AIR CONDITIONING
Charging Hose
Service Valve
N13795
– AIR CONDITIONING SYSTEM
AC09E–01
EVACUATING
1.
CONNECT QUICK DISCONNECT ADAPTER TO
CHARGING HOSES
2.
REMOVE CAPS FROM SERVICE VALVES ON RE-
FRIGERANT LINES
3.
SET ON MANIFOLD GAUGE SET
(a) Close both hand valves of manifold gauge set.
(b) Connect the quick disconnect adapter to the service valves.
4.
EVACUATE AIR FROM REFRIGERATION SYSTEM
(a) Connect the vacuum pump adapter to the vacuum pump.
Vacuum Pump
Vacuum Pump Adapter
Manifold
Gauge Set
Low Pressure
Service Valve
N13794
(b) Connect the center hose of the manifold gauge set to the vacuum pump adapter.
(c) Open both the high and low hand valves and run the vacuum pump.
(d) After 10 minutes or more, check that the low pressure gauge indicates 750 mmHg (30 in.Hg) or more.
HINT:
If the reading is not 750 mmHg (30 in.Hg) or more, close both hand valves of manifold gauge set and stop the vacuum pump.
Check the system for leaks and repair as necessary.
(e) Close both the high and low hand valves and stop the vacuum pump.
(f) Leave the system in this condition for 5 minutes or more and check that there is no gauge indicator.
High Pressure
Service Valve
Vacuum Pump
Adapter
N13791
1997 LEXUS ES300 (RM511U)
Author: Date: 1567
Air
Push
Low Pressure
Service Valve
High Pressure
Service Valve
Charging Cylinder
AC–11
AIR CONDITIONING – AIR CONDITIONING SYSTEM
AC09F–01
CHARGING
1.
INSTALL CHARGING CYLINDER
HINT:
When handling the charging cylinder, always follow the directions given in the instruction manual.
(a) Charge proper amount of refrigerant into the charging cylinder.
(b) Connect the center hose to the charging cylinder.
CAUTION:
Do not open both high and low pressure hand valves of manifold gauge set.
(c) Open the valve of charging cylinder.
(d) Press the valve core on the side of manifold gauge and expel the air inside of the center hose.
N13793
2.
INSPECT REFRIGERATION SYSTEM FOR LEAKS
(a) Open the high pressure hand valve and charge refrigerant.
(b) When the low pressure gauge indicates 98 kPa
(1 kgf/cm
2
, 14 psi), close the high pressure hand valve.
(c) Using a gas leak detector, check the system for leakage.
(d) If leak is found, repair the faulty component or connection.
CAUTION:
Use the refrigerant recovery/ recycling machine to recover the refrigerant whenever replacing parts.
Gas Leak
Detector
N13792
1997 LEXUS ES300 (RM511U)
Author: Date:
1568
AC–12
Low Pressure
Service Valve
High Pressure
Service Valve
AIR CONDITIONING – AIR CONDITIONING SYSTEM
N13790
3.
CHARGE REFRIGERANT INTO REFRIGERANT SYS-
TEM
If there is no leak after refrigerant leak check, charge the proper amount of refrigerant into refrigeration system.
CAUTION:
Never run the engine when charging system through the high pressure side.
Do not open the low pressure hand valve when the system is being charged with liquid refrigerant.
(a) Open the high pressure and valve fully.
(b) Charge specified amount of refrigerant, then close the high pressure hand valve.
HINT:
A fully charged system is indicated by the sight glass being free of any bubbles.
4.
SET OFF MANIFOLD GAUGE SET
(a) Close both hand valves of manifold gauge set.
(b) Disconnect the quick disconnect adapters from the service valve.
5.
INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINES
1997 LEXUS ES300 (RM511U)
Author: Date: 1569
AC–13
AIR CONDITIONING – AIR CONDITIONING SYSTEM
LOCATION
No. 1 Engine Coolant Temperature
(ECT) Switch
No. 2 Engine Coolant Temperature
(ECT) Switch
Water Valve
Compressor
Condenser Fan
Pressure
Switch
Receiver
Solar Sensor
Ambient Temperature Sensor
Condenser
A/C Unit Blower Unit
Engine Room Relay
Block No. 1
Heater Main Relay
(Marking: HTR RLY)
Magnetic Clutch Relay
(Marking: MG CLT RLY)
No. 2 Cooling Fan Relay
(Marking: FAN RLY NO.2)
No. 3 Cooling Fan Relay
(Marking: FAN RLY NO.3)
Engine Room Junction
Block No. 2
Engine Main Relay
(Marking: ENGINE MAIN RLY)
No. 1 Cooling Fan Relay
(Marking: FAN RLY NO.1)
A/C Control Assembly
A/C Control Panel
A/C Amplifier
Room Temperature Sensor
Blower Resistor
Blower Motor Linear Controller
Air Outlet Servomotor
Air Mix Servomotor
Evaporator
Expansion Valve
Air Inlet Servomotor
Blower Motor
Evaporator Temperature Sensor
Heater Radiator
Z19363
1997 LEXUS ES300 (RM511U)
Author: Date:
1570
AC09G–03
AC–14
Correct
Crankshaft Pulley
DENSO
Wrong
AIR CONDITIONING – DRIVE BELT
AC09H–01
ON–VEHICLE INSPECTION
1.
INSPECT DRIVE BELT’S INSTALLATION CONDITION
Check that the drive belt fits properly in the ribbed grooves.
CH0086
Generator
2.
INSPECT DRIVE BELT TENSION
Using a belt tension gauge, check the drive belt tension.
Drive belt tension:
New belt: 165 ± 26 lbf
Used belt: 110
±
11 lbf
Compressor
N17028
Borroughs
HINT:
”New belt” refers to a belt which has been used less than
5 minutes on a running engine.
”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more.
After installing the drive belt, check that it fits properly in the ribbed grooves.
N01881
1997 LEXUS ES300 (RM511U)
Author: Date: 1571
Adjusting
Lock Bolt
Pivot Bolt
AC–15
AIR CONDITIONING
Adjusting Bolt
P19938
– DRIVE BELT
AC09I–01
REMOVAL
REMOVE DRIVE BELT
(a) Loosen the pivot bolt and adjusting lock bolt.
Torque:
Pivot bolt: 56 N·m (570 kgf·cm, 41 ft·lbf)
Adjusting lock bolt: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Loosen the belt tension by adjusting bolt and remove the drive belt.
1997 LEXUS ES300 (RM511U)
Author: Date:
1572
AC–16
AIR CONDITIONING – DRIVE BELT
INSTALLATION
Installation is in the reverse order of removal (See page AC–14 ).
AC09J–02
1997 LEXUS ES300 (RM511U)
Author: Date: 1573
Low Pressure
Charging Hose
AC–17
AIR CONDITIONING – MANIFOLD GAUGE SET
AC09K–01
SET ON
1.
CONNECT CHARGING HOSES TO MANIFOLD
GAUGE SET
Tighten the nuts by hand.
CAUTION:
Do not connect the wrong hoses.
2.
CONNECT QUICK DISCONNECT ADAPTERS TO
CHARGING HOSES
Tighten the nuts by hand.
3.
CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
4.
REMOVE CAPS FROM SERVICE VALVES ON RE-
FRIGERANT LINE
High Pressure
Charging Hose
N21127
Sleeve
5.
CONNECT QUICK DISCONNECT ADAPTERS TO SER-
VICE VALVES
HINT:
Push the quick disconnect adapter onto the service valve, then slide the sleeve of the quick disconnect adapter downward to lock it.
N04392
1997 LEXUS ES300 (RM511U)
Author: Date:
1574
AC–18
AIR CONDITIONING
N06553
– MANIFOLD GAUGE SET
AC09L–01
SET OFF
1.
CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
2.
DISCONNECT QUICK DISCONNECT ADAPTERS
FROM SERVICE VALVES ON REFRIGERANT LINE
HINT:
Slide the sleeve of the quick disconnect adapter upward to unlock the adapter and remove it from the service valve.
3.
INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINE
1997 LEXUS ES300 (RM511U)
Author: Date: 1575
AIR CONDITIONING – REFRIGERANT LINE
ON–VEHICLE INSPECTION
1.
INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS
2.
INSPECT HOSES AND TUBES FOR LEAKAGE
Using a gas leak detector, check for leakage of refrigerant.
AC–19
AC09M–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1576
AC–20
AIR CONDITIONING – REFRIGERANT LINE
LOCATION
22 (225, 16)
Suction Tube
Suction Tube
32 (330, 24)
Liquid Tube
Discharge Hose
5.4 (55, 48 in.·lbf)
Suction
Hose
Receiver
10 (100, 7)
Evaporator 5.4 (55, 48 in.·lbf)
Condenser
Liquid Tube
Discharge
Hose
Compressor
10 (100, 7)
N·m (kgf·cm, ft·lbf) : Specified torque
14 (140, 10)
Suction Hose
Expansion Valve
10 (100, 7)
AC09N–02
N21108
1997 LEXUS ES300 (RM511U)
Author: Date: 1577
AC–21
AIR CONDITIONING – REFRIGERANT LINE
REPLACEMENT
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2.
REPLACE FAULTY TUBE OR HOSE
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
3.
TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TORQUE
NOTICE:
Connections should not be torqued tighter than the specified torqued.
Part tightened
Receiver x Liquid tube
Condenser x Discharge hose
Condenser x Liquid tube
Compressor x Discharge hose
Compressor x Suction hose
A/C unit x Liquid and Suction tube
14
10
10
10
N·m
5.4
22 kgf·cm
55
225
140
100
100
100
Evaporator x Expansion valve
Liquid line (Block joint)
5.4
10
55
100
Suction line (Block joint) 10 100
Suction line (Piping joint) 32 330
4.
EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT
Specified amount: 800
±
50 g (28.22
± 1.76 oz.)
5.
INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
6.
INSPECT AIR CONDITIONING OPERATION
48 in.·lbf
7
7
24 ft·lbf
48 in.·lbf
16
7
7
10
7
AC09O–02
1997 LEXUS ES300 (RM511U)
Author: Date:
1578
AC–22
AIR CONDITIONING – AIR CONDITIONING UNIT
COMPONENTS
Instrument Panel
Reinforcement
No. 1 Brace
Water Hose
A/C Unit
Rear Heater Duct
No. 2 Brace
Blower Unit
AC09P–03
Water Valve Control
Cable
Side Air Duct RH
Side Air Duct LH
Air Outlet Servomotor
Blower Resistor
A/C Unit Case
5.4 (55, 48)
Evaporator
Evaporator Temperature
Sensor
X7
Blower Motor
Linear
Controller
Air Mix Servomotor
Clamp
Heater Radiator
Pipe
Heater
Radiator
Insulator
Evaporator Cover
O–Ring
Expansion Valve
O–Ring
Drain Hose
O–Ring
Clamp
Heater Protector
Foot Air Duct LH
N·m (kgf·cm, in.·lbf)
Non–reusable part
: Specified torque
Liquid and Suction Tube
Foot Air Duct RH
Z19364
1997 LEXUS ES300 (RM511U)
Author: Date: 1579
AC–23
AIR CONDITIONING – AIR CONDITIONING UNIT
AC09Q–01
REMOVAL
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of the installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 800
±
50 g (28.22
±
1.76 oz.)
2.
DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all the coolant.
N21067
3.
DISCONNECT WATER VALVE CONTROL CABLE
FROM WATER VALVE
HINT:
At the in time of the installation, please refer to the following item.
For installing the control cable, refer to ”INSTALLATION” of
”WATER VALVE” on page AC–60 .
4.
DISCONNECT WATER HOSES FROM HEATER RA-
DIATOR PIPES
(a) Using pliers, grip the claw of the hose clip and slide the hose clip along the hose.
(b) Disconnect the water hoses.
Heater Radiator Pipe
Marking
Upper
45
±
10
°
RH LH
Hose Clip
Water Hose
Lower
N20237
HINT:
At the time of the installation, please refer to the following items.
Push the water hose onto the heater radiator pipe as far as the pipe grommet and install the hose clip.
Install the hose clip in a position, as shown in the illustration.
1997 LEXUS ES300 (RM511U)
Author: Date:
1580
AC–24
AIR CONDITIONING – AIR CONDITIONING UNIT
5.
REMOVE THESE PARTS:
(a) Blower unit (See page AC–29 )
(b) Instrument panel and reinforcement (See page BO–82 )
N21063
6.
DISCONNECT LIQUID AND SUCTION TUBES
Remove the bolt and slide the plate, then disconnect both tubes.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
HINT:
At the time of the installation, please refer to the following item.
Lubricate 2 new O–rings with compressor oil and install the tubes.
N21065
7.
REMOVE A/C UNIT
(a) Slide the floor carpet backward.
(b) Remove the rear heater ducts.
(c) Disconnect the connectors.
(d) Remove the 2 nuts and A/C unit.
1997 LEXUS ES300 (RM511U)
Author: Date: 1581
AIR CONDITIONING – AIR CONDITIONING UNIT
DISASSEMBLY
1.
REMOVE THESE PARTS:
(a) Side air ducts LH, RH
(b) Foot air ducts LH, RH
2.
REMOVE EVAPORATOR TEMP. SENSOR
Remove the screw and pull out the sensor.
3.
REMOVE EVAPORATOR
(a) Remove the 6 screws and evaporator cover.
HINT:
At the time of reassembly, please refer to the following item.
Do not reuse the evaporator cover.
(b) Pull out the evaporator.
HINT:
At the time of reassembly, please refer to the following item.
If evaporator is replaced, add compressor oil to evaporator.
Add 40 cc (1.4 fl.oz.)
Compressor oil: ND–OIL 8 or equivalent
4.
REMOVE EXPANSION VALVE
Using a hexagon wrench, remove the 2 bolts and separate the evaporator and expansion valve.
HINT:
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
At the time of reassembly, please refer to the following item.
Lubricate 4 new O–rings with compressor oil and install the valve.
5.
REMOVE AIR MIX SERVOMOTOR
(a) Remove the 3 screws and servomotor.
(b) Remove the water valve control cable from the servomotor.
6.
REMOVE AIR OUTLET SERVOMOTOR
Remove the 2 screws and servomotor.
7.
REMOVE HEATER RADIATOR
(a) Release the 3 claws and remove the heater protector.
(b) Remove the 2 screws and 2 clamps, then pull out the heater radiator.
(c) Remove the 2 screws, 2 clamps and heater radiator pipes from the heater radiator.
8.
REMOVE BLOWER RESISTOR
(a) Disconnect the connector.
(b) Remove the 2 screws and blower resistor.
9.
REMOVE BLOWER MOTOR LINEAR CONTROLLER
(a) Disconnect the connector.
(b) Remove the 2 screws and blower motor linear controller.
10.
REMOVE WIRE HARNESS
Release the claw and remove the wire harness.
AC–25
AC09R–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1582
AC–26
AIR CONDITIONING – AIR CONDITIONING UNIT
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page AC–25 ).
AC09T–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1583
AIR CONDITIONING – AIR CONDITIONING UNIT
INSTALLATION
Installation is in the reverse order of removal (See page AC–23 ).
AC–27
AC09S–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1584
AC–28
COMPONENTS
AIR CONDITIONING – BLOWER UNIT
Evaporator Temp. Sensor
Connector w/ CD Changer:
CD Changer Assembly
Air Inlet Servomotor
Connector w/ CD Changer:
Finish Upper Panel
Connector Bracket
AC09U–02
Glove Compertment
Blower Unit
Audio Amplifier
ECM
Blower Motor Connector
Cowl Side Trim RH
Front Door Scuff Plate RH
No. 2 Instrument Panel Under Cover
Blower Unit Case
Air Inlet Servomotor
Blower Motor
1997 LEXUS ES300 (RM511U)
Author: Date:
Z19365
1585
AIR CONDITIONING – BLOWER UNIT
REMOVAL
1.
REMOVE THESE PARTS:
(a) Cowl side trim RH
(b) Front door scuff plate RH
(c) No.2 instrument panel under cover
(d) Glove Compartment
(e) w/ CD Changer:
Finish upper panel
(f) w/ CD Changer:
CD change assembly
(g) Audio amplifier
(h) ECM
2.
REMOVE CONNECTOR BRACKET SET SCREWS
3.
REMOVE BLOWER UNIT
(a) Disconnect the connectors from blower unit.
(b) Disconnect the wire harness clamps.
(c) Disconnect the evaporator temp. sensor connector clamp.
(d) Remove the 2 screws, bolt and nut, then remove the blower unit.
AC–29
AC09V–02
1997 LEXUS ES300 (RM511U)
Author: Date:
1586
AC–30
AIR CONDITIONING – BLOWER UNIT
DISASSEMBLY
1.
REMOVE BLOWER MOTOR
Remove the 3 screws and blower motor.
2.
REMOVE AIR INLET SERVOMOTOR
Remove the 3 screws and servomotor.
AC09W–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1587
AIR CONDITIONING – BLOWER UNIT
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page AC–30 ).
AC–31
AC09X–02
1997 LEXUS ES300 (RM511U)
Author: Date:
1588
AC–32
AIR CONDITIONING – BLOWER UNIT
INSTALLATION
Installation is in the reverse order of removal (See page AC–29 ).
AC09Y–02
1997 LEXUS ES300 (RM511U)
Author: Date: 1589
AC–33
AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH
AC09Z–01
ON–VEHICLE INSPECTION
1.
INSPECT COMPRESSOR FOR METALLIC SOUND
(a) Start the engine.
(b) Check if there is metallic sound from the compressor when the A/C switch is on.
If metallic sound is heard, replace the compressor assembly.
2.
INSPECT REFRIGERANT PRESSURE
(See page AC–3 )
3.
INSPECT VISUALLY FOR LEAKAGE OF REFRIGER-
ANT FROM SAFETY SEAL
Using a gas leak detector, check for leakage of refrigerant.
If there is any leakage, replace the compressor assembly.
4.
INSPECT COMPRESSOR LOCK SENSOR
(See page DI–552 )
5.
MAKE THESE VISUAL CHECKS:
(a) Leakage of grease from the clutch bearing.
(b) Signs of oil on the pressure plate or rotor.
If necessary, repair or replace.
6.
INSPECT MAGNETIC CLUTCH BEARING FOR NOISE
(a) Start the engine.
(b) Check for abnormal noise from near the compressor when the A/C switch is OFF.
If abnormal noise is being emitted, replace the magnetic clutch.
7.
INSPECT MAGNETIC CLUTCH
(a) Disconnect the connector from the magnetic clutch.
(b) Connect the positive (+) lead from the battery to the terminal 4 and the negative (–) lead to the body ground.
(c) Check that the magnetic clutch is energized.
If operation is not as specified, replace the magnetic clutch.
N01150
1997 LEXUS ES300 (RM511U)
Author: Date:
1590
AC–34
COMPONENTS
AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH
Drive Belt
18 (185, 13)
56 (570, 41)
Generator
O–Ring
10 (100, 7)
Discharge Hose
O–Ring
10 (100, 7)
25 (250, 18)
32 (330, 24)
O–Ring
Suction Hose
25 (250,18)
Compressor Bracket
Compressor
25 (250,18)
25 (250,18)
Drive Belt Adjusting
Bar Bracket
AC0A0–01
Stator
Pressure plate
Shim
13.2 (135, 9)
Rotor
N·m (kgf·cm, ft·lbf) : Specified torque
Snap Ring
Non–reusable part
Snap Ring Compressor
I01448
1997 LEXUS ES300 (RM511U)
Author: Date: 1591
AC–35
AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH
AC0A1–01
REMOVAL
1.
RUN ENGINE AT IDLE SPEED WITH A/C ON FOR
APPROX.10 MINUTES
2.
STOP ENGINE
3.
DISCONNECT NEGATIVE (–) TERMINAL CABLE
FROM BATTERY
4.
DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
5.
REMOVE DRIVE BELT
(See page AC–15 )
N20277
6.
REMOVE SUCTION HOSE
(a) Remove the suction hose clamping bolt.
(b) Disconnect the wire harness clamp.
(c) Loosen the nut and bolts and remove the suction hose.
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
7.
DISCONNECT DISCHARGE HOSE
Remove the bolt and disconnect the hose.
NOTICE:
Cap the open fitting immediately to keep moisture or dirt out of the system.
1997 LEXUS ES300 (RM511U)
P19978
8.
REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire.
(c) Disconnect the wire harness from the clip.
(d) Remove the pivot bolt, plate washer, adjusting lock bolt and generator.
Author: Date:
1592
AC–36
AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH
9.
REMOVE COMPRESSOR
(a) Disconnect the connector.
(b) Remove the 2 bolts, nut and generator drive belt adjusting bar bracket.
N20259
(c) Remove the 3 bolts and compressor.
N20241
1997 LEXUS ES300 (RM511U)
Author: Date: 1593
SST
SST
AC–37
AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH
AC0A2–03
DISASSEMBLY
1.
REMOVE PRESSURE PLATE
(a) Using SST and a socket wrench, remove the shaft bolt.
Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf)
SST 07112–76060
AC0943
(b) Install SST on the pressure palate.
SST 07112–66040
SST
SST
AC0944
(c) Using SST and socket wrench, remove the pressure plate.
SST 07112–76060
AC0945
(d) Remove the shims from the pressure palate.
Shim
Pressure
Plate
AC0946
2.
REMOVE ROTOR
(a) Using SST, remove the snap ring.
SST 07114–84020
1997 LEXUS ES300 (RM511U)
AC0947
Author: Date:
1594
AC–38
Snap Ring
R–Shape
Rotor
AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH
NOTICE:
At the time of reassembly, please refer to the following item.
The snap ring should be installed so that beveled side faces up.
Compressor
N20013
(b) Using a plastic hammer, tap the rotor off the shaft.
NOTICE:
Be careful not to damage the pulley when tapping on the rotor.
AC1743
3.
REMOVE STATOR
(a) Disconnect the stator lead wire from the compressor housing.
AC1744
(b) Using SST, remove the snap ring.
SST 07114–84020
SST
R–Shape
Snap Ring
Stator
Compressor
1997 LEXUS ES300 (RM511U)
AC0950
NOTICE:
At the time of reassembly, please refer to the following item.
The snap ring should be installed so that its beveled side faces up.
N20012
Author: Date: 1595
Stator
AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH
(c) Remove the stator.
AC–39
AC0951
1997 LEXUS ES300 (RM511U)
Author: Date:
1596
AC–40
Dial Indicator
AIR CONDITIONING
N04963
– COMPRESSOR AND MAGNETIC CLUTCH
AC0A3–03
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page AC–37 ).
CHECK CLEARANCE OF MAGNETIC CLUTCH
HINT:
After reassembly, check the magnetic clutch clearance.
(a) Set the dial indicator to the pressure plate of the magnetic clutch.
(b) Connect the magnetic clutch lead wire to the positive (+) terminal of the battery.
(c) Check the clearance between the pressure plate and rotor when connecting the negative (–) terminal battery.
Standard clearance:
0.5
±
0.15 mm (0.020
±
0.0059 in.)
If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance.
Shim thickness:
0.1 mm (0.004 in.)
0.3 mm (0.012 in.)
0.5 mm (0.020in.)
1997 LEXUS ES300 (RM511U)
Author: Date: 1597
(A)
(B)
1997 LEXUS ES300 (RM511U)
AC–41
AIR CONDITIONING
N20259
– COMPRESSOR AND MAGNETIC CLUTCH
AC0A4–03
INSTALLATION
1.
INSTALL COMPRESSOR
(a) Install the compressor with 3 bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Install the generator drive belt adjusting bar bracket with
2 bolts and a nut.
Torque:
Bolt (A): 18 N·m (185 kgf·cm, 13 ft·lbf)
Bolt (B): 25 N·m (250 kgf·cm, 18 ft·lbf)
Nut: 25 N·m (250 kgf·cm, 18 ft·lbf)
2.
INSTALL GENERATOR
(a) Mount generator on the generator bracket with the pivot bolt and adjusting lock bolt. Do not tighten the bolts yet.
(b) Connect the generator connector.
(c) Connect the generator wire with the nut.
3.
CONNECT DISCHARGE HOSE
Torque:10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Hoses should be connected immediately after the caps have been removed.
HINT:
Lubricate a new O–ring with compressor oil and install the tube.
4.
INSTALL SUCTION HOSE
(a) Install the suction hose and tighten the bolt and nut.
Torque:
Piping joint: 32 N·m (330 kgf·cm, 24 ft·lbf)
Block joint: 10 N·m (100 kgf·cm, 7 ft·lbf)
HINT:
Lubricate 2 new O–rings with the compressor oil and install the hose.
(b) Install the suction hose clamping bolt.
(c) Connect the wire harness clamp.
5.
INSTALL DRIVE BELT
(See page AC–16 )
6.
INSPECT DRIVE BELT
(See page AC–14 )
7.
CONNECT NEGATIVE (–) TERMINAL CABLE TO BAT-
TERY
8.
EVACUATE AIR IN REFRIGERATION SYSTEM AND
CHARGE WITH REFRIGERANT
Specified amount: 800
±
50 g (28.22
±
1.76 oz.)
9.
INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.
10.
INSPECT A/C OPERATION
Author: Date:
1598
AC–42
AIR CONDITIONING – RECEIVER
ON–VEHICLE INSPECTION
INSPECT FITTINGS FOR LEAKAGE
Using a gas leak detector, check for leakage.
If there is leakage, check the tightening torque at the joints.
AC0A7–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1599
AC–43
AIR CONDITIONING – RECEIVER
AC0A6–01
REMOVAL
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 800
±
50 g (28.22
±
1.76 oz.)
2.
REMOVE RADIATOR UPPER SUPPORT SEAL
N21081
3.
DISCONNECT 2 LIQUID TUBES FROM RECEIVER
Remove the 2 bolts and both tubes.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O–rings with compressor oil and install the tubes.
4.
REMOVE RECEIVER
(a) Remove the holder bolt and pull out receiver downward.
HINT:
At the time of installation, please refer to the following item.
If receiver is replaced, add compressor oil to receiver.
Add 20 cc (0.71 fl.oz.)
Compressor oil: ND–OIL 8 or equivalent
(b) Remove the 2 bolts and holder.
1997 LEXUS ES300 (RM511U)
Author: Date:
1600
AC–44
AIR CONDITIONING – RECEIVER
INSTALLATION
Installation is in the reverse order of removal (See page AC–43 ).
AC0A5–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1601
AIR CONDITIONING – CONDENSER
ON–VEHICLE INSPECTION
1.
INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE
If the fins are clogged, wash them with water and dry with compressed air.
NOTICE:
Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver or pliers.
2.
INSPECT CONDENSER AND FITTINGS FOR LEAKAGE
Using a gas leak detector, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.
AC–45
AC0A8–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1602
AC–46
1997 LEXUS ES300 (RM511U)
AIR CONDITIONING – CONDENSER
AC0A9–02
REMOVAL
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 800
±
50 g (28.22
±
1.76 oz.)
2.
REMOVE THESE PARTS:
(a) Radiator upper support seal
(b) Receiver and holder
(See page AC–43 )
(c) Radiator upper support
(d) Clearance lights
(e) Headlights
(f) Radiator fan and condenser fan
N21087
Discharge Hose
Liquid Tube
I16648
3.
DISCONNECT DISCHARGE HOSE
Loosen the nut and disconnect the discharge hose.
Torque: 22 N·m (225 kgf·cm, 16 ft·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
HINT:
At the time of installation, please refer to the following item
Lubricate a new O–ring with compressor oil and install the tube.
4.
REMOVE LIQUID TUBE
Loosen the nut and remove the liquid tube.
Torque: 14 N·m (140 kgf·cm, 10 ft·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
HINT:
At the time of installation, please refer to the following item
Lubricate a new O–ring with compressor oil and install the tube.
N21085
5.
REMOVE CONDENSER
(a) Remove the 2 nuts from condenser upper mountings.
(b) Push the radiator toward the engine.
(c) Push the condenser toward the radiator and pull it upward.
HINT:
At the time of installation, please refer to the following item.
If condenser is replaced, add compressor oil to the compressor.
Add 40–50 cc (1.4–1.7 fl.oz.)
Compressor oil: ND–OIL 8 or equivalent
Author: Date: 1603
AIR CONDITIONING – CONDENSER
INSTALLATION
Installation is in the reverse order of removal (See page AC–46 ).
AC–47
AC0AA–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1604
AC–48
AIR CONDITIONING – EVAPORATOR
AC0AB–02
REMOVAL
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 800
±
50 g (28.22
±
1.76 oz.)
2.
REMOVE BLOWER UNIT
(See page AC–29 )
N21063
3.
DISCONNECT LIQUID AND SUCTION TUBE
Remove the bolt and slide the plate, then disconnect both tubes.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O–rings with compressor oil and install the tubes.
1997 LEXUS ES300 (RM511U)
Author: Date: 1605
AC–49
AIR CONDITIONING – EVAPORATOR
N21091
4.
REMOVE EVAPORATOR
(a) Disconnect the connector.
(b) Remove the screw and pull out the evaporator temp. sensor.
(c) Remove the 5 screws and evaporator cover.
HINT:
At the time of installation, please refer to the following item.
Do not reuse the evaporator cover.
(d) Pull out the evaporator.
HINT:
At the time of installation, please refer to the following item.
If evaporator is replaced, add compressor oil to evaporator.
Add 40 cc (1.4 fl.oz.)
Compressor oil: ND–OIL 8 or equivalent
1997 LEXUS ES300 (RM511U)
Author: Date:
1606
AIR CONDITIONING – EVAPORATOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–48 ).
AC–51
AC0AD–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1608
AC–52
AIR CONDITIONING – HEATER RADIATOR
REMOVAL
1.
DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all coolant.
2.
REMOVE THESE PARTS:
(a) No.1 lower panel
(b) Lower panel LH
AC0AE–01
3.
REMOVE HEATER RADIATOR
(a) Release the 3 claws and remove the heater protector.
N21092
N21061
(b) Remove 2 screws and 2 clamps.
(c) Remove the 2 screws and 2 clips, then disconnect the heater radiator pipes from heater radiator.
(d) Remove 2 O–rings from heater radiator pipes.
HINT:
At the time of installation, please refer to the following item.
Do not reuse 2 O–rings.
(e) Pull out the heater radiator.
1997 LEXUS ES300 (RM511U)
Author: Date: 1609
AIR CONDITIONING – HEATER RADIATOR
INSPECTION
INSPECT FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
AC–53
AC0AF–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1610
AC–54
AIR CONDITIONING – HEATER RADIATOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–52 ).
AC0AG–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1611
AC–55
AIR CONDITIONING – EXPANSION VALVE
AC0AH–01
ON–VEHICLE INSPECTION
1.
CHECK QUANTITY OF GAS IN REFRIGERATION CYCLE
2.
SET ON MANIFOLD GAUGE SET
(See page AC–17 )
3.
RUN ENGINE
Run the engine at 1,500 rpm for at least 5 minutes.
Then check that the high pressure reading is 1.37 – 1.57 MPa (14 – 16 kgf/cm
2
, 199 –228 psi).
4.
CHECK EXPANSION VALVE
If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/cm 2 , 0 psi).
HINT:
When the low pressure drops to 0 kPa (0 kgf/cm
2
, 0 pis), check the receiver’s IN and OUT sides for no temperature difference.
1997 LEXUS ES300 (RM511U)
Author: Date:
1612
AC–56
AIR CONDITIONING
N21066
– EXPANSION VALVE
AC0AI–02
REMOVAL
1.
REMOVE EVAPORATOR
(See page AC–48 )
2.
REMOVE EXPANSION VALVE
Using a hexagon wrench, remove the 2 bolts and separate the expansion valve, evaporator and tube.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
HINT:
At the time of installation, please refer to the following item.
Lubricate 4 new O–rings with compressor oil and install the tube and valve.
1997 LEXUS ES300 (RM511U)
Author: Date: 1613
AIR CONDITIONING – EXPANSION VALVE
INSTALLATION
Installation is in the reverse order of removal (See page AC–56 ).
AC–57
AC0AJ–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1614
AC–58
AIR CONDITIONING – WATER VALVE
ON–VEHICLE INSPECTION
1.
WARM UP ENGINE
2.
DISCONNECT WATER VALVE CONTROL CABLE
3.
INSPECT WATER VALVE OPERATION
(a) Check that warm air blown out when the water valve lever is moved to ”WARM” position.
(b) Check that cool air blown out when the water valve is moved to the ”COOL” position.
If operation is not as specified, replace the water valve.
4.
CONNECT WATER VALVE CONTROL CABLE
HINT:
After connection, adjust the control cable.
AC0AK–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1615
AIR CONDITIONING – WATER VALVE
REMOVAL
1.
DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all the coolant.
AC–59
AC0AL–02
2.
DISCONNECT WATER HOSES FROM WATER VALVE
AND HEATER RADIATOR PIPE
(a) Using pliers, grip the claws of the hose clip and slide the hose clip along the hose.
(b) Disconnect the water hose.
N21070
Heater Radiator Pipe
Marking
Hose Clip
Water Valve
Marking
45
±
10
°
Upper
RH
Water Hose
LH
Hose Clip
Fr.
Rr.
Lower
N21068
HINT:
At the time of installation, please refer to the following items.
Push the water hose onto the heater radiator pipe as far as the pipe grommet.
Install the hose clip in a position, as shown in the illustration.
3.
DISCONNECT WATER VALVE CONTROL CABLE
FROM WATER VALVE
HINT:
At the time of installation, please refer to the following item.
For installing the control cable, refer to ”INSTALLATION”.
N21071
4.
REMOVE WATER VALVE
Remove the bolt and water valve.
1997 LEXUS ES300 (RM511U)
N21072
Author: Date:
1616
AC–60
To COOL
Clamp
AIR CONDITIONING
N01181
– WATER VALVE
AC0AM–02
INSTALLATION
Installation is in the reverse order of removal (See page
AC–59 ).
HINT:
After installation, adjust water valve control cable.
ADJUST WATER VALVE CONTROL CABLE
(a) Turn ignition switch to ON.
(b) Set temperature control switch at ”COOL”.
(c) Set the water valve control lever on the ”COOL” position and install the control cable and lock the clamp.
HINT:
Lock the clamp while lightly pushing the outer cable in the direction shown by arrow.
1997 LEXUS ES300 (RM511U)
Author: Date: 1617
AIR CONDITIONING – BLOWER MOTOR
REMOVAL
1.
REMOVE THESE PARTS:
(a) Cowl side trim RH
(b) Front door scuff plate RH
(c) No. 2 instrument panel under cover
AC–61
AC0AN–02
2.
REMOVE 2 CONNECTOR BRACKET SET SCREWS
N21089
3.
REMOVE BLOWER MOTOR
(a) Disconnect the connector.
(b) Remove the 3 screws and blower motor.
N21064
1997 LEXUS ES300 (RM511U)
Author: Date:
1618
AC–62
AIR CONDITIONING – BLOWER MOTOR
INSPECTION
INSPECT BLOWER MOTOR CIRCUIT
(See page DI–583 )
AC0AO–02
1997 LEXUS ES300 (RM511U)
Author: Date: 1619
AIR CONDITIONING – BLOWER MOTOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–61 ).
AC–63
AC0AP–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1620
AC–64
AIR CONDITIONING – BLOWER RESISTOR
REMOVAL
1.
REMOVE THESE PARTS:
(a) No. 1 instrument lower panel
(b) Instrument lower panel LH
2.
REMOVE BLOWER RESISTOR
(a) Disconnect the connector.
(b) Remove the 2 screws and blower resistor.
AC0AQ–02
N12077
1997 LEXUS ES300 (RM511U)
Author: Date: 1621
2 1
AC–65
AIR CONDITIONING – BLOWER RESISTOR
AC2SZ–01
INSPECTION
INSPECT BLOWER RESISTOR RESISTANCE
Measure resistance between terminals.
Standard resistance:
1.8 – 2.2
Ω
If resistance is not as specified, replace the blower resistor.
Z14433
1997 LEXUS ES300 (RM511U)
Author: Date:
1622
AC–66
AIR CONDITIONING – BLOWER RESISTOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–64 ).
AC0AS–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1623
AC–67
AIR CONDITIONING – BLOWER MOTOR LINEAR CONTROLLER
REMOVAL
1.
REMOVE THESE PARTS:
(a) No. 1 instrument lower panel
(b) Instrument lower panel LH
AC0AT–02
2.
REMOVE BLOWER MOTOR LINEAR CONTROLLER
(a) Disconnect the connector.
(b) Remove the 2 screws and controller.
N12820
1997 LEXUS ES300 (RM511U)
Author: Date:
1624
AC–68
AIR CONDITIONING – BLOWER MOTOR LINEAR CONTROLLER
INSPECTION
INSPECT BLOWER MOTOR LINEAR CONTROLLER CIRCUIT
(See page DI–583 )
AC0AU–02
1997 LEXUS ES300 (RM511U)
Author: Date: 1625
AIR CONDITIONING – BLOWER MOTOR LINEAR CONTROLLER
INSTALLATION
Installation is in the reverse order of removal (See page AC–67 ).
AC–69
AC0AV–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1626
AC–70
AIR CONDITIONING – AIR INLET SERVOMOTOR
REMOVAL
1.
REMOVE THESE PARTS:
(a) Cowl side trim RH
(b) Front door scuff plate RH
(c) No. 2 instrument panel under cover
(d) Glove compartment
2.
REMOVE ECM
(a) Disconnect the connectors.
(b) Remove the 2 nuts and ECM.
AC0AW–02
N21073
3.
REMOVE AIR INLET SERVOMOTOR
(a) Disconnect the connector.
(b) Remove the 3 screws and servomotor.
N21074
1997 LEXUS ES300 (RM511U)
Author: Date: 1627
AIR CONDITIONING – AIR INLET SERVOMOTOR
INSPECTION
1.
INSPECT AIR INLET SERVOMOTOR CIRCUIT
(See page DI–566 )
2.
INSPECT AIR INLET DAMPER POSITION SENSOR CIRCUIT
(See page DI–560 )
AC–71
AC0AX–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1628
AC–72
AIR CONDITIONING – AIR INLET SERVOMOTOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–70 ).
AC0AY–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1629
AIR CONDITIONING – AIR MIX SERVOMOTOR
REMOVAL
1.
REMOVE THESE PARTS:
(a) No. 1 instrument lower panel
(b) Instrument lower panel LH
AC–73
AC0AZ–02
2.
REMOVE AIR MIX SERVOMOTOR
(a) Disconnect the connector.
(b) Remove the 3 screws and servomotor, then disconnect the control cable.
N21060
1997 LEXUS ES300 (RM511U)
Author: Date:
1630
AC–74
AIR CONDITIONING – AIR MIX SERVOMOTOR
INSPECTION
1.
INSPECT AIR MIX SERVOMOTOR CIRCUIT
(See page DI–563 )
2.
INSPECT AIR MIX DAMPER POSITION SENSOR CIRCUIT
(See page DI–557 )
AC0B0–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1631
AIR CONDITIONING – AIR MIX SERVOMOTOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–73 ).
AC–75
AC0B1–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1632
AC–76
AIR CONDITIONING – AIR OUTLET SERVOMOTOR
REMOVAL
1.
REMOVE THESE PARTS:
(a) No. 1 instrument lower panel
(b) Instrument lower panel LH
AC0B2–02
2.
REMOVE AIR OUTLET SERVOMOTOR
(a) Disconnect the connector.
(b) Remove the 2 screws and servomotor.
N21059
1997 LEXUS ES300 (RM511U)
Author: Date: 1633
AIR CONDITIONING – AIR OUTLET SERVOMOTOR
INSPECTION
INSPECT AIR OUTLET SERVOMOTOR CIRCUIT
(See page DI–574 )
AC–77
AC0B3–02
1997 LEXUS ES300 (RM511U)
Author: Date:
1634
AC–78
AIR CONDITIONING – AIR OUTLET SERVOMOTOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–76 ).
AC0B4–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1635
AC–79
AIR CONDITIONING – SOLAR SENSOR
AC0B5–01
REMOVAL
REMOVE SOLAR SENSOR
Using a screwdriver, pull out the sensor, then disconnect the connector.
HINT:
Tape the screwdriver tip before use.
N21083
1997 LEXUS ES300 (RM511U)
Author: Date:
1636
AC–80
AIR CONDITIONING – SOLAR SENSOR
INSPECTION
INSPECT SOLAR SENSOR CIRCUIT
(See page DI–549 )
AC0B6–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1637
AIR CONDITIONING – SOLAR SENSOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–79 ).
AC–81
AC0B7–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1638
AC–82
AIR CONDITIONING – ROOM TEMPERATURE SENSOR
AC0B8–02
REMOVAL
REMOVE ROOM TEMP. SENSOR
(a) Remove the No. 1 instrument lower panel set screws.
(b) Disconnect the aspirator hose.
(c) Disconnect the connector.
(d) Release the 2 claws and pull out the sensor from No. 1 instrument lower panel.
N21090
1997 LEXUS ES300 (RM511U)
Author: Date: 1639
AIR CONDITIONING – ROOM TEMPERATURE SENSOR
INSPECTION
INSPECT ROOM TEMP. SENSOR CIRCUIT
(See page DI–537 )
AC–83
AC0B9–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1640
AC–84
AIR CONDITIONING – ROOM TEMPERATURE SENSOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–82 ).
AC0BA–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1641
AIR CONDITIONING – AMBIENT TEMPERATURE SENSOR
REMOVAL
REMOVE AMBIENT TEMPERATURE SENSOR
(a) Disconnect the connector.
(b) Pull out the sensor from bumper reinforcement.
AC–85
AC0BE–01
N21077
1997 LEXUS ES300 (RM511U)
Author: Date:
1642
AC–86
AIR CONDITIONING – AMBIENT TEMPERATURE SENSOR
INSPECTION
INSPECT AMBIENT TEMPERATURE SENSOR CIRCUIT
(See page DI–540 )
AC0BF–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1643
AIR CONDITIONING – AMBIENT TEMPERATURE SENSOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–85 ).
AC–87
AC0BG–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1644
AC–88
AIR CONDITIONING – EVAPORATOR TEMPERATURE SENSOR
REMOVAL
1.
REMOVE THESE PARTS:
(a) Cowl side trim RH
(b) Front door scuff plate RH
(c) No. 2 instrument panel under cover
(d) Glove compartment
(e) w/ CD Changer:
Finish upper panel
(f) w/ CD Changer:
CD changer assembly
(g) Audio amplifier
(h) ECM
(i) Blower unit (See page AC–29 )
AC0BB–02
2.
REMOVE EVAPORATOR TEMP. SENSOR
(a) Disconnect the connector.
(b) Remove the screw and pull out the sensor.
N21062
1997 LEXUS ES300 (RM511U)
Author: Date: 1645
AIR CONDITIONING – EVAPORATOR TEMPERATURE SENSOR
INSPECTION
INSPECT EVAPORATOR TEMP. SENSOR CIRCUIT
(See page DI–543 )
AC–89
AC0BC–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1646
AC–90
AIR CONDITIONING – EVAPORATOR TEMPERATURE SENSOR
INSTALLATION
Installation is in the reverse order of removal (See page AC–88 ).
AC0BD–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1647
AC–91
AIR CONDITIONING – PRESSURE SWITCH
AC0BH–01
ON–VEHICLE INSPECTION
1.
SET ON MANIFOLD GAUGE SET
(See page AC–17 )
2.
DISCONNECT CONNECTOR FROM PRESSURE
SWITCH
3.
RUN ENGINE AT APPROX. 1,500 RPM
N20291
Magnetic Clutch Control
Low Pressure Side High Pressure Side
ON (Continuity)
196 kpa
(2.0 kgf·cm
2
, 28 psi)
OFF (No Continuity)
3,140 kpa
(32.0 kgf·cm
2
, 455 psi)
OFF (No Continuity)
Z13470
4.
Magnetic Clutch Control:
INSPECT PRESSURE SWITCH OPERATION
(a) Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative (–) lead to terminal 1.
(b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration.
If operation is not as specified, replace the pressure switch.
Cooling Fan Control
1,520 kpa
(15.5 kgf·cm
2
, 220 psi)
ON
(Continuity)
1,226 kpa
(12.5 kgf·cm
2
OFF
(No Continuity)
, 178 psi)
Z13471
5.
Cooling Fan Control:
INSPECT PRESSURE SWITCH OPERATION
(a) Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative (–) lead to terminal 3.
(b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration.
If operation is not as specified, replace the pressure switch.
6.
STOP ENGINE AND SET OFF MANIFOLD GAUGE SET
7.
CONNECT CONNECTOR TO PRESSURE SWITCH
1997 LEXUS ES300 (RM511U)
Author: Date:
1648
AC–92
AIR CONDITIONING – PRESSURE SWITCH
AC0BI–01
REMOVAL
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 800
±
50 g (28.22
±
1.76 oz.)
N20292
2.
REMOVE PRESSURE SWITCH FROM LIQUID TUBE
Disconnect the connector and remove the pressure switch.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
HINT:
Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch.
At the time of installation, please refer to the following item.
Lubricate a new O–ring with compressor oil and install the switch.
1997 LEXUS ES300 (RM511U)
Author: Date: 1649
AIR CONDITIONING – PRESSURE SWITCH
INSTALLATION
Installation is in the reverse order of removal (See page AC–92 ).
AC–93
AC0BJ–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1650
AC–94
3 4 5
1 2
3
1
4
2
5
AIR CONDITIONING – RELAY
Z19533
INSPECTION
1.
INSPECT HEATER MAIN RELAY
(Marking: HTR RLY) CONTINUITY
AC2T0–01
Condition
Constant
Tester connection
2 – 4
1 – 3
Specified condition
Continuity
Apply B+ between terminals 3 and 5.
1 – 2 Continuity
If continuity is not as specified, replace the relay.
2 3
5
1
3
2
2.
INSPECT MAGNETIC CLUTCH RELAY
(Marking: MG CLT RLY) CONTINUITY
Condition
Constant
Tester connection
1 – 2
Specified condition
Continuity
Apply B+ between terminals 1 and 2.
3 – 5 Continuity
If continuity is not as specified, replace the relay.
1
5
Z18060
3
1
2
3 1 4 5
2
4
3
1
4
2
3.
INSPECT No.1 COOLING FAN RELAY
(Marking: FAN RLY NO.1) CONTINUITY
Condition
Constant
Tester connection
1 – 2
3 – 4
Specified condition
Continuity
Apply B+ between terminals 1 and 2.
3 – 4 No continuity
If continuity is not as specified, replace the relay.
Z12319
1 3
2 5 4
N02832
4.
INSPECT No. 2 COOLING FAN RELAY
(Marking: FAN RLY NO.2) CONTINUITY
Condition
Constant
Tester connection
1 – 2
3 – 4
Specified condition
Continuity
Apply B+ between terminals 1 and 2
3 – 5
If continuity is not as specified, replace the relay
Continuity
1997 LEXUS ES300 (RM511U)
Author: Date: 1651
5
3 2
4
1
3
5
2
4
AC–95
AIR CONDITIONING – RELAY
5.
INSPECT No.3 COOLING FAN RELAY
(Marking: FAN RLY NO.3) CONTINUITY
Condition Tester connection Specified condition
Constant 1 – 2 Continuity
Apply B+ between terminals 1 and 2.
3 – 5 Continuity
If continuity is not as specified, replace the relay.
Z05932
1
6.
INSPECT ENGINE MAIN RELAY
(Marking: ENGINE MAIN RLY) CONTINUITY
Condition
Constant
Tester connection
1 – 3
2 – 4
Specified condition
Continuity
Apply B+ between terminals 1 and 3.
4 – 5 Continuity
If continuity is not as specified, replace the relay.
Z06166
1997 LEXUS ES300 (RM511U)
Author: Date:
1652
AC–96
AIR CONDITIONING – CONDENSER FAN
AC0BL–01
ON–VEHICLE INSPECTION
1.
INSPECT CONDENSER FAN OPERATION
Inspect the fan operation, as shown in the chart below.
Test conditions:
Ignition switch ON
Blower speed control switch position ”HI”
Temperature control dial at ”MAX. COOL”
Install on manifold gauge set”
A/C switch ON
Condition
Engine coolant temperature
83 ° C (181 ° F) or below
Engine coolant temperature
98
°
C (208
°
F) or above
Refrigerant pressure is less than
1,520 kPa (15.5 kgf/cm 2 , 220 psi)
Fan operation
Not rotate
Rotate
Not rotate
Refrigerant pressure is 1,520 kPa
(15.5 kgf/cm 2 , 220 psi) or above
Rotate
If operation is not as specified, proceed to the next inspection.
A
1
2
N20290
2.
INSPECT CONDENSER FAN MOTOR OPERATION
(a) Disconnect the fan connector.
(b) Connect battery and ammeter.
(c) Check that the fan rotates smoothly, and then check that the reading on the ammeter.
Specified amperage: 10.1
±
1.8 A at 20
°
C (68
°
F)
If operation is not as specified, replace the fan motor.
If operation is as specified, check the pressure switch, cooling fan relays and engine coolant temp. switch.
1997 LEXUS ES300 (RM511U)
Author: Date: 1653
COMPONENTS
AIR CONDITIONING – CONDENSER FAN
AC–97
AC0BM–01
Condenser Fan Connector
Condenser Fan
Upper Radiator Hose Fan
Clip
Fan Shroud
Fan Motor
Non–reusable part
Z19368
1997 LEXUS ES300 (RM511U)
Author: Date:
1654
AC–98
AIR CONDITIONING – CONDENSER FAN
REMOVAL
1.
DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all the coolant.
2.
DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR
3.
REMOVE CONDENSER FAN
(a) Disconnect the connector.
(b) Remove the 3 bolts and fan.
AC0BN–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1655
Protrusion
AC–99
AIR CONDITIONING
I03508
– CONDENSER FAN
AC0BO–01
DISASSEMBLY
1.
REMOVE FAN
Remove the clip and fan.
NOTICE:
When removing the clip and fan, do not apply too much force to the motor shaft. And do not scratch the motor shaft.
HINT:
At the time of installation, please refer to the following item.
Install a new clip from the side opposite the protrusion on the fan.
2.
REMOVE FAN MOTOR
(a) Disconnect the lead wire from the fan shroud.
(b) Remove the 3 screws and fan motor.
1997 LEXUS ES300 (RM511U)
Author: Date:
1656
AC–100
AIR CONDITIONING – CONDENSER FAN
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page AC–99 ).
AC0BP–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1657
AIR CONDITIONING – CONDENSER FAN
INSTALLATION
Installation is in the reverse order of removal (See page AC–98 ).
AC–101
AC0BQ–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1658
AC–102
AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY
COMPONENTS
AC0BR–02
Center Cluster Finish
Control Panel
Bracket
A/C Control Assembly
Connector
Bracket
Radio
Center Cluster Finish
Panel
A/C Control Assembly
Amplifier Case
Rear Cover
A/C Amplifier
Bulb
A/C Control Panel
1997 LEXUS ES300 (RM511U)
Author: Date:
Z19367
1659
AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY
REMOVAL
1.
REMOVE THESE PARTS:
(a) End cluster finish panel
(b) Center cluster finish panel
AC–103
AC0BS–01
2.
REMOVE A/C CONTROL ASSEMBLY
(a) Remove the 4 bolts and pull out the A/C control assembly with radio, then disconnect the connectors.
N21082
(b) Remove the 8 bolts, 4 screws and bracket.
(c) Remove the A/C control assembly from the radio.
N21084
1997 LEXUS ES300 (RM511U)
Author: Date:
1660
AC–104
AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY
AC0BT–01
DISASSEMBLY
1.
REMOVE A/C AMPLIFIER
(a) Release the 4 claws and remove the rear cover.
(b) Pull out the A/C amplifier backward.
HINT:
Hold the supply parts A/C amplifier using the electrostatic prevention bag it comes packed in.
N21075
2.
SEPARATE A/C CONTROL PANEL AND A/C AMPLIFI-
ER CASE
(a) Remove the 3 screws.
(b) Release the 4 claws, then separate the A/C control panel and A/C amplifier case.
LCD Lighting
N21076
3.
REMOVE BULB
Using a screwdriver, turn the bulb to left and pull out the bulb.
Night Lighting
Night Lighting
N21078
1997 LEXUS ES300 (RM511U)
Author: Date: 1661
AC–105
AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY
AC0BU–02
INSPECTION
1.
INSPECT NIGHT LIGHTING
Connect the positive (+) lead from the battery to terminal 28 and the negative (–) lead to terminal 18, then check that the illumination lights up.
If there is bulb not light up, replace the bulb only.
If all bulb does not light up, replace the A/C control panel.
28
18
Z19570
29
42
30
Z19568
2.
INSPECT LCD LIGHTING
Connect the positive (+) lead from the battery to terminal 29, 42 and the negative (–) lead to terminal 30, then check that the illumination lights up.
If there is bulb not light up, replace the replace the bulb only.
If the 2 bulbs do not light up, try replace the bulb with a new one
If the bulbs do not light up, replace the A/C control panel.
1997 LEXUS ES300 (RM511U)
Author: Date:
1662
AC–106
AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY
3.
INSPECT SWITCH OPERATION
(a) Connect the positive (+) lead from the battery to terminal
29, 42 and the negative (–) lead to terminal 30.
(b) Operate the switches and check that the indicator and
LCD indication change, as shown in the illustration.
If operation is not as specified, replace the A/C control panel.
29
42
21
30
Z19567
4.
INSPECT SECURITY INDICATOR
Connect the positive (+) lead from the battery to terminal 21 and negative (–) lead to terminal 30, then check that the indicator light up.
If operation is not as specified, replace the A/C control panel.
5.
INSPECT A/C CONTROL ASSEMBLY CIRCUIT (See page DI–526 )
30
Z19569
1997 LEXUS ES300 (RM511U)
Author: Date: 1663
AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page AC–104 ).
AC–107
AC0BV–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1664
AC–108
AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY
INSTALLATION
Installation is in the reverse order of removal (See page AC–103 ).
AC0BW–01
1997 LEXUS ES300 (RM511U)
Author: Date: 1665
AC–109
AIR CONDITIONING – ENGINE COOLANT TEMPERATURE (ECT) SWITCH
REMOVAL
1.
DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all the coolant.
AC0BX–02
No. 1 ECT Switch
2.
REMOVE ECT SWITCHES
No. 2 ECT Switch
P19584
1997 LEXUS ES300 (RM511U)
Author: Date:
1666
AC–110
AIR CONDITIONING
P01924
– ENGINE COOLANT TEMPERATURE (ECT) SWITCH
AC0BY–01
INSPECTION
1.
INSPECT No. 1 SWITCH CONTINUITY
(a) Using an ohmmeter, check that no continuity exists between the terminals when the coolant temperature is above 98
°
C (208
°
F).
If continuity exists, replace the switch.
(b) Using an ohmmeter, check that continuity exists between the terminals when the coolant temperature is below
88
°
C (190
°
F).
If no continuity exists, replace the switch.
P06722
2.
INSPECT No. 2 SWITCH CONTINUITY
(a) Using an ohmmeter, check that no continuity exists between the terminal and switch body when the coolant temperature is above 93
°
C (199
°
F).
If continuity exists, replace the switch.
(b) Using an ohmmeter, check that continuity exists between the terminals when the coolant temperature is below
83
°
C (181
°
F).
If no continuity exists, replace the switch.
1997 LEXUS ES300 (RM511U)
Author: Date: 1667
AIR CONDITIONING – ENGINE COOLANT TEMPERATURE (ECT) SWITCH
INSTALLATION
Installation is in the reverse order of removal (See page AC–109 ).
AC–111
AC0BZ–01
1997 LEXUS ES300 (RM511U)
Author: Date:
1668
01-1
INTRODUCTION HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL
0103A-07
GENERAL INFORMATION
1.
GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains” Removing and Installing, Replacing, Disassembling ,Instaling and Checking,
Adjusting” , but” Final inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2.
INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be repaired.
3.
PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending on the repairing condition. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4.
REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the” disassembled parts drawing” so that it enables you to understand the fitting condition of the components.
(c) Non-reusable parts, grease applied parts, precoated parts and tightening torque are specified in the components drawing.
Example:
Stator Shaft Assy
Oil Seal Ring
Oil Pump Drive Gear
Oil Seal
O-ring
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Oil Pump Driven Gear
Author: x13
10 (100, 7)
Date:
D25697
1
01-2
INTRODUCTION HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL
(d) Tightening torque, oil applying position, and non-reusable parts are described as important points in the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the information such as torque, oil, etc are described in the illustration.
(e) Installing procedure of operation item is performed in the reverse order of the removing, and only the important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are placed using an illustration. In the explanations, details of the operational method, standard value and notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may be different from the actual vehicle.
(h) The procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications and warnings.
Example:
D26831
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task heading can be read at a glance when necessary, and the text below provides detailed information. Important specifications and warnings always stand out in bold type.
5.
SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the procedure to look up your specifications. The specifications are also found in the Service Specifications section for a quick reference.
6.
TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 2
INTRODUCTION HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL
01-3
7.
SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N
⋅ m (310 kgf
⋅ cm, 22 ft
⋅ lbf)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
3
01-4
INTRODUCTION REPAIR INSTRUCTION FOR AUTOMATIC
TRANSAXLE REPAIR MANUAL
PRECAUTION
1.
BASIC REPAIR HINT
0103B-07
Seal Lock Adhesive
Z11554
(a) PRECOATED PARTS
(1) Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive.
(3) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads.
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave it for a specified time until it hardens.
(b) GASKETS
When necessary, use a sealer on gaskets to prevent leaks.
(c) BOLTS, NUTS AND SCREWS
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 4
INTRODUCTION REPAIR INSTRUCTION FOR AUTOMATIC
TRANSAXLE REPAIR MANUAL
D02612
01-5
(d) TORQUE WHEN USING EXTENSION TOOL WITH
TORQUE WRENCH
(1) In case of tightening by extending the entire length of the torque wrench combined with SST or tool, if you tighten until the reading of the torque wrench reached the specified torque value, the actual torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the reading of the torque wrench by the formula.
(3) Formula T’=T x L2/(L1 + L2)
T’
T
L1
L2
Reading of torque wrench
{
N
⋅ m
( kgf
⋅ cm
, ft
⋅ lbf
)}
Torque
{
N
⋅ m
( kgf
⋅ cm
, ft
⋅ lbf
)}
Length of SST or tool (cm)
Length of torque wrench (cm)
D01201
D01202
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
5
01-6
INTRODUCTION TERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
0103C-05
ABBREVIATIONS USED IN THIS MANUAL
Abbreviations Meaning w/ w/o
1st
2nd
ASSY
ATF
B
3
C
2
C
3
FIPG
O/D
SSM
SST
U/D
Assembly
Automatic Transaxle Fluid
U/D Brake
Reverse Clutch
U/D Clutch
Formed In Place Gasket
Overdrive
Special Service Materials
Special Service Tools
Underdrive
With
Without
First
Second
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 6
01-7
INTRODUCTION TERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
0103D-09
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents.
CTP
DFI
DI
DLC1
DLC2
DLC3
DTC
DTM
ECL
ECM
ECT
CFI
CKP
CL
CMP
CPP
CTOX
SAE
ABBREVIATIONS
A/C
ACL
AIR
AP
B+
BARO
CAC
CARB
EEPROM
SAE TERMS
Air Conditioning
Air Cleaner
Secondary Air Injection
Accelerator Pedal
Battery Positive Voltage
Barometric Pressure
Charge Air Cooler
Carburetor
Continuous Fuel Injection
Crankshaft Position
Closed Loop
Camshaft position
Clutch Pedal Position
Continuous Trap Oxidizer
Closed Throttle Potion
Direct Fuel Injection (Diesel)
Distributor Ignition
Data Link Connector 1
Data Link Connector 2
Data Link Connector 3
Diagnostic Trouble Code
Diagnostic Test Mode
Engine Control Level
Engine Control Module
Engine Control Temperature
Electrically Erasable Programmable Read Only memory
EFE
EGR
EI
EM
EPROM
EVAP
FC
Early Fuel Evaporation
Exhaust Gas Recirculation
Electronic Ignition
Engine Modification
Erasable Programmable Read Only Memory
FEEPROM
Evaporative Emission
Fan Control
Flash Electrically Erasable Programmable
Read Only Memory
Flash Erasable Programmable Read Only Memory
Flexible Fuel
FEPROM
FF
FP
GEN
GND
HO2S
IAC
IAT
ICM
Fuel Pump
Generator
Ground
Heated Oxygen Sensor
Idol Air Control
Intake Air Temperature
Ignition Control Module
IFI
IFS
Indirect Fuel Injection
Inertia Fuel-Shutoff
U151E, U151F A/T REPAIR MANUAL (RM1021U)
-
Air Conditioner
Air Cleaner
Air Injection (AI)
-
+B, Battery Voltage
TOYOTA TERMS
( )--ABBREVIATIONS
-
Inter cooler
Carburetor
-
Crank Angle
Closed Loop
-
-
Cam Angle
-
-
Direct Injection (DI)
1: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
-
Diagnostic Code
-
Engine ECU (Electronic Control Unit)
Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only memory
(EEPROM),
Erasable Programmable Read Only memory (EPROM)
Cold Mixture Heater (CMH), Heat Control Valve (HCV)
Exhaust Gas Recirculation (EGR)
Distributorless Ignition (DI)
Engine Modification (EM)
Programmable Read Only Memory (PROM)
-
Evaporative Emission Control (EVAP)
-
-
Fuel Pump
Alternator
Ground (GND)
Heated Oxygen Sensor (HO2S)
Idol Speed Control (ISC)
-
Intake or Inlet Air Temperature
-
Indirect Injection
Author: Date:
7
01-8
RAM
RM
ROM
RPM
SC
SCB
SFI
SPL
SRI
SRT
ST
TB
TBI
TC
TCC
TCM
TP
TR
TVV
MDP
MFI
MIL
MST
MVZ
NVRAM
O2S
OBD
OC
OP
PAIR
PCM
PNP
PROM
PSP
PTOX
ISC
KS
MAF
MAP
MC
TWC
TWC+OC
VAF
VR
VSS
WOT
Idle Speed Control
Knock Sensor
Mass Air Flow
Manifold Absolute Pressure
Mixture Control
Manifold Differential Pressure
Multiport Fuel Injection
Malfunction Indicator Lamp
Manifold Surface temperature
Manifold Vacuum Zone
Non-V olatile Random Access Memory
Oxygen Sensor
On-Board Diagnostic
Oxidation Catalytic Converter
Open Loop
Pulsed Secondary Air Injection
Powertrain Control Module
Park/Neutral Position
Programmable Read Only Memory
Power Steering Pressure
Periodic Trap Oxidizer
Random Access Memory
Relay Module
Read Only Memory
Engine Speed
Supercharger
Supercharger Bypass
Sequential Multiport Fuel Injection
Smoke Puff Limiter
Service Reminder Indicator
System Readiness Test
Scan Tool
Throttle Body
Throttle Body Fuel Injection
Turbocharger
Torque Converter Clutch
Transmission Control Module
Throttle Position
Transmission Range
Thermal Vacuum Valve
Three-W ay Catalytic Converter
Three-W ay + Oxidation Catalytic Converter
Volume Air Flow
Voltage Regulator
Vehicle Speed Sensor
Wide Open Throttle
U151E, U151F A/T REPAIR MANUAL (RM1021U)
INTRODUCTION TERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
-
Knock Sensor
Air Flow Meter
Manifold Pressure
Intake Vacuum
-
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
-
Electronic Fuel Injection (EFI)
Check Engine Light
-
-
Oxygen Sensor, O
2
Sensor (O
2S)
On-Board Diagnostic (OBD)
Oxidation Catalyst Converter (OC), CC
0
Open Loop
Air Suction (AS)
-
-
-
-
Diesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
-
Random Access Memory (RAM)
Read Only Memory (ROM)
-
Engine Speed
Supercharger
-
Electronic Fuel Injection (EFI), Sequential Injection
-
-
-
Throttle Body
Single Point Injection
Central Fuel Injection (Ci)
Turbocharger
Torque Converter
Transmission ECU (Electronic Control Unit)
Throttle Position
-
Bimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
Three-W ay Catalytic (TWC)
CC
RO
CC
R
+ CC
O
Air Flow Meter
Voltage Regulator
Vehicle Speed Sensor (Read Switch Type)
Full Throttle
Author: Date: 8
WU-OC
WU-TWC
3GR
4GR
INTRODUCTION TERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
Warm Up Oxidation Catalytic Converter
Warm Up Three-Way Catalytic Converter
Third Gear
Fourth Gear
-
-
-
Manifold Converter
01-9
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
9
02-1
PREPARATION AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
09214-7601 1 Crankshaft Pulley Replacer
022FX-01
FRONT DIFFERENTIAL
ASSY(U151F)
09215-00013 Crankshaft Bearing Remover &
Replacer Set B
(09215-00471) Camshaft Bearing Remover &
Replacer
09223-15020 Oil Seal & Bearing Replacer
09223-15030 Oil Seal & Bearing Replacer
09308-00010 Oil Seal Puller
09316-12010 Transfer Bearing Replacer
09316-2001 1 Transfer Bearing Replacer
09350-32014 TOYOTA Automatic Transmission
Tool Set
(09351-32070) No.2 Piston Spring Compressor
(09351-32140) Oil Seal Replacer
FRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
OIL PUMP ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
OIL PUMP ASSY(U151E/U151F)
UNDERDRIVE CLUTCH
ASSY(U151E/U151F)
UNDERDRIVE CLUTCH
ASSY(U151E/U151F)
OIL PUMP ASSY(U151E/U151F)
09387-00020 Direct Clutch Wrench
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author:
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FORWARD CLUTCH
ASSY(U151E/U151F)
DIRECT CLUTCH
ASSY(U151E/U151F)
Date:
10
02-2
PREPARATION AUTOMATIC TRANSMISSION / TRANS
09387-00030 Counter Drive Gear Holding Tool AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00041 Bearing Puller Assembly
(09387-01010)
(09387-01021)
(09387-01030)
(09387-01040)
09387-00050
09387-00060
09387-00070
09387-00080
09502-12010
09506-35010
09514-3501 1
Claw No.1
Claw No.2
Pin
Bearing Puller Body
Under Drive Gear Puller
Second Brake Wrench
First & Reverse Brake Wrench
Counter Drive Gear Nut Wrench
Differential Bearing Replacer
Differential Drive Pinion Rear
Bearing Replacer
Rear Wheel Bearing Puller
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
SECOND BRAKE PISTON
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 11
02-3
PREPARATION AUTOMATIC TRANSMISSION / TRANS
09527-1701 1
09550-60010
Rear Axle Shaft Bearing Remover
Differential Side Bearing
Replacer
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
(09951-00490) Replacer 49
09564-3201 1 Differential Preload Adaptor
09608-10010 Steering Knuckle Oil Seal
Replacer
09649-17010 Steering Knuckle Tool
09710-30050 Suspension Arm Bushing Replacer
09726-40010 Lower Control Shaft Bearing
Replacer
FRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09930-00010 Drive Shaft Nut Chisel
(09931-00010) Handle
(09931-00020) Nut Chisel
09950-00020 Bearing Remover
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
12
02-4
PREPARATION AUTOMATIC TRANSMISSION / TRANS
09950-00030
09950-4001 1
(09957-04010)
09950-60010
(09951-00230)
Bearing Remover Attachment
Puller B Set
Attachment
Replacer Set
Replacer 23
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00260) Replacer 26
(09951-00320)
(09951-00450)
(09951-00480)
(09951-00490)
(09951-00500)
Replacer 32
Replacer 45
Replacer 48
Replacer 49
Replacer 50
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 13
02-5
PREPARATION AUTOMATIC TRANSMISSION / TRANS
(09951-00590) Replacer 59 AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00600) Replacer 60
(09952-06010) Adapter
09950-60020 Replacer Set No.2
(09951-00730) Replacer 73
(09951-00750) Replacer 75
(09951-00810) Replacer 81
(09951-00890) Replacer 89
(09951-00910) Replacer 91
(09951-01030) Replacer 103
09950-70010 Handle Set
FRONT DIFFERENTIAL
ASSY(U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
14
02-6
Recomended Tools
PREPARATION AUTOMATIC TRANSMISSION / TRANS
(09951-07100)
(09951-07150)
Handle 100
Handle 150
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09031-00030 Pin Punch AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09031-00040 Pin Punch .
09905-00012
09905-00013
Snap Ring No.1 Expander
Snap Ring Pliers
FRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FORWARD CLUTCH
ASSY(U151E/U151F)
DIRECT CLUTCH
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
Equipment
Feeler gauge
Vernier calipers
Torque wrench
Plastic hammer
Straight edge
Press
Seal packing 2403, THREE BOND 2403 or equivalent
Seal packing 2430, THREE BOND 2430 or equivalent
Lubricant item
U151E / U151F
Automatic transaxle fluid
Dry fill
Drain and refill
6.8 liter (7.2 USqts, 6.0 lmp.qts)
2.9 liter (3.1 USqts, 2.6 lmp.qts)
ATF type T-IV
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 15
PREPARATION AUTOMATIC TRANSMISSION / TRANS
SSM (Special Service Materials)
08826-00090 Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)
08833-00080 Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalent
02-7
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
16
03-1
SERVICE SPECIFICATIONS STANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
030JK-02
HOW TO DETERMINE BOLT STRENGTH
Hexagon head
bolt
Hexagon flange bolt w/ washer hexagon bolt
Hexagon head bolt
Mark
Bolt head No.
4-
9-
10-
11-
5-
6-
7-
8-
No mark
No mark
Class
4T
5T
6T
7T
8T
9T
10T
11T
4T
Hexagon flange bolt w/ washer hexagon bolt
Hexagon flange bolt w/ washer hexagon bolt
Hexagon flange bolt w/ washer hexagon bolt
Stud bolt
4T
Mark
4
Protruding lines
Class
9T
5
Protruding lines
10T
6
Protruding lines
No mark
11T
4T
Hexagon flange bolt w/ washer hexagon bolt
Hexagon head bolt
Hexagon head bolt
2
Protruding lines
2
Protruding lines
3
Protruding lines
5T
6T
7T
Welded bolt
4
Protruding lines
8T
Grooved
6T
4T
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
V06821
17
03-2
SERVICE SPECIFICATIONS STANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
SPECIFIED TORQUE FOR STANDARD BOLTS
Class
Diameter mm
Pitch mm
N·m
Specified torque
Hexagon head bolt kgf·cm ft·lbf N·m
Hexagon flange bolt kgf·cm ft·lbf in.·lbf in.·lbf
030JL-02 in.·lbf in.·lbf in.·lbf in.·lbf
U151E, U151F A/T REPAIR MANUAL (RM1021U)
V00079
Author: Date: 18
03-3
SERVICE SPECIFICATIONS STANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
HOW TO DETERMINE NUT STRENGTH
Present Standard
Hexagon Nut
Nut Type
Old Standard Hexagon Nut
Cold Forging Nut Cutting Processed Nut
Class
030JM-02
4N
No Mark
5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark
6N
6N
7N (5T)
*
8N
8N
10N (7T)
10N
No Mark
11N
11N
12N
12N
*: Nut with 1 or more marks on one side surface of the nut.
B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
19
03-4
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
SERVICE DATA
Oil pump
Body clearance
Tip clearance
Side clearance
Drive gear thickness
Driven gear thickness
Pump body bushing inside diameter
Stator shaft bushing inside diameter
Mark
A
B
C
D
E
Mark
A
B
C
D
E
STD
Max.
STD
Max.
STD
Max.
STD
Max.
STD
Max.
0.10 - 0.17 mm (0.0039 - 0.0067 in.)
0.17 mm (0.0067 in.)
0.07 - 0.15 mm (0.0028 - 0.0059 in.)
0.15 mm (0.0059 in.)
0.02 - 0.05 mm (0.0008 - 0.0020 in.)
0.05 mm (0.0020 in.)
11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)
11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)
38.113 - 38.138 mm (1.50050 - 1.50149 in.)
38.188 mm (1.50346 in.)
21.500 - 21.526 mm (0.84646 - 0.84748 in.)
21.57 mm (0.8492 in.)
Multiple disc clutch
Inside diameter STD
Max.
23.025 - 23.045 mm (0.9065 - 0.9073 in.)
23.09 mm (0.9091 in.)
Forward clutch
Pack clearance
Return spring free length
Flange thickness Mark
1
2
3
4
5
1.00 - 1.25 mm (0.0394 - 0.4921 in.)
26.74 mm (1.0528 in.)
3.00 mm (0.1181 in.)
3.15 mm (0.1240 in.)
3.30 mm (0.1299 in.)
3.45 mm (0.1358 in.)
3.60 mm (0.1417 in.)
Reverse clutch
Pack clearance:
Flange thickness
0.60 - 0.82 mm (0.02362 - 0.03228 in.)
Mark
1
2
3
6
7
4
5
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
3.5 mm (0.138 in.)
3.6 mm (0.142 in.)
0305K-11
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 20
Direct clutch & O/D clutch
Pack clearance
Return spring free length
Flange thickness
2nd brake
Pack clearance
Return spring free length
Flange thickness
U/D clutch
Pack clearance
U/D clutch drum bushing inside diameter
Return spring free length
Flange thickness
U/D brake
Pack clearance
Return spring free length
Flange thickness
1st & reverse brake
Pack clearance
Return spring free length
Flange thickness
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
Mark
0
1
STD
Max.
Mark
1
4
5
2
3
2
3
4
5
6
Mark
1
2
3
4
5
6
7
Mark
1
2
3
Mark
1
2
3
4
5
6
7
8
0.61 - 0.83 mm (0.02401 - 0.03268 in.)
25.91 mm (1.0201 in.)
2.5 mm (0.098 in.)
2.6 mm (0.102 in.)
2.7 mm (0.106 in.)
2.8 mm (0.110 in.)
2.9 mm (0.114 in.)
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
0.62 - 0.91 mm (0.0244 - 0.0358 in.)
16.61 mm (0.6539 in.)
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
3.5 mm (0.138 in.)
3.6 mm (0.142 in.)
1.51 - 1.71 mm (0.0594 - 0.0673 in.)
37.06 - 37.08 mm (1.4591 - 1.4598 in.)
37.13 mm (1.4618 in.)
17.14 mm (0.6752 in.)
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
1.81 - 2.20 mm (0.0713 - 0.0866 in.)
14.04 mm (0.5528 in.)
3.0 mm (0.118 in.)
3.2 mm (0.126 in.)
3.4 mm (0.134 in.)
1.16 - 1.35 mm (0.0457 - 0.0531in.)
15.53 mm (0.6114 in.)
1.8 mm (0.071 in.)
1.9 mm (0.075 in.)
2.0 mm (0.079 in.)
2.1 mm (0.083 in.)
2.2 mm (0.087 in.)
2.3 mm (0.091 in.)
2.4 mm (0.094 in.)
2.5 mm (0.098 in.)
03-5
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
21
03-6
U/D planetary gear
Preload (at 60 rpm)
Front planetary gear
Turning torque (at 60 rpm)
Input shaft
End play
Transaxle rear cover
Bearing press fit depth
Transmission valve body
Valve body installation bolt length
Accumulator
Praload (at 60 rpm)
Flange thickness
Spring
B
3
C
2
C
3
Front differential(U151E)
Backlash
Thrust washer thickness
Front differential (U151F)
Side gear backlash
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
Inner
Outer
New Bearing
Used Bearing
0.50 - 1.42 N
⋅ m (5.1 - 14.5 kgf
⋅ cm, 0.06 - 0.17 in.
⋅ lbf)
0.51 - 1.02 N
⋅ m (5.1 - 10.0 kgf
⋅ cm, 4.4 - 8.7 in.
⋅ lbf)
0.26 - 0.51 N
⋅ m (2.7 - 5.2 kgf
⋅ cm, 2.3 - 4.5 in.
⋅ lbf)
0.262 - 1.249 mm (0.0103 - 0.0492 in.)
A
B
C
Free length/Outer diameter
62.00 (2.4409) / 15.50 (0.610)
74.23 (2.9224) / 16.50 (0.649)
60.96 (2.3999) / 14.10 (0.555)
72.20 (2.8425) / 19.0 (0.748)
Mark
-
-
-
New bearing
Used bearing
C
D
E
A
B
8
9
6
7
F
G
H
Mark
0
1
2
3
4
5
20.55 - 21.25 mm (0.8091 - 0.8366 in.)
41 mm (1.614 in.)
57 mm (2.244 in.)
25 mm (0.984 in.)
Color
Purple
Purple
Yellow
Colorless
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
1.625 mm (0.0640 in.)
1.725 mm (0.0679 in.)
1.825 mm (0.0719 in.)
0.20 - 0.69 N
⋅ m (2.0 - 7.0 kgf
⋅ cm, 1.8 - 6.1 in.
⋅ lbf)
0.10 - 0.35 N
⋅ m (1.0 - 3.6 kgf
⋅ cm, 0.9 - 3.1 in.
⋅ lbf)
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 22
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
Thrust washer thickness
= Clearance - 0.162 - 0.265 mm (0.0064 - 0.0104 in.)
Pinion’s backlash
Thrust washer thickness
Mark
A
B
C
D
E
F
G
H
J
K
0.95 mm (0.0373 in.)
1.00 mm (0.0393 in.)
1.05 mm (0.0413 in.)
1.10 mm (0.0433 in.)
1.15 mm (0.0453 in.)
1.20 mm (0.0472 in.)
1.25 mm (0.0492 in.)
1.30 mm (0.0512 in.)
1.35 mm (0.0532 in.)
1.40 mm (0.0552 in.)
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Praload (at 60 rpm)
Flange thickness
Oil seal press in depth
Mark
MA
MB
MC
MD
ME
MF
MG
MH
MJ
MK
ML
MM
MN
New bearing
Used bearing
B
C
D
E
8
9
A
F
G
H
Mark
0
1
2
3
4
5
6
7
0.20 - 0.69 N
0.10 - 0.35 N
⋅
⋅
0.80 mm (0.0313 in.)
0.85 mm (0.0333 in.)
0.90 mm (0.0353 in.)
0.95 mm (0.0373 in.)
1.00 mm (0.0393 in.)
1.05 mm (0.0413 in.)
1.10 mm (0.0433 in.)
1.15 mm (0.0453 in.)
1.20 mm (0.0472 in.)
1.25 mm (0.0492 in.)
1.30 mm (0.0512 in.)
1.35 mm (0.0532 in.)
1.40 mm (0.0552 in.) m (2.0 - 7.0 kgf m (1.0 - 3.6 kgf
⋅
⋅ cm, 1.8 - 6.1 in.
cm, 0.9 - 3.1 in.
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
5.5 - 6.5 mm (0.217 - 0.256 in.)
⋅
⋅ lbf) lbf)
03-7
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
23
03-8
Pawl shaft clamp x Transaxle case
Oil pump assy x Transaxle case
Transaxle housing x Transaxle case
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
TORQUE SPECIFICATION
Part Tightened
Differential gear lube apply tube x Transaxle housing
Front planetary gear lock nut
Brake apply tube clamp x Transaxle case
Transaxle case No. 1 plug x Transaxle rear cover
Transaxle rear cover x Transaxle case
Automatic transmission case plug x Transaxle housing
Automatic transmission case plug x Transaxle case
Parking lock pawl bracket x Transaxle case
Manual detent spring x Transaxle case
Transmission wire x Transaxle housing
Transmission valve body x Transaxle case
ATF temperature sensor clamp x Transmission valve body
Valve body oil strainer assy x Transmission valve body
Automatic transaxle oil pan sub-assy x Transaxle case
Drain plug x Automatic transaxle oil pan sub-assy
Speed sensor x Transaxle case
Oil cooler tube union x Transaxle case
Park/neutral start switch x nut
Park/neutral start switch x Bolt
Park/neutral start switch x Control shaft lever
Speedometer driven hole cover sub-assy x Transaxle case
Oil pump body x Stator shaft assy
Line pressure control solenoid assy x Transmission valve body assy
Shift solenoid valve SL1x Transmission valve body assy
Shift solenoid valve SL2x Transmission valve body assy
Shift solenoid valve SL3x Transmission valve body assy
Shift solenoid valve S4x Transmission valve body assy
Shift solenoid valve DSL x Transmission valve body assy
Front differential case x Front differential ring gear
Bolt A
Other bolt
Bolt A
Bolt B
Bolt C
Bolt D
Bolt A
Bolt B
Union
Elbow
7.4
7.4
20
20
12
5.4
11
6.6
11
7.8
49
11
27
27
6.6
6.6
10.8
6.6
10.8
10.8
95.1
6.9
5.4
13
6.9
9.8
N
⋅ m
9.8
210-350
5.4
7.4
19
25
9.8
22
25
33
29
22
75
75
205
205
120
55
110
67
110
80
500
115
276
276
67
67
110
67
110
110
970
70
55
130
70
100 kgf
⋅ cm
100
2141-3569
55
75
190
250
100
226
255
337
295
226
15
9
48 in.
⋅ lbf
8
58 in
⋅ lbf
8
69 in.
⋅ lbf
36
8
20
20
61 in.
⋅ lbf
48 in.
⋅ lbf
9
61
87 in.
⋅ lbf
58 in.
⋅ lbf
58 in.
⋅ lbf
8
58 in.
⋅ lbf
8
8
70 ft
⋅ lbf
87 in.
⋅ lbf
155-258
48 in.
⋅ lbf
65 in.
⋅ lbf
14
18
87 in.
⋅ lbf
16
18
24
21
16
65 in.
⋅ lbf
65 in.
⋅ lbf
15
0305L-11
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 24
40-1
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
4010I-01
COMPONENTS
U151E:
11.3 (158, 8)
5.4 (55, 48 in.
⋅ lbf)
Transmission Wire
O-Ring
Union
25 (255, 18)
Automatic Transmission
Case Plug
7.4 (75, 65 in.
⋅ lbf) O-Ring
Speed Sensor
Speed Sensor
11.3 (158, 8)
Automatic Transmission
Case Plug
7.4 (75, 65 in.
⋅ lbf)
O-Ring
O-Ring
Elbow
27 (276, 20)
O-Ring
O-Ring
Automatic Transmission
Case Plug
7.4 (75, 65 in.
⋅ lbf)
Drain Plug Gasket
Drain Plug
47 (479, 34)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
C86320
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
25
40-2
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
U151E:
Case Plug
7.4 (75, 65 in.
⋅ lbf)
29 (295, 21)
Transaxle Apply Tube Clamp
9.8 (100, 87 in.
⋅ lbf)
Automatic Transaxle
Case Sub-assy
Transaxle Rear Cover
Bolt A: 18.6 (190, 14)
Other bolt: 24.5 (250, 18) x 11
O-Ring x 8 x 3
O-Ring
33 (337, 24) x 5
Differential Gear
Lube Apply Tube
Spacer
Transaxle Case
2nd Brake Gasket
Governor Apply Gasket
Brake Drum Gasket
25 (255, 18)
Transmission Valve Body Assy
Retainer Spring
Sloted Spring Pin
Manual Valve Lever Shaft
Manual Valve Lever Shaft Oil Seal
5.4 (55, 48 in.
⋅ lbf)
6.9 (70, 61 in.
⋅ lbf)
11 (110, 8)
Valve Body
Oil Strainer Assy x 17
Oil Strainer Gasket
Parking Lock
Rod Sub-assy
Oil Cleaner
Magnet
Park/ Neutral
Position Switch
Parking Lock
Pawl Bracket
Spring
11 (110, 8 )
Check Ball
Body
20 (205, 15)
Automatic Transaxle
Oil Pan Gasket
Manual Detent
Spring Sub-assy
Nut Stopper
Control Shaft Lever
13 (130, 9)
Washer
Compression Spring
C-3 Accumulator
Piston
Compression Spring
Automatic Transaxle
Oil Pan Sub-assy x 18
7.8 (80, 69 in.
⋅ lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Precoated part
20 (205, 15)
O-Ring
11.8 (120, 9)
Reverse Clutch
Accumulator Piston
O-Ring
O-Ring
Compression
Spring
O-Ring B-3 Accumulator
Piston
C89119
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 26
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
40-3
U151E:
Thrust Needle
Roller Bearing
Forward Clutch Assy
Oil Pump Assy
Thrust Needle
Roller Bearing
Counter
Drive Gear
Counter Drive
Gear Bearing
22 (226, 16) x 7
Thrust Needle
Roller Bearing
Washer
O/D Brake gasket
Multiple
Disc Clutch
Clutch Hub
1st & Reverse
Brake Piston
Thrust Bearing
Race No. 1
Snap Ring
Nut
210 (2,141, 155) - 350 (3,569, 258)
Plate
Flange
Front Planetary
Gear Assy
Snap Ring
O-Ring
Brake Hub
Disc
Snap Ring
Flange 1st & Reverse Brake
Return Spring
Plate
Counter Drive
Gear Bearing
Second Brake Piston Assy Front Planetary
Ring Gear
Rear Planetary
Sun Gear Assy
Thrust Bearing Race
1-W ay Clutch Assy
Disc
1-W ay Clutch Sleeve Outer
Snap Ring
Thrust Needle
Roller Bearing
Rear Planetary
Thrust Bearing
Gear Assy
Race No. 2
Snap Ring
Thrust Needle
Roller Bearing
1-W ay Clutch
Planetary Carrier
Inner Race
Planetary Carrier Thrust Needle
Thrust Washer No. 2
Thrust Washer No. 1 Roller Bearing
Input Sun Gear
Thrust Needle
Roller Bearing
Transaxle Rear Cover
Thrust Bearing
Thrust Bearing
Direct Clutch Assy
O/D Direct
Clutch Hub Sub-assy
Thrust Bearing Race
Needle Roller Bearing
Outer Rear Clutch Oil Seal Ring
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
D26457
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
27
40-4
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
U151E:
Underdrive Clutch Assy
Underdrive
Planetary
Gear Assy
Thrust Bearing
Underdrive Race No. 2
Snap Ring
Flange
Plate
Underdrive Brake Piston
Needle Roller
Bearing
Disc
Underdrive 1-Way
Clutch Assy
Bearing Race
Thrust Bearing
Underdrive Clutch
Drum Oil Seal Ring
Snap Ring
O-Ring
Underdrive Brake Return
Spring Sub-assy
Thrust Needle
Roller Bearing
Parking Lock Pawl
Parking Lock Pawl Shaft
9.8 (100, 87 in.
⋅ lbf)
Torsion
Spring
Parking Lock Pawl Pin
Pawl Shaft Clamp
Front Differential Assy
Clutch Apply Tube
Brake Apply Tube
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author:
5.4 (55, 48 in.
⋅ lbf)
Transaxle Apply
Tube Clamp
Governor Apply Gasket No. 1
D26594
Date: 28
U151F:
69 (704, 51)
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
40-5
Gascket
39 (387, 29)
X6
Transmission Wire
5.4 (55, 48 in.
⋅ lbf)
11.3 (158, 8)
Speed Sensor
Speed Sensor
11.3 (158, 8)
Automatic Transmission
Case Plug
7.4 (75, 65 in.
⋅ lbf)
O-Ring
O-Ring
Union
27 (275, 20)
Automatic Transmission
Case Plug
7.4 (75, 65 in.
⋅ lbf)
Elbow
27 (276, 20)
O-Ring
O-Ring
O-Ring
O-Ring
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Automatic Transmission
Case Plug
Drain Plug Gasket
Drain Plug
49 (500, 36)
C86315
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
29
40-6
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
U151F:
Case Plug
7.4 (75, 65 in.
⋅ lbf)
29.4 (300, 21.7)
Transaxle Apply Tube Clamp
9.8 (100, 87 in.
⋅ lbf)
Automatic Transaxle
Case Sub-assy
Transaxle Rear Cover
Bolt A: 18.6 (190, 14)
Other bolt: 24.5 (250, 18) x 11
O-Ring x 8
O-Ring
33 (337, 24) x 3 x 5
Differential Gear
Lube Apply Tube
Spacer
Transaxle Case
2nd Brake Gasket
Governor Apply Gasket
Brake Drum Gasket
25 (255, 18)
Transmission Valve Body Assy
Retainer Spring
Sloted Spring Pin
Manual Valve Lever Shaft
Manual Valve Lever Shaft Oil Seal
5.4 (55, 48 in.
⋅ lbf)
6.9 (70, 61 in.
⋅ lbf)
11 (110, 8)
Valve Body
Oil Strainer Assy x 17
Oil Strainer Gasket
Parking Lock
Rod Sub-assy
Oil Cleaner
Magnet
Park/ Neutral
Position Switch
Parking Lock
Pawl Bracket
Spring
11 (110, 8 )
Check Ball
Body
20.1 (205, 15)
Automatic Transaxle
Oil Pan Gasket
Manual Detent
Spring Sub-assy
Nut Stopper
Control Shaft Lever
13 (130, 9)
Washer
Compression Spring
C-3 Accumulator
Piston
Compression Spring
Automatic Transaxle
Oil Pan Sub-assy x 18
7.8 (80, 69 in.
⋅ lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Precoated part
20 (205, 15)
O-Ring
12 (120, 9)
Reverse Clutch
Accumulator Piston
O-Ring
O-Ring
Compression
Spring
O-Ring B-3 Accumulator
Piston
C89116
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 30
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
40-7
U151F:
Thrust Needle
Roller Bearing
Forward Clutch Assy
Oil Pump Assy
Thrust Needle
Roller Bearing
Counter
Drive Gear
Counter Drive
Gear Bearing
22 (226, 16) x 7
Thrust Needle
Roller Bearing
Washer
O/D Brake gasket
Multiple
Disc Clutch
Clutch Hub
1st & Reverse
Brake Piston
Thrust Bearing
Race No. 1
Snap Ring
Nut
210 (2,141, 155) - 350 (3,569, 258)
Plate
Flange
Front Planetary
Gear Assy
Snap Ring
O-Ring
Brake Hub
Disc
Snap Ring
Flange 1st & Reverse Brake
Return Spring
Plate
Counter Drive
Gear Bearing
Second Brake Piston Assy Front Planetary
Ring Gear
Rear Planetary
Sun Gear Assy
Thrust Bearing Race
1-W ay Clutch Assy
Disc
1-W ay Clutch Outer Sleeve
Snap Ring
Thrust Needle
Roller Bearing
Rear Planetary
Thrust Bearing
Gear Assy
Race No. 2
Snap Ring
Thrust Needle
Roller Bearing
1-W ay Clutch
Planetary Carrier
Inner Race
Planetary Carrier Thrust Needle
Thrust Washer No. 2
Thrust Washer No. 1 Roller Bearing
Input Sun Gear
Thrust Needle
Roller Bearing
Transaxle Rear Cover
Thrust Bearing
Thrust Bearing
Direct Clutch Assy
O/D Direct
Clutch Hub Sub-assy
Thrust Bearing Race
Needle Roller Bearing
Outer Rear Clutch Oil Seal Ring
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
D26457
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
31
40-8
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
U151F:
Underdrive Brake Piston
Needle Roller
Bearing
Underdrive Clutch Assy
Underdrive Planetary
Gear Assy
Snap Ring
Flange
Thrust Bearing
Underdrive Race No. 2
Plate
Disc
Underdrive 1-Way
Clutch Assy
Thrust Bearing Race
Needle Roller Bearing
Underdrive Clutch
Drum Oil Seal Ring
Snap Ring
O-Ring
Underdrive Brake Return
Spring Sub-assy
Thrust Needle
Roller Bearing
Parking Lock Pawl
Parking Lock Pawl Shaft
Torsion
Spring
9.8 (100, 87 in.
⋅ lbf)
Parking Lock Pawl Pin
Pawl Shaft Clamp
Clutch Apply Tube
Brake Apply Tube
Front Differential Assy
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
U151E, U151F A/T REPAIR MANUAL (RM1021U)
5.4 (55, 48 in.
⋅ lbf)
Transaxle Apply
Tube Clamp
Author:
Governor Apply Gasket No. 1
C89125
Date: 32
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
40-9
O-ring
Oil Pump Body Oil Pump Driven Gear
Stator Shaft Assy
9.8 (100, 87 in.
⋅ lbf) x11
Clutch Drum
Oil Seal Ring
Oil Pump Drive Gear
Front Oil Pump Oil Seal
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Apply petroleum jelly
U151E, U151F A/T REPAIR MANUAL (RM1021U)
D03643
Author: Date:
33
40-10
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
Snap Ring
Flange
Disc
Cushion Plate
Plate
Plate
Snap Ring
Flange
Overdrive Direct
Clutch Piston
Overdrive Direct
Clutch Balancer
O-ring
Disc
Snap Ring
Non-reusable part
Overdrive Direct Clutch
Return Spring Sub-assy
Overdrive Direct Clutch
Drum Sub-assy
Intermediate Shaft
D26471
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 34
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
Forward Clutch Return Spring Sub-assy
Forward Clutch Piston Sub-assy
Forward Clutch Drum
Forward Clutch Balancer
Snap Ring
Input Shaft Oil Seal Ring
40-1 1
Flange
Snap Ring
Plate
Non-reusable part
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Disc
C89127
Author: Date:
35
40-12
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
2nd Brake Piston
2nd Brake Cylinder
Snap Ring
2nd Brake Piston Return Spring Sub-assy
O-ring
Non-reusable part
U151E, U151F A/T REPAIR MANUAL (RM1021U)
D26702
Author: Date: 36
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
Cylindrical
Roller Bearing
Inner Race
Parking Lock Gear
40-13
Lock Nut
280 (2,855, 207)
Radial Ball Bearing FR
Differential
Drive Pinion
Underdrive Planetary
Ring Gear
Snap Ring
Counter Driven Gear
Underdrive Planetary Gear
Radial Ball Bearing RR
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
U151E, U151F A/T REPAIR MANUAL (RM1021U)
D03683
Author: Date:
37
40-14
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
Plate
Snap Ring
Flange
Disc
Underdrive Clutch Piston Set
Underdrive Clutch Drum
Non-reusable part
Snap Ring
Underdrive Clutch Piston
Return Spring
O-ring
U151E, U151F A/T REPAIR MANUAL (RM1021U)
D03697
Author: Date: 38
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
40-15
Shift Solenoid Valve SR
Shift Solenoid Valve S4
10.8 (110, 8)
10.8 (110, 8)
6.6 (67, 58 in.
⋅ lbf)
Shift Solenoid Valve SL2
Line Pressure
Control Solenoid Assy
6.6 (67, 58 in.
⋅ lbf)
Shift Solenoid Valve SL3
10.8 (110, 8)
Shift Solenoid Valve DSL
Shift Solenoid Valve SL1
N·m (kgf·cm, ft·lbf) : Specified torque
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
C89117
39
40-16
U151E:
Oil Seal
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
Transaxle Housing
Pin
Differential Pinion Thrust Washer
Differential Pinion Shaft
Differential Side Gear
Differential Side Gear
Thrust Washer
Differential Pinion
Differential Ring Gear
Tapered Roller Bearing FR
Bearing Outer Race
95.1 (970, 70) x14
Differential Case
Oil Seal
Bearing Outer Race
Tapered Roller Bearing RR
Shim
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
U151E, U151F A/T REPAIR MANUAL (RM1021U)
D03761
Author: Date: 40
U151F:
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
40-17
Bearing Race
Differential RH Case
Conical Spring
Center Differential
Side Gear
Oil Seal
Center Differential
Pinion Spider
Center Differential Pinion
95.1 (970, 70)
Center Differential
Pinion Thrust Washer x16
Center Differential
Side Gear Thrust
Washer No.1
Tapered Roller
Bearing
Pin
Front Differential
Pinion Shaft
Front Differential
Side Gear
Front Differential
Pinion Thrust Washer
Front Differential
Pinion Shaft Holder
Front Differential
Case No.2
Pinion Shaft
Spacer Snap
Ring
Front Differential
Pinion Shaft x15
Differential
Intermediate
63 (642, 46)
Case
Front Differential
Side Gear Thrust
Washer
Front Differential
Pinion
Oil Seal
Front Differential
Side Gear Thrust
Washer
Center Differential
Side Gear Thrust
Washer No.2
Differential Ring Gear
Plate Washer
Differential
LH Case
Bearing Race
Conical
Spring
Front Differential
Side Gear Tapered Roller Bearing
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
D03707
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
41
40-18
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
OVERHAUL
1.
REMOVE SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY
(a) Remove the bolt and speedometer driven hole cover sub-assy from the transaxle assy.
(b) Remove the O-ring from the speedometer driven hole cover.
4010K-01
2.
REMOVE PARK/NEUTRAL POSITION SWITCH ASSY
(a) Remove the nut, washer and control shaft lever.
Control Shaft Lever
D09644
(b) Using a screwdriver, unstake the nut stopper, and remove the lock nut and nut stopper.
Lock Nut
Nut Stopper
Park/neutral Position Switch
D09643
(c) Remove the 2 bolts and pull out the park/neutral position switch.
D09639
3.
REMOVE BREATHER PLUG HOSE
(a) Remove the breather plug hose from the transaxle case.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 42
Union
O-ring
40-19
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
4.
REMOVE OIL COOLER TUBE UNION (INLET OIL
COOLER UNION)
(a) Remove the union.
(b) Remove the O-ring from the union.
C83143
5.
REMOVE OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Remove the elbow.
(b) Remove the O-ring from the elbow.
Elbow
O-ring
C83144
6.
REMOVE SPEED SENSOR
(a) Remove the 2 bolts and the 2 speed sensors from the transaxle assy.
Speed Sensor
D03900
D30672
7.
REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 4 transaxle case No. 1 plugs from the transaxle case.
(b) Remove the 4 O-rings from the 4 transaxle case No.1
plugs.
D26716
8.
FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle assy.
D09176
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
43
40-20
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
9.
REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
C91925
(b) Remove the 2 magnets from the oil pan.
Magnet
Magnet
C86316
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
AT0103
11.
DISCONNECT TRANSMISSION WIRE
(a) Remove the 7 connectors from the shift solenoid valves.
(b) Remove the bolt, lock plate and ATF temperature sensor.
Temperature
Sensor
Transmission Wire
C91927
12.
REMOVE TRANSMISSION WIRE
(a) Remove the bolt and transmission wire from the transaxle case.
D03547
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 44
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
13.
REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
40-21
Valve Body Oil
Strainer Assy
C91931
(b) Remove the O-ring from the oil strainer.
O-ring
C91932
14.
REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy and remove the 17 bolts and valve body assy.
C91933
15.
REMOVE GOVERNOR APPLY GASKET NO.1
(a) Remove the governor apply gasket No.1 from the transaxle case.
C83127
16.
REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the transaxle case 2nd brake gasket from the transaxle case.
C83128
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
45
40-22
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
17.
REMOVE BRAKE DRUM GASKET
(a) Remove the brake drum gasket from the transaxle case.
C83129
18.
REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the transaxle case.
Check Ball
D03554
19.
REMOVE C-3 ACCUMULATOR PISTON
(a) Remove the spring from the C-3 accumulator piston.
D03555
(b) Apply compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi) to the oil hole and remove the C-3 accumulator piston.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using a waste cloth.
Take care not to splash ATF when air-blowing.
D03556
(c) Remove the O-ring from the C-3 accumulator piston.
O-ring
C-3 Accumulator Piston
D03902
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 46
40-23
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Reverse clutch Accumulator Piston
D26401
20.
REMOVE REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi) to the oil hole and remove the reverse accumulator piston and spring.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using a waste cloth.
Take care not to splash ATF when air-blowing.
(b) Remove the 2 O-rings from the reverse clutch accumulator piston.
O-ring
O-ring
D26402
D03558
21.
REMOVE B-3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using a waste cloth.
Take care not to splash ATF when air-blowing.
(b) Remove the O-ring from the B-3 accumulator piston.
O-ring
B-3 Accumulator Piston
D03904
22.
REMOVE MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using a needle-nose pliers, remove the manual valve lever shaft retainer spring.
D03559
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
47
40-24
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
23.
REMOVE MANUAL DETENT SPRING SUB-ASSY
(a) Remove the 2 bolts, the manual detent spring sub-assy and cover.
D03560
24.
REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
C56727
25.
REMOVE MANUAL VALVE LEVER SUB-ASSY
(a) Using a chisel and hammer, cut off and remove the spacer.
D03563
(b) Using a pin punch (
φ
35 mm) and hammer, drive out the pin.
HINT:
Slowly drive out the pin so that it will not fall into the transaxle case.
D03564
(c) Remove the manual valve lever shaft and manual valve lever.
D03565
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 48
40-25
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Parking Lock Rod Sub-assy
26.
REMOVE PARKING LOCK ROD SUB-ASSY
(a) Remove the parking lock rod from the manual valve lever.
D26382
27.
REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the transaxle case.
D03566
28.
FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle case with the oil pump side facing up.
29.
INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft endplay.
Endplay: 0.262 - 1.244 mm (0.01 - 0.049 in.)
Oil Pump Assy
D08046
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
49
40-26
U151E:
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
30.
REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.
NOTICE:
Differential may be accidentally removed when the transaxle housing is removed.
U151F:
D25608
Oil Pump Assy
31.
REMOVE OIL PUMP ASSY
(a) Remove the 7 bolts and oil pump from the transaxle case.
D03569
Thrust Needle
Roller Bearing
Differential Gear Assy Forward Clutch Assy
32.
REMOVE THRUST NEEDLE ROLLER BEARING
(a) Remove the thrust needle roller bearing from the underdrive planetary gear assy.
D25505
Thrust Bearing Underdrive Race No.2
Differential
Gear Assy Forward Clutch Assy
33.
REMOVE THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Remove the thrust bearing underdrive race No. 2 from the underdrive planetary gear assy.
Underdrive Planetary Gear Assy
D25506
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 50
40-27
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Differential
Gear Assy
34.
REMOVE DIFFERENTIAL GEAR ASSEMBLY
(a) Remove the differential gear assy from the transaxle case.
D26450
35.
REMOVE OVERDRIVE BRAKE GASKET
(a) Remove the 2 overdrive brake gaskets from the transaxle case.
D03573
Forward Clutch
Assy
36.
REMOVE FORWARD CLUTCH ASSY
(a) Remove the forward clutch assy from the transaxle case.
D03574
Thrust Needle
Roller Bearing
(b) Remove the thrust needle roller bearing from the forward clutch.
D03906
Multiple Disc
Clutch Clutch
Hub
Thrust
Bearing
Race
No.1
Thrust Needle
Roller Bearing
Thrust Needle
Roller Bearing
D26787
U151E, U151F A/T REPAIR MANUAL (RM1021U)
37.
REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Remove the thrust needle roller bearing, multiple disc clutch clutch hub, thrust needle roller bearing and thrust bearing race No.1 from the transaxle case.
Author: Date:
51
40-28
Dial Indicator
Pawl Shaft Clamp
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Forward Clutch Hub
D03829
38.
INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Using a dial indicator, measure the inside diameter of the forward clutch hub bushing
Standard inside diameter:
23.025 - 23.046 mm (0.9065 - 0.9073 in.)
Maximum inside diameter: 23.09 mm (0.9091 in.)
NOTICE:
When the diameter is over the maximum, replace the multiple disc clutch hub with new one.
Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch sub-assy with new one.
If the inside diameter is greater than the maximum, replace the forward clutch hub.
39.
REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Remove the bolt and pawl shaft clamp.
D03576
(b) Remove the parking lock pawl shaft.
D09652
(c) Push the parking lock pawl.
HINT:
Failure to do so will cause interference when the underdrive planetary gear is removed.
D09689
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 52
40-29
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Underdrive
Planetary
Gear Assy
(d) Remove the underdrive planetary gear assy from the transaxle case.
NOTICE:
Be careful so that the underdrive planetary gear assy will not fall out.
D03579
40.
REMOVE PARKING LOCK PAWL
(a) Remove the spring, pawl pin and parking lock pawl.
Thrust Bearing
D26386
Bearing Race
41.
REMOVE UNDERDRIVE CLUTCH ASSY
(a) Remove the underdrive clutch assy, thrust bearing and bearing race from the transaxle case.
D03580
42.
REMOVE UNDERDRIVE 1 WAY CLUTCH ASSY
(a) Using a screwdriver, remove the snap ring from the transaxle case.
Snap Ring
D03581
(b) Remove the underdrive 1-way clutch from the transaxle case.
Underdrive
1-W ay
Clutch
D03627
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
53
40-30
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
(c) Remove the outer race retainer from the 1-way clutch.
Outer Race
Retainer
D03907
Snap
Ring
43.
REMOVE UNDERDRIVE CLUTCH DISC NO.2
(a) Using a screwdriver, remove the snap ring.
D26466
Flange
(b) Remove the flange, 4 discs and 4 plates from the transaxle case.
D26385
D09196
44.
INSPECT UNDERDRIVE CLUTCH DISC NO.2
(a) Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.
NOTICE:
If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes.
45.
REMOVE TRANSAXLE REAR COVER SUB-ASSY
(a) Remove the 11 bolts.
(b) Tap in the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.
D26387
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 54
SST
40-31
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
46.
REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 4 transaxle case No.1 plugs from the transaxle rear cover.
(b) Remove the 4 O-rings from the 4 transaxle case No.1
plugs.
D26388
Rear Clutch
Oil Seal
Ring Outer
47.
REMOVE REAR CLUTCH OIL SEAL RING OUTER
(a) Remove the 3 rear clutch oil seal rings from the transaxle rear cover.
D26389
48.
REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle-roller bearing from the transaxle rear cover.
SST 09387- 00041 (09387- 01021, 09387- 01030,
09387-01040)
D26472
49.
REMOVE GOVERNOR APPLY GASKET NO.1
(a) Using a screwdriver, remove the 3 apply gaskets.
Brake Apply Tube
Clutch Apply Tube
D26391
U151E, U151F A/T REPAIR MANUAL (RM1021U)
D26390
50.
REMOVE BRAKE APPLY TUBE
(a) Remove the bolt, clamp and brake apply tube.
(b) Remove the clutch apply tube.
(c) Remove the brake apply tube from the clamp.
Author: Date:
55
40-32
Thrust Bearing
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
51.
REMOVE DIRECT CLUTCH ASSY
(a) Remove the thrust bearing and the direct clutch assy from the transaxle case.
Direct Clutch Assy
Overdrive Direct Clutch Hub
Thrust Bearing
D26403
52.
REMOVE OVERDREVE DIRECT CLUTCH HUB
SUB-ASSY
(a) Remove the thrust bearing race, thrust bearing and overdrive direct clutch hub from the planetary gear assy.
Thrust Bearing Race
Dial Indicator
D26392
Overdrive
Direct Clutch
Drum Sub-assy
D03829
53.
INSPECT OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the forward clutch hub bushing.
Standard inside diameter:
23.025 - 23.046 mm (0.9065 - 0.9073 in.)
Maximum inside diameter: 23.09 mm (0.9091 in.)
NOTICE:
When the diameter is over the maximum, replace the multiple disc clutch hub with new one.
Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch sub-assy with new one.
If the inside diameter is greater than the maximum, replace the forward clutch hub.
54.
REMOVE REAR PLANETARY SUN GEAR ASSY
(a) Remove the rear planetary sun gear assy from the transaxle case.
Rear Planetary Sun Gear Assy
D26714
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 56
40-33
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Thrust Needle Roller Bearing
(b) Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assy.
Thrust Bearing Race
Planetary
Carrier
Thrust
Washer
No.2
D26404
Rear
Planetary
Sun Gear
D26393
(c) Remove the planetary carrier thrust washer No.2 from the rear planetary sun gear assy.
Thrust Needle
Roller Bearing
55.
REMOVE 1 WAY CLUTCH ASSY
(a) Remove the 1-way clutch assy and the thrust needle roller bearing from the transaxle case.
1-W ay Clutch Assy
D26598
1-W ay
Clutch
Inner Race
(b) Remove the 1-way clutch inner race from the 1-way clutch assy.
1-W ay Clutch
Sleeve Outer
D03909
56.
REMOVE 1WAY CLUTCH SLEEVE OUTER
(a) Remove the 1-way clutch sleeve outer from the transaxle case.
D03589
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
57
40-34
Planetary Carrier
Thrust Washer No.1
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
57.
REMOVE PLANETARY CARRIER THRUST WASHER
NO.1
(a) Remove the planetary carrier thrust washer No.1 from the planetary gear assy.
Snap Ring
D26394
58.
REMOVE 2ND BRAKE CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the transaxle case.
D26395
D26717
59.
INSPECT 2ND BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.
NOTICE:
If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes.
60.
REMOVE SECOND BRAKE PISTON ASSY
(a) Using a screwdriver, remove the snap ring.
Snap Ring
D08058
(b) Remove the second brake piston assy from the transaxle case.
Second Brake
Piston Assy
D26396
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 58
Rear Planetary
Gear Assy
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
61.
REMOVE REAR PLANETARY GEAR ASSY
(a) Using a screwdriver, remove the snap ring.
Snap Ring
40-35
D03616
(b) Remove the rear planetary gear assy from the transaxle case.
Thrust Bearing
Race No.2
D26591
Input
Sun
Gear
62.
REMOVE INPUT SUN GEAR
(a) Remove the 2 thrust needle roller bearings, thrust bearing race No.2 and input sun gear from the transaxle case.
Thrust Needle Roller Bearing
D03873
63.
REMOVE 1ST & REVERSE BRAKE CLUTCH DISC
(a) Remove the flange, 6 discs and 6 plates from the transaxle case.
D26397
D09189
64.
INSPECT 1ST & REVERSE BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.
NOTICE:
If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
59
40-36
Lock Washer
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
65.
REMOVE FRONT PLANETARY GEAR ASSY
(a) Using a chisel and hammer, unstake the lock washer.
NOTICE:
Push down all claws of the washer. Otherwise SST cannot be fully pressed against the nut, and cannot loosen the nut.
SST
D03595
(b) Using SST, remove the nut.
SST 09387-00030, 09387-00080
SST
D03596
(c) Using SST and a press, remove the front planetary gear assy from the counter drive gear.
SST 09950- 60010 (09951- 00450), 09950- 70010
(09951-07100)
D26398
(d) Remove the front planetary gear assy from the brake hub.
Front Planetary
Gear Assy
Brake Hub
Snap Ring
D26763
Front Planetary Ring Gear
66.
REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.
Brake Hub
D03615
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 60
40-37
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
SST
D03600
67.
REMOVE 1ST & REVERSE BRAKE RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring, and compress the return spring with a press.
SST 09387-00070
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Stop the press when the spring sheet is lowered 1 -
2 mm (0.039 - 0.078 in.) from the snap ring groove, to prevent the spring sheet from deforming.
Do not expand the snap ring excessively.
68.
INSPECT 1ST & REVERSE BRAKE RETURN SPRING
SUB-ASSY
(a) Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 17.61 mm (0.6933 in.)
1st & Reverse Brake Piston
C89128
D26405
69.
REMOVE 1ST & REVERSE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi) to the transaxle case to remove 1st & reverse brake piston.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using a waste cloth.
Take care not to splash ATF when air-blowing.
(b) Remove the 2 O-rings from the 1st & reverse brake piston.
O-ring
O-ring
D26713
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
61
40-38
SST
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
SST
70.
REMOVE COUNTER DRIVE GEAR
(a) Using SST and a press, remove the counter drive gear from the transaxle case.
SST 09950- 60010 (09951- 00590), 09950- 70010
(09951-07100)
C89120
(b) As shown in the illustration, tighten 2 bolts evenly and make clearance of approx. 20.0 mm (0.797 in.) between the counter drive gear and the inner race.
Hold
D03602
Turn
(c) Using SST, remove the tapered roller bearing.
SST 09950- 60010 (09951- 00590), 09950- 70010
(09951-07100), 09950-00020, 09950-00030,
09950-4001 1 (09957-04010)
SST
D03603
Snap Ring
71.
REMOVE COUNTER DRIVE GEAR BEARING
(a) Using a snap ring expander, remove the snap ring.
D26467
(b) Using SST and a press, remove the bearing outer race.
SST 09950- 60020 (09951- 00910), 09950- 70010
(09951-07100)
SST
C89121
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 62
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
72.
REMOVE BREATHER PLUG NO.2 (ATM)
40-39
SST
Snap Ring
D26407
73.
REMOVE UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring, and compress the return spring with a press.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Stop the press when the spring sheet is lowered 1 -
2 mm (0.039 - 0.078 in.) from the snap ring groove, to prevent the spring sheet from deforming.
Do not expand the snap ring excessively.
74.
INSPECT UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSY
(a) Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 13.24 mm (0.5213 in.)
Underdrive
Brake Return
Spring
D03806
Underdrive Brake Piston
D30852
75.
REMOVE UNDERDRIVE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi) to the transaxle case to remove the underdrive brake piston.
O-ring
D26406
(b) Remove the 2 O-rings from the underdrive brake piston.
O-ring
D03794
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
63
40-40
Hold
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
SST
76.
REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle-roller bearing from the transaxle case.
SST 09387- 00041 (09387- 01010, 09387- 01030,
09387-01040)
Turn
D03605
77.
REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Remove the 2 oil seal rings from the transaxle case.
Underdrive
Clutch Drum
Oil Seal Ring
D03914
78.
REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 2 transaxle case No. 1 plugs.
(b) Remove the 2 O-rings from the 2 transaxle case No. 1 plugs.
Turn
SST
Hold
D26383
79.
REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the underdrive cylindrical roller bearing from the transaxle case.
SST 09514-3501 1
D03606
Underdrive
Output
Shaft Oil
Seal Ring
80.
REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.
D03915
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 64
Transaxle Apply
Tube Clamp
40-41
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Differential
Gear Lube
Apply Tube
81.
REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing.
D26400
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
65
40-42
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
82.
BEARING POSITION
B
A
C
D
E
F
G
U151E, U151F A/T REPAIR MANUAL (RM1021U)
J
K
H
I
C89118
Author: Date: 66
Mark
J
K
H
I
E
F
G
A
B
C
D
40-43
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Front Race Diameter
Inside / Outside mm (in.)
-
-
-
24.94 (0.982)
-
34.35 (1.352) / 56.57 (2.227)
40.15 (1.581) / 59.25 (2.333)
-
33.02 (1.3) / 45.8 (1.803)
-
-
Thrust Bearing Diameter
Inside / Outside mm (in.)
57.2 (2.252) / 84.96 (3.3449)
37.73 (1.4854) / 58.0 (2.283)
33.85 (1.3327) / 52.2 (2.055)
23.5 (0.925) / 44.0(1.732)
36.3 (1.429) / 51.93 (2.044)
32.45 (1.278) / 56.48 (2.223)
38.65 (1.522) / 59.79 (2.354)
53.6 (2.110) / 69.6 (2.740)
31.85 (1.254) / 57.3 (2.256)
24.79 (0.976) / 39.5 (1.555)
56.3 (2.216) / 75.96 (2.991)
Rear Race Diameter
Inside / Outside mm (in.)
56.4 (2.220) / 83.0 (3.268)
-
-
-
34.5 (1.358) / 48.35 (1.904)
-
38.65 (1.522) / 59.25 (2.332)
-
-
23.6 (0.929) / 37.95 (1.494)
-
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
67
40-44
Transaxle Apply
Tube Clamp
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
83.
INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube and transaxle apply tube clamp with the bolt to the transaxle housing.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 87 in.
⋅ lbf)
NOTICE:
Make sure to insert the pipe to the stopper.
Differential Gear Lube Apply Tube
D26400
84.
INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install the 2 new O-rings to the 2 transaxle case No.1
plugs.
(b) Install the 2 transaxle case No.1 plugs to the transaxle rear cover.
Torque: 7.4 N
⋅ m (75 kgf
⋅ cm, 65 in.
⋅ lbf)
D26383
ATF
Underdrive
Output Shaft
Oil Seal Ring
85.
INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Coat the new oil seal ring with ATF and install it to the transaxle housing.
D03915
SST
D03807
86.
INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, install the underdrive cylindrical roller bearing.
SST 09950- 60020 (09951- 00810), 09950- 70010
(09951-07100)
NOTICE:
Do not apply excessive pressure to it.
ATF
Underdrive
Clutch Drum
Oil Seal Ring
D03914
87.
INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Coat the 2 new oil seal rings with ATF, install them to the transaxle rear cover.
NOTICE:
Do not expand the gap of the oil seal ring too much.
Fix the hooks certainly. Confirm the smooth rotation.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 68
40-45
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Vinyl Tape
SST
88.
INSTALL NEEDLE ROLLER BEARING
(a) Wind a vinyl tape around SST at the place 4.0 mm (0.157
in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.).
NOTICE:
Clean SST to remove deposited oil, before winding a vinyl tape.
(b) Coat the needle roller bearing with ATF.
D03809
SST
(c) Using SST and a press, install the needle-roller bearing to the transaxle case.
SST 09950- 60010 (09951- 00320), 09950- 70010
(09951-07100)
NOTICE:
When the wound vinyl tape contacts the transaxle case, stop press-fitting.
O-ring
D03810
O-ring
89.
INSTALL UNDERDRIVE BRAKE PISTON
(a) Coat the 2 new O-rings with ATF, install them to the underdrive brake piston.
NOTICE:
Assemble the O-ring carefully not to have a twist and a pinching.
Apply enough ATF to the O-ring prior to assembling.
(b) Coat the underdrive brake piston with ATF.
D03794
Underdrive
Brake Piston
(c) Install the underdrive brake piston to the transaxle case.
NOTICE:
Be careful not to damage the O-ring.
D26764
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
69
40-46
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Snap Ring
SST
D26407
90.
INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring and compress the return spring with a press.
SST 09387-00020
(b) Using a snap ring expander, install the snap ring to the transaxle case.
NOTICE:
Stop the press when the spring sheet is lowered 1 -
2 mm (0.039 - 0.078 in.) from the snap ring groove, to prevent the spring sheet from deforming.
Do not expand the snap ring excessively.
Installing the spring sub-assembly, check all of the springs are fit in the piston correctly.
The snap ring should be fixed surely in the groove of the transaxle case.
91.
INSTALL BREATHER PLUG NO.2 (ATM)
SST
C89126
92.
INSTALL COUNTER DRIVE GEAR BEARING
(a) Coat the counterdrive gear bearing with ATF.
(b) Using SST and a press, install the bearing outer race.
SST 09950- 60020 (09951- 01030), 09950- 70010
(09951-07150), 09649-17010
NOTICE:
Do not apply excessive pressure to it.
Press-fit the bearing outer race until it contacts the transaxle case.
(c) Using a snap ring expander, install the snap ring.
NOTICE:
Face the white mark side of the snap ring up.
Snap Ring
SST
D26467
93.
INSTALL COUNTER DRIVE GEAR
(a) Coat the couterdrive gear with ATF.
(b) Using SST and a press, install the tapered roller bearing to the counter drive gear.
SST 09950-70010 (09951-07150), 09649-17010
NOTICE:
Do not apply excessive pressure to it.
D26410
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 70
Counter Drive
Gear
40-47
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
SST
Bearing
(c) Using SST and a press, install the counter drive gear and bearing to the transaxle case.
SST 09223- 15030, 09527- 17011, 09950- 60020
(09951-00750), 09950-70010 (09951-07150)
NOTICE:
Do not apply excessive pressure to it.
SST
1st & Reverse
Brake Piston
O-ring
C89122
O-ring
94.
INSTALL 1ST & REVERSE BRAKE PISTON
(a) Coat the 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st & reverse brake piston.
NOTICE:
Assemble the O-ring carefully not to have a twist and a pinching.
Apply enough ATF to the O-ring prior to assembling.
D26713
(c) Coat a 1st & reverse brake piston with ATF, install it to the transaxle case.
NOTICE:
Be careful not to damage the O-ring.
D26593
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
71
40-48
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
SST
D03600
95.
INSTALL 1ST & REVERSE BRAKE RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring and compress the return spring with a press.
SST 09387-00070
(b) Using a snap ring expander, install the snap ring to the transaxle case.
NOTICE:
Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove, preventing the spring sheet from being deformed.
Do not expand the snap ring excessively.
Installing the spring sub-assembly, check all of the springs are fit in the piston correctly.
The snap ring should be fixed surely in the groove of the cylinder.
Fix the snap ring to the inside of the claw of the spring seat surely.
Front Planetary Ring Gear
96.
INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
NOTICE:
Confirm the snap ring is fixed in the groove of the brake hub correctly.
Snap Ring
Brake Hub
D03615
97.
INSTALL FRONT PLANETARY GEAR ASSY
(a) Install the front planetary gear assy to the brake hub.
Front Planetary
Gear Assy
Brake Hub
D26763
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 72
SST
Counter Drive
Gear
40-49
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
SST
(b) Using SST and a press, press-fit the front planetary gear assy.
SST 09950- 60010 (09951- 00500), 09950- 70010
(09951-07100)
NOTICE:
Do not apply excessive pressure to it.
Press the inner race of LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no pre-load should be applied to one pair of tapered roller bearings (left and right).
2nd Brake Hub w/ Front Planetary
Gear Assy
Transaxle
Case
D03916
(c) Install the new washer, as shown in the illustration.
SST
D03917
(d) Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 210 - 350 N
⋅ m
(2,141 kgf
⋅ cm, 155 ft
⋅ lbf - 3,569 kgf
⋅ cm, 258 ft
⋅ lbf)
NOTICE:
Assemble the washer after pressing each part, then tighten the nut to minimum tightening torque.
D03596
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
73
40-50
Lock Washer
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
SST
D03918
(e) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
SST 09387-00080
Turning torque at 60 rpm:
New Bearing
0.51 - 1.02 N
⋅ m (5.1 - 10.0 kgf
⋅ cm, 4.4 - 8.7 in.
⋅ lbf)
Used Bearing
0.26 - 0.51 N
⋅ m (2.7 - 5.2 kgf
⋅ cm, 2.3 - 4.5 in.
⋅ lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
(f) Tighten the nut gradually until the specified rotation torque of tapered roller bearing is measured.
Torque: 350 N
⋅ m (3,569 kgf
⋅ cm, 258 ft
⋅ lbf) (a limit)
(g) Using a chisel and hammer, stake the front lock washer.
D C
B A
Input Sun Gear
D08074
C89123
98.
INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, the bearing race and the front planetary sun gear to the front planetary gear assy.
NOTICE:
Install the bearing race on the side of the front planetary carrier. Be careful about the orientation of the race.
Installing thrust bearing and front sun gears, be careful about the orientation of the parts.
Install the bearing race on the side of the front sun gear. Be careful about the orientation of the race.
Install the thrust bearing and the race after holding the parts on the rear planetary carrier by applying grease. Be sure the assembling order.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 74
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Thrust bearing and bearing race diameter: mm (in.)
Thrust Bearing, A
Bearing Race, B
Thrust Bearing, C
Bearing Race, D inside
32.5 (1.28)
40.2 (1.583)
38.6 (1.520)
38.6 (1.520) outside
56.5 (2.224)
59.3 (2.335)
59.7 (2.35)
59.3 (2.335)
40-51
99.
INSTALL REAR PLANETARY GEAR ASSY
(a) Install the rear planetary gear assy to the rear planetary ring gear.
Rear Planetary Gear Assy
Snap Ring
D26591
(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm the snap ring is fixed in the groove of the 1st & reverse brake hub correctly.
Disc
D03616
Plate
100. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Be careful about the order of discs, plates and flange assembly.
D26413
A
D26452
101. INSPECT PACK CLEARANCE OF FIRST & REVERSE
BRAKE
(a) Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case(Dimension A).
(b) Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 1.16 - 1.35 mm (0.0457 - 0.0531 in.)
HINT:
Piston stroke = Dimension A -Flange thickness
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
75
40-52
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Flange thickness: mm (in.)
Mark
1
2
3
4
Thickness
1.8 (0.071)
1.9 (0.075)
2.0 (0.079)
2.1 (0.083)
Mark
5
6
7
8
Thickness
2.2 (0.087)
2.3 (0.091)
2.4 (0.094)
2.5 (0.098)
(c) Install the flange.
D03815
102. INSTALL SECOND BRAKE PISTON ASSY
(a) Install the second brake piston assy to the transaxle case.
Second Brake Piston Assy
D26396
Snap Ring
D08058
(b) Install the snap ring and measure the inside diameter.
Inside diameter: More than 167 mm (6.57 in.)
NOTICE:
Because the taper snap ring has the positioning direction, check it when installing.
When the diameter does not meet the specified value, replace the snap ring with new one.
After assembling, confirm that there is no clearance between the second brake cylinder and the fitting surface of the cylinder in the transaxle case.
103. INSTALL 1WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch sleeve outer to the 2nd brake cylinder assy.
NOTICE:
Check the positioning direction of the outer sleeve.
1-W ay Clutch Sleeve Outer
C92977
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 76
1-W ay Clutch
Inner Race
40-53
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
104. INSTALL 1 WAY CLUTCH ASSY
(a) Install the 1-way clutch inner race to the 1-way clutch.
NOTICE:
Check the direction of the inner race.
Confirm that the discrimination mark can be seen by the worker.
D03909
(b) Check the rotating direction of 1-way clutch for the lock or free operation, as shown in the illustration.
Free
Thrust Needle
Roller Bearing
1-W ay Clutch Assy
Planetary Carrier
Thrust Washer No.1
Planetary Carrier Thrust Washer No.2
D09638
D03588
(c) Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer.
Bearing diameter: mm (in.)
Inside Outside
Bearing 53.6 (2.110) 69.4 (2.732)
NOTICE:
Install the thrust bearing properly so that no-colored race will be visible.
105. INSTALL PLANETARY CARRIER THRUST WASHER
NO.1
(a) Coat the planetary carrier thrust washer No. 1 with yellow petrolatum, install it onto the planetary sun gear assy.
NOTICE:
After assembling, confirm that the projection should be fixed surely in the hole of the planetary sun gear assembly.
D26394
106. INSTALL REAR PLANETARY SUN GEAR ASSY
(a) Coat the planetary carrier thrust washer No. 2 with yellow petrolatum, install it onto the rear planetary sun gear.
Rear Planetary Sun Gear
D26393
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
77
40-54
B
A
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
(b) Coat the bearing with yellow petrolatum, install it onto the rear planetary sun gear.
Bearing diameter: mm (in.)
Race, A
Bearing, B
Inside
33.0 (1.299)
31.85 (1.254)
Outside
45.4 (1.787)
45.2 (1.78)
D26404
(c) Install the rear planetary sun gear assy to the rear planetary gear.
NOTICE:
Installing the rear planetary sun gear assembly, confirm that the B1 discs engage.
Disc
Rear Planetary Sun Gear Assy
D26714
107. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 4 plates to the transaxle case.
(c) Temporarily install the snap ring.
Plate
D26412
B
D26453
108. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using a vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).
(b) Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 0.62 - 0.91 mm (0.0244 - 0.0358 in.)
HINT:
Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
Mark
1
2
3
4
Thickness
3.0 (0.118)
3.1 (0.122)
3.2 (0.126)
3.3 (0.130)
Mark
5
6
7
8
Thickness
3.4 (0.134)
3.5 (0.138)
3.6 (0.142)
-
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 78
Snap Ring
40-55
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
(c) Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
NOTICE:
Secure the snap ring so that its gap is visible through the groove of the transaxle case.
B
A
Overdrive Direct
Clutch Hub
D03623
D26392
109. INSTALL OVERDREVE DIRECT CLUTCH HUB
SUB-ASSY
(a) Install the direct clutch hub to the planetary gear assy.
NOTICE:
Be careful not to damage the bush inside of the overdrive clutch hub during instaling.
(b) Coat the thrust bearing with ATF.
(c) Install the bearing race and the thrust bearing to the direct clutch hub.
NOTICE:
Installing the bearing, hold the part on the side of the overdrive clutch hub.
Bearing and race diameter: mm (in.)
Bearing, A
Race, B
Inside
24.7 (0.972)
23.6 (0.929)
Outside
39.5 (1.555)
38.0 (1.496)
Thrust Bearing
Direct Clutch Assy
C
D26403
110. INSTALL DIRECT CLUTCH ASSY
(a) Coat the thrust bearing with ATF.
(b) Install the direct clutch assy and thrust bearing to the rear planetary sun gear assy.
NOTICE:
The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear.
Otherwise, the rear cover can not be installed.
(c) Clean the connecter part of the transaxle case and the rear cover.
(d) As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between transaxle case and the straight edge using vernier calipers (Dimension C).
D26469
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
79
40-56
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
D
D26470
(e) Using vernier calipers and a simple straightedge, measure the position shown in the illustration.
(f) Calculate the end play value using the following formula.
Select a thrust bearing which satisfies the end play value and install it.
End play: 0.244 - 0.901 mm (0.0096 - 0.0355 in.)
NOTICE:
Make sure that the no colored race side is facing the direct clutch assy.
HINT:
End play = Dimension D - Dimension C
Bearing thickness and diameter : mm (in.)
Thickness
3.6 (0.1417)
3.8 (0.1496)
Inside
56.3 (2.217)
56.3 (2.217)
Outside
75.7 (2.980)
75.7 (2.980)
111. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install the 3 new governor apply gaskets No. 1 to the transaxle case.
D26390
112. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.
(b) Install the clutch apply tube.
D03923
Clutch Apply Tube
Brake Apply
Tube
D26391
(c) Install the brake apply tube and a bolt to the transaxle case.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
NOTICE:
Each pipe should be securely inserted until it reaches the stopper.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 80
SST
FIPG
40-57
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
113. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing to the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
D26766
Rear Clutch
Oil Seal
Ring Outer
NOTICE:
Face the inscribed mark side of the bearing race up.
Repeat the press fit until the specified value is obtained.
(b) Coat a needle roller bearing with ATF.
114. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat the 3 new rear clutch oil seal rings with ATF, install them to the transaxle rear cover.
NOTICE:
The snap ring should be fixed certainly in the groove of the drum.
D26389
115. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install the 4 new O-ring to the 4 transaxle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle rear cover.
Torque: 7.4 N
⋅ m (75 kgf
⋅ cm, 65 in.
⋅ lbf)
D26388
D26454
116. INSTALL TRANSAXLE REAR COVER SUB-ASSY
(a) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle case.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent.
NOTICE:
Concerning about the amount of the FIPG application, the amount should be controlled to from even sealing film on entire flange surface and have slight protrusion of the FIPG all around of the connecting area. The FIPG shall be applied continuously on the flange. (Reference value of the section diameter:
φ
1.2)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
81
40-58
Disc
A
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
(c) Apply liquid sealer to the ”A” bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent.
(d) Install the 11 bolts.
Torque:
Bolt A: 19.0 N
⋅ m (190 kgf
⋅ cm, 14 ft
⋅ lbf)
Other bolt: 25.0 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
A
D26387
Flange
Plate
117. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the transaxle case.
NOTICE:
Be careful about the order of discs, plate and flange assembly.
D26414
Snap Ring
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fixed certainly in the groove of the drum.
D26466
D08082
118. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2
, 57 psi).
Pack clearance: 1.81 - 2.20 mm (0.0713 - 0.0866 in.)
HINT:
Select an appropriate flange from the table below so that it will meet the specified value.
Flange thickness: mm (in.)
Mark
1
2
3
Thickness
3.0 (0.118)
3.2 (0.126)
3.4 (0.134)
Mark
4
-
5
Thickness
3.1 (0.122)
3.3 (0.130)
-
(b) Temporally remove the snap ring and attach to the flange.
(c) Restore the snap ring.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 82
Mark
Free
40-59
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
119. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSY
(a) Install the underdrive clutch assy to the 1-way clutch.
(b) Rotate the underdrive clutch assy to check the rotating direction for the lock or free operation.
Free
D03925
120. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSY
(a) Install the outer race retainer to the 1-way clutch.
NOTICE:
Fix the outer race retainer to the external tooth of the one way clutch surely.
Outer Race
Retainer
D03907
Mark
(b) Install the 1-way clutch to the transaxle case.
NOTICE:
Make sure that the mark on the 1-way clutch outer race is visible.
Snap Ring
D03627
(c) Using a screwdriver, install the snap ring to the transaxle case.
NOTICE:
The snap ring should be fixed certainly in the groove of the transaxle case as the gap exists except in the lock of teeth.
D03581
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
83
40-60
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
D03580
121. INSTALL UNDERDRIVE CLUTCH ASSY
(a) Coat the bearing and bearing race with petroleum jelly, install them onto the underdrive clutch.
Bearing and bearing race diameter: mm (in.)
Bearing
Race
Inside
37.73 (1.4854)
29.9 (1.1772)
Outside
58.0 (2.2835)
55.5 (2.185)
(b) Install the underdrive clutch assy to the transaxle case.
NOTICE:
Installing the underdrive clutch drum sub-assy, be sure not to damage the oil seal ring.
Parking Lock Pawl
122. INSTALL PARKING LOCK PAWL
(a) Install the pawl pin and spring to the parking lock pawl.
Spring
Pawl Pin
D09691
(b) Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.
D26386
Underdrive
Planetary
Gear Assy
123. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Install the underdrive planetary gear assy to the transaxle case.
NOTICE:
Engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear assy firmly and assemble them securely.
D03579
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 84
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
(b) Install the parking lock pawl shaft.
40-61
D09693
(c) Install the pawl shaft clamp with the bolt.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 87 in.
⋅ lbf)
Pawl Shaft Clamp
E
D03576
D03875
(d) Using a straight edge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle case and housing (Dimension E).
NOTICE:
Note down the dimension E as it is necessary for the following process.
Dimension (1) Dimension (2)
(e) As shown in the illustration, measure the 2 places of the transaxle housing, calculate the dimension F using the formula.
NOTICE:
Note down the dimension F as it is necessary for the following process.
HINT:
Dimension F = Dimension (1) - Dimension (2)
D25511
Thrust Bearing Race No.1
124. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the thrust bearing race No.1 to the transaxle case while checking its direction.
Bearing race diameter: mm (in.)
Bearing race
Inside
39.5 (1.555)
Outside
45.8 (1.803)
D08087
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
85
40-62
Thrust Needle
Roller Bearing
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Multiple Disc
Clutch Clutch
Hub
(b) Coat the thrust needle roller bearing and race with yellow petrolatum, install them onto the multiple disc clutch hub.
Thrust bearing and race diameter: mm (in.)
Thrust Bearing
Inside
36.4 (1.433)
(c) Coat the needle roller bearing with ATF.
Outside
52.2 (2.055)
Thrust Needle
Roller Bearing
D26710
Multiple Disc
Clutch Clutch
Hub
(d) Install the needle roller bearing to the multiple clutch hub.
Bearing diameter: mm (in.)
Bearing
Inside
23.6 (0.929)
Outside
44 (1.732)
(e) Install the multiple clutch hub to the transaxle case.
D26711
Thrust Needle
Roller Bearing
D03820
125. INSTALL FORWARD CLUTCH ASSY
(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward clutch.
Thrust bearing diameter: mm (in.)
Inside Outside
Thrust Bearing 33.58 (1.3220) 51.9 (2.043)
NOTICE:
Install the thrust bearing properly so that the no colored race or blue ink jet race will be visible.
Forward Clutch Assy
(c) Install the forward clutch to the forward clutch assy.
NOTICE:
Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.
Be careful not to damage the bush inside of the forward clutch hub during installing.
D03574
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 86
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
126. INSTALL OVERDRIVE BRAKE GASKET
(a) Install the 2 new overdrive brake gaskets.
40-63
D03573
Differential
Gear Assy
127. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assy to the transaxle case.
Thrust Bearing
Underdrive
Race No.2
D26450
Underdrive Planetary
Gear Assy
Forward Clutch
Assy
128. INSTALL THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Install the thrust bearing underdrive race No.2 to the underdrive planetary gear assy.
Differential Gear Assy
D25506
Thrust
Needle
Roller Bearing
Differential Gear Assy
Underdrive Planetary
Gear Assy
Forward Clutch
Assy
D25505
129. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following formula and values of Dimension E and F that ware measured when installing cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and install it.
End play: 0.498 - 0.993 mm (0.01961 - 0.03909 in.)
HINT:
End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 in.) - underdrive thrust bearing race No.
2 thickness.
Race thickness: mm (in.)
F - E
Less than 7.72 (0.3039)
7.72 (0.3039)
Thickness
3.5 (0.138)
3.8 (0.150)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
87
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AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Bearing and bearing race diameter: mm (in.)
Bearing
Bearing race
Inside
57.2 (2.252)
56.4 (2.22)
Outside
84.96 (3.345)
83 (3.268)
130. INSTALL OIL PUMP ASSY
(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22.0 N
⋅ m (226 kgf
⋅ cm, 16 ft
⋅ lbf)
D03569
(b) Coat the O-ring of oil pump with ATF.
NOTICE:
Confirm the input shaft rotates smoothly with the manual operation after assembling the oil pump.
O-ring
D03629
FIPG
Seal Bend Width 1.2 mm (0.047 in.)
D03630
131. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and be careful not to get oil on the contacting surface of the transaxle case or transaxle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 88
2WD:
C
C
4WD:
C
C
C
C
C
40-65
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
B
A
A
B
B
D
A
B
D25608
(c) Install the transaxle housing and 16 bolts to the transaxle case.
HINT:
Torque:
Bolt A: 25 N
⋅ m (255 kgf
⋅ cm, 18 ft
⋅ lbf)
Bolt B: 33 N
⋅ m (337 kgf
⋅ cm, 24 ft
⋅ lbf)
Bolt C: 29 N
⋅ m (295 kgf
⋅ cm, 21 ft
⋅ lbf)
Bolt D: 22 N
⋅ m (226 kgf
⋅ cm, 16.0 ft
⋅ lbf)
Apply seal packing or equivalent to the bolt A and D.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)
NOTICE:
Because the bolt A is a seal bolt, apply the seal packing to new bolts and tighten them within 10 minutes after application.
132. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft end play.
End play: 0.262 - 1.249 mm (0.0100 - 0.0494 in.)
D08091
133. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle assy.
SST
D03631
134. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST 09950- 60010 (09951- 00230), 09950- 70010
(09951-07100)
Oil seal drive in depth: 0 0.5 mm (0 0.0197 in.)
D26468
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
89
40-66
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Parking Lock Rod Sub-assy
135. INSTALL PARKING LOCK ROD SUB-ASSY
(a) Install the parking lock rod to the manual valve lever.
D26382
Spacer
136. INSTALL MANUAL VALVE LEVER SUB-ASSY
(a) Install a new spacer and manual valve lever shaft to the transaxle case.
NOTICE:
Do not damage on the oil seal during assembling the shaft to the transaxle case.
D03565
(b) Using a pin punch and hammer, drive in a new pin.
D03564
(c) Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the small hole.
(e) Check that the spacer does not turn.
D26765
137. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, install the retainer spring.
NOTICE:
Hang the spring on the shaft certainly.
D03559
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 90
ATF
40-67
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
138. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 N
⋅ m (205 kgf
⋅ cm, 15 ft
⋅ lbf)
Bolt length: 25 mm (0.984 in.)
NOTICE:
Be sure the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is assembled.
D03561
B
A
D03560
139. INSTALL MANUAL DETENT SPRING SUB-ASSY
(a) Install the manual detent spring with the 2 bolts.
NOTICE:
Make sure to install the manual detent spring and cover in this order.
HINT:
Tighten them in the order, A and B.
Torque:
Bolt A: 20 N
⋅ m (205 kgf
⋅ cm, 15 ft
⋅ lbf)
Bolt B: 12 N
⋅ m (120 kgf
⋅ cm, 9 ft
⋅ lbf)
Bolt length:
Bolt A: 27 mm (1.063 in.)
Bolt B: 16 mm (0.630 in.)
B-3 Accumulator Piston
O-ring
140. INSTALL B-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, install it to the B-3 accumulator piston.
NOTICE:
Install the O-ring to the accumulator piston and the accumulator sleeve not to have a twist and a protrusion. Moreover, apply enough ATF prior to assembling. Be sure to the installed position.
D03904
D25512
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with checking of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)
Inner 62.00 (2.4409) /
15.50 (0.610)
Outer 74.23 (2.9224) /
21.70 (0.854)
Color
Purple
Purple
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
91
40-68
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Reverse clutch Accumulator Piston
O-ring
O-ring
D26402
141. INSTALL REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Coat the 2 new O-rings with ATF, install them to the reverse accumulator piston.
NOTICE:
Install the O-ring to the accumulator piston and the accumulator sleeve not to have a twist and a protrusion. Moreover, apply enough ATF prior to assembling. Be sure to the installed position.
ATF
C-3 Accumulator Piston
C92978
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with checking of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)
60.96 (2.3999) /
14.10 (0.555)
Color
Yellow
O-ring
142. INSTALL C-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, install it to the C-3 accumulator piston.
NOTICE:
Install the O-ring to the accumulator piston and the accumulator sleeve not to have a twist and a protrusion. Moreover, apply enough ATF prior to assembling. Be sure to the installed position.
D03902
C83146
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with checking of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)
72.20 (2.8425) /
19.0 (0.748)
Color
Colorless
(c) Install the spring from the C-3 accumulator piston.
NOTICE:
Install the springs to each accumulator piston with checking of the identification color or each spring.
D03555
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 92
40-69
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
143. INSTALL CHECK BALL BODY
(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTICE:
Regarding the installation of the spring for the check ball body, be sure to place the spring in the hole in the ball body.
Be careful about the parts orientation.
Check Ball
D03554
144. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, install it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case brake gasket when inserting the gasket to the case. Moreover, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
C83129
145. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with ATF, install it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case brake gasket when inserting the gasket to the case. Moreover, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
C83128
146. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Coat a new governor apply gasket No. 1 with ATF, install it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case brake gasket when inserting the gasket to the case. Moreover, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
C83127
ATF
D03636
U151E, U151F A/T REPAIR MANUAL (RM1021U)
147. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, install it to the transmission wire.
NOTICE:
Be careful about the O-ring not to have a twist, a protrusion and a pinching during installing the wire transmission to the transaxle case. Moreover, apply enough ATF to the Oring prior to assembling.
Author: Date:
93
40-70
Transmission Wire
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
(b) Install the transmission wire retaining bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
B
A
C
D03547
B
A
G F E
C
A
D
C
B
C91927
C91933
148. CONNECT TRANSMISSION WIRE
(a) Coat a O-ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor, with the lock plate and bolt.
Torque: 6.6 N
⋅ m (67 kgf
⋅ cm, 58 in.
⋅ lbf)
(c) Connect the 7 solenoid connectors.
NOTICE:
Connect the connector to A, B, C, D, E, F, G, from shorter one.
Apply ATF to the bolt.
149. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Make sure that the manual valve lever position, install the valve body with 17 bolts to the transaxle case.
Torque: 11 N
⋅ m (110 kgf
⋅ cm, 8 ft
⋅ lbf)
Bolt length:
Bolt A: 41 mm (1.614 in.)
Bolt B: 57 mm (2.244 in.)
Bolt C: 25 mm (0.984 in.)
NOTICE:
Push the valve body against the accumulator piston spring and the check ball body to install it.
When installing the valve body to the transaxle case, do not hold the solenoids.
Tighten temporarily those bolts marked by in the illustration first because they are positioning bolts.
150. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O-ring with ATF, install it to the oil strainer.
NOTICE:
Assemble the O-ring carefully not to have a twist and a pinching. Moreover, apply enough ATF to the O-ring prior to assembling.
O-ring
C91932
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 94
Speed Sensor
40-71
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
Valve Body Oil
Strainer Assy.
(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 N
⋅ m (110 kgf
⋅ cm, 8 ft
⋅ lbf)
NOTICE:
Apply ATF to the bolts.
C91931
Magnet
151. INSTALL AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
C86316
C91925
(c) Install the new oil pan gasket with the 18 bolts to the transaxle case.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
NOTICE:
Because the bolts should be seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application.
Remove any oil or grease from the contacting surface of the transaxle case and the oil pan with the gasket completely before the oil pan to the case.
152. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat the 4 new O-rings with ATF, install them to the 4 transaxle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle case.
Torque: 7.4 N
⋅ m (75 kgf
⋅ cm, 65 in.
⋅ lbf)
D26716
153. INSTALL SPEED SENSOR
(a) Install them to the 2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2 bolts.
Torque: 11.0 N
⋅ m (115 kgf
⋅ cm, 8 ft
⋅ lbf)
D03900
D30672
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
95
40-72
Elbow
O-ring
Union
O-ring
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
154. INSTALL OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 N
⋅ m (276 kgf
⋅ cm, 20 ft
⋅ lbf)
C83144
155. INSTALL OIL COOLER TUBE UNION (INLET OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the union.
(b) Install the union to the transaxle case.
Torque: 25 N
⋅ m (255 kgf
⋅ cm, 18 ft
⋅ lbf)
C83143
156. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose into the transaxle case certainly.
157. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 N
⋅ m (70 kgf
⋅ cm, 61 in.
⋅ lbf)
D09639
(c) Temporarily install control shaft lever.
Control Shaft Lever
D09640
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 96
40-73
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
(d) Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
(e) Remove the control shaft lever.
D09641
(f) Align the groove with neutral basic line.
(g) Tighten the 2 bolts.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
D09642
(h) Using a screwdriver, stake the nut with the nut stopper.
D09643
(i) Install the control shaft lever, washer and nut.
Torque: 13 N
⋅ m (130 kgf
⋅ cm, 9 ft
⋅ lbf)
D09644
158. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY
(a) Coat a new O-ring with ATF and install it to the speedometer driven hole cover.
(b) Install the bolt and speedometer driven hole cover sub-assy to the transaxle assy.
Torque: 6.9 N
⋅ m (70 kgf
⋅ cm, 61 ft
⋅ lbf)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
97
40-74
AUTOMATIC TRANSMISSION / TRANS OIL PUMP ASSY (U151E/U151F)
OVERHAUL
4006F-03
1.
INSPECT OIL PUMP ASSY
(a) Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.
D09205
Clutch
Drum Oil
Seal Ring
2.
REMOVE CLUTCH DRUM OIL SEAL RING
(a) Remove the 2 clutch drum oil seal rings.
D03650
3.
REMOVE STATOR SHAFT ASSY
(a) Using a torx socket (T30), remove the 11 bolts and stator shaft.
(b) Keep the gears in assembling order.
Oil Pump Drive Gear
D03651
Oil Pump
Driven Gear
D09207
4.
INSPECT CLEARANCE OF OIL PUMP ASSEMBLY
(a) Push the driven gear to one side of the body.
(b) Using a feeler gauge, measure the clearance.
Standard body clearance:
0.10 - 0.17 mm (0.0039 - 0.0067 in.)
Side clearance: 0.02 - 0.05 mm (0.001 - 0.02 in.)
Maximum body clearance: 0.17 mm (0.0067 in.)
If the body clearance is greater than the maximum, replace the oil pump body sub-assy.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 98
40-75
AUTOMATIC TRANSMISSION / TRANS OIL PUMP ASSY (U151E/U151F)
(c) Using a feeler gauge measure the tip clearance between the driven gear teeth and drive gear teeth.
Standard tip clearance:
0.07 - 0.15 mm (0.0028 - 0.0059 in.)
Maximum tip clearance: 0.15 mm (0.0059 in.)
If the tip clearance is greater than the maximum, replace the oil pump body sub-assy.
D09208
D09209
(d) Using a straight edge and feeler gauge, measure the side clearance of both gears.
Standard side clearance:
0.02 - 0.05 mm (0.0008 - 0.0020 in.)
Maximum side clearance: 0.05 mm (0.0020 in.)
Drive gear thickness: mm (in.)
Mark
A
B
C
D
E
Thickness
11.690 - 11.699 (0.4602 - 0.4606)
11.700 - 11.709 (0.4606 - 0.4610)
11.710 - 11.720 (0.4610 - 0.4614)
11.721 - 11.730 (0.4615 - 0.4618)
11.731 - 11.740 (0.4619 - 0.4622)
Driven gear thickness: mm (in.)
Mark
A
B
C
D
E
Thickness
11.690 - 11.699 (0.4602 - 0.4606)
11.700 - 11.709 (0.4606 - 0.4610)
11.710 - 11.720 (0.4610 - 0.4614)
11.721 - 11.730 (0.4615 - 0.4618)
11.731 - 11.740 (0.4619 - 0.4622)
5.
REMOVE FRONT OIL PUMP DRIVE GEAR
(a) Remove the front oil pump drive gear.
D09206
6.
REMOVE FRONT OIL PUMP DRIVEN GEAR
(a) Remove the front oil pump driven gear.
D09206
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
99
40-76
O-ring
AUTOMATIC TRANSMISSION / TRANS OIL PUMP ASSY (U151E/U151F)
7.
REMOVE FRONT OIL PUMP BODY O-RING
(a) Using a screwdriver, remove the O-ring.
HINT:
Tape the screwdriver before use.
SST
D25586
8.
REMOVE FRONT OIL PUMP OIL SEAL
(a) Mount oil pump in a soft jaw vise.
(b) Using SST, remove the oil seal from the oil pump body.
SST 09308-00010
SST
D03647
D03648
9.
INSPECT FR OIL PUMP & GEAR BODY SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the oil pump body bushing.
Standard inside diameter:
38.113 - 38.138 mm (1.50051 - 1.50149 in.)
Maximum inside diameter: 38.188 mm (1.50346 in.)
If the inside diameter is greater than the maximum, replace the oil pump body sub-assy.
10.
INSPECT STATOR SHAFT ASSY
(a) Using a dial indicator, measure the inside diameter of the stator shaft.
Standard inside diameter:
21.500 - 21.526 mm (0.84646 - 0.84748 in.)
Maximum inside diameter: 21.57 mm (0.8492 in.)
If the indicator diameter is greater than maximum, replace the stator shaft.
D03653
11.
INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST and a hammer, install a new oil seal to the oil pump body.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flat with the outer edge of the oil pump.
(b) Coat the lip of the oil seal with MP grease.
D03654
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 100
O-ring
Oil Pump
Driven
Gear
40-77
AUTOMATIC TRANSMISSION / TRANS OIL PUMP ASSY (U151E/U151F)
12.
INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat the new O-ring with ATF, install it to the oil pump body.
NOTICE:
Assemble the O-ring carefully not to have a twist and a pinching. Moreover, apply enough ATF to the O-ring prior to assembling.
C55817
Mark
13.
INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, install it to the oil pump body with the marked side up.
D09206
Mark
Oil
Pump
Drive
Gear
14.
INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, install it to the oil pump body with the marked side up.
D09206
15.
INSTALL STATOR SHAFT ASSY
(a) Set the stator shaft aligned with each bolt hole.
(b) Using a torx socket (T30), install the 11 bolts.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 87 in.
⋅ lbf)
Clutch Drum
Oil Seal Ring
D03651
16.
INSTALL CLUTCH DRUM OIL SEAL RING
(a) Coat the 2 new clutch drum oil seal rings with ATF.
(b) Install the 2 new clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.
D26627
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
101
40-78
AUTOMATIC TRANSMISSION / TRANS OIL PUMP ASSY (U151E/U151F)
17.
INSPECT OIL PUMP ASSY
(a) Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.
D09205
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 102
40-79
AUTOMATIC TRANSMISSION / TRANS FORWARD CLUTCH ASSY (U151E/U151F)
OVERHAUL
400H1-02
1.
INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil pump.
(b) Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2
, 57 psi).
Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
If the clearance is not within standard, inspect the discs, plates and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the compressed air from being released.
D26715
2.
REMOVE FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
Snap Ring
D26753
(b) Remove the flange, 5 discs and 5 plates from the input shaft assy.
D26754
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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103
40-80
Snap Ring
AUTOMATIC TRANSMISSION / TRANS FORWARD CLUTCH ASSY (U151E/U151F)
SST
D09189
D26418
3.
INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.
HINT:
If the lining of the disc comes off or discolors, or even if replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes.
4.
REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the spring retainer and compress the return spring with a press.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Stop the press when the spring sheet is lowered 1 -
2 mm (0.039 - 0.078 in.) from the snap ring groove, preventing the spring sheet from deforming.
Do not expand the snap ring excessively.
Clutch
Balancer
(c) Remove the clutch balancer from the input shaft.
Input Shaft
Forward Clutch
Return Spring
D26709
(d) Remove the forward clutch return spring from the input shaft.
Input Shaft
D26708
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 104
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AUTOMATIC TRANSMISSION / TRANS FORWARD CLUTCH ASSY (U151E/U151F)
5.
INSPECT FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 26.74 mm (1.0528 in.)
Forward Clutch Return Spring
D09211
D03664
6.
REMOVE FORWARD CLUTCH PISTON SUB-ASSY
(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil pump to remove the forward clutch piston.
HINT:
When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed, or remove the piston using the needle nose plier with vinyl tape on the tip.
7.
REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the input shaft oil seal ring to the input shaft.
A
C56374
D25587
8.
INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress the new input shaft oil seal ring from both sides to reduce dimension A.
Dimension A: 5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the input shaft.
NOTICE:
Do not expand the gap of the oil seal ring too much. Fix the hooks certainly.
9.
INSTALL FORWARD CLUTCH PISTON SUB-ASSY
(a) Coat the forward clutch piston with ATF, and install it to the input shaft.
NOTICE:
Be careful not to damage the lip seal of the forward clutch piston.
Forward Clutch Piston
D26707
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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105
40-82
Forward Clutch
Return Spring
Clutch Balancer
AUTOMATIC TRANSMISSION / TRANS FORWARD CLUTCH ASSY (U151E/U151F)
Input Shaft
10.
INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Install the return spring to the input shaft.
NOTICE:
Installing the spring sub- assembly, check all of the springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
D26708
Input Shaft
(c) Install the clutch balancer to the input shaft.
NOTICE:
Be careful not to damage the lip seal of the forward clutch balancer.
Install the clutch balancer carefully not to have a pinching and any other defects at the sealing lip.
Apply enough ATF to the sealing lip prior to assembling.
D26709
SST
Snap Ring
D26418
(d) Place SST on the clutch balancer, and compress the clutch balancer with a press.
SST 09387-00020
(e) Install the snap ring with a snap ring expander.
(f) Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
NOTICE:
Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
Stopper Stopper
(g) Set the end gap of the snap ring in the piston shown in the illustration.
NOTICE:
The end gap of the snap ring should not coincide with any of the stoppers.
D26788
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 106
Disc
40-83
AUTOMATIC TRANSMISSION / TRANS FORWARD CLUTCH ASSY (U151E/U151F)
Flange
Plate
11.
INSTALL FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Coat the 5 discs with ATF.
(b) Install the 5 plates, 5 discs and flange input shaft.
NOTICE:
Be careful about the order of discs, plates and flange assembly.
D26415
Snap Ring
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the drum.
D26753
12.
INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air
(392 kgf
⋅ cm
2
, 4.0 kPa, 57 psi).
Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
If the piston stroke is less than the minimum, parts may have been assembled incorrectly. Check and reassemble again.
If the clearance is not standard, select another flange.
HINT:
There are 5 different flanges in thickness.
Flange thickness: mm (in.)
No.
1
2
3
Thickness
3.00 (0.1181)
3.15 (0.1240)
3.30 (0.1299)
No.
4
-
5
Thickness
3.45 (0.1358)
3.60 (0.1417)
-
D26715
13.
INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the forward clutch assy after inserting the multiple disc clutch into it.
NOTICE:
Do not place the forward clutch assy in a vise.
D03672
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
107
40-84
AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U151E/U151F)
OVERHAUL
400H2-02
1.
INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft and needle roller bearing on the transaxle rear cover .
(b) Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2
, 57 psi).
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
If the pack clearance is not within standard, inspect the discs, plates and flange.
D26426
2.
INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi).
Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)
If the pack clearance is not within standard, inspect the discs, plates and flange.
D26427
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 108
40-85
AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U151E/U151F)
3.
REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Using a screwdriver, remove the snap ring from the intermediate shaft.
Snap Ring
D26419
(b) Remove the flange, 3 discs,, 3 plates and cushion plate from the intermediate shaft.
D26420
D26718
4.
INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.
HINT:
If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes.
5.
REMOVE OVERDRIVE DIRECT CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the intermediate shaft.
(b) Remove the flange, 4 discs and 4 plates from the intermediate shaft.
D26422
D26719
6.
INSPECT OVERDRIVE DIRECT CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.
HINT:
If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
109
40-86
Direct Clutch
Drum
AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U151E/U151F)
SST
D03677
7.
REMOVE OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the clutch balancer and compress the spring with a press.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring from the direct clutch drum.
NOTICE:
Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the direct clutch drum.
Clutch
Balancer
D26424
Overdrive
Clutch Return
Spring
(d) Remove the overdrive clutch return spring from the direct clutch drum.
Direct Clutch
Drum
Overdrive Clutch
Return Spring
D26423
8.
INSPECT OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 25.91 mm (1.0201 in.)
D09211
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 110
40-87
AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U151E/U151F)
9.
REMOVE OVERDRIVE DIRECT CLUTCH PISTON
(a) Install intermediate shaft on the transaxle rear cover.
(b) Holding the direct clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi) to the transaxle rear cover to remove the direct clutch piston.
D26463
10.
REMOVE OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY
(a) Holding the direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the transaxle rear cover to remove the direct clutch drum.
O-ring
D26425
11.
REMOVE OVERDRIVE DIRECT CLUCH O-RING
(a) Using a screwdriver, remove the O-ring from the direct clutch drum.
O-ring
D26464
12.
INSTALL OVERDRIVE DIRECT CLUCH O-RING
(a) Coat a O-ring with ATF, and install it to the direct clutch drum.
NOTICE:
Assemble the O-ring carefully not to have a twist and a pinching.
D26464
Intermediate
Shaft
Direct Clutch
Drum
D26462
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13.
INSTALL OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY
(a) Coat the direct clutch drum with ATF, and install it to the intermediate shaft.
NOTICE:
Be careful not to damage the O-ring.
Be careful not to damage the lip seal of the direct clutch drum.
Author: Date:
111
40-88
Clutch
Balancer
AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U151E/U151F)
Overdrive Direct
Clutch Piston
14.
INSTALL OVERDRIVE DIRECT CLUTCH PISTON
(a) Apply the overdrive direct clutch piston with ATF, and install it to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch piston.
D26461
Overdrive
Clutch Return
Spring
15.
INSTALL OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Install the piston return spring to the direct clutch drum.
NOTICE:
Installing the spring sub- assembly, check all of the springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
D26423
Direct Clutch
Drum
(c) Install the clutch balancer to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch balancer.
Install the clutch balancer carefully not to have a pinching and any other defects at the sealing lip.
Apply enough ATF to the sealing lip prior to assembling.
D26424
SST
D03677
(d) Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09387-00020
(e) Using a snap ring expander, install the snap ring to the direct clutch drum.
(f) Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
NOTICE:
Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring grove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 112
Stopper
40-89
AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U151E/U151F)
Stopper
(g) Set the end gap of the snap ring in the piston shown in the illustration.
NOTICE:
The end gap of the snap ring should not coincide with any of the stoppers.
Flange
Plate
Flange
Plate
Cushion
Plate
D25588
Disc
16.
INSTALL OVERDRIVE DIRECT CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the intermediate shaft.
NOTICE:
Be careful about the order of discs, plates and flange assembly.
D26417
Snap Ring
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the drum.
D26421
Disc
D26416
Snap Ring
17.
INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Apply the 3 discs with ATF.
(b) Install the cushion plate, 3 plates, 3 discs and flange to the intermediate shaft.
NOTICE:
Install the cushion plate with the mark on the white surface facing to plate.
Be careful about the order of discs, plates and flange assembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the drum.
D26419
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113
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AUTOMATIC TRANSMISSION / TRANS DIRECT CLUTCH ASSY (U151E/U151F)
18.
INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft on the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2
, 57 psi).
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 6 flanges of different thickness.
Flange thickness: mm (in.)
No.
1
2
3
4
Thickness
3.0 (0.118)
3.1 (0.122)
3.2 (0.126)
3.3 (0.130)
No.
5
6
7
-
Thickness
3.4 (0.134)
3.5 (0.138)
3.6 (0.142)
-
D26426
19.
INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi).
Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 7 flanges in different thickness.
Flange thickness: mm (in.)
No.
0
1
2
3
Thickness
2.5 (0.098)
2.6 (0.102)
2.7 (0.106)
2.8 (0.110)
No.
4
-
5
6
Thickness
2.9 (0.114)
3.0 (0.118)
3.1 (0.122)
-
D26427
(b) Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.
D26428
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 114
40-91
AUTOMATIC TRANSMISSION / TRANS SECOND BRAKE PISTON ASSY (U151E/U151F)
OVERHAUL
SST
4006I-03
1.
REMOVE 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring and compress.
SST 09387-00060
(b) Using a screwdriver, remove the snap ring.
D26703
(c) Remove the 2nd brake piston return spring.
2nd Brake Piston
Return Spring
2nd Brake Piston
Return Spring
D26704
2.
INSPECT 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 16.61 mm (0.6539 in.)
C89124
3.
REMOVE 2ND BRAKE PISTON
(a) Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
D26705
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Author: Date:
115
40-92
2nd Brake Piston
Return Spring
AUTOMATIC TRANSMISSION / TRANS SECOND BRAKE PISTON ASSY (U151E/U151F)
4.
REMOVE 2ND BRAKE PISTON O-RING
(a) Remove the 2 O-rings from the 2nd brake piston.
O-ring
O-ring
O-ring
D26706
5.
INSTALL 2ND BRAKE PISTON O-RING
(a) Apply the 2 new O-rings with ATF, install them in the 2nd brake piston.
NOTICE:
Assemble the O-ring carefully not to have a twist and a pinching.
O-ring
D26706
6.
INSTALL 2ND BRAKE PISTON
(a) Apply the 2nd brake piston with ATF, and install it to the
2nd brake cylinder.
NOTICE:
Be careful not to damage the O-ring.
D26775
7.
INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Install the 2nd brake piston return spring.
NOTICE:
Installing the spring sub- assembly, check all of the springs are fit in the piston correctly.
D26704
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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AUTOMATIC TRANSMISSION / TRANS SECOND BRAKE PISTON ASSY (U151E/U151F)
SST
D26703
(b) Place SST on the piston return spring, and compress the piston return spring with a press.
SST 09387-00060
(c) Using a screwdriver, install the snap ring.
(d) Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
NOTICE:
Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove.
This prevents the spring sheet from being deformed.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
117
40-94
AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE CLUTCH ASSY (U151E/U151F)
OVERHAUL
400H3-02
1.
INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/ cm
2
, 57 psi).
Pack clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
If the pack clearance is not within standard, inspect the discs, plates and flange.
D26429
Snap Ring
2.
REMOVE UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive clutch flange
No.2 snap ring.
D03701
Underdrive
Clutch Drum
3.
REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Remove the flange, 4 discs and 4 plates from the underdrive clutch drum.
D26430
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 118
Clutch
Balancer
40-95
AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE CLUTCH ASSY (U151E/U151F)
4.
INSPECT UNDERDRIVE CLUTCH DISC NO.1
(a) Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.
HINT:
If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes.
D04077
5.
INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the underdrive clutch drum bushing.
Standard drum bushing:
37.06 - 37.08 mm (1.4591 - 1.4598 in.)
Maximum drum bushing: 37.13 mm (1.4618 in.)
If the inside diameter is greater than the maximum, replace the underdrive clutch drum.
D08129
SST
Snap Ring
D03703
6.
REMOVE UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the clutch balancer and compress the spring with a press.
SST 09350-32014 (09351-32070)
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the underdrive clutch drum.
Underdrive
Clutch Drum
C56359
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Author: Date:
119
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AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE CLUTCH ASSY (U151E/U151F)
(d) Remove the return spring from the underdrive clutch drum.
C56360
7.
INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 17.14 mm (0.6752 in.)
D03824
8.
REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi) to the transaxle case to remove the underdrive clutch piston.
D03705
9.
REMOVE UNDERDRIVE CLUTCH DRUM O-RING
(a) Using a screwdriver, remove the O-ring from the underdrive clutch drum.
O-ring
D26465
O-ring
D26465
U151E, U151F A/T REPAIR MANUAL (RM1021U)
10.
INSTALL UNDERDRIVE CLUTCH DRUM O-RING
(a) Apply the new O-ring with ATF, install it to the underdrive clutch drum.
NOTICE:
Assemble the O-ring carefully not to have a twist and a pinching.
Author: Date: 120
Underdrive
Clutch
Return
Spring
Clutch
Balancer
40-97
AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE CLUTCH ASSY (U151E/U151F)
11.
INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the underdrive clutch piston with ATF, install it to the underdrive clutch piston drum.
NOTICE:
Be careful not to damage the O-ring.
Be careful not to damage the lip seal of the piston.
D03860
Underdrive
Clutch Drum
12.
INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Install the return spring to the underdrive clutch drum.
NOTICE:
Installing the spring sub- assembly, check all of the springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
C56360
(c) Install the clutch balancer to the underdrive clutch drum.
NOTICE:
Be careful not to damage the lip seal of the clutch balancer.
Underdrive
Clutch Drum
C56359
SST
D03703
(d) Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09350-32014 (09351-32070)
(e) Using a snap ring expander, install the snap ring to the underdrive clutch drum.
(f) Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
NOTICE:
Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring grove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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121
40-98
Stopper
AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE CLUTCH ASSY (U151E/U151F)
Stopper
(g) Set the end gap of the snap ring in the underdrive clutch drum shown in the illustration.
NOTICE:
The end gap of the snap ring should not coincide with any of the stopper.
D25592
Flange
Plate
Disc
13.
INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Apply the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the underdrive clutch drum.
NOTICE:
Be careful about the order of discs, plates and flange assembly.
D26431
D03701
14.
INSTALL UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, install the underdrive clutch flange
No.2 hole snap ring.
(b) Check that the end gap of snap ring is not aligned with one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the drum.
D26429
15.
INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Set a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 ,
57 psi).
Park clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.
If the pack clearance is not within standard, select another flange.
HINT:
There are 5 flanges in different thickness.
Flange thickness: mm (in.)
Mark
1
2
3
Thickness
3.0 (0.118)
3.2 (0.126)
3.4 (0.134)
Mark
-
4
5
Thickness
3.1 (0.122)
3.3 (0.130)
-
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)
OVERHAUL
40-99
4006K-03
Underdrive
Planetary Gear
1.
INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST, fix the underdrive planetary gear assy.
SST 09387-00050
SST
SST
D25593
SST
D25594
(b) Using SST and a torque wrench, measure the turning torque of underdrive planetary gear assy while rotating the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.50 - 1.42 N
⋅ m (5.1 - 14.5 kgf
⋅ cm, 0.06 - 0.17 in.
⋅ lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
2.
REMOVE FRONT PLANETARY GEAR NUT
(a) Using SST, loosen the staked part of the lock nut.
SST 09930- 00010 (09931- 00010, 09931- 00020),
09387-00050
Underdrive
Planetary Gear
D03686
(b) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
D03687
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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40-100
AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)
(c) Using a socket wrench, remove the lock nut.
Underdrive
Planetary Gear
Hold
SST
Hold
SST
Turn
D25609
3.
REMOVE CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using SST, remove the cylindrical roller bearing race inner.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00320), 09950-40011 (09957-04010)
SST
D03689
4.
REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear and front tapered roller bearing.
SST 09950-60010 (09951-00320), 09387-00050
Turn
D26437
(b) Clamp the underdrive planetary gear in soft jaw vise.
(c) Using SST, remove the rear tapered roller bearing form the underdrive planetary gear.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00320), 09950-40011 (09957-04010)
SST
D03691
5.
REMOVE UNDERDRIVE PLANETARY RING GEAR
(a) Using a snap ring pliers, remove the snap ring.
Snap Ring
D03826
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 124
Underdrive
Planetary Ring Gear
AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)
40-101
(b) Remove the underdrive planetary ring gear from the counter driven gear.
Snap Ring
Counter Driven Gear
D03827
6.
INSTALL UNDERDRIVE PLANETARY RING GEAR
(a) Install a new snap ring to the outer race of the tapered roller bearing.
HINT:
When replacing the bearing, also replace the counter driven gear with a new one.
D08112
(b) Using a piston ring compressor, squeeze the snap ring.
Underdrive
Planetary Ring Gear
SST
SST
D08113
(c) Using SST and a press, press in the outer race of the tapered roller bearing.
SST 09950- 60020 (09951- 00890), 09950- 70010
(09951-07100)
NOTICE:
Be sure not to damage on the snap ring during the outer race installation.
D08114
(d) Install the underdrive planetary ring gear to the counter driven gear.
Counter Driven Gear
D03827
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125
40-102
AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)
(e) Using a snap ring pliers, install the snap ring.
Snap Ring
D08115
SST
7.
INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Using a press, press the rear tapered roller bearing to the underdrive planetary gear.
SST 09502- 12010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100), 09316-20011
NOTICE:
Press the bearing until it becomes flat at the bottom.
D26435
(b) Install the counter driven gear with planetary ring gear to the underdrive planetary gear.
SST
D08117
(c) Using SST and a press, press in the front tapered roller bearing.
SST 09502- 12010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100), 09316-20011
NOTICE:
Press the counter driven gear while rotating it.
SST
D26436
(d) Using a press, press in the parking lock gear.
SST 09502- 12010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100), 09316-20011
NOTICE:
Press the counter driven gear while rotating it.
D26433
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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AUTOMATIC TRANSMISSION / TRANS UNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)
SST
40-103
8.
INSTALL DIFFERENTIAL DRIVE PINION
(a) Using a press, press the differential drive pinion.
SST 09726- 40010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
Differential
Drive Pinion
Underdrive
Planetary Gear
D26434
SST
9.
INSTALL CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using a press, press the cylindrical roller bearing race inner.
SST 09506- 35010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
D26432
Underdrive
Planetary Gear
D25609
10.
INSTALL FRONT PLANETARY GEAR NUT
(a) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(b) Using a socket wrench, install a new lock nut.
Torque: 280 N
⋅ m (2,855 kgf
⋅ cm, 207 in.
⋅ lbf)
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53
in.).
SST
D25594
11.
INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST and a torque wrench, measure the turning torque of underdrive planetary gear assy while rotating the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.5 - 1.42 N
⋅ m (5.1 - 14.5 kgf
⋅ cm, 0.06 - 0.17 in.
⋅ lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(b) Using a pin punch and hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.
C56809
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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127
40-104
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U151E/U151F)
OVERHAUL
4010J-01
1.
REMOVE SHIFT SOLENOID VALVE SL3
(a) Remove the bolt and shift solenoid valve SL3 from the valve body assy.
2.
REMOVE LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Remove the shift solenoid valve SLT from the valve body assy.
C89112
3.
REMOVE SHIFT SOLENOID VALVE S4
(a) Remove the bolt and shift solenoid valve S4 from the valve body assy.
D26442
4.
REMOVE SHIFT SOLENOID VALVE SR
(a) Remove the shift solenoid valve SR from the valve body assy.
D26438
5.
REMOVE SHIFT SOLENOID VALVE DSL
(a) Remove the bolt and shift solenoid valve DSL from the valve body assy.
D26443
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40-105
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U151E/U151F)
6.
REMOVE SHIFT SOLENOID VALVE SL2
(a) Remove the bolt and shift solenoid valve SL2 from the valve body assy.
C89113
7.
REMOVE SHIFT SOLENOID VALVE SL1
(a) Remove the bolt and shift solenoid valve SL1 from the valve body assy.
C89115
8.
REMOVE MANUAL VALVE
(a) Remove the manual valve from the valve body assy.
9.
INSTALL MANUAL VALVE
(a) Install the manual valve to the valve body assy.
10.
INSTALL SHIFT SOLENOID VALVE SL1
(a) Install the shift solenoid valve SL1 to the valve body assy with the bolt.
Torque: 6.6 N
⋅ m (67 kgf
⋅ cm, 58 in.
⋅ lbf)
C89115
C89112
11.
INSTALL LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Install the shift solenoid valve SLT to the valve body assy with the bolt.
Torque: 6.6 N
⋅ m (67 kgf
⋅ cm, 58 in.
⋅ lbf)
12.
INSTALL SHIFT SOLENOID VALVE SL3
(a) Install the shift solenoid valve SL3 to the valve body assy with the bolt.
Torque: 6.6 N
⋅ m (67 kgf
⋅ cm, 58 in.
⋅ lbf)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
129
40-106
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U151E/U151F)
13.
INSTALL SHIFT SOLENOID VALVE SL2
(a) Install the shift solenoid valve SL2 to the valve body assy with the bolt.
Torque: 10.8 N
⋅ m (110 kgf
⋅ cm, 8 ft
⋅ lbf)
C89113
14.
INSTALL SHIFT SOLENOID VALVE DSL
(a) Install the shift solenoid valve DSL to the valve body assy with the bolt.
Torque: 10.8 N
⋅ m (110 kgf
⋅ cm, 8 ft
⋅ lbf)
D26443
15.
INSTALL SHIFT SOLENOID VALVE SR
(a) Install the shift solenoid valve SR to the valve body assy.
D26438
16.
INSTALL SHIFT SOLENOID VALVE S4
(a) Install the shift solenoid valve S4 to the valve body assy with the bolt.
Torque: 10.8 N
⋅ m (110 kgf
⋅ cm, 8 ft
⋅ lbf)
D26442
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40-107
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151E)
OVERHAUL
Mark
4006M-03
Front
Differential
Ring Gear
1.
REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match-marks on the front differential ring gear and differential case.
D26445
(b) Remove the 14 bolts.
Front
Differential
Ring Gear
D26446
(c) Using a plastic hammer, tap on the front differential ring gear to remove it from the case.
Front Differential Ring Gear
Hold
SST
C50237
Turn
SST
D25595
2.
REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front differential tapered roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00490), 09950-40011 (09957-04010)
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Author: Date:
131
40-108
SST
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151E)
(b) Using SST, remove the front differential case front tapered roller bearing outer race.
SST 09308-00010
Hold
SST
SST
D25596
Turn
SST
3.
REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00490), 09950-40011 (09957-04010)
D25597
(b) Using SST, remove the front differential case rear tapered roller bearing outer race.
SST 09308-00010
D25598
4.
REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, install the straight pin.
NOTICE:
Before removing the straight pin, unstake it with a pin punch.
C50240
Differential Case
5.
REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No.1 from the differential case.
Front Differential Pinion Shaft No.1
C50241
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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40-109
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151E)
Front
Differential
Side Gear
6.
REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears and 2 side gear thrust washers from the differential case.
Front Differential
Side Gear
C50242
7.
REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950- 70010 (09951- 07100), 09215- 00013
(09215-00471)
SST
D25599
8.
REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
SST
Front
Differential
Side Gear
D25600
9.
INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Apply the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.
Front Differential
Side Gear
C50242
Differential Case
10.
INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
(a) Apply the front differential pinion shaft No.1 with ATF, install it to the differential case.
Front Differential Pinion Shaft No.1
C50241
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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133
40-1 10
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151E)
C50252
11.
INSPECT BACKLASH
(a) Using a dial indicator, inspect the backlash of the side gear.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness
Mark
-
-
-
Thickness
1.625 mm (0.0640 in.)
1.725 mm (0.0679 in.)
1.825 mm (0.0719 in.)
12.
INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, install the pinion shaft straight pin.
C50253
(b) Using a chisel and hammer, stake the differential case.
NOTICE:
Stake it after adjusting the backlash.
C50254
SST
D26447
13.
INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case rear tapered roller bearing to the differential case.
SST 09316- 12010, 09550- 60010 (09951- 00490),
09950-70010 (09951-07100)
NOTICE:
Do not make a damage on the bearing cage during the bearing inner race installation.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 134
SST
40-1 11
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151E)
(b) Using SST and a hammer, install the front differential case tapered roller bearing front outer race to the transaxle housing.
SST 09550- 60010 (09951- 00490), 09950- 60020
(09951-00910)
C83736
SST
D26448
14.
INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case front tapered roller bearing to the differential case.
SST 09316- 12010, 09550- 60010 (09951- 00490),
09950-70010 (09951-07100)
NOTICE:
Do not make a damage on the bearing cage during the bearing inner race installation.
(b) Using SST and a hammer, install the front differential case tapered roller bearing front outer race to the transaxle housing.
SST 09950- 70010 (09951- 07150), 09950- 60020
(09951-00890)
NOTICE:
Clearance is not allowed between the bearing and transaxle housing.
D26449
Differential Assy
15.
ADJUST DIFFERENTIAL SIDE BEARING RRELOAD
(a) Install the differential assy to the transaxle case.
D26450
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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135
40-1 12
C
C
C
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151E)
C
A
B
A
D26384
(b) Clean the matching surfaces of the transaxle case and transaxle housing.
(c) Install the transaxle housing to the transaxle case and tighten them with the 16 bolts.
HINT:
Torque:
Bolt A: 25 N
⋅ m (255 kgf
⋅ cm, 18 ft
⋅ lbf)
Bolt B: 33 N
⋅ m (337 kgf
⋅ cm, 24 ft
⋅ lbf)
Bolt C: 29 N
⋅ m (295 kgf
⋅ cm, 21 ft
⋅ lbf)
Bolt D: 22 N
⋅ m (226 kgf
⋅ cm, 16.0 ft
⋅ lbf)
Apply seal packing or equivalent to the A and D.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it can be used after cleaning it.
SST
D25604
(d) Using SST, turn the differential assy right and left 2 or 3 times to settle the bearing.
SST 09564-3201 1
(e) Using SST and a torque wrench, measure the turning torque of the differential.
SST 09564-3201 1
Turning torque at 60 rpm:
New bearing
0.20 - 0.69 N
⋅ m (2.0 - 7.0 kgf
⋅ cm, 1.8 - 6.1 in.
⋅ lbf)
Used bearing
0.10 - 0.35 N
⋅ m (1.0 - 3.6 kgf
⋅ cm, 0.9 - 3.1 in.
⋅ lbf)
HINT:
If the turning torque is not within the specified value, refer to the table below to select a thrust washer which turning torque is within the specified value.
Flange thickness: mm (in.)
Mark
0
1
2
3
4
5
6
Thickness
2.00 (0.0787)
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
2.25 (0.0886)
2.30 (0.0906)
Mark
9
A
B
C
D
E
F
Thickness
2.45 (0.0965)
2.50 (0.0984)
2.55 (0.1004)
2.60 (0.1024)
2.65 (0.1043)
2.70 (0.1063)
2.75 (0.1083)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 136
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151E)
Mark
7
8
Thickness
2.35 (0.0925)
2.40 (0.0945)
Mark
G
H
Thickness
2.80 (0.1102)
2.85 (0.1122)
40-1 13
(f) Remove the 16 bolts and the transaxle housing.
D26384
Differential Assy
(g) Remove the differential assy.
Mark
90 - 100 C (194 - 230 F)
D26450
16.
INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear to 90 - 110 C (194.0 - 230.0 F).
NOTICE:
Do not overheat the ring gear to 110 C (230.0 F) or more.
(b) Clean the contact surface of the front differential case.
D25215
(c) Align the match-marks, install the front differential ring gear case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.
D26445
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40-1 14
SST
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151E)
(d) Tighten the 14 bolts.
Torque: 95.0 N
⋅ m (970 kgf
⋅ cm, 70 ft
⋅ lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
D26446
17.
INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
(b) Apply the rip of oil seal with a little MP grease.
SST 09223-15020, 09950-70010 (09951-07150)
Oil seal drive in depth: 0 0.5 mm (0 0.0197 in.)
SST
D26451
18.
INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, drive into a new oil seal.
(b) Apply the lip of the oil seal with a little MP grease.
SST 09710-30050, 09950-70010 (09951-07150)
Oil seal drive in depth: 0 0.5 mm (0 0.0197 in.)
D25606
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Author: Date: 138
40-1 15
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
OVERHAUL
4006N-02
Match-marks
1.
REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match-marks on the ring gear and differential case.
Front Differential Ring Gear
C50182
Front Differential
Ring Gear
(b) Remove the 16 bolts.
C50183
(c) Using a plastic hammer, tap on the ring gear to remove it from the case.
Front Differential Ring Gear
C50184
Differential
Case Assy
2.
REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the differential LH case from the differential case assy.
Differential
LH Case
C50187
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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139
40-1 16
Differential
Case No.2
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
(b) Remove the differential case No.2 from the differential case LH.
Differential
Case LH
Front
Differential
Side Gear
Conical Spring
Differential
Case LH
C50188
Front
Differential
Side Gear
Thrust Washer
Center
Differential
Side Gear
Thrust Washer
No.2
C50189
(c) Remove the front differential side gear, front differential side gear thrust washer, conical spring and center differential side gear thrust washer No.2 from the differential case LH.
(d) Using a snap ring expander, remove the pinion shaft spacer snap ring.
D25610
(e) Using a pin punch and a hammer, remove 3 straight pins.
C50190
(f) Remove the center differential pinion shaft and 2 differential pinion shafts.
C50191
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 140
Hold
SST
SST
40-1 17
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
(g) Remove 4 front differential pinions, 4 front differential pinion thrust washers, front differential pinion shaft holder, front differential planetary ring gear and differential side gear thrust washer No. 1.
C50943
Turn
SST
3.
REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00480)
D25597
(b) Using SST, remove the front differential case rear tapered roller bearing outer race and differential case washer.
SST 09308-00010
D25598
4.
REMOVE CENTER DIFFERENTIAL PINION
(a) Using torx socket (T50), remove the 15 bolts.
C50193
Differential
RH Case
(b) Place the matchmarks on the differential intermediate case and differential case.
(c) Remove the differential intermediate case from the differential case RH.
Differential
Intermediate Case
C50230
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
141
40-1 18
Differential Case RH
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
(d) Remove the center differential side gear, conical spring washer and center differential side gear thrust washer No.
1 RH from the differential case RH.
Center Differential
Side Gear
C50196
(e) Remove the differential spider, 5 center differential pinions and 5 center differential pinion thrust washers from the differential intermediate case.
Hold
SST
SST
C50194
Turn
SST
5.
REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front tapered roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00600)
D25611
(b) Using SST, remove the front differential case front tapered roller bearing outer race and differential case washer.
SST 09308-00010
D25596
6.
REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09649-17010
SST
D25599
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 142
40-1 19
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
7.
REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
SST
D25600
8.
INSTALL DIFFERENTIAL CASE SUB-ASSY NO.2
(a) Coat the front differential side gear thrust washer No.1, front differential planetary ring gear, front differential pinion No.2, front differential pinion thrust washer No.2, front differential pinion shaft holder, front differential pinion shaft and 2 differential pinion shafts with ATF, install them to the differential case No.2.
C50943
C50216
(b) Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which contacts with bushing in a vise.
If the backlash is not within the specified value, refer to the table below and select a thrust washer which will ensure that the backlash is within the specified value.
Thrust washer thickness: mm (in.)
Mark
A
B
C
D
E
Thickness
0.95 (0.0373)
1.00 (0.0393)
1.05 (0.0413)
1.10 (0.0433)
1.15 (0.0453)
Mark
F
G
H
J
K
Thickness
1.20 (0.0472)
1.25 (0.0492)
1.30 (0.0512)
1.35 (0.0532)
1.40 (0.0552)
Differential
Case LH
Differential
Case No.2
C50213
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Engage the front differential side gear to the above mentioned front differential case.
(d) Install the differential case LH to the front differential case and measure its center.
(e) After that, remove the differential case LH.
Author: Date:
143
40-120
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
C50214
(f) Using a straight edge and feeler gauge, measure the clearance between the front differential case and the front differential side gear.
t= Thrust washer thickness
L= Clearance t= L-0.162 - 0.265 mm (0.0064 - 0.0104 in.)
If the clearance is not within the specified value, refer to the table below and select a thrust washer which will ensure that the clearance is within the specified value.
Thrust washer thickness: mm (in.)
Mark
A
B
C
D
E
Thickness
0.95 (0.0373)
1.00 (0.0393)
1.05 (0.0413)
1.10 (0.0433)
1.15 (0.0453)
Mark
F
G
H
J
K
Thickness
1.20 (0.0472)
1.25 (0.0492)
1.30 (0.0512)
1.35 (0.0532)
1.40 (0.0552)
If the clearance is not within the specified value, parts may have been assembled incorrectly, so check and reassemble it.
(g) Using a pin punch and a hammer, install 3 straight pins.
C50217
(h) Using a snap ring expander, install the pinion shaft spacer snap ring.
D25610
Differential Case RH
Center Differential
Side Gear
C51252
U151E, U151F A/T REPAIR MANUAL (RM1021U)
9.
INSTALL CTR DIFFERENTIAL PLANETARY GEAR
ASSY
(a) Install the center differential side gear, conical spring washer and center differential side gear thrust washer
No.2 RH from the differential case RH.
HINT:
Ensure that the conical washers is installed correctly.
Author: Date: 144
40-121
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
(b) Hold the differential case RH by vice. Install the center differential pinion and pinion thrust washer to the differential spider and install them to the differential case RH.
NOTICE:
When holding the differential case RH by vise, be sure to place an aluminum sheet between them and use a minimum force.
C50950
C50205
(c) Pressing and holding the differential spider toward the differential case RH, measure the pinion’s backlash with a dial indicator as illustrated.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer to the table below and select a thrust washer which will ensure that the backlash is within the specified value.
Thrust washer thickness: mm (in.)
Mark
MA
MB
MC
MD
ME
MF
MG
Thickness
0.80 (0.0313)
0.85 (0.0333)
0.90 (0.0353)
0.95 (0.0373)
1.00 (0.0393)
1.05 (0.0413)
1.10 (0.0433)
Mark
MH
MJ
MK
ML
MM
MN
-
Thickness
1.15 (0.0453)
1.20 (0.0472)
1.25 (0.0492)
1.30 (0.0512)
1.35 (0.0532)
1.40 (0.0552)
-
(d) Temporarily install the differential side gear thrust washer
No.2 LH, center differential side gear conical spring washer and differential case No.2 to the differential case LH.
HINT:
Ensure that the conical washers is installed correctly.
C50206
(e) Install the differential intermediate case to the above and fix them with 4 bolts.
C50207
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
145
40-122
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
(f) Remove the differential spider, 5 center differential pinions and 5 center differential pinion thrust washers from the differential case RH. Put them in the differential intermediate case and fix the case.
C50208
C50209
(g) Pressing and holding the differential spider toward the differential intermediate case, measure the pinion’s backlash with a dial indicator.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer to the table below and select a thrust washer which will ensure that the backlash is within the specified value.
Thrust washer thickness: mm (in.)
Mark
MA
MB
MC
MD
ME
MF
MG
Thickness
0.80 (0.0313)
0.85 (0.0333)
0.90 (0.0353)
0.95 (0.0373)
1.00 (0.0393)
1.05 (0.0413)
1.10 (0.0433)
Mark
MH
MJ
MK
ML
MM
MN
-
Thickness
1.15 (0.0453)
1.20 (0.0472)
1.25 (0.0492)
1.30 (0.0512)
1.35 (0.0532)
1.40 (0.0552)
-
(h) Remove the 4 bolts and disconnect the differential case
LH from the differential intermediate case.
Differential
Case No.2
C50210
Differential
Case LH
(i) Remove the differential case No.2 from the differential case LH.
C51468
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 146
40-123
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
(j) Install the selected differential side gear thrust washer
No. 2 LH and center differential planetary gear to the differential case LH.
Differential
Case No.2
C51469
(k) Install the differential case No. 2 to the differential case LH again.
Differential
Case LH
C50188
(l) Install the adjusted differential case RH to the intermediate case and tighten the 15 bolts using a torx socket wrench (T50).
Torque: 63 N
⋅ m (642 kgf
⋅ cm, 46 ft
⋅ lbf)
NOTICE:
Align the matchmarks.
SST
SST
C50193
D25612
10.
INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case tapered roller bearing FR to the differential case.
SST 09950-70010 (09951-07100), 09649-17010
NOTICE:
Do not make a damage on the bearing cage during the bearing inner race installation.
(b) Using SST, install the outer race of the tapered roller bearing FR.
SST 09527-1701 1, 09950-60020 (09951-01030)
NOTICE:
Clearance is not allowed between the plate washer and transaxle housing.
D25603
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
147
40-124
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
SST
SST
D25613
11.
INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case tapered roller bearing RR to the differential case.
SST 09316-2001 1, 09214-76011
NOTICE:
Do not make a damage on the bearing cage during the bearing inner race installation.
(b) Install the front differential case shim RR to the transaxle case.
If the bearing is new, check to select a front differential case shim RR of proper thickness starting from the thinner ones.
If the bearing is reused, check to select a front differential case shim RR starting from the same thickness as one installed before disassembly.
(c) Using SST, install the outer race of the front differential case tapered roller bearing RR.
SST 09950- 60020 (09951- 00890), 09950- 70010
(09951-07100)
NOTICE:
Clearance is not allowed between the differential case shim and transaxle case.
D25601
12.
ADJUST TAPERED POLLER BEARING PRELOAD
(a) Install the intermediate case to the differential case LH and fix them with 4 bolts.
(b) Install the differential assy to the transaxle case.
C50224
C
C
C
C
A
A
B
D03568
(c) Clean the matching surfaces of the transaxle case and transaxle housing.
(d) Install the transaxle housing to the transaxle case and tighten them with the 16 bolts.
Torque:
Bolt A: 25 N
⋅ m (255 kgf
⋅ cm, 18 ft
⋅ lbf)
Bolt B 33 N
⋅ m (337 kgf
⋅ cm, 24 ft
⋅ lbf)
Bolt C 29 N
⋅ m (295 kgf
⋅ cm, 21 ft
⋅ lbf)
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it can be used after cleaning it.
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 148
40-125
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
SST
C50227
5
6
7
8
Mark
0
1
2
3
4
(e) Using SST, turn the differential assy right and left 2or 3 times to allow the bearing settle.
SST 09564-3201 1
(f) Using SST and a torque wrench, measure the turning torque of the differential case assy.
SST 09564-3201 1
Turning torque at 60 rpm:
New bearing
0.20 - 0.69 N
⋅ m (2.0 - 7.0 kgf
⋅ cm, 1.8 - 6.1 in.
⋅ lbf)
Used bearing
0.10 - 0.35 N
⋅ m (1.0 - 3.6 kgf
⋅ cm, 0.9 - 3.1 in.
⋅ lbf)
HINT:
If the turning torque is not within the specified value, refer to the table below and select a thrust washer which turning torque is within the specified value.
Flange thickness: mm (in.)
Thickness
2.00 (0.0787)
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
2.25 (0.0886)
2.30 (0.0906)
2.35 (0.0925)
2.40 (0.0945)
E
F
G
H
Mark
9
A
B
C
D
Thickness
2.45 (0.0965)
2.50 (0.0984)
2.55 (0.1004)
2.60 (0.1024)
2.65 (0.1043)
2.70 (0.1063)
2.75 (0.1083)
2.80 (0.1102)
2.85 (0.1122)
(g) Remove the 16 bolts and the transaxle housing.
D25614
(h) Remove the differential assy.
C50224
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
149
40-126
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
90 - 100 C (194 - 230 F)
13.
INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear to 90 - 110 C. (194.0 - 230.0 F)
NOTICE:
Do not overheat the ring gear to 110 C (230.0 F) or more.
(b) Clean the contact surface of the front differential case.
D25215
Match-marks
(c) Set the match-marks, install the front differential ring gear case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.
C50186
(d) Temporarily install the 8 bolts as shown in the illustration.
C50232
(e) Remove the 4 bolts shown in the illustration.
(f) Temporarily install the remaining 8 set bolts.
(g) Fully tighten the set bolts.
Torque: 95.1 N
⋅ m (970 kgf
⋅ cm, 70 ft
⋅ lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
C50233
SST
14.
INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09223-15020, 09950-70010 (09951-07100)
(b) Coat the rip of oil seal with a little MP grease.
D25605
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date: 150
40-127
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL ASSY (U151F)
Vinyl Tape
SST
D03809
15.
INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Wind a vinyl tape around SST at the place 6.0 mm (0.236
in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.).
SST 09950-60020 (09951-00730)
NOTICE:
Remove foreign matter such as grease on the SST before winding the tape.
(b) Coat the rip of oil seal with a little MP grease.
(c) Using SST, install a new oil seal.
SST 09950- 60020 (09951- 00730), 09950- 70010
(09951-07150)
Standard press in depth:
5.5 - 6.5 mm (0.217 - 0.256 in.)
NOTICE:
Stop pressing when the would vinyl tape is contact with the transaxle housing.
D25615
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Author: Date:
151
AX–1
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX01L–01
PRECAUTION
If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section.
1997 LEXUS ES300 (RM511U)
Author: Date:
1021
AX–2
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
OPERATION
Planetary Gear Unit
O/D Brake (B
0
)
O/D Direct
Clutch (C
0
)
No.2 (F
2
)
1st and Reverse
Brake (B
3
)
One–Way Clutch Forward
Clutch (C
1
2nd Brake (B
2
)
)
2nd Coast
Brake (B
1
)
Direct Clutch (C
2
)
AX0WG–01
O/D One–Way Clutch
No.2 (F
V08426
0
)
O/D Planetary
Gear
Counter
Drive Gear
Shaft
Rear Planetary
Gear
Intermediate
No.1 (F
1
)
Front Planetary Gear
One–Way Clutch Input Shaft
D09109
Shift Lever
Position
Gear Position
P
R
N
D
2
L
2nd
3rd
O/D
1st
2nd
*3rd
1st
*2nd
Parking
Reverse
Neutral
1st
D01018
*Down–shift only–no up–shift
: Operating
C
0
C
1
C
2
B
0
B
1
B
2
B
3
F
0
F
1
F
2
D09110
1997 LEXUS ES300 (RM511U)
Author: Date: 1022
AX–3
AUTOMATIC TRANSAXLE – VEHICLE SPEED SENSOR
AX01N–02
ON–VEHICLE REPAIR
1.
REMOVE AIR CLEANER ASSEMBLY
2.
DISCONNECT VEHICLE SPEED SENSOR CONNEC-
TOR
3.
REMOVE VEHICLE SPEED SENSOR ASSEMBLY
(a) Remove the bolt and vehicle speed sensor assembly.
Q05725
Vehicle Speed Sensor
Driven Gear
O–Ring
Clip
Q04678
(b) Remove the clip and driven gear from the vehicle speed sensor.
(c) Remove the O–ring from the vehicle speed sensor.
4.
INSTALL VEHICLE SPEED SENSOR ASSEMBLY
(a) Coat a new O–ring with ATF and install it to the vehicle speed sensor.
(b) Install the driven gear to the vehicle speed sensor and clip.
(c) Install the vehicle speed sensor assembly with the bolt.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
5.
CONNECT VEHICLE SPEED SENSOR CONNECTOR
6.
INSTALL AIR CLEANER ASSEMBLY
1997 LEXUS ES300 (RM511U)
Author: Date:
1023
AX–4
O–Ring
AUTOMATIC TRANSAXLE – DIRECT CLUTCH SPEED SENSOR
AX01O–02
ON–VEHICLE REPAIR
1.
DISCONNECT DIRECT CLUTCH SPEED SENSOR
CONNECTOR
2.
REMOVE DIRECT CLUTCH SPEED SENSOR
(a) Remove the bolt and direct clutch speed sensor.
Q05726
(b) Remove the O–ring from direct clutch speed sensor.
3.
INSTALL DIRECT CLUTCH SPEED SENSOR
(a) Coat a new O–ring with ATF and install it to the direct clutch speed sensor.
(b) Install the direct clutch speed sensor with the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
Q04733
1997 LEXUS ES300 (RM511U)
Author: Date: 1024
AX–5
AUTOMATIC TRANSAXLE – PARK/NEUTRAL POSITION (PNP) SWITCH
AX01P–02
ON–VEHICLE REPAIR
1.
DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
Q00229
2.
REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Remove the clip from the shift control cable.
(b) Remove the nut and control cable.
Q06496
(c) Remove the nut, washer and transaxle control shaft lever.
(d) Using a screwdriver, pry off the lock plate.
(e) Remove the nut and lock plate.
(f) Remove the 2 bolts and pull out the park/neutral position switch.
1997 LEXUS ES300 (RM511U)
Q05727
3.
INSTALL AND ADJUST PARK/NEUTRAL POSITION
SWITCH
(a) Temporarily install the park/neutral position switch with the 2 bolts.
(b) Install a new lock plate and nut.
Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf)
(c) Stake the nut with the lock plate.
Neutral
Basic
Line
Q04617
(d) Adjust the park/neutral position switch.
(See page DI–150 )
Groove
Z10304
Author: Date:
1025
AX–6
AUTOMATIC TRANSAXLE – PARK/NEUTRAL POSITION (PNP) SWITCH
(e) Install the transaxle control shaft lever and washer.
Q04687
Q06496
(f) Install and torque the nut.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(g) Install the control cable and nut.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(h) Install the clip to the shift control cable.
4.
CONNECT PARK/NEUTRAL POSITION SWITCH CON-
NECTOR
5.
TEST DRIVE VEHICLE
1997 LEXUS ES300 (RM511U)
Author: Date: 1026
AX–7
AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY
AT3785
AX0WH–01
ON–VEHICLE REPAIR
1.
CLEAN TRANSAXLE EXTERIOR
To help prevent contamination, clean the exterior of the transaxle.
2.
DRAIN ATF
Using a hexagon wrench, remove the drain plug and fluid into the suitable container.
3.
REMOVE OIL PAN AND GASKET
NOTICE:
Some fluid will remain in the oil pan.
Remove oil pan bolts, and carefully remove the pan assembly.
Discard the gasket.
1997 LEXUS ES300 (RM511U)
4.
EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect any steel chips.
Look at the chips and particles in the pan and magnet carefully to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non–magnetic): bushing wear
AT0103
5.
REMOVE OIL STRAINER AND APPLY PIPE BRACKET
(a) Remove the 3 bolts and oil strainer.
NOTICE:
Be careful as oil will come out of the strainer when it is removed.
(b) Remove the 3 bolts and apply pipe bracket.
D01019
Connector
6.
REMOVE OIL PIPES
Pry up both pipe ends with a large screwdriver and remove the
5 pipes.
7.
DISCONNECT SOLENOID CONNECTORS
Q05728
Author: Date:
1027
AX–8
AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY
8.
REMOVE TRANSFER LUBRICATION APPLY PIPE
(a) Remove the 2 bolts and detent spring.
(b) Remove the pipe set bolts.
(c) Pry up the pipe with a screwdriver and remove the pipe.
D01020
9.
REMOVE MANUAL VALVE BODY
Remove the 5 bolts and manual valve body.
D01021
10.
REMOVE B
3
APPLY PIPE
(a) Remove the pipe retainer.
(b) Pry up the pipe with a screwdriver and remove the pipe.
NOTICE:
Be careful not to bend or damage the pipe.
D01058
11.
REMOVE VALVE BODY
(a) Remove the 9 bolts.
D01023
(b) Disconnect the throttle cable from the cam and remove the valve body.
12.
REMOVE 2ND BRAKE APPLY GASKET
1997 LEXUS ES300 (RM511U)
OR0038
Author: Date: 1028
AX–9
AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY
13.
REMOVE SOLENOID VALVES
(a) Remove the 3 bolts, shift solenoid valve No.1 and No.2
with the retainer.
NOTICE:
When removing solenoid, do not use a screwdriver, etc. to pry up the solenoid.
(b) Remove the O–rings from the shift solenoid valve No.1
and No.2.
Q05643
(c) Remove the bolt and shift solenoid valve SL.
(d) Remove the O–ring from the shift solenoid valve SL.
Q05657
(e) Remove the bolt and shift solenoid valve SLN.
(f) Remove the O–ring from the shift solenoid valve SLN.
1997 LEXUS ES300 (RM511U)
Q05402
14.
INSTALL SOLENOID VALVES
(a) Coat the 2 new O–rings with ATF and install it to the shift solenoid valve SL.
(b) Install the shift solenoid valve SL.
(c) Install and torque the bolt.
Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf)
Q05657
(d) Coat the 2 new O–rings with ATF and install it to the shift solenoid valve SLN.
(e) Install the shift solenoid valve SLN.
(f) Install and torque the bolt.
Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf)
Q05402
Author: Date:
1029
AX–10
AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY
(g) Coat the 2 new O–rings with ATF and install it to the shift solenoid valve No.1 and No.2.
(h) Install the No.1 and No.2 solenoids.
(i) Install and torque the 3 bolts.
Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf)
15.
PLACE NEW 2ND BRAKE APPLY GASKET
Q05643
16.
INSTALL VALVE BODY TO TRANSAXLE CASE
(a) While holding the cam down with your hand, slip the cable end into the slot.
(b) Lower the valve body into place.
NOTICE:
Be careful not to entangle the solenoid wire.
C
D
B C
D
OR0038
A
C
D01023
(c) Install and tighten the 9 bolts.
HINT:
Hand tighten the 9 bolts first, then torque with a torque wrench.
Bolt length:
Bolt A: 30 mm (1.181 in.)
Bolt B: 43 mm (1.693 in.)
Bolt C: 48 mm (1.890 in.)
Bolt D: 52 mm (2.047 in.)
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
17.
INSTALL B
3
APPLY PIPE
NOTICE:
Be careful not to bend or damage the pipe.
B
1997 LEXUS ES300 (RM511U)
A
D01058
18.
INSTALL CONNECTOR CLAMP AND PIPE RETAINER
(a) Install the connector clamp and pipe retainer.
(b) Install and torque the 2 bolts.
Bolt length:
Bolt A: 48 mm (1.890 in.)
Bolt B: 39 mm (1.535 in.)
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
D01059
Author: Date: 1030
B
30
(1.18)
B
A
B A
AX–11
AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY
D01021 mm (in.)
Z19257
19.
INSTALL MANUAL VALVE BODY
(a) Align the manual valve with the pin on the manual shaft lever.
(b) Lower the manual valve body into place.
(c) Hand tighten the 5 bolts first. Then, tighten them with a torque wrench.
Bolt length:
Bolt A: 22 mm (0.866 in.)
Bolt B: 36 mm (1.417 in.)
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
20.
INSTALL TRANSFER LUBRICATION APPLY PIPE
(a) Place the detent springs on the manual valve body and hand tighten the 2 bolts first. Then, tighten them with a torque wrench.
Bolt length:
Bolt A: 14 mm (0.551 in.)
Bolt B: 36 mm (1.417 in.)
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
(b) Check that the manual valve lever is touching the center of the detent spring tip roller.
(c) Using a plastic hammer, install the pipe into the position.
NOTICE:
Be careful not to bend or damage the pipe.
(d) Install and torque the bolt.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
Connector
21.
CONNECT SOLENOID CONNECTORS
22.
INSTALL OIL PIPES
Using a plastic hammer, install the pipes into the positions.
NOTICE:
Be careful not to bend or damage the pipes.
B
A
1997 LEXUS ES300 (RM511U)
A
Q05728
B
Z19256
23.
INSTALL OIL STRAINER AND APPLY PIPE BRACKET
(a) Install the oil strainer and apply pipe bracket.
(b) Install and torque the 6 bolts.
Bolt length:
Bolt A: 22 mm (0.866 in.)
Bolt B: 52 mm (2.047 in.)
Torque:
Bolt A: 10 N·m (100 kgf·cm, 7 ft·lbf)
Bolt B: 11 N·m (110 kgf·cm, 8 ft·lbf)
Author: Date:
1031
AX–12
AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY
24.
INSTALL MAGNETS IN PLACE
Install the 3 magnets in the indentations of the oil pan, as shown in the illustration.
NOTICE:
Make sure that the magnet does not interfere with the oil pipes.
AT3741
AT3785
25.
INSTALL OIL PAN AND GASKET
(a) Install the oil pan and a new gasket.
(b) Install and torque the 17 new bolts.
Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
26.
INSTALL AND TORQUE DRAIN PLUG
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
27.
FILL ATF AND CHECK FLUID LEVEL
(See page DI–150 )
1997 LEXUS ES300 (RM511U)
Author: Date: 1032
AUTOMATIC TRANSAXLE – THROTTLE CABLE
ON–VEHICLE REPAIR
1.
REMOVE BATTERY
2.
REMOVE CRUISE CONTROL ACTUATOR
Remove the 3 bolts and cruise control actuator.
AX–13
AX01R–02
Q09982
3.
DISCONNECT THROTTLE CABLE FROM ENGINE
Disconnect the cable from the throttle linkage.
4.
REMOVE PARK/NEUTRAL POSITION SWITCH
(See page AX–5 )
5.
REMOVE VALVE BODY
(See page AX–7 )
Q00225
6.
REMOVE THROTTLE CABLE
(a) Remove the bolt and retaining plate.
(b) Pull out the cable from the transaxle case.
Q00270
7.
INSTALL CABLE INTO TRANSAXLE CASE
(a) Make sure to push it in all the way.
(b) Install the retaining plate.
(c) Install and torque the bolt.
8.
INSTALL VALVE BODY
(See page AX–7 )
Q00270
200 mm
(7.87 in.)
0.8–1.5 mm (0.031–0.059 in.)
Q05731
9.
IF THROTTLE CABLE IS NEW, STAKE STOPPER OR
PAINT MARK ON INNER CABLE
HINT:
New cables do not have a staked cable stopper.
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull the inner cable lightly until slight resistance is felt, and hold it there.
(c) Stake the stopper, 0.8–1.5 mm (0.031–0.059 in.) from the end of outer cable.
1997 LEXUS ES300 (RM511U)
Author: Date:
1033
AX–14
AUTOMATIC TRANSAXLE – THROTTLE CABLE
10.
CONNECT THROTTLE CABLE TO ENGINE
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
11.
ADJUST THROTTLE CABLE
(See page DI–150 )
12.
INSTALL PARK/NEUTRAL POSITION SWITCH
(See page AX–5 )
Q00225
13.
INSTALL CRUISE CONTROL ACTUATOR
Install the cruise control actuator with the 3 bolts.
14.
INSTALL BATTERY
15.
TEST DRIVE VEHICLE
Q09982
1997 LEXUS ES300 (RM511U)
Author: Date: 1034
SST
SST
AX–15
AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL
ON–VEHICLE REPAIR
1.
REMOVE FRONT DRIVE SHAFT
(See page SA–15 )
2.
REMOVE SIDE GEAR SHAFT OIL SEAL
Using SST, pull out the oil seal.
SST 09308–00010
Q00394
AX01S–02
3.
INSTALL LEFT SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09223–15020, 09351–32014 (09351–32130)
Oil seal depth: 0 ± 0.5 mm (0 ± 0.02 in.)
(b) Coat the lip of the oil seal with MP grease.
SST
Q06348
Q00238
4.
INSTALL RIGHT SIDE GEAR SHAFT OIL SEAL
(a) Using SST, drive in a new oil seal.
SST 09316–60010 (09316–00010)
Oil seal depth: 0
±
0.5 mm (0
±
0.02 in.)
(b) Coat the lip of the oil seal with MP grease.
5.
INSTALL FRONT DRIVE SHAFT
(See page SA–15 )
6.
CHECK TRANSAXLE FLUID LEVEL
(See page DI–150 )
1997 LEXUS ES300 (RM511U)
Author: Date:
1035
AX–16
AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM
LOCATION
Shift Lock Override Cover
AX01T–02
Shift Lock Override Button
Stop Light Switch
Key Interlock Solenoid
Shift Lock Control Unit Assembly
AM1
ALT
MAIN
FL
Battery
Q10348
STOP
Ignition Switch
ACC
IG
ECU–IG
Stop Light
Switch
STP
CIG
IG ACC
Shift Lock
Control Unit
Assembly
KLS+
Key Interlock Solenoid
Stop
Light
E
D09111
1997 LEXUS ES300 (RM511U)
Author: Date: 1036
5 (IG)
4 (KLS+)
3 (E)
2 (STP)
Wire Harness Side
AX–17
AUTOMATIC TRANSAXLE
1 (ACC)
– SHIFT LOCK SYSTEM
AX01U–01
INSPECTION
1.
INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the shift lock control unit assembly connector.
Q09455
Terminal
1 – 3 (ACC – E)
5 – 3 (IG – E)
2 – 3 (STP – E)
4 – 3 (KLS + – E)
Measuring Condition
Ignition switch ACC
Ignition switch ON
Depressing brake pedal
(1) Ignition switch ACC and P position
(2) Ignition switch ACC and except P position
(3) Ignition switch ACC and except P position (After approx. 1 second)
Voltage (V)
10 – 14
10 – 14
10 – 14
0
7.5 – 11
6 – 9.5
1 (KLS+)
2 (E)
1 (KLS+)
2 (E)
2.
INSPECT KEY INTERLOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure resistance between terminals.
Standard resistance: 12.5–16.5
Ω
If resistance value is not as specified, replace the solenoid.
Q09456
(c) Apply battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid.
If the solenoid does not operated, replace the solenoid.
(–) (+)
Q09457
1997 LEXUS ES300 (RM511U)
Author: Date:
1037
AX–18
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
COMPONENTS
Engine Hood
AX01V–02
Cruise Control Actuator
RH Drive Shaft
14 (145, 10)
Air Cleaner
Assembly
Snap Ring
32 (330, 24)
27 (280, 20)
15 (150, 11) x6
48 (490, 35)
Torque Converter
Clutch
Hole Cover
Exhaust manifold
Bracket
Clip
Shift Control Cable
66 (670, 48)
Starter
20 (200, 15)
Shift Control
Cable Clamp
39 (400, 29) x5
20 (200, 15)
Battery
Insulator
Battery
Battery Tray
Plug for Line
Pressure Test
Snap Ring
LH Drive Shaft
N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part
1997 LEXUS ES300 (RM511U)
Author: Date:
Hold–Down
Clamp
Q10283
1038
AX–19
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
RH Fender Apron Seal Rear Side Engine
Mounting Insulator
RH Rear Lower Brace
36 (370, 27)
Steering Return Pipe
10 (100, 7)
32 (330, 24)
66 (670, 48)
Stabilizer Bar Link
Stabilizer Bar
39 (400, 29)
19 (195, 14)
181 (1,850, 134)
80 (820, 59)
181 (1,850, 134)
LH Fender Apron Seal
LH Rear Lower Brace
Front Side Engine
Mounting Insulator
RH Front
Lower Brace
36 (370, 27)
181 (1,850, 134)
80 (820, 59)
RH Fender Liner
48 (490, 35)
LH Front
Lower Brace
Exhaust Front Pipe
Support Bracket
21 (210, 15)
Gasket
Tie Rod End
Lock Cap
49 (500, 36)
Grommet
80 (820, 59)
127 (1,300, 94)
Cotter PIn
294 (3,000, 217)
Gasket
Cotter
Pin
Gasket
56 (570, 41)
62 (630, 46)
Center Engine Under Cover
33 (330, 24)
Exhaust Front Pipe Support Stay
33 (330, 24)
LH Fender Liner
Engine Under Cover
N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part
1997 LEXUS ES300 (RM511U)
Author: Date:
Q10282
1039
AX–20
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX01W–02
REMOVAL
1.
REMOVE BATTERY
2.
REMOVE AIR CLEANER ASSEMBLY
3.
REMOVE THROTTLE CABLE FROM THROTTLE
BODY
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
Q00225
4.
w/ Cruise Control:
REMOVE CRUISE CONTROL ACTUATOR
(a) Disconnect the connector.
(b) Remove the 3 bolts and disconnect cruise control actuator with the bracket.
Q09982
Q10287
5.
DISCONNECT GROUND CABLE
6.
DISCONNECT VEHICLE SPEED SENSOR CONNEC-
TOR
7.
DISCONNECT DIRECT CLUTCH SPEED SENSOR
CONNECTOR
8.
DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
9.
DISCONNECT SOLENOID CONNECTOR
10.
DISCONNECT SHIFT CONTROL CABLE
(a) Remove the nut and disconnect the shift control cable from the park/neutral position switch.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(b) Remove the clip and disconnect the shift control cable.
Q00075
11.
REMOVE 2 ENGINE MOUNTING ABSORBER BOLTS
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
1997 LEXUS ES300 (RM511U)
Q10028
Author: Date: 1040
AX–21
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
12.
REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)
Q06478
13.
REMOVE STARTER AND SHIFT CONTROL CABLE
CLAMP
(a) Disconnect the connector and remove the nut.
(b) Remove the 2 bolts, starter and shift control cable clamp.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
Q10286
14.
REMOVE EXHAUST MANIFOLD BRACKET MOUNT-
ING BOLT
Torque: 20 N·m (200 kgf·cm, 15 ft·lbf)
1997 LEXUS ES300 (RM511U)
Q06530
Q10038
15.
REMOVE 5 TRANSAXLE–TO–ENGINE BOLTS AND
DISCONNECT GROUND TERMINAL
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
16.
REMOVE ENGINE HOOD
(a) Disconnect the washer pipe.
(b) Remove the 4 bolts and engine hood.
Torque: 14 N·m (145 kgf·cm, 10 ft·lbf)
17.
RAISE AND SUPPORT VEHICLE SECURELY
18.
REMOVE FRONT WHEELS
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
19.
REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND
GASKET
HINT:
At the time of installation, please refer to the following item.
Replace the used gasket with a new gasket.
20.
DRAIN DIFFERENTIAL FLUID
21.
REMOVE LH AND RH ENGINE SIDE COVERS
22.
REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA–15 )
Author: Date:
1041
AX–22
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
23.
REMOVE ENGINE UNDER FRONT COVER AND CEN-
TER ENGINE UNDER COVER
Q10030
24.
REMOVE EXHAUST FRONT PIPE
(a) Remove the 2 bolts and exhaust front pipe support stay.
Torque: 33 N·m (330 kgf·cm, 24 ft·lbf)
(b) Remove the 4 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Replace the used nuts with new once.
(c) Remove the 2 bolts and nuts.
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Replace the used nuts with new once.
(d) Remove the 2 exhaust front pipe clamp bolts and exhaust front pipe.
Torque: 33 N·m (330 kgf·cm, 24 ft·lbf)
(e) Remove the 3 gaskets.
HINT:
At the time of installation, please refer to the following item.
Replace the used gaskets with new once.
(f) Remove the 2 nuts, 2 bolts, exhaust front pipe support bracket and hole cover.
Torque:
Exhaust front pipe support bracket mounting nut:
21 N·m (210 kgf·cm, 15 ft·lbf)
Hole plug mounting bolt:
20 N·m (200 kgf·cm, 15ft·lbf)
Q10341
25.
REMOVE FRONT SIDE ENGINE MOUNTING INSULA-
TOR BOLT
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)
1997 LEXUS ES300 (RM511U)
Q00235
Author: Date: 1042
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
26.
DISCONNECT 2 OIL COOLER HOSES
AX–23
Q10027
27.
REMOVE REAR SIDE ENGINE MOUNTING NUT
(a) Remove the 2 grommets.
(b) Remove the 4 nuts.
Torque: 66 N·m (670 kgf·cm, 48 ft·lbf)
Q10071
28.
REMOVE LEFT SIDE TRANSAXLE MOUNTING NUT
(a) Remove the 2 grommets.
(b) Remove the 2 nuts.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)
Q10034
Q10035
29.
REMOVE STEERING GEAR HOUSING
(a) Remove the 4 bolts, LH and RH stabilizer bar brackets and bushings.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(b) Remove the front stabilizer bar.
(See page SA–41 )
(c) Remove the 2 steering gear housing mounting bolts and nuts.
Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
30.
SUPPORT STEERING GEAR HOUSING, AS SHOWN
1997 LEXUS ES300 (RM511U)
Q10040
Author: Date:
1043
AX–24
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
Engine
Hanger
P19478
31.
ATTACH ENGINE SLING DEVICE TO ENGINE HANG-
ERS
(a) Install the No.2 engine hanger in the correct direction.
Part No.: No.2 engine hanger: 12282–20020
Bolt: 91642–80825
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Attach the engine chain hoist to the engine hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to any other part.
32.
REMOVE FRONT FRAME ASSEMBLY
(a) Remove the 2 bolts and steering return pipe mounting brackets.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
Q06479
(b) Remove the screws and turn over the front side of the LH and RH fender liners.
Q10041
(c) Remove the screws and turn over the rear side of LH and
RH fender liners.
Q10037
1997 LEXUS ES300 (RM511U)
Author: Date: 1044
Front
AX–25
AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
(d) Remove the 6 bolts and 4 nuts.
Torque:
19 mm head bolt: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
14 mm head bolt: 32 N·m (330 kgf·cm, 24 ft·lbf)
Nut: 36 N·m (370 kgf·cm, 27 ft·lbf)
(e) Remove the front frame assembly.
Q10172
Rear
Q10064
Q04660
33.
SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
34.
REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
Turn the crankshaft to gain access to each bolt, remove the 6 bolts with holding the crankshaft pulley bolt by a wrench.
Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
First install black colored bolt and then the 5 other bolts.
35.
REMOVE EXHAUST MANIFOLD PLATE
Remove the bolt, nut and exhaust manifold plate.
Torque: 20 N·m (200 kgf·cm, 15 ft·lbf)
Left and Lower
1997 LEXUS ES300 (RM511U)
Q10036
36.
REMOVE 3 LOWER TRANSAXLE–TO–ENGINE
BOLTS
Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)
37.
REMOVE TRANSAXLE ASSEMBLY
Separate the transaxle and engine, and lower the transaxle.
Z14284
Author: Date:
1045
AX–26
AUTOMATIC TRANSAXLE
AT3412
– AUTOMATIC TRANSAXLE UNIT
AX01X–02
INSTALLATION
1.
CHECK TORQUE CONVERTER CLUTCH INSTALLA-
TION
Using a scale and straight edge, measure from the installed surface to the transaxle housing.
Correct distance: 13.7 mm (0.539 in.) or more
2.
TRANSAXLE INSTALLATION
Installation is in the reverse order of removal.
(See page AX–20 )
HINT:
After installation, check and inspect items as follows.
Fluid level. (See page DI–150 )
Front wheel alignment. (See page SA–4 )
Do the road test.
Hood. (See page BO–7 )
1997 LEXUS ES300 (RM511U)
Author: Date: 1046
SST
SST
AX–27
AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE
INSPECTION
AX01Y–02
1.
INSPECT ONE–WAY CLUTCH
(a) Install SST into the inner race of the one–way clutch.
SST 09350–32014 (09351–32020)
AT0952
(b) Install SST so that it fits in the notch of the converter hub and outer race of the one–way clutch.
SST 09350–32014 (09351–32010)
Hold
Turn
AT0953
(c) With the torque converter clutch standing on its side,the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch.
Replace the converter if the clutch still fails the test.
Lock
Free
AT3306
AT2821
2.
MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
(a) Set up a dial indicator, and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within specification or ring gear is damaged, replace the drive plate.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
3.
MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
(a) Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator and measure the torque converter clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correct by reorienting the installation of the converter.
AT4184
1997 LEXUS ES300 (RM511U)
Author: Date:
1047
AX–28
AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE
HINT:
Mark the position of the converter to ensure the correct installation.
(b) Remove the torque converter clutch.
1997 LEXUS ES300 (RM511U)
Author: Date: 1048
40-1
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE FLUID
ON-VEHICLE INSPECTION
4005R-08
1.
CHECK THE FLUID LEVEL
HINT:
Drive the vehicle so that the engine and transaxle are at normal operating temperature.
Fluid temperature: 70 - 80
°
C (158 - 176
°
F)
Add if hot
OK if hot
D25120
(a) Park the vehicle on a level surface and set the parking brake.
(b) With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position, and return to P position.
(c) take out the dipstick and wipe it clean.
(d) Put it back fully into the pipe.
(e) take it out and check that the fluid level is in the HOT position.
If there are leaks, it is necessary to repair or replace O-rings,
FIPGs, oil seals, plugs and/or other parts.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2516
40-2
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY
400FX-04
PRECAUTION
1.
The automatic transaxle is composed of highly precision-finished parts, if nequine careful inspection before reassembly therefore even a small nick may cause fluid leakage or may degrade the performance. The instructions here are organized so that you work on only one component group at a time. This will help you to avoid confusion about similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. Inspectio, repair and reassembly
As much as possible, before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups.
Recommended ATF: T-IV
2.
All disassembled parts should be washed clean and any fluid passages and holes should be blown with compressed air.
3.
Dry all parts with compressed airnever use shop rags.
4.
When using compressed air, do not aim at yourself to prevent accidentally spraying ATF or kerosene on your face.
5.
The recommended automatic transaxle fluid or kerosene should be used for cleaning.
6.
After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs, and reassembly.
7.
When disassembling a valve body, be sure to match each valve together with the corresponding spring.
8.
New discs for the brakes and clutches that are to be used for replacement must be soaked in
ATF for at least 15 minutes before reassembly.
9.
All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly.
10.
All gaskets and rubber O-rings should be replaced.
11.
Do not apply adhesive cements to gaskets and similar parts.
12.
Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
13.
If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be replaced.
14.
Check thrust bearings and races for wear or damage. Replace if necessary.
15.
Use petroleum jelly to keep parts in place.
16.
When working with FIPG material, you must perform the following.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2517
40-3
AUTOMATIC TRANSMISSION / TRANS PARK/NEUTRAL POSITION SWITCH ASSY (U151E)
REPLACEMENT
1.
REMOVE BATTERY
2.
REMOVE AIR CLEANER ASSY
3.
REMOVE AIR CLEANER HOSE NO.1
4.
REMOVE AIR CLEANER BRACKET
5.
REMOVE AIR CLEANER INLET NO.1
6.
REMOVE INTAKE AIR RESONATOR SUB-ASSY
7.
REMOVE ENGINE UNDER COVER NO.1
4010O-05
8.
DISCONNECT TRANSMISSION CONTROL CABLE
ASSY
(a) Remove the nut from the control shaft lever.
(b) Disconnect the control cable from the control shaft lever.
D30614
(c) Remove the clip and disconnect the control cable from the control cable bracket.
D25415
9.
REMOVE PARK/NEUTRAL POSITION SWITCH ASSY
(a) Disconnect the park/neutral position switch connector.
(b) Remove the nut, washer and control shaft lever.
C99458
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2518
40-4
AUTOMATIC TRANSMISSION / TRANS PARK/NEUTRAL POSITION SWITCH ASSY (U151E)
(c) Pry out the lock plate.
C99457
(d) Remove the lock nut and lock plate.
C87814
(e) Remove the 2 bolts and pull out the park/neutral position switch.
C99454
Manual Valve Shaft
C99454
10.
INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) Install the park/neutral position switch to the manual valve shaft.
(b) Temporarily install the 2 bolts.
(c) Place the lock plate and tighten the nut.
Torque: 6.9 N
⋅ m (70 kgf
⋅ cm, 61 in.
⋅ lbf)
(d) Temporarily install the control shaft lever.
(e) Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
(f) Remove the control shaft lever.
C99455
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2519
AUTOMATIC TRANSMISSION / TRANS PARK/NEUTRAL POSITION SWITCH ASSY (U151E)
Neutral
Basic
Line
(g) Align the groove with neutral basic line.
(h) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
40-5
Groove
C99456
(i) Using a screwdriver, stake the nut with the lock plate.
C99457
(j) Install the control shaft lever, washer and nut.
Torque: 13 N
⋅ m (130 kgf
⋅ cm, 9 ft
⋅ lbf)
(k) Connect the park/neutral position switch connector.
C99458
11.
CONNECT TRANSMISSION CONTROL CABLE ASSY
(a) Temporarily install the control cable to the control shaft lever with the nut.
D30614
(b) Install the control cable and a new clip to the bracket.
D25415
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2520
40-6
AUTOMATIC TRANSMISSION / TRANS PARK/NEUTRAL POSITION SWITCH ASSY (U151E)
12.
ADJUST SHIFT LEVER POSITION (SEE PAGE 40-40 )
13.
INSPECT SHIFT LEVER POSITION (SEE PAGE 40-40 )
14.
INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (SEE PAGE 40-7 )
15.
INSTALL ENGINE UNDER COVER NO.1
16.
INSTALL INTAKE AIR RESONATOR SUB-ASSY
17.
INSTALL AIR CLEANER INLET NO.1
18.
INSTALL AIR CLEANER BRACKET
19.
INSTALL AIR CLEANER HOSE NO.1
20.
INSTALL AIR CLEANER ASSY
21.
INSTALL BATTERY
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2521
40-7
AUTOMATIC TRANSMISSION / TRANS PARK/NEUTRAL POSITION SWITCH ASSY (U151E)
4010P-03
ADJUSTMENT
1.
INSPECT PARK/NEUTRAL POSITION SWITCH ASSY
(a) Apply the parking brake and turn the ignition switch to ON.
(b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P position.
(c) Check that the back-up light is lit and the reverse warning buzzer sounds only when the shift lever is set in R position.
If a failure is found, check the continuity of the park/neutral position switch.
Groove
Neutral
Basic Line
C99453
2.
ADJUST PARK/NEUTRAL POSITION SWITCH ASSY
(a) Loosen the 2 bolts of park/neutral position switch and set the shift lever to the N position.
(b) Align the groove with neutral basic line.
(c) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
(d) After adjustment, perform the inspection described in step 1.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2522
40-8
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E)
COMPONENTS
8.4 (86, 74 in.
⋅ lbf) Bearing Bracket Hole Snap Ring
32 (326, 24)
Front Drive Shaft Assy RH
4010Q-02
Wire Harness Clamp
12 (122, 9)
Transmission Control
Cable Bracket No.2
13 (130, 9)
Wire Harness
Automatic
Transmission Case
Cover
12 (122, 9)
41 (418, 30)
64 (653, 47) x 5
37 (377, 27)
Torque Converter Clutch
7.8 (80, 69 in.
⋅ lbf)
Exhaust Pipe Support Bracket
Flywheel Housing
Under Cover
Transmission Control
Cable Bracket No.1
Oil Cooler Tube Clamp
5.4 (55, 48 in.
⋅ lbf)
X6
Engine
Mounting
Bracket FR
64 (653, 47)
Transimission Oil
Filler Tube Sub-assy
46 (470, 34)
12 (122, 9)
Front Drive
ShaftLH Hole
Snap Ring
Oil Cooler Inlet
Tube No.1
34 (350, 25)
12 (122, 9)
Oil Cooler
Outlet Tube No.1
ATF Level
Gauge
34 (350, 25)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
O-ring
5.5 (56, 49 in.
⋅ lbf)
Front Drive Shaft
Assy LH
Starter Assy
9.8 (100, 87 in.
⋅ lbf)
37 (377, 27)
D31337
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2523
40-9
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E)
REPLACEMENT
1.
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-29 )
2.
REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-8 )
3.
REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-8 )
4010R-03
4.
REMOVE TRANSMISSION CONTROL CABLE
BRACKET NO.2
(a) Remove the bolt and transmission control cable bracket
No.2.
C91731
5.
REMOVE WIRE HARNESS CLAMP
(a) Disconnect the wire harnesses from the clamps.
(b) Remove the 2 bolts and 2 clamps.
D31338
6.
DISCONNECT WIRE HARNESS
(a) Remove the bolt and wire harness.
D30466
7.
REMOVE STARTER ASSY
(a) Disconnect the connector.
(b) Remove the nut and disconnect the starter wire.
(c) Remove the 2 bolts and starter assy.
D30464
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2524
40-10
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E)
Transmission
Wire Connector
8.
DISCONNECT CONNECTORS
(a) Disconnect the transmission wire connector.
(b) Disconnect the park/neutral position switch connector.
(c) Disconnect the 2 transmission revolution sensor connectors.
Park/neutral Position Switch Connector
Transmission Revolution
Sensor Connectors
SST
D30864
9.
REMOVE TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Remove the bolt and oil cooler tube clamp.
(b) Remove the 2 bolts and transmission control cable bracket.
C91736
10.
REMOVE TRANSMISSION OIL FILLER TUBE
SUB-ASSY
(a) Remove the ATF level gauge.
(b) Remove the bolt and oil filler tube.
(c) Remove the O-ring from the oil filler tube.
C91737
11.
REMOVE OIL COOLER INLET TUBE NO.1
(a) Using SST and spanner, disconnect the oil cooler inlet tube No.1.
SST 09023-12701
C88047
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2525
40-1 1
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E)
(b) Disconnect the breather hose from the wire harness bracket.
D31339
12.
REMOVE OIL COOLER OUTLET TUBE NO.1
(a) Using SST and spanner, disconnect the oil cooler outlet tube No.1.
SST 09023-12701
13.
REMOVE ENGINE MOUNTING BRACKET FR
(a) Remove the 3 bolts and engine mounting bracket FR.
D30472
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
D25420
14.
REMOVE AUTOMATIC TRANSAXLE ASSY
(a) Remove the 2 bolts and fryweel housing under cover.
D31340
(b) Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.
Author: Date:
2526
40-12
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E)
(c) Remove the 8 bolts.
(d) Separate and remove the automatic transaxle.
D30511 D30668
15.
REMOVE TORQUE CONVERTER CLUTCH ASSY
16.
REMOVE TRANSAXLE CASE COVER UPPER
(a) Remove the 3 bolts and transmission case cover.
C88136
17.
INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-17 )
SST 09350-32014 (09351-32010, 09351-32020)
18.
INSTALL TRANSAXLE CASE COVER UPPER
(a) Install the transmission case cover with the 3 bolts.
Torque: 12 N
⋅ m (122 kgf
⋅ cm, 9 ft
⋅ lbf)
C88136
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2527
40-13
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E)
19.
INSTALL TORQUE CONVERTER CLUTCH ASSY
(a) Install the torque converter clutch to the automatic transaxle.
(b) Using vernier calipers, measure dimension ”A” between the transaxle fitting part and the converter fitting part of the drive plate.
C83051
D30511
A
B
A
(c) Using vernier calipers and a straight edge, measure dimension ”B” shown in the illustration and check that ”B” is greater than ”A” measured in (b).
Standard: A + 1 mm or more
NOTICE:
Do not add the thickness of the straight edge.
C
A
B
Dimension B
D31341
A
A
20.
INSTALL AUTOMATIC TRANSAXLE ASSY
(a) Install the automatic transaxle and 8 bolts to the engine.
Torque:
Bolt A: 64 N
⋅ m (653 kgf
⋅ cm, 47 ft
⋅ lbf)
Bolt B: 46 N
⋅ m (470 kgf
⋅ cm, 34 ft
⋅ lbf)
Bolt C: 37 N
⋅ m (377 kgf
⋅ cm, 27 ft
⋅ lbf)
C
D31482
(b) Apply a few drops of adhesive to each 2 threads on the tip of the 6 torque converter clutch mounting bolts.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
(c) Install the 6 torque converter clutch mounting bolts.
Torque: 41 N
⋅ m (418 kgf
⋅ cm, 30 ft
⋅ lbf)
HINT:
First install green colored bolt, and then install the other 5 bolts.
D30472
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2528
40-14
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E)
(d) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
D31340
D25420
21.
INSTALL ENGINE MOUNTING BRACKET FR
(a) Install the engine mounting bracket FR with the 3 bolts to the automatic transaxle.
Torque: 64 N
⋅ m (653 kgf
⋅ cm, 47 ft
⋅ lbf)
22.
INSTALL TRANSMISSION OIL FILLER TUBE
SUB-ASSY
(a) Coat a new O-ring with ATF, and install it to the oil filler tube.
(b) Install the oil filler tube with the bolt to the automatic transaxle.
Torque: 5.5 N
⋅ m (56 kgf
⋅ cm, 49 in.
⋅ lbf)
(c) Install the ATF level gauge.
Breather Hose
C88135
(d) Connect the breather hose to the wire harness bracket.
D31339
C88278
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
23.
INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Install the control cable bracket No.1 with the 2 bolts.
Torque: 12 N
⋅ m (122 kgf
⋅ cm, 9 ft
⋅ lbf)
24.
INSTALL OIL COOLER INLET TUBE NO.1
(a) Temporarily install the oil cooler outlet tube No.1.
(b) Temporarily install the oil cooler inlet tube No.1.
Author: Date: 2529
SST
40-15
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E)
Oil cooler tube cushion
(c) Install the oil cooler tube clamp with the bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
HINT:
Install them so that the oil cooler tube cushion is positioned as shown in the illustration.
C91745
(d) Using SST and spanner, tighten the oil cooler inlet tube
No.1.
Torque: 34 N
⋅ m (350 kgf
⋅ cm, 25 ft
⋅ lbf)
SST 09023-12701
C92540
25.
INSTALL OIL COOLER OUTLET TUBE NO.1
(a) Using SST and spanner, tighten the oil cooler outlet tube No.1.
Torque: 34 N
⋅ m (350 kgf
⋅ cm, 25 ft
⋅ lbf)
SST 09023-12701
Transmission
Wire Connector
26.
CONNECT CONNECTORS
(a) Connect the transmission wire connector.
(b) Connect the park/neutral position switch connector.
(c) Connect the 2 transmission revolution sensor connectors.
Park/neutral Position Switch Connector
Transmission Revolution
Sensor Connectors
D30864
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2530
40-16
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U151E)
27.
INSTALL STARTER ASSY
(a) Install the starter assy with the 2 bolts.
Torque: 37 N
⋅ m (377 kgf
⋅ cm, 27 ft
⋅ lbf)
(b) Connect the connecter.
(c) Install the starter wire and nut.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 87 in
⋅ lbf)
D30464
28.
INSTALL WIRE HARNESS
(a) Install the wire harness and bolt.
Torque: 13 N
⋅ m (130 kgf
⋅ cm, 9 ft
⋅ lbf)
D30466
29.
INSTALL WIRE HARNESS CLAMP
(a) Install the 2 clamps and 2 bolts.
Torque: 8.4 N
⋅ m (86 kgf
⋅ cm, 74 in.
⋅ lbf)
(b) Connect the wire harnesses to the clamps.
D31338
30.
INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO.2
(a) Install the transmission control cable bracket No.2 with a bolt.
Torque: 12 N
⋅ m (122 kgf
⋅ cm, 9 ft
⋅ lbf)
C91731
31.
INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-8 )
32.
INSTALL FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-8 )
33.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-29 )
34.
RESET MEMORY(SEE PAGE 05-604 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2531
40-17
AUTOMATIC TRANSMISSION / TRANS TORQUE CONVERTER CLUTCH AND DRIVE PLATE
INSPECTION
40063-10
SST
1.
INSPECT TORQUE CONVERTER CLUTCH ASSY
(a) Inspect the one-way clutch.
(1) Set SST into the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(2) Install hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
AT0953
Hold
Turn
Lock
Free
AT3306
(3) With the torque converter clutch setting up on its side, check that the one-way clutch locks when it is turned counterclockwise, and rotates clockwise smoothly.
If necessary, clean the converter and retest the one- way clutch.
Replace the converter if the one-way clutch still fails the test.
Sample showing minimum amount of powders in ATF
Actual Size
D25367
(b) Determine the condition of the torque converter clutch assy.
(1) If the inspection result of the torque converter clutch assy meets the following item, replace the torque converter clutch.
Malfunction item:
Any metallic sound is heard from the torque converter clutch during stall test or when the shift lever is in neutral position.
One-way clutch is free or locked in both directions.
Fine powders exceeding the sample limit is identified in ATF. (See the sample.)
HINT:
The sample shows the auto fluid of approx. 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch
(c) Replace the ATF in the torque converter clutch.
(1) If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the face for installation facing up.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2532
40-18
OK NG
AUTOMATIC TRANSMISSION / TRANS TORQUE CONVERTER CLUTCH AND DRIVE PLATE
C11090
(d) Clean and check the oil cooler and oil pipe line.
(1) If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line.
HINT:
Spray compressed air of 196 kPa (2 kgf/cm
2
, 28 psi) from the inlet hose.
If plenty of fine powders are identified in the ATF, add new
ATF using a bucket pump and clean it again.
(2) If the ATF is cloudy, inspect the oil cooler (radiator).
The Bottom is
Damaged
(e) Prevent deformation of the torque converter clutch and damage to the oil pump gear.
(1) When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and the torque converter clutch.
(2) All of the bolts must be have the same length.
(3) No missing spring washer.
D25368
2.
INSPECT DRIVE PLATE & RING GEAR SUB-ASSY
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or ring gear is damaged, replace the drive plate.
C81014
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2533
AUTOMATIC TRANSMISSION / TRANS SPEED SENSOR
REPLACEMENT
1.
REMOVE BATTERY
2.
REMOVE AIR CLEANER ASSY
3.
REMOVE AIR CLEANER HOSE NO.1
4.
REMOVE SPEED SENSOR (NT SENSOR)
(a) Disconnect the speed sensor connector.
(b) Remove the bolt and speed sensor.
40-19
40060-08
C90569
5.
REMOVE SPEED SENSOR (NC SENSOR)
(a) Disconnect the speed sensor connector.
(b) Remove the bolt and speed sensor.
C90570
6.
INSTALL SPEED SENSOR (NC SENSOR)
(a) Coat O-ring with ATF.
(b) Install the speed sensor with the bolt.
Torque: 11.3 N
⋅ m (115 kgf
⋅ cm, 8 ft
⋅ lbf)
HINT:
Make sure of the manufacturer’s name.
(c) Connect the speed sensor connector.
C90570
7.
INSTALL SPEED SENSOR (NT SENSOR)
(a) Coat O-ring with ATF.
(b) Install the speed sensor with the bolt.
Torque: 11.3 N
⋅ m (115 kgf
⋅ cm, 8 ft
⋅ lbf)
HINT:
Make sure of the manufacturer’s name.
(c) Connect the speed sensor connector.
C90569
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2534
40-20
AUTOMATIC TRANSMISSION / TRANS SPEED SENSOR
8.
INSTALL AIR CLEANER HOSE NO.1
9.
INSTALL AIR CLEANER ASSY
Torque: 5.0 N
⋅ m (51 kgf
⋅ cm, 44 in.
⋅ lbf)
10.
INSTALL BATTERY
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2535
40-21
AUTOMATIC TRANSMISSION / TRANS 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 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
4010V-04
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.
C91925
(b) Remove the 2 magnets from the oil pan.
D30865
(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
AT0103
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.
C91927
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2536
40-22
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION WIRE (U151E)
5.
REMOVE TRANSMISSION WIRE
(a) Disconnect the transmission wire connectors.
(b) Remove the bolt and transmission wire.
D03547
6.
INSTALL TRANSMISSION WIRE
(a) Coat a O-ring of the transmission wire connector with
ATF.
(b) Install the transmission wire with the bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
D03547
7.
CONNECT TRANSMISSION WIRE
(a) Coat a O-ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 N
⋅ m (67 kgf
⋅ cm, 58 in.
⋅ lbf)
(c) Connect the 7 shift solenoid valve connectors.
C91927
8.
INSTALL AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing to the 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
D30865
(c) Install a new gasket, oil pan and 18 bolts to the transaxle case.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
NOTICE:
Since the bolts should be seal bolts, apply seal packing to the bolts and tighten them within 10 minutes after applying.
C91925
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2537
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION WIRE (U151E)
9.
ADD AUTOMATIC TRANSAXLE FLUID
10.
INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-1 )
11.
INSTALL ENGINE UNDER COVER NO.1
12.
RESET MEMORY (SEE PAGE 05-604 )
40-23
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2538
40-24
AUTOMATIC TRANSMISSION / TRANS 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 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
4010W-04
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.
C91925
(b) Remove the 2 magnets from the oil pan.
D30865
(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
AT0103
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.
C91927
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AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U151E)
5.
REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
NOTICE:
Be careful that some fluid will come out from the oil strainer.
C91931
(b) Remove the O-ring from the oil strainer.
C91932
6.
REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy and remove the 17 bolts and the valve body assy.
NOTICE:
Be careful not to drop the check valve body, spring and accumulator piston.
C91933
(b) Remove the check ball body and spring.
G30205
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AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U151E)
(c) Remove the 5 bolts and 7 shift solenoid valves.
D30644
7.
INSTALL TRANSMISSION VALVE BODY ASSY
(a) Install the spring and check ball body.
C
A
B
G30205
B
(b) Install the 7 shift solenoid valves with the 5 bolts.
Torque:
Bolt A, B: 11 N·m (110 kgf·cm, 8 ft.
⋅ lbf)
Bolt C, D: 6.6 N·m (67 kgf·cm, 58 in. lbf)
Bolt length:
Bolt A: 16 mm (0.63 in.)
Bolt B: 57 mm (2.2 in.)
Bolt C: 23 mm (0.9 in.)
Bolt D: 12 mm (0.47 in.)
D
D30644
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2541
B
A
C
B
B
B
C
B
40-27
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U151E)
A
C
C
C
C91933
(c) Align the groove of the manual valve with the pin of lever.
(d) Install the 17 bolts.
Torque: 11 N
⋅ m (110 kgf
⋅ cm, 8 ft
⋅ lbf)
NOTICE:
Push the valve body against the accumulator piston spring and the check ball body to install it.
Temporarily tighten those bolts marked by in the illustration first because they are positioning bolts.
Bolt length:
Bolt A: 25 mm (0.984 in.)
Bolt B: 57 mm (2.244 in.)
Bolt C: 41 mm (1.614 in.)
8.
INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O-ring with ATF.
(b) Install the O-ring to the oil strainer.
C91932
(c) Install the oil strainer with the 3 bolts.
Torque: 11 N
⋅ m (110 kgf
⋅ cm, 8 ft
⋅ lbf)
C91931
9.
INSTALL TRANSMISSION WIRE
(a) Coat a O-ring with ATF.
(b) Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 N
⋅ m (67 kgf
⋅ cm, 58 in.
⋅ lbf)
(c) Connect the 7 shift solenoid valve connectors.
C91927
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AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U151E)
10.
INSTALL AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing to 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
D30865
(c) Install a new gasket, oil pan and 18 bolts to the transaxle case.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
NOTICE:
Since the bolts should be seal bolts, apply seal packing to the bolts and tighten them within 10 minutes after applying.
C91925
11.
ADD AUTOMATIC TRANSAXLE FLUID
12.
INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-1 )
13.
INSTALL ENGINE UNDER COVER NO.1
14.
RESET MEMORY (SEE PAGE 05-604 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U151E)
REPLACEMENT
1.
REMOVE FRONT WHEELS
2.
REMOVE ENGINE UNDER COVER NO.1
3.
DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
4.
REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-8 )
5.
REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-8 )
SST
6.
REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09308-00010
40-29
4010X-04
SST
D25831
7.
REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09308-00010
SST
D25832
D25833
8.
INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09316-6001 1 (09316-00011)
Oil seal drive in depth:
0 0.5 mm (0 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
SST 09316-6001 1 (09316-00011)
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AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U151E)
9.
INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09223-15020, 09950-70010 (09951-07150)
Oil seal drive in depth:
0 0.5 mm (0 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
SST
D25834
10.
INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-8 )
11.
INSTALL FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-8 )
12.
INSTALL FRONT WHEELS
13.
ADD AUTOMATIC TRANSAXLE FLUID
14.
INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-1 )
15.
CHECK ABS SPEED SENSOR SIGNAL w/ VSC (SEE PAGE 05-471 ) w/o VSC (SEE PAGE 05-420 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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AUTOMATIC TRANSMISSION / TRANS SHIFT LOCK SYSTEM
40067-09
ON-VEHICLE INSPECTION
1.
CHECK SHIFT LOCK OPERATION
(a) Shift the shift lever to P position.
(b) Turn the ignition switch to LOCK.
(c) Check that the shift lever cannot be shifted to any other positions other than P.
(d) Turn the ignition switch to ON, depress the brake pedal and check that the shift lever can be shifted to any other positions.
2.
CHECK SHIFT LOCK RELEASE BUTTON OPERATION
(a) Using a small screwdriver, remove the shift lock release cover.
(b) When operating the shift lever with the shift lock release button pressed, check that the lever can be shifted to any position other than P.
3.
CHECK KEY INTERLOCK OPERATION
(a) Turn the ignition switch to ON.
(b) Depress the brake pedal and shift the shift lever to any other position other than P.
(c) Check that the ignition key cannot be turned to LOCK.
(d) Shift the shift lever to P position, turn the ignition key to LOCK and check that the ignition key can be removed.
4.
INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY
(a) Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the shift lock control unit assembly connector.
IG
Terminal
3 (STP) - 1 (E)
3 (STP) - 1 (E)
5 (IG) - (E)
5 (IG) - (E)
STP E
C63995
Depress brake pedal
Release brake pedal
Ignition switch ON
Ignition switch OFF
Measuring Condition Voltage (V)
10 - 14
0
10 - 14
0
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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AUTOMATIC TRANSMISSION / TRANS SHIFT LOCK SYSTEM
(b) Using an ohmmeter, measure the resistance at terminal
E (1) and body ground.
HINT:
Do not disconnect the shift lock control unit assembly connector.
Terminal
1 (E) - Body ground Always
E
C93272
Measuring Condition Specified Value
Continuity
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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40-33
AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT ASSY
OVERHAUL
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 BOX ASSY (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 RH (SEE PAGE 71-1 1 )
11.
REMOVE INSTRUMENT PANEL FINISH PANEL END LH (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 )
400FU-02
15.
DISCONNECT FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Disconnect the parking lock cable end from the lever pin of the floor shift assembly.
C93015
(b) Using a screwdriver, disconnect the parking lock cable from the floor shift assembly and clamp.
(c) Disconnect the cable clamp.
C92370
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AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT ASSY
16.
DISCONNECT TRANSMISSION CONTROL CABLE
ASSY
(a) Disconnect the floor shift transmission control cable from the rod of the floor shift assy.
C93149
17.
REMOVE FLOOR SHIFT ASSY
(a) Disconnect the shift lock control computer connector.
(b) Disconnect the indicator lamp wire connector.
(c) Remove the 4 bolts and transmission floor shift assy.
C93016
18.
REMOVE SHIFT LEVER KNOB SUB-ASSY
(a) Remove the floor shift lever knob from the shift lever.
C93017
19.
REMOVE FLOOR SHIFT POSITION INDICATOR
HOUSING SUB-ASSY
(a) Disconnect the wire harness from the clamp.
C92448
C92801
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AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT ASSY
(b) Using a screwdriver, release the 4 claws and remove the position indicator housing.
C93018
20.
REMOVE POSITION INDICATOR LIGHT GUIDE
(a) Using a screwdriver, release the 4 claws and remove the position indicator light guide.
C93019
21.
REMOVE INDICATOR LAMP WIRE SUB-ASSY
(a) Remove the indicator lamp wire from the position indicator light guide.
C93020
22.
REMOVE POSITION INDICATOR LAMP CAP
(a) Remove the floor shift position indicator lamp cap from the floor shift position indicator lamp bulb.
23.
REMOVE POSITION INDICATOR LAMP BULB
(a) Remove the floor shift position indicator lamp bulb from the indicator lamp wire.
24.
REMOVE SHIFT LOCK RELEASE BUTTON COVER
(a) Using a screwdriver, remove the shift lock release button cover.
C93021
C93271
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2550
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AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT ASSY
25.
REMOVE POSITION INDICATOR SLIDE COVER
(a) Remove the position indicator slide cover from the shift lever.
C93022
26.
REMOVE POSITION INDICATOR SLIDE COVER
(a) Remove the position indicator slide cover from the position indicator slide cover.
C92149
27.
REMOVE SHIFT LOCK RELEASE BUTTON
(a) While pressing the 2 claws, remove the shift lock release button and shift lock release spring.
C93023
28.
INSTALL SHIFT LOCK RELEASE BUTTON
(a) Apply MP grease to the shift lock release spring and shift lock release button.
(b) Install the shift lock release button and shift lock release spring to the shift lever.
C93023
29.
INSTALL POSITION INDICATOR SLIDE COVER
(a) Install the position indicator slide cover to the position indicator slide cover.
C92149
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AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT ASSY
30.
INSTALL POSITION INDICATOR SLIDE COVER
(a) Install the position indicator slide cover to the shift lever.
C93022
31.
INSTALL POSITION INDICATOR LAMP BULB
(a) Install the floor shift position indicator lamp bulb to the indicator lamp wire.
32.
INSTALL POSITION INDICATOR LAMP CAP
(a) Install the floor shift position indicator lamp cap to the floor shift position indicator lamp bulb.
33.
INSTALL INDICATOR LAMP WIRE SUB-ASSY
(a) Install the indicator lamp wire to the position indicator light guide.
C93020
34.
INSTALL POSITION INDICATOR LIGHT GUIDE
(a) Install the position indicator light guide to the floor shift position indicator housing.
HINT:
Fit the claws securely.
C93019
35.
INSTALL FLOOR SHIFT POSITION INDICATOR
HOUSING SUB-ASSY
(a) Install the floor shift position indicator housing to the shift lever.
HINT:
Fit the claws securely.
C93018
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AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT ASSY
36.
INSTALL SHIFT LOCK RELEASE BUTTON COVER
(a) Install the shift lock release button cover to the position indicator housing.
C93021
37.
INSTALL SHIFT LEVER KNOB SUB-ASSY
(a) Install the floor shift lever knob to the shift lever.
C93024
38.
INSTALL FLOOR SHIFT ASSY
(a) Install the floor shift assy to the vehicle with the 4 bolts.
Torque: 11.8 N
⋅ m (122 kgf
⋅ cm, 9 ft
⋅ lbf)
(b) Connect the shift lock control computer.
(c) Connect the indicator lamp wire connector.
C93016
39.
INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Install the floor shift transmission control cable to the shift lever.
HINT:
Install it with the uneven surface facing up.
C93149
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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Lock Key
40-39
AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT ASSY
40.
INSTALL FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Using a screwdriver, unlock the claw of the lock key of automatic adjustment part.
C93323
(b) Insert the slide cap into the through hole and install.
(c) Shift the shift lever to P position and turn the ignition switch to Lock.
C92370
(d) Insert the lever pin into the hole of the parking lock cable.
C93015
(e) Lock the lock key.
C93325
41.
INSTALL BATTERY
42.
ADJUST SHIFT LEVER POSITION(SEE PAGE 40-40 )
43.
INSPECT SHIFT LEVER POSITION(SEE PAGE 40-40 )
44.
INSPECT CHECK KEY INTERLOCK OPERATION(SEE PAGE 40-31 )
45.
INSPECT CHECK SHIFT LOCK OPERATION(SEE PAGE 40-31 )
46.
INSPECT CHECK SHIFT LOCK RELEASE BUTTON OPERATION(SEE PAGE 40-31 )
47.
INSTALL CONSOLE BOX DUCT NO.1(SEE PAGE 55-17 )
48.
INSTALL AIR DUCT REAR NO.2(SEE PAGE 55-17 )
49.
INSTALL AIR DUCT REAR NO.1(SEE PAGE 55-17 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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2554
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AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT ASSY
400H6-03
ADJUSTMENT
1.
INSPECT SHIFT LEVER POSITION
(a) When shifting from P to R position only with ignition switch ON and brake pedal, make sure that the shifting lever moves smoothly and can be moderately operated.
(b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position.
2.
ADJUST SHIFT LEVER POSITION
(a) Loosen the nut on the control shaft lever.
D25118
D25119
(b) Push the control shaft fully downward.
(c) Return the control shaft lever 2 notches to N position.
(d) Set the shift lever to N position.
(e) While holding the shift lever lightly toward the R position side, tighten the shift lever nut.
Torque: 14.7 N·m (150 kgf·cm, 10 ft·lbf)
(f) Start the engine and make sure that the vehicle moves forward when shifting the lever from N to D position and moves rearward when shifting it to R position.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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40-41
AUTOMATIC TRANSMISSION / TRANS 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 )
400FV-02
15.
REMOVE FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Disconnect the parking lock cable end from the lever pin of the floor shift assembly.
C93015
(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.
C92370
(e) Using a screwdriver, remove the cable from the upper bracket.
C93152
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2556
40-42
Lock Key
AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT PARKING LOCK CABLE ASSY
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.
C93152
(e) Using a screwdriver, unlock the claw of the lock key of automatic adjustment part.
C93323
(f) Insert the slide cap into the through hole and install.
C92370
(g) Insert the lever pin into the hole of the parking lock cable.
C93015
(h) Lock the lock key.
C93325
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AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT PARKING LOCK CABLE ASSY
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
40-43
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AUTOMATIC TRANSMISSION / TRANS TRANSMISSION CONTROL CABLE ASSY
REPLACEMENT
1.
REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1 )
2.
REMOVE AIR CONDITIONING RADIATOR ASSY (SEE PAGE 55-17 )
3.
REMOVE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-55 )
4.
REMOVE BATTERY
5.
REMOVE AIR CLEANER ASSY
6.
REMOVE AIR CLEANER HOSE NO.1
7.
REMOVE INTAKE AIR RESONATOR SUB-ASSY
400FW-02
8.
REMOVE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the nut from the control shaft lever.
(b) Disconnect the control cable from the control shaft lever.
D25414
(c) Remove the clip and disconnect the control cable from the control cable bracket.
D25415
(d) Disconnect the control cable from the control cable clamp.
C93327
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AUTOMATIC TRANSMISSION / TRANS TRANSMISSION CONTROL CABLE ASSY
(e) Disconnect the floor shift cable from the rod of the floor shift assy.
C93149
(f) Remove the 2 bolts and shift cable grommet retainer
No.2.
(g) Pull out the control cable from the body.
C90581
9.
INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) put in the control cable to the body.
(b) Install the shift cable grommet retainer No.2 to the floor shift cable.
(c) Install the floor shift cable, as shown in the illustration.
HINT:
Install it with the uneven surface facing up.
C92829
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AUTOMATIC TRANSMISSION / TRANS TRANSMISSION CONTROL CABLE ASSY
(d) Install the shift cable grommet retainer No.2 with the 2 bolts.
Torque: 4.9 N
⋅ m (50 kgf
⋅ cm, 43 in.
⋅ lbf)
C90581
(e) Connect the control cable to the control cable clamp.
C93327
(f) Temporarily install the control cable to the control shaft lever with nuts.
D25414
(g) Install the control cable and a new clip to the bracket.
D25415
10.
INSTALL INTAKE AIR RESONATOR SUB-ASSY
11.
INSTALL AIR CLEANER HOSE NO.1
12.
INSTALL AIR CLEANER ASSY
13.
INSTALL AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-55 )
14.
INSTALL AIR CONDITIONING RADIATOR ASSY (SEE PAGE 55-17 )
15.
INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1 )
16.
INSTALL BATTERY
17.
ADJUST SHIFT LEVER POSITION (SEE PAGE 40-40 )
18.
INSPECT SHIFT LEVER POSITION (SEE PAGE 40-40 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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32-1
BRAKE BRAKE SYSTEM
32038-03
PRECAUTION
Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts having the same part number or equivalent.
It is very important to keep parts and the area clean when repairing the brake system.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
INTRODUCTION section.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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2435
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BRAKE BRAKE SYSTEM
32039-18
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.
Symptom
Low pedal or spongy pedal
Brake drag
Brake pull
Hard pedal but brake inefficient
Suspect Area
2. Fluid leaks for brake system
3. Air in brake system
4. Piston seals (Worn or damaged)
5. Master cylinder (Fauly)
6. Booster push rod (Out of adjustment)
1. Brake pedal free play (Minimal)
2. Parking brake pedal travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Parking brake shoe clearance (Out of adjustment)
5. Pad (Cracked or distorted)
6. Piston (Stuck)
7. Piston (Frozen)
8. Tension or return spring (Faulty)
9. Booster push rod (Out of adjustment)
10.Vacuum leaks for booster system
11.Master cylinder (Faulty)
1. Piston (Stuck)
2. Pad (Oily)
3. Piston (Frozen)
4. Disc (Scored)
5. Pad (Cracked or distorted)
1. Fluid leaks for brake system
2. Air in brake system
3. Pad (Worn)
4. Pad (Cracked or distorted)
5. Pad (Oily)
6. Pad (Glanzed)
7. Disc (Scored)
8. Booster push rod (Out of adjustment)
9. Vacuum leaks for booster system
32-8
32-12
33-2
33-8
33-1 1
33-14
33-2
32-33
32-41
32-33
32-41
32-33
32-41
33-16
32-8
32-12
32-26
32-21
32-33
32-41
32-33
32-41
32-33
32-41
32-33
32-41
32-33
32-41
-
32-4
32-33
32-41
32-33
32-41
32-33
32-41
32-33
32-41
32-33
32-41
32-8
32-12
32-26
See page
-
32-4
32-33
32-41
32-21
32-8
32-12
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2436
Noise from brakes
BRAKE BRAKE SYSTEM
1. Pad (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad (dirty)
7. Pad (Glanzed)
8. Tension or return spring (Faulty)
9. Anti-squeal shim (Damaged)
10.Shoe hold-down spring (Damaged)
32-33
32-41
32-33
32-41
32-33
32-41
33-16
32-33
32-41
33-16
32-33
32-41
32-33
32-41
32-33
32-41
32-33
32-41
32-3
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2437
32-4
BRAKE BRAKE FLUID
3211W-03
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
F41694
F41695
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.
F41696
C80826
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 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2438
DLC3
Hand-held Tester
G23361
32-5
BRAKE BRAKE FLUID
(f) Repeat the above procedure to bleed the air out of the brake line for each wheel.
4.
BLEED BRAKE ACTUATOR ASSY (W/ VSC)
NOTICE:
After performing the usual air bleeding in the brake system, if the height or feel of the brake pedal cannot be obtained, perform air bleeding in the brake actuator assy with a hand-held tester by following procedures below.
(a) Depress the brake pedal more than 20 times with the engine off.
(b) Connect the hand-held tester to the DLC3, then turn the ignition switch to the ON position.
NOTICE:
Do not start the engine.
(c) Select ”AIR BLEEDING” on the hand-held tester.
HINT:
Please refer to the Hand-Held Tester Operator’s Manual for further details.
(d) Bleed the air out of the regular brake line in ”Step1: Increase” on the hand-held tester display.
NOTICE:
Perform the air bleeding by following the steps displayed on the hand-held tester.
Make sure that the brake fluid in the master cylinder reservoir tank does not become empty.
(1) Connect the vinyl tube to either one of the bleeder plugs.
C80826
(2) Depress the brake pedal several times, then loosen the bleeder plug of one of the above wheels with the pedal depressed.
(3) When fluid stops coming out, tighten the bleeder plug, then release the brake pedal.
(4) Repeat (2) and (3) until all air in the fluid is completely bled out.
(5) Tighten the bleeder plug certainly.
Torque: 8.3 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
(6) Repeat the above procedure to bleed the air out of the brake line for each wheel.
(e) Bleed the air out of the suction line in ”Step2: Inhalation” on the hand-held tester display.
NOTICE:
Perform the air bleeding by following the steps displayed on the hand-held tester.
Make sure that the brake fluid in the master cylinder reservoir tank does not become empty.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2439
32-6
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE BRAKE FLUID
(1) Connect the vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug.
(2) Operate the brake actuator assy using the handheld tester to bleed the air.
NOTICE:
The operation stops automatically in 4 seconds.
At this time, be sure to release the brake pedal.
(3) Check that the operation has stopped, by referring to the hand-held tester display.
(4) Repeat (2) and (3) until all the air in the fluid is completely bled out.
(5) Tighten the bleeder plug certainly.
Torque: 8.3 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
(6) For the rest of the wheels, bleed the air in the same way as stated in the above procedure.
(f) Bleed the air out of the pressure reduction line in ”Step3:
Decrease” on the hand-held tester display.
NOTICE:
Perform air bleeding by following the steps displayed on the hand-held tester.
Make sure that the brake fluid in the master cylinder reservoir tank does not become empty.
(1) Connect a vinyl tube to either one of the bleeder plugs.
(2) Loosen the bleeder plug.
(3) Using the hand-held tester, operate the brake actuator assy using hand-held tester, completely depress the brake pedal and keep it.
NOTICE:
The operation stops automatically in 4 seconds.
When performing this procedure continuously, an interval of at least 20 seconds is required.
When the operation is completed, the brake pedal slightly goes down. This is a normal phenomenon caused when the solenoid opens.
During this procedure, the pedal seems heavy, but completely depress it so that the brake fluid comes out from the bleeder plug.
Be sure to keep depressing the brake pedal. Never depress and release the pedal repeatedly.
(4) Tighten the bleeder plug, then release the brake pedal.
(5) Repeat (2) to (4) until all the air in the fluid is completely bled out.
(6) Tighten the bleeder plug certainly.
Torque: 8.3 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
(7) Repeat the above procedure to bleed the air out of the brake line for each wheel.
Author: Date: 2440
C80826
32-7
BRAKE BRAKE FLUID
(g) Bleed the air out of the regular brake line again in ”Step4:
Increase” on the hand-held tester display.
NOTICE:
Perform air bleeding by following the steps displayed on the hand-held tester.
Make sure that the brake fluid in the master cylinder reservoir tank does not become empty.
(1) Connect the vinyl tube to either one of the bleeder plug.
(2) Depress the brake pedal several times, then loosen the bleeder plug of one of the above wheels with the pedal depressed.
(3) When fluid stops coming out, tighten the bleeder plug, then release the brake pedal.
(4) Repeat (2) and (3) until all the air in the fluid is completely bled out.
(5) Tighten the bleeder plug certainty.
Torque: 8.3 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
(6) Repeat the above procedure to bleed the air out of the brake line for each wheel.
5.
CHECK FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3
F41007
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2441
32-8
BRAKE BRAKE PEDAL SUPPORT ASSY
ADJUSTMENT
Push Rod
320DV-02
Stop Lamp
Switch
Pedal Height
F41697
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 subassy 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 N
⋅ m (265 kgf
⋅ cm, 19 ft
⋅ lbf)
(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 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 lower.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2442
32-9
BRAKE BRAKE PEDAL SUPPORT ASSY
2.
CHECK PEDAL FREE PLAY
(a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
(b) Push in the pedal until the beginning of the resistance is felt. Measure the distance, as shown.
Pedal free play: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop lamp switch clearance.
If the clearance is OK, then troubleshoot the brake system.
Stop lamp switch clearance:
0.5 - 2.5 mm (0.020 - 0.098 in.)
Pedal Free play
F41698
Pedal Reserve
Distance
R00934
3.
CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake pedal.
With engine running, depress the pedal and measure the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 70 mm (2.76 in.)
If incorrect, troubleshoot the brake system.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2443
32-10
COMPONENTS
Stop Lamp
Switch Assy
Lock Nut
26 (265, 19)
13 (130, 9)
BRAKE BRAKE PEDAL SUPPORT ASSY
20 (204, 15)
Brake Pedal Support
37 (375, 27)
320DW-02
13 (130, 9)
Brake Pedal Bush
Stop Light Switch Cushion
Brake Pedal Return Spring
Clip
Brake Pedal Pad
Brake Pedal Bush
Brake Pedal
Push Rod Pin
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
Lithium soap base glycol grease
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
F42132
Author: Date: 2444
BRAKE BRAKE PEDAL SUPPORT ASSY
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 N
⋅ m (375 kgf
⋅ cm, 27 ft
⋅ lbf)
15.
INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch with the lock nut.
Torque: 26 N
⋅ m (265 kgf
⋅ cm, 19 ft
⋅ lbf)
16.
INSTALL BRAKE PEDAL SUPPORT ASSY
(a) Install the brake pedal support assy with the bolt and 4 nuts.
Torque:
Bolt: 20 N
⋅ m (204 kgf
⋅ cm, 15 ft
⋅ lbf)
Nut: 13 N
⋅ m (130 kgf
⋅ cm, 9 ft
⋅ lbf)
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 )
32-1 1
320DX-02
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2445
32-12
BRAKE ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
ADJUSTMENT
320OF-03
Push Rod
Stop Lamp
Switch Assy
Pedal Height
F42717
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 subassy 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 N
⋅ m (265 kgf
⋅ cm, 19 ft
⋅ lbf)
(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 lower.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2446
BRAKE ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
32-13
2.
CHECK PEDAL FREE PLAY
(a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
(b) Push in the pedal until the beginning of the resistance is felt. Measure the distance, as shown.
Pedal free play: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop lamp switch assy clearance.
If the clearance is OK, then troubleshoot the brake system.
Stop lamp switch clearance:
0.5 - 2.5 mm (0.020 - 0.098 in.)
Pedal Free Play
F42718
Pedal Reserve
Distance
R00934
3.
CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake pedal.
With engine running, depress the pedal and measure the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 63 mm (2.48 in.)
If incorrect, troubleshoot the brake system.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2447
32-14
COMPONENTS
BRAKE ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
320OJ-03
Instrument Cluster Finish Panel
Steering Column Cover Upper
20.6 (210, 15)
Steering Column Assy
Steerig Wheel Assy
Steering Wheel Cover
No.2
Horn Button Assy
8.8 (90, 78 in.
⋅ lbf)
Steering Intermediate
Shaft Sub-assy
20.6 (210, 15)
Steering Column
Cover Lower No.2
Steering Column Cover Lower
50 (510, 37)
Steering Wheel
Cover No.3
Connector Cover
Driver Side
Junction Block Assy
Heater to Foot Duct No.3
Instrument Panel Insert
Sub-assy Lower LH
Instrument Panel
Sub-assy Upper
Front Door Scuff Plate LH
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
F16915
Author: Date: 2448
BRAKE ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
32-15
Clip
Stop Lamp
Switch Cushion
Brake Pedal
Push Rod Pin
Return Spring
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Lithium soap base glycol grease
Stop Lamp Switch Connector
Stop Lamp Switch Assy
26 (265, 19)
Brake Pedal Support Assy
19.1 (194, 14)
Accelerator Pedal Assy
Accel Position
Sensor Connector
Brake Pedal Pad
12 (122, 8.8)
13 (130, 9)
Accelerator Pedal Pad
F16916
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2449
32-16
BRAKE ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
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 )
320OG-05
20.
REMOVE DRIVER SIDE JUNCTION BLOCK ASSY
(a) Remove the 3 nuts and junction bloke assy, then disconnect the connector.
F16911
21.
REMOVE BRAKE PEDAL RETURN SPRING
F16914
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2450
BRAKE ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
22.
REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
32-17
F16908
23.
REMOVE ACCELERATOR & BRAKE PEDAL ASSY
(a) Disconnect the stop lamp switch connector.
F16906
(b) Disconnect the accel position sensor connector.
F16910
(c) Remove the 4 bolts, nuts and accelerator & brake pedal assy.
F16907
24.
REMOVE STOP LAMP SWITCH ASSY
(a) Loosen the nut and remove the stop lamp switch assy.
F16909
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2451
32-18
25.
REMOVE BRAKE PEDAL PAD
BRAKE ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
26.
REMOVE STOP LAMP SWITCH CUSHION
F16905
30.
INSTALL BRAKE PEDAL PAD
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
F16905
27.
REMOVE ACCELERATOR PEDAL ASSY
(a) Remove the bolt, nut and accelerator pedal assy.
F16904
28.
INSTALL ACCELERATOR PEDAL ASSY
(a) Install the accelerator pedal assy with nut and bolt.
Torque: 12 N
⋅ m (122 kgf
⋅ cm, 8.8 ft
⋅ lbf)
F16904
29.
INSTALL STOP LAMP SWITCH CUSHION
Author: Date: 2452
BRAKE ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
31.
INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch assy with a nut.
Torque: 26 N
⋅ m (265 kgf
⋅ cm, 19 ft
⋅ lbf)
32-19
F16909
32.
INSTALL ACCELERATOR & BRAKE PEDAL ASSY
(a) Install the accelerator & brake pedal assy with the 4 nuts and bolts.
Torque:
Nut: 13 N
⋅ m (130 kgf
⋅ cm, 9 ft
⋅ lbf)
Bolt: 19.1 N
⋅ m (194 kgf
⋅ cm, 14 ft
⋅ lbf)
F16907
(b) Connect the accel position sensor connector.
F16910
(c) Connect the stop lamp switch connector.
F16906
33.
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 32-14 ).
F16908
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2453
32-20
BRAKE ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
34.
INSTALL BRAKE PEDAL RETURN SPRING
F16914
35.
INSTALL DRIVER SIDE JUNCTION BLOCK ASSY
(a) Install the junction block assy with the 3 nuts, then connect the each connector.
F16911
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 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2454
32-21
BRAKE BRAKE MASTER CYLINDER SUB-ASSY
OVERHAUL
1.
REMOVE AIR CLEANER ASSY
2.
DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluied immediately if it comes into contact with a painted surface.
320DY-06
Front Brake Tube
Frame No.1
F40991
3.
REMOVE BRAKE MASTER CYLINDER SUB-ASSY
(a) Disconnect the level warning switch connector.
(b) Using SST, remove the front brake tube frame No.1.
SST 09023-00101
(c) Using SST, disconnect the 4 brake tubes from the master cylinder.
SST 09023-00101
(d) Remove the 2 nuts, pull out the 2-way and brake master cylinder sub-assy.
F40992
4.
REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY
(a) Remove the master cylinder reservoir filler cap assy.
5.
REMOVE BRAKE MASTER CYLINDER RESERVOIR STRAINER
(a) Remove the master cylinder reservoir strainer.
6.
REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
(a) Remove the screw and pull out the master cylinder reservoir sub-assy.
7.
REMOVE MASTER CYLINDER RESERVOIR GROMMET
(a) Remove the 2 master cylinder reservoir grommets.
8.
REMOVE BRAKE MASTER CYLINDER KIT (W/O VSC)
(a) Place master cylinder in vise.
(b) Remove the O-ring.
(c) Push in the piston and remove the snap ring with snap ring pliers.
F40004
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2455
32-22
BRAKE BRAKE MASTER CYLINDER SUB-ASSY
(d) Push in the piston and remove the piston stopper bolt and gasket.
(e) Remove the No.1 piston sub-assy, pulling straight out not at an angle.
NOTICE:
If pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
C69097
(A)
R12236
(f) Place a waste cloth and 2 wooden blocks on the work table and lightly edges until the No.2 piston sub-assy drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag the top of the blocks is at least 100 mm (3.94 in.).
NOTICE:
If pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
9.
REMOVE BRAKE MASTER CYLINDER KIT (W/ VSC)
(a) Place master cylinder in vise.
(b) Remove the O-ring.
(c) Push in the piston and remove the snap ring with snap ring pliers.
NOTICE:
If pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
F41707
F09717
(d) Push in the piston with a screwdriver, and remove the straight pin by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(e) Remove the No.1 piston sub-assy, pulling straight out not at an angle.
NOTICE:
If pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
(A)
R12236
(f) Place a waste cloth and 2 wooden blocks on the work table and lightly edges until the No.2 piston sub-assy drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag the top of the blocks is at least 100 mm (3.94 in.).
NOTICE:
If pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2456
32-23
BRAKE BRAKE MASTER CYLINDER SUB-ASSY
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 possibility that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pistons.
(d) Push in the piston and install a new gasket and a new piston stopper bolt.
Torque: 10 N
⋅ m (100 kgf
⋅ cm, 7 ft
⋅ lbf)
C69097
(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 Oring and install the O-ring to the master cylinder.
F40004
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 possibility that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pistons.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2457
32-24
BRAKE BRAKE MASTER CYLINDER SUB-ASSY
(d) Install a straight pin.
HINT:
Insert the No.2 piston with the groove positioning horizontally.
F09718
(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 Oring and install the O-ring to the master cylinder.
F41707
13.
INSTALL MASTER CYLINDER RESERVOIR GROMMET
(a) Apply the lithium soap base glycol grease on the 2 master cylinder reservoir grommets.
(b) Install the 2 master cylinder reservoir grommets to the master cylinder reservoir sub-assy.
14.
INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
(a) Install the master cylinder reservoir sub-assy to the master cylinder with the screw.
15.
INSTALL BRAKE MASTER CYLINDER RESERVOIR STRAINER
(a) Install the brake master cylinder reservoir strainer.
16.
INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY
(a) Install the brake master cylinder reservoir filler cap assy.
SST
F42650
17.
INSPECT AND ADJUST BRAKE BOOSTER PUSH
ROD
(a) Apply SST to the master cylinder.
SST 09737-00013
(b) Set SST, on the master cylinder, lower the pin of the SST until it slightly touches the piston.
(c) Apply the chalk to the flat surfaced tip of the SST pin.
(d) Turn SST upside down and place it clearance between the brake booster and SST.
Clearance: 0 mm (0 in.)
HINT:
If there is a clearance between the SST main body and the booster shell. It means that the specified value, and no chalk attachment on the booster push rod means that it is more than the specified value.
Brake booster push rod clearance before shipment is adjusted to be 0.105 mm ( 0.004 in.).
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2458
32-25
BRAKE BRAKE MASTER CYLINDER SUB-ASSY
(e) Using SST, adjust the booster push rod length until the push rod lightly touches the pin head.
SST 09737-00020
SST
F40006
18.
INSTALL BRAKE MASTER CYLINDER SUB-ASSY
(a) Install the master cylinder sub-assy and 2-way with the
2 nuts.
Torque: 13 N
⋅ m (130 kgf
⋅ cm, 9 ft
⋅ lbf)
F40992
Front Brake Tube
Frame No. 1
F40991
(b) Using SST and connect the 4 front brake tubes to the master cylinder sub-assy.
Torque: 15 N
⋅ m (155 kgf
⋅ cm, 11 ft
⋅ lbf)
SST 09023-00101
(c) Using SST and install the front brake tube frame No.1 to the master cylinder.
Torque: 15 N
⋅ m (155 kgf
⋅ cm, 11 ft
⋅ lbf)
SST 09023-00101
(d) Connect the level warnig switch connector.
19.
FILL RESERVOIR WITH BRAKE FLUID
20.
BLEED MASTER CYLINDER (SEE PAGE 32-4 )
SST 09023-00101
21.
BLEED BRAKE LINE (SEE PAGE 32-4 )
22.
INSTALL AIR CLEANER ASSY
23.
CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 )
24.
CHECK BRAKE FLUID LEAKAGE
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2459
32-26
BRAKE BRAKE BOOSTER ASSY
ON-VEHICLE INSPECTION
GOOD
1st
2nd
3rd
3203F-08
NO GOOD
BR2238
1.
INSPECT BRAKE BOOSTER
(a) Air tightness check.
(1) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly.
HINT:
If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight.
(2) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding the pedal for 30 seconds, the booster is air tight.
BR2237
(b) Operating check.
(1) Depress the brake pedal several times with the ignition switch OFF and check that there is no change in the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2.
INSPECT VACUUM CHECK VALVE
(a) Check vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
Ventilation
No Ventilation
C16481
(3) Check that there is ventilation from the booster to engine, and no ventilation from the engine to the booster.
(4) If any fault is found, replace the vacuum check valve.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2460
BRAKE BRAKE BOOSTER ASSY
32-27
320DZ-05
COMPONENTS
Vacuum Hose Assy
Front Brake
Tube No.3
15 (155, 11)
Front Brake
Tube No.2
15 (155, 11)
Vacuum Hose Bracket
5.4 (55, 48 in.
⋅ lbf)
15 (155, 11)
Brake Master
Cylinder Sub-Assy
2-W ay
13 (130, 9)
13 (130, 9)
Clip
Gasket
Push Rod Pin
Push Rod Clevis
Brake Booster
Front Brake Tube Frame No.1
15 (155, 11)
13 (130, 9)
Clip
15 (155, 11)
Front Brake
Tube No.5
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
F46404
Author: Date:
2461
32-28
BRAKE BRAKE BOOSTER ASSY
REPLACEMENT
1.
REMOVE AIR CLEANER ASSY
2.
DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluid immediately if it comes into contact with a painted surface.
3.
REMOVE BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21 )
SST 09023-00101
3211X-04
4.
REMOVE VACUUM HOSE ASSY
(a) Remove the bolt and separate the vacuum hose from the vacuum hose bracket.
(b) Slide the clip and disconnect the vacuum hose from the brake booster.
F40995
5.
REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1 )
6.
REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1 )
7.
REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1 )
8.
REMOVE BRAKE PEDAL RETURN SPRING
9.
REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
10.
REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Loosen the lock nut and remove the push rod clevis.
11.
REMOVE FRONT BRAKE TUBE NO.5
(a) Using SST and remove the front brake tube No.5.
SST 09023-00101
F40996
12.
REMOVE BRAKE BOOSTER ASSY
(a) Remove the 4 nuts.
(b) Pull out the brake booster assy.
BR3753
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2462
BRAKE BRAKE BOOSTER ASSY
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 N
⋅ m (130 kgf
⋅ cm, 9 ft
⋅ lbf)
32-29
BR3753
16.
INSTALL FRONT BRAKE TUBE NO.5
(a) Using SST and install the front brake tube No.5.
Torque: 15 N
⋅ m (155 kgf
⋅ cm, 11 ft
⋅ lbf)
SST 09023-00101
F40996
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 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
(b) Connect the vacuum hose to the brake booster with the clip.
F40995
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
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2463
32-30
BRAKE BRAKE BOOSTER ASSY
27.
BLEED MASTER CYLINDER (SEE PAGE 32-4 )
SST 09023-00101
28.
BLEED BRAKE LINE (SEE PAGE 32-4 )
29.
INSTALL AIR CLEANER ASSY
30.
CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 )
31.
CHECK BRAKE FLUID LEAKAGE
32.
CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8 or 32-12 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2464
BRAKE FRONT BRAKE
COMPONENTS
Single Piston Type:
Front Disc Brake
Bleeder Plug Cap
Union Bolt
29.4 (300, 22)
Front Disc Brake
Bleeder Plug
8.3 (85, 74 in.
⋅ lbf)
Front Disc
34.3 (350, 25)
Disc Brake
Cylinder Assy LH
Front Disc Brake
Cylinder Slide Pin
Gasket
Front Flexible Hose
Front Disc
Brake Piston
34.3 (350, 25)
Piston Seal
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Cylinder Boot
Set Ring
106.9 (1,090, 79)
Wear Indicator
Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Disc Brake
Pad Kit Front
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
Lithium soap base glycol grease
Disc brake grease
Anti Squeal
Shim No.1
Anti Squeal
Shim No.2
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
106.9 (1,090, 79)
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Mounting LH
32-31
320E5-02
Front Disc Brake
Pad Support Plate
F41863
2465
32-32
BRAKE FRONT BRAKE
Twin Piston Type:
Front Disc Brake
Bleeder Plug Cap
Front Disc Brake
Bleeder Plug
8.3 (85, 74 in.
⋅ lbf)
Union Bolt
29.4 (300, 22)
34.3 (350, 25)
Front Disc
Piston Seal
Front Disc Brake
Cylinder Slide Pin
Gasket
Front Flexible Hose
34.3 (350, 25)
Disc Brake
Cylinder Assy LH
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc
Brake Piston
Cylinder Boot
Set Ring
Front Disc Brake
Bush Dust Boot
106.9 (1,090, 79)
Wear Indicator
Anti Squeal
Shim
106.9 (1,090, 79)
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Anti Squeal
Shim
Disc Brake
Pad Kit Front
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
Lithium soap base glycol grease
Disc brake grease
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
F41533
2466
32-33
BRAKE FRONT BRAKE
320E6-04
OVERHAUL
HINT:
Overhaul the RH side by the same procedures with LH side.
1.
REMOVE FRONT WHEEL
2.
DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surfaces.
3.
DISCONNECT FRONT 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 DISC BRAKE CYLINDER ASSY LH
(a) Remove the 2 bolts and disc brake cylinder.
F41534
5.
REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Remove the 2 brake pads with anti squeal shims.
6.
REMOVE ANTI SQUEAL SHIM KIT FRONT
(a) Remove the 2 anti squeal shims from 2 brake pads.
(b) Using a screwdriver, remove the wear indicator from 2 brake pads.
F41535
7.
REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the upper side front disc brake pad support plate.
8.
REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the bottom side front disc brake pad support plate.
9.
REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the 2 cylinder slide pins from the disc brake cylinder mounting.
F41536
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2467
32-34
BRAKE FRONT BRAKE
10.
REMOVE FRONT DISC BRAKE CYLINDER SLIDE
BUSH
(a) Remove the cylinder slide bush from the cylinder slide pin.
F41537
11.
REMOVE FRONT DISC BRAKE CYLINDER
MOUNTING LH
(a) Remove the 2 bolts and disc brake cylinder mounting.
F41561
12.
REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Using a screwdriver and hammer, remove the 2 bush dust boots from the disc brake cylinder mounting.
C68791
13.
REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder boot from the disc brake cylinder (Single piston Type).
F41563
(b) Using a screwdriver, remove the 2 set rings and 2 cylinder boots from the disc brake cylinder (Twin piston Type).
F41564
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2468
F41539
32-35
BRAKE FRONT BRAKE
14.
REMOVE FRONT DISC BRAKE PISTON
(a) Remove the front disc brake piston (Single piston Type).
(1) Place a piece of cloth or like, between the piston and the disc brake cylinder.
(2) Use compressed air to remove the piston from the disc brake cylinder.
CAUTION:
Do not place your fingers in front of the piston when using compressed air.
NOTICE:
Do not spatter the brake fluid.
(b) Remove the 2 front disc brake pistons (Twin piston Type).
(1) Place a piece of cloth or like, between the piston and the disc brake cylinder.
(2) Use compressed air to remove one of the piston from the disc brake cylinder.
F41560
(3) Press the removed piston to the cylinder with a certain force that prevent the piston from flying out via a chip of wood. Then blow into the air of compressor again to remove the other piston.
CAUTION:
Do not place your fingers in front of the piston when using compressed air.
NOTICE:
Do not spatter the brake fluid.
15.
REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the disc brake cylinder (Single piston Type).
NOTICE:
Do not damage the inner cylinder and the cylinder groove.
(b) Using a screwdriver, remove the 2 piston seals from the disc brake cylinder (Twin piston Type).
NOTICE:
Do not damage the inner cylinder and the cylinder groove.
16.
REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
17.
REMOVE FRONT DISC BRAKE BLEEDER PLUG
18.
INSPECT BRAKE CYLINDER AND PISTON
(a) Check the cylinder bore and piston for rust or scoring.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2469
32-36
BRAKE FRONT BRAKE
19.
INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
Single piston type:
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Twin piston type:
Standard thickness: 10.6 mm (0.417 in.)
Minimum thickness: 1.0 mm (0.039 in.)
F41541
20.
INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are cleaned off.
21.
INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are cleaned off.
22.
INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 in.)
Minimum thickness: 26.0 mm (1.024 in.)
Matchmarks
F41542
23.
REMOVE FRONT DISC
(a) Put matchmarks on the disc and the axle hub.
(b) Remove the disc.
F41543
24.
INSTALL FRONT DISC
(a) Aligning the matchmarks, install the front disc.
HINT:
When replacing the disc with a new one, select the installation position where the disc has the minimum runout.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2470
32-37
BRAKE FRONT BRAKE
25.
INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
(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
F41544 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 ”On-car” 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.
F41565
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 piston.
(3) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2471
32-38
F41566
BRAKE FRONT BRAKE
(b) Install the 2 cylinder boots (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 new cylinder boots.
(2) Install the 2 cylinder boots to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and piston.
(3) Using a screwdriver, install the 2 new set rings.
NOTICE:
Do not damage the cylinder boot.
31.
INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Apply the lithium soap base glycol grease to seal surface of 2 new bush dust boots.
(c) Using a socket wrench (19 mm) and hammer, drive the 2 brake bush dust boots into the brake cylinder mounting.
C68792
32.
INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 106.9 N
⋅ m (1,090 kgf
⋅ cm, 79 ft
⋅ lbf)
33.
INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylinder slide bush.
(b) Install the cylinder slide bush to the cylinder slide pin.
34.
INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide pins.
(b) Install the 2 cylinder slide pins to the disc brake cylinder mounting.
HINT:
Install the cylinder slide pin with cylinder slide bush into the bottom side.
35.
INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side front disc brake pad support plate.
36.
INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side front disc brake pad support plate.
Wear Indicator
Anti squeal
Shim No.1
Anti squeal
Shim No.1
Anti squeal
Shim No.2
F41703
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
37.
INSTALL ANTI SQUEAL SHIM KIT FRONT
(a) Install the anti squeal shim kit front (Single piston Type).
(1) Apply the both sides of anti squeal shim No.1 with pad grease, and install the shim together with anti squeal shim No.2 to each pad.
Author: Date: 2472
32-39
BRAKE FRONT BRAKE
(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.
Anti Squeal
Shim
Wear Indicator
F41866
(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 N
⋅ m (350 kgf
⋅ cm, 25 ft
⋅ lbf)
40.
CONNECT FRONT FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 N
⋅ m (300 kgf
⋅ cm, 22 ft
⋅ lbf)
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 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2473
32-40
BRAKE REAR BRAKE
COMPONENTS
320E7-03
Union Bolt
29.4 (300, 22)
Rear LH
Flexible Hose
Gasket
Rear Disc Brake
Cylinder Slide Pin
34.3 (350, 25)
Rear Disc Brake
Bleeder Plug Cap
Rear Disc Brake
Cylinder Slide Bush
Rear Disc Brake
Bleeder Plug
8.3 (85, 74 in.
⋅ lbf)
Disc Brake Cylinder
Assy Rear LH
Piston Seal
Rear Disc Brake
Disc Brake Piston
Set Ring
Rear Disc Brake
Bush Dust Boot
Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Disc Brake
Pad Kit Rear
Rear Disc Brake
Cylinder Slide Pin
39.2 (400, 29)
Rear Disc Brake
Pad Support Plate
Cylinder Boot
Rear Disc
Wear Indicator
61.8 (630, 46)
Disc Brake
Pad Kit Rear
Anti Squeal
Shim No.2
61.8 (630, 46)
Rear Disc Brake
Cylinder Mounting LH
Parking Brake Shoe
Adjusting Hole Plug
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
Lithium soap base glycol grease
Disc brake grease
Wear Indicator
Anti Squeal
Shim No.1
F41864
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2474
32-41
BRAKE REAR BRAKE
320E8-04
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.
F41547
5.
REMOVE DISC BRAKE CYLINDER ASSY REAR LH
(a) Lift up the disc brake cylinder and remove the disc brake cylinder.
F41548
6.
REMOVE REAR DISC BRAKE CYLINDER SLIDE
BUSH
(a) Remove the cylinder slide bush from the disc brake cylinder.
F41550
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2475
32-42
BRAKE REAR BRAKE
7.
REMOVE REAR DISC BRAKE BUSH DUST BOOT
(a) Remove the bush dust boot from the cylinder slide pin.
F41549
8.
REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), remove the cylinder slide pin.
F41551
9.
REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Remove the 2 brake pads with anti squeal shims.
10.
REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT
(a) Remove the 2 anti squeal shims from 2 brake pads.
(b) Using a screwdriver, remove the wear indicator from 2 brake pads.
F41535
11.
REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the upper side rear disc brake pad support plate.
12.
REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the bottom side rear disc brake pad support plate.
13.
REMOVE REAR DISC BRAKE CYLINDER MOUNTING
LH
(a) Remove the 2 bolts and disc brake cylinder mounting.
F41552
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2476
32-43
BRAKE REAR BRAKE
14.
REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder boot from the disc brake cylinder.
F41553
C82872
15.
REMOVE REAR DISC BRAKE PISTON
(a) Place a piece of cloth or like, between the piston and the disc brake cylinder.
(b) Use compressed air to remove the piston from the disc brake cylinder.
CAUTION:
Do not place your fingers in front of the piston when using compressed air.
NOTICE:
Do not spatter the brake fluid.
16.
REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the disc brake cylinder.
NOTICE:
Do not damage the inner cylinder and the cylinder groove.
17.
REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
18.
REMOVE REAR DISC BRAKE BLEEDER PLUG
19.
INSPECT BRAKE CYLINDER AND PISTON
(a) Check the cylinder bore and piston for rust or scoring.
20.
INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
USA, Canada models:
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Brazil models:
Standard thickness: 11.0 mm (0.433 in.)
Minimum thickness: 1.0 mm (0.039 in.)
F41541
21.
INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are cleaned off.
22.
INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are cleaned off.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2477
32-44
BRAKE REAR BRAKE
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.)
F41554
24.
REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
Matchmarks
25.
REMOVE REAR DISC
(a) Put matchmarks on the disc and the axle hub.
(b) Remove the disc.
F41555
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 runout.
27.
INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
28.
INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
(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
F41556 axle hub runout are normal, adjust the disc runout or grind it on a ”On-car” 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
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2478
32-45
BRAKE REAR BRAKE
32.
INSTALL PISTON SEAL
(a) Apply the lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder.
33.
INSTALL REAR DISC BRAKE PISTON
(a) Apply the lithium soap base glycol grease to the piston.
(b) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
34.
INSTALL CYLINDER BOOT
(a) Apply the lithium soap base glycol grease to a new cylinder boot.
(b) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and piston.
F41559
(c) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.
35.
INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 61.8 N
⋅ m (630 kgf
⋅ cm, 46 ft
⋅ lbf)
36.
INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side rear disc brake pad support plate.
37.
INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side rear disc brake pad support plate.
Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Anti Squeal
Shim No.2
38.
INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT
(a) Apply the both sides of anti squeal shim No.1 with pad grease, and install the shim together with anti squeal shim
No.2 to each pad.
(b) Install the wear indicator to the 2 brake pads.
NOTICE:
When replacing worn pads, the anti squeal shims
Anti Squeal
Shim No.1
Wear Indicator
F41865 must be replaced together with the pads.
Install the shims and pad wear indicator correctly of which positions and directions.
39.
INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing downward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2479
32-46
BRAKE REAR BRAKE
40.
INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), install the cylinder slide pin.
Torque: 39.2 N
⋅ m (400 kgf
⋅ cm, 29 ft
⋅ lbf)
Cylinder Slide Pin
F41551
41.
INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a) Apply the lithium soap base glycol grease to seal surface of a new bush dust boot.
(b) Install the bush dust boot to the cylinder slide pin.
Cylinder Mounting
Lithium soap base glycol grease
F41562
42.
INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylinder slide bush.
(b) Install the cylinder slide bush to the disc brake cylinder.
Lithium soap base glycol grease
F41558
43.
INSTALL DISC BRAKE CYLINDER ASSY REAR LH
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the disc brake cylinder to the cylinder slide pin.
44.
INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the cylinder slide pin to the disc brake cylinder.
Torque: 34.3 N
⋅ m (350 kgf
⋅ cm, 25 ft
⋅ lbf)
45.
CONNECT REAR LH FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 N
⋅ m (300 kgf
⋅ cm, 22 ft
⋅ lbf)
HINT:
Install the flexible hose lock securely in the lock hole of the disc brake cylinder.
46.
FILL RESERVOIR WITH BRAKE FLUID
47.
BLEED MASTER CYLINDER (SEE PAGE 32-4 )
SST 09023-00101
48.
BLEED BRAKE LINE (SEE PAGE 32-4 )
49.
CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 )
50.
CHECK BRAKE FLUID LEAKAGE
51.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1050 kgf
⋅ cm, 76 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2480
32-47
BRAKE BRAKE ACTUATOR ASSY (W/O VSC)
320E1-02
ON-VEHICLE INSPECTION
1.
CONNECT HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operator’s manual for further details.
2.
INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be depressed.
(d) With the motor relay ON, check that the pedal does not pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3.
INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously, set the interval of more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4.
INSPECT OTHER WHEEL OPERATION
(a) As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2481
32-48
BRAKE BRAKE ACTUATOR ASSY (W/O VSC)
REPLACEMENT
1.
DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluid immediately if it comes into contact with a painted surface.
320E2-04
2.
REMOVE BRAKE ACTUATOR WITH BRACKET
(a) Using SST, disconnect the 6 brake lines from the actuator.
SST 09023-00101
F40998
To RL W/C
To FR W/C
(b) Use tags or make a memo to identify the place to reconnect.
(c) Disconnect the brake actuator connector.
(d) Remove the 3 nuts and brake actuator with bracket.
From M/C 2nd
From M/C 1st
To FL W/C
To RR W/C
C84798
3.
REMOVE BRAKE ACTUATOR ASSY
(a) Remove the 2 nuts and brake actuator from the bracket.
(b) Remove the 2 holders and 3 cushions from the brake actuator.
4.
INSTALL BRAKE ACTUATOR ASSY
(a) Install the 3 cushions and 2 holders to the brake actuator.
(b) Install the brake actuator to the bracket with the 2 nuts.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
5.
INSTALL BRAKE ACTUATOR WITH BRACKET
(a) Install the brake actuator with the 3 nuts.
Torque: 19 N
⋅ m (194 kgf
⋅ cm, 14 ft
⋅ lbf)
(b) Connect the brake actuator connector.
F40998
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2482
To RL W/C
To FR W/C
32-49
BRAKE BRAKE ACTUATOR ASSY (W/O VSC)
(c) Using SST, connect the each brake line to the correct position of brake actuator, as shown in the illustration.
SST 09023-00101
Torque: 15 N
⋅ m (155 kgf
⋅ cm, 11 ft
⋅ lbf)
From M/C 2nd
From M/C 1st
To FL W/C
To RR W/C
C84798
6.
FILL RESERVOIR WITH BRAKE FLUID
7.
BLEED MASTER CYLINDER (SEE PAGE 32-4 )
SST 09023-00101
8.
BLEED BRAKE LINE (SEE PAGE 32-4 )
9.
CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 )
10.
CHECK BRAKE FLUID LEAKAGE
11.
CHECK OPERATION OF BRAKE ACTUATOR (SEE PAGE 32-47 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2483
32-50
BRAKE BRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
3203J-09
ON-VEHICLE INSPECTION
1.
CONNECT HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operator’s manual for further details.
2.
INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be depressed.
(d) With the motor relay ON, check that the pedal does not pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3.
INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously, set the interval of more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4.
INSPECT OTHER WHEEL OPERATION
(a) As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2484
32-51
BRAKE BRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
REPLACEMENT
1.
DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluid immediately if it comes into contact with a painted surface.
2.
REMOVE BRAKE ACTUATOR WITH BRACKET
3211Y-04
(a) Using SST, disconnect the 6 brake lines from the actuator.
SST 09023-00101
From M/C 1st From M/C 2nd
F45680
(b) Use tags or make a memo to identify the place to reconnect.
To FR W/C
To FL W/C
To RR W/C To RL W/C
F45681
(c) Disconnect the actuator connector.
F45682
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2485
32-52
BRAKE BRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
(d) Remove the 3 nuts and brake actuator with bracket.
F45683
3.
REMOVE BRAKE ACTUATOR ASSY
(a) Remove the 2 nuts and brake actuator from the bracket.
4.
INSTALL BRAKE ACTUATOR ASSY
(a) Install the brake actuator to the bracket with the 2 nuts.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
5.
INSTALL BRAKE ACTUATOR WITH BRACKET
(a) Install the brake actuator with the 3 nuts.
Torque: 19 N
⋅ m (194 kgf
⋅ cm, 14 ft
⋅ lbf)
(b) Connect the brake actuator connector.
From M/C 2nd From M/C 1st
F40999
(c) Using SST, connect the each brake line to the correct position of brake actuator, as shown in the illustration.
SST 09023-00101
Torque: 15 N
⋅ m (155 kgf
⋅ cm, 11 ft
⋅ lbf)
To FR W/C
To FL W/C
To RR W/C To RL W/C
C86250
6.
FILL RESERVOIR WITH BRAKE FLUID
7.
BLEED MASTER CYLINDER (SEE PAGE 32-4 )
SST 09023-00101
8.
BLEED BRAKE LINE (SEE PAGE 32-4 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2486
BRAKE BRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
9.
BLEED BRAKE ACTUATOR ASSY (W/ VSC) (SEE PAGE 32-4 )
SST 09992-00242, 09992-00350
10.
CHECK FLUID LEVEL IN RESERVOIR(SEE PAGE 32-4 )
11.
CHECK BRAKE FLUID LEAKAGE
12.
CHECK OPERATION OF BRAKE ACTUATOR (SEE PAGE 32-47 )
32-53
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2487
32-54
BRAKE SPEED SENSOR FRONT LH
REPLACEMENT
HINT:
Replace the RH side by the same procedures with LH side.
1.
REMOVE FRONT WHEEL
2.
REMOVE FRONT FENDER LINER LH
3.
REMOVE SPEED SENSOR FRONT LH
(a) Disconnect the speed sensor connector and clamp.
3203N-09
F41016
(b) Remove the 2 clamp bolts holding the sensor harness and clamp from the body and shock absorber.
F41018 F41017
(c) Remove the bolt and speed sensor FR LH.
NOTICE:
Do not stick and foreign matter on the sensor tip.
C84803
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2488
F41018
A
BRAKE SPEED SENSOR FRONT LH
4.
INSTALL SPEED SENSOR FRONT LH
(a) Install the speed sensor FR LH with the bolt.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
NOTICE:
Make sure the sensor tip is clean.
32-55
C84803
(b) Install the sensor harness clamps with the 2 bolts ”A” and
”B” to the body and shock absorber.
Torque:
Bolt A: 5.0 N
⋅ m (51 kgf
⋅ cm, 44 in.
⋅ lbf)
Bolt B: 18.8 N
⋅ m (192 kgf
⋅ cm, 14 ft
⋅ lbf)
(c) Connect the clamp to the knuckle.
B
F41017
(d) Connect the speed sensor connector and clamp.
F41016
5.
INSTALL FRONT FENDER LINER LH
6.
INSTALL FRONT WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
7.
CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-420 or 05-471 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2489
32-56
BRAKE SKID CONTROL SENSOR
REPLACEMENT
HINT:
Replace the RH side by the same procedure with LH side.
1.
REMOVE REAR WHEEL
3203O-06
2.
SEPARATE SKID CONTROL SENSOR WIRE
(a) Disconnect the connector from the skid control sensor.
F40301
3.
REMOVE REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 32-41 )
4.
REMOVE REAR DISC
5.
REMOVE REAR AXLE HUB & BEARING ASSY LH
(a) Remove the 4 bolts and rear axle hub & bearing assy.
C83035
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2490
SST
LH
Bolt
32-57
BRAKE SKID CONTROL SENSOR
6.
REMOVE SKID CONTROL SENSOR
(a) Mount the rear axle hub in a soft jaw vise.
NOTICE:
Replace the axle hub assembly if it is dropped or a strong shock is given to it.
(b) Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments from SST.
(c) Using SST and 2 bolts (Diameter: 12 mm, pitch: 1.5 mm), remove the skid control sensor from the rear axle hub.
SST 09520- 00031 (09520- 00040), 09521- 00020,
09950-00020
NOTICE:
If a damage is inflicted to the sensor rotor, replace the axle hub assembly.
Do not scratch the contacting surface of axle hub and speed sensor.
7.
INSTALL SKID CONTROL SENSOR
(a) Clean the contacting surface of the axle hub and a new skid control sensor.
NOTICE:
Make sure the sensor rotor is clean.
SST
RH
F40303
(b) Place the speed sensor on the axle hub so that the connector is positioned, as shown in the illustration.
F40302
SST
F40304
(c) Using SST and a press, install the skid control sensor to the axle hub.
NOTICE:
Do not tap the skid control sensor with a hammer directly.
Check that the skid control sensor detection part is clean.
Press in the skid control sensor straight and slowly.
SST 09830- 36010, 09950- 60010 (09951- 00650),
09950-70010 (09951-07100)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2491
32-58
BRAKE SKID CONTROL SENSOR
8.
INSTALL REAR AXLE HUB & BEARING ASSY LH
(a) Install the rear axle hub & bearing assy with the 4 bolts.
Torque: 80 N
⋅ m (816 kgf
⋅ cm, 59 ft
⋅ lbf)
C83035
9.
INSTALL REAR DISC
10.
INSTALL REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 32-41 )
11.
CONNECT SKID CONTROL SENSOR WIRE
12.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
13.
INSPECT TIRE (SEE PAGE 28-1 )
14.
MEASURE VEHICLE HEIGHT (SEE PAGE 27-3 )
15.
INSPECT SIDE SLIP (SEE PAGE 27-3 )
16.
INSPECT CAMBER (SEE PAGE 27-3 )
17.
INSPECT TOE-IN (SEE PAGE 27-3 )
18.
ADJUST CAMBER AND TOE-IN (SEE PAGE 27-3 )
19.
CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-420 or 05-471 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2492
BRAKE YAWRATE SENSOR (From July, 2003)
REPLACEMENT
NOTICE:
Do not separate the sensor from the bracket.
1.
REMOVE CONSOLE PANEL UPPER REAR (SEE PAGE 71-1 1 )
2.
REMOVE RR CONSOLE BOX (SEE PAGE 71-1 1 )
3.
REMOVE YAWRATE SENSOR
(a) Disconnect the yawrate sensor connector.
(b) Remove the 2 bolts and yawrate sensor.
32-59
320E4-03
F45687
4.
INSTALL YAWRATE SENSOR
(a) Install the yawrate sensor with the 2 bolts.
Torque: 12.5 N
⋅ m (127 kgf
⋅ cm, 9 ft
⋅ lbf)
(b) Connect the yawrate sensor connector.
F45687
5.
INSTALL RR CONSOLE BOX (SEE PAGE 71-1 1 )
6.
INSTALL CONSOLE PANEL UPPER REAR (SEE PAGE 71-1 1 )
7.
PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (SEE PAGE 05-471 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2493
32-60
BRAKE STEERING SENSOR
REPLACEMENT
1.
PRECAUTION (SEE PAGE 60-1 )
2.
SEPARATE BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 )
3.
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4.
REMOVE HORN BUTTON ASSY (SEE PAGE 60-22 )
5.
REMOVE STEERING WHEEL ASSY (SEE PAGE 50-8 )
6.
REMOVE STEERING COLUMN LOWER COVER (SEE PAGE 50-8 )
7.
REMOVE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-31 )
8.
REMOVE WINDSHIELD WIPER SWITCH ASSY
9.
REMOVE STEERING SENSOR
10.
INSTALL STEERING SENSOR
11.
INSPECT SPIRAL CABLE SUB-ASSY
(a) If the following condition is identified, replace the spiral cable sub-assy with new one.
Condition:
Scratches or cracks on the connector
Cracks, dents or chipping of the spiral cable sub-assy
12.
INSTALL WINDSHIELD WIPER SWITCH ASSY
13.
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
14.
INSTALL SPIRAL CABLE SUB-ASSY (SEE PAGE 60-31 )
15.
INSTALL STEERING COLUMN LOWER COVER (SEE PAGE 50-8 )
16.
CENTER SPIRAL CABLE (SEE PAGE 60-31 )
17.
INSTALL STEERING WHEEL ASSY (SEE PAGE 50-8 )
18.
INSPECT STEERING WHEEL CENTER POINT (SEE PAGE 50-8 )
19.
INSTALL HORN BUTTON ASSY (SEE PAGE 60-22 )
20.
INSPECT SRS WARNING LIGHT (SEE PAGE 05-818 )
3203S-11
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2494
32-61
BRAKE ADJUSTABLE PEDAL SWITCH (From August, 2002)
INSPECTION
320OH-03
1.
REMOVE ADJUSTABLE PEDAL SWITCH
(a) Using a screwdriver, remove the adjustable pedal switch, then disconnect the connector.
F16912
4 3 2 1
2.
INSPECT ADJUSTABLE PEDAL SWITCH
Switch position
OFF
Tester connection
1 - 2 - 3
1 - 3
2 - 4
1 - 2
3 - 4
Specified condition
Continuity
F42753
3.
INSTALL ADJUSTABLE PEDAL SWITCH
(a) Connect the connector.
(b) Install the adjustable pedal switch.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2495
32-62
BRAKE ADJUSTABLE PEDAL RELAY (From August, 2002)
INSPECTION
Engine Room J/B:
Adjustable Pedal
Relay
320OI-03
1.
REMOVE ADJUSTABLE PEDAL RELAY
(a) Remove the adjustable pedal relay from the engine room
J/B.
F42754
3
5
2
2.
INSPECT ADJUSTABLE PEDAL RELAY
Condition
Apply +B between terminals 1 and 2
1
F42755
3.
INSTALL ADJUSTABLE PEDAL RELAY
(a) Install the adjustable pedal relay to the engine room J/B.
Tester condition
1 - 2
3 - 5
3 - 5
Specified condition
Continuity
No continuity continuity
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2496
33-1
PARKING BRAKE PARKING BRAKE SYSTEM
3305F-02
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.
Symptom See page Suspect Area
1. Parking brake pedal or lever travel (Out of adjustment)
2. Parking brake wire (Sticking)
Brake drag
3. Parking brake shoe clearance (Out of adjustment)
4. Parking brake shoe lining (Cracked or distorted)
5. Tension or return spring (Damaged)
33-2
33-8
33-1 1
33-14
33-16
33-16
33-16
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2497
33-2
PARKING BRAKE PARKING BRAKE SYSTEM
ADJUSTMENT
1.
REMOVE REAR WHEEL
2.
ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16 )
3.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
4.
INSPECT PARKING BRAKE PEDAL TRAVEL
(a) Slowly depress the parking brake pedal all the way, and count the number of clicks.
Parking brake pedal travel: 3 - 6 clicks at 300 N (31 kgf, 68.3 lbf)
Lock Nut
3305G-02
Adjusting Nut
F41011
5.
ADJUST PARKING BRAKE PEDAL TRAVEL
(a) Depress the parking brake pedal 3 notches to make a room for the procedure, and loosen the lock nut.
(b) Return the parking brake pedal to the original position.
(c) Turn the adjusting nut until the parking brake pedal travel is correct.
(d) Depress the parking brake pedal 3 notches to make a room for the procedure, and tighten the lock nut.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
(e) Return the parking brake pedal to the original position.
(f) Check whether parking brake drags or not.
(g) When operating the parking brake pedal, check that the parking brake pedal indicator light lights up.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2498
COMPONENTS
Parking Brake Control Pedal Assy:
PARKING BRAKE PARKING BRAKE
Adjusting Nut
Lock Nut
5.4 (55, 48 in.
⋅ lbf)
Parking Pedal Pad
39 (398, 29)
Parking Brake Control Pedal Assy
39 (398, 29) 39 (398, 29)
Parking Brake Switch Assy
Return Spring Damper
Tension Spring
Parking Brake Cable Assy No.1
Clip
33-3
3305H-02
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
F41008
2499
33-4
PARKING BRAKE PARKING BRAKE
Parking Brake Cable:
Parking Brake Control Pedal Models:
Parking Brake Cable Assy No.4
12.5 (128, 9)
Consol Box Mounting Bracket No.2
12.5 (128, 9)
12.5 (128, 9)
12.5 (128, 9)
Parking Brake Equalizer
5.4 (55, 48 in.
⋅ lbf)
Parking Brake Cable Assy No.3
5.4 (55, 48 in.
⋅ lbf)
5.4 (55, 48 in.
⋅ lbf)
5.4 (55, 48 in.
⋅ lbf)
Parking Brake Cable Heat Insulator
7.8 (80, 69 in.
⋅ lbf)
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
C90467 F41686
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2500
33-5
PARKING BRAKE PARKING BRAKE
Parking Brake Assy:
Rear Disc Brake Caliper Assy LH
47 (480, 35)
Shoe Hold-down Spring Pin
Parking Brake Shoe
C-W asher
Shim
Parking Brake Shoe Return
Tension Spring
Parking Brake
Shoe Strut
Compression
Spring Parking Brake
Shoe Lever
Parking Brake Shoe Strut LH
Parking Brake Shoe
Return Tension Spring
Parking Brake Shoe
Adjusting Bolt
Shoe Hold-down Spring
Adjusting Bolt
Shoe Adjusting Screw Set
Shoe Hold-down Spring Cup
Rear Disc
Hole Plug
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
C90458
High Temperature grease
F41967
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2501
33-6
PARKING BRAKE PARKING BRAKE CONTROL PEDAL ASSY
OVERHAUL
HINT:
COMPONENTS: See page 71-8 and 33-3
1.
REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY(See page 71-1 1 )
2.
REMOVE COMBINATION METER ASSY(See page 71-1 1 )
3.
REMOVE FRONT DOOR SCUFF PLATE LH(See page 71-1 1 )
4.
REMOVE INSTRUMENT PANEL SUB-ASSY UPPER(See page 71-1 1 )
5.
REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH(See page 71-1 1 )
3305I-02
6.
REMOVE PARKING BRAKE CONTROL PEDAL ASSY
(a) Disconnect the parking brake switch connector.
(b) Remove the 2 bolts, nut and parking brake control pedal assy.
F41009
7.
DISCONNECT PARKING BRAKE CABLE ASSY NO.1
(a) Remove the lock nut, adjusting nut and clip, then disconnect the parking brake cable assy No.1 from the parking brake control pedal assy.
F41010
8.
REMOVE PARKING BRAKE SWITCH ASSY
(a) Remove the screw and parking brake switch assy.
9.
REMOVE TENSION SPRING
10.
REMOVE RETURN SPRING DAMPER
11.
REMOVE PARKING PEDAL PAD
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2502
33-7
PARKING BRAKE PARKING BRAKE CONTROL PEDAL ASSY
12.
INSTALL PARKING PEDAL PAD
13.
INSTALL RETURN SPRING DAMPER
14.
INSTALL TENSION SPRING
15.
INSTALL PARKING BRAKE SWITCH ASSY
(a) Install the parking brake switch assy with the screw.
16.
CONNECT PARKING BRAKE CABLE ASSY NO.1
(a) Connect the parking brake cable assy No.1 with the clip, adjusting nut and lock nut.
F41010
17.
INSTALL PARKING BRAKE CONTROL PEDAL ASSY
(a) Install the parking brake control pedal assy with the 2 bolts and nut.
Torque: 39 N
⋅ m (398 kgf
⋅ cm, 29 ft
⋅ lbf)
(b) Connect the parking brake switch connector.
F41009
18.
INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
19.
INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
20.
INSTALL FRONT DOOR SCUFF PLATE LH
21.
INSTALL COMBINATION METER ASSY
22.
INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY
23.
INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2503
33-8
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.1
REPLACEMENT
HINT:
COMPONENTS: See page 71-8 and 33-3
1.
REMOVE FRONT DOOR SCUFF PLATE RH
2.
REMOVE FRONT DOOR SCUFF PLATE LH
3.
REMOVE INSTRUMENT PANEL SUB-ASSY UPPER(See page 71-1 1 )
4.
REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH(See page 71-1 1 )
5.
REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1(See page 71-1 1 )
6.
REMOVE INSTRUMENT PANEL SUB-ASSY LOWER(See page 71-1 1 )
7.
REMOVE CONSOLE PANEL UPPER REAR(See page 71-1 1 )
8.
REMOVE CONSOLE BOX CARPET
9.
REMOVE RR CONSOLE BOX(See page 71-1 1 )
10.
REMOVE INSTRUMENT PANEL FINISH PANEL END RH
11.
REMOVE INSTRUMENT PANEL FINISH PANEL END LH(See page 71-1 1 )
12.
REMOVE AIR DUCT REAR NO.1
13.
REMOVE AIR DUCT REAR NO.2
14.
REMOVE CONSOLE BOX DUCT NO.1
15.
REMOVE YAWRATE SENSOR (W/ VSC)(See page 32-59 )
3305J-02
Turn
Buckle
16.
REMOVE PARKING BRAKE CABLE ASSY NO.1
(a) Loosen the turn buckle, disconnect the parking brake cable assy No.1 from the parking brake cable assy No.4.
(b) Remove the 2 bolts and console box mounting bracket
No.2.
C90470
(c) Remove the lock nut, adjusting nut and clip, then disconnect the parking brake cable assy No.1 from the parking brake control pedal assy.
F41010
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2504
33-9
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.1
(d) Remove the 2 nuts, 2 bolts, clip and parking brake cable assy No.1.
F41687
17.
INSTALL PARKING BRAKE CABLE ASSY NO.1
(a) Install the parking brake cable assy No.1 with the 2 nuts,
2 bolts and clip.
Turn
Buckle
F41687
(b) Install the parking brake cable assy No.1 with the clip, adjusting nut and lock nut to the parking brake control pedal assy.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
(c) Install the console box mounting bracket No.2 with the 2 bolts.
Torque: 12.5 N
⋅ m (128 kgf
⋅ cm, 9 ft
⋅ lbf)
F41010
(d) Tighten the turn buckle, connect the parking brake cable assy No.1 to the parking brake cable assy No.4.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
C90470
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2505
33-10
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.1
18.
INSTALL YAWRATE SENSOR (W/ VSC)(See page 32-59 )
19.
INSTALL CONSOLE BOX DUCT NO.1
20.
INSTALL AIR DUCT REAR NO.2
21.
INSTALL AIR DUCT REAR NO.1
22.
INSTALL INSTRUMENT PANEL FINISH PANEL END LH
23.
INSTALL INSTRUMENT PANEL FINISH PANEL END RH
24.
INSTALL RR CONSOLE BOX
25.
INSTALL CONSOLE BOX CARPET
26.
INSTALL CONSOLE PANEL UPPER REAR
27.
INSTALL INSTRUMENT PANEL SUB-ASSY LOWER
28.
INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1
29.
INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
30.
INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
31.
INSTALL FRONT DOOR SCUFF PLATE LH
32.
INSTALL FRONT DOOR SCUFF PLATE RH
33.
INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2 )
34.
CHECK VSC SENSOR SIGNAL (W/ VSC)(See page 05-471 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2506
33-1 1
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
REPLACEMENT
HINT:
COMPONENTS: See page 33-3
For parking brake cable No.2, employ the same procedure to the RH side.
1.
REMOVE REAR WHEEL
2.
REMOVE REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the 2 bolts and separate the rear disc brake caliper assy LH.
HINT:
Do not the flexible hose from the brake caliper assy LH.
3.
REMOVE REAR DISC(See page 33-16 )
4.
REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING(See page 33-16 )
5.
REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING(See page 33-16 )
6.
REMOVE PARKING BRAKE SHOE STRUT LH(See page 33-16 )
7.
REMOVE PARKING BRAKE SHOE(See page 33-16 )
8.
REMOVE PARKING BRAKE CABLE HEAT INSULATOR
(a) Remove the 3 nuts and parking brake heat insulator.
3305K-02
9.
REMOVE PARKING BRAKE CABLE ASSY NO.3
(a) Remove the 2 bolts and disconnect the parking brake cable assy No.3 from the backing plate.
(b) Remove the 2 nuts, bolt and parking brake cable assy
No.3.
C90471
C90462
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
F41690
2507
33-12
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
(c) Disconnect the parking brake cable assy No.3 from the parking brake equalizer.
10.
INSTALL PARKING BRAKE CABLE ASSY NO.3
(a) Connect the parking brake cable assy No.3 to the parking brake equalizer.
(b) Install the parking brake cable assy No.3 with the 2 nuts and bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
C90462
F41690
(c) Install the parking brake cable assy No.3 with the 2 bolts to the backing plate.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
C90471
11.
INSTALL PARKING BRAKE CABLE HEAT INSULATOR
(a) Install the parking brake heat insulator with the 3 nuts.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 kgf
⋅ cm)
12.
APPLICATION HIGH TEMPERATURE GREASE(See page 33-16 )
13.
INSTALL PARKING BRAKE SHOE(See page 33-16 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2508
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
14.
INSTALL PARKING BRAKE SHOE STRUT LH(See page 33-16 )
15.
INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING(See page 33-16 )
16.
INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING(See page 33-16 )
17.
CHECK PARKING BRAKE INSTALLATION(See page 33-16 )
18.
INSTALL REAR DISC(See page 33-16 )
19.
ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16 )
20.
INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper with the 2 bolts.
Torque: 47 N
⋅ m (480 kgf
⋅ cm, 35 ft
⋅ lbf)
21.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
22.
INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2 )
33-13
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2509
33-14
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.4
REPLACEMENT
HINT:
COMPONENTS: See page 71-8 and 33-3
1.
REMOVE CONSOLE PANEL UPPER REAR(See page 71-1 1 )
2.
REMOVE CONSOLE BOX CARPET
3.
REMOVE RR CONSOLE BOX(See page 71-1 1 )
4.
REMOVE CONSOLE BOX MOUNTING BRACKET NO.2
(a) Remove the 2 bolts and console box mounting bracket No.2.
5.
REMOVE YAWRATE SENSOR (W/ VSC)(See page 32-59 )
3305L-02
Turn
Buckle
6.
REMOVE PARKING BRAKE CABLE ASSY NO.4
(a) Loosen the turn buckle, disconnect the parking brake cable assy No.4 from the parking brake cable assy No.1.
(b) Disconnect the parking brake cable assy No.4 from the parking brake equalizer.
C90470
(c) Remove the 2 bolts and parking brake cable assy No.4.
C90464
7.
INSTALL PARKING BRAKE CABLE ASSY NO.4
(a) Install the parking brake cable No.4 with the 2 bolts.
Torque: 12.5 N
⋅ m (128 kgf
⋅ cm, 9 ft
⋅ lbf)
(b) Connect the parking brake cable assy No.4 to the parking brake equalizer.
C90464
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2510
Turn
Buckle
33-15
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.4
(c) Tighten the turn buckle, connect the parking brake cable assy No.4 to the parking brake cable assy No.1.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
C90470
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 N
⋅ m (128 kgf
⋅ cm, 9 ft
⋅ lbf)
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 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2511
33-16
PARKING BRAKE PARKING BRAKE ASSY
OVERHAUL
HINT:
COMPONENTS: See page 33-3
Overhaul the RH side by the same procedures with LH side.
1.
REMOVE REAR WHEEL
2.
REMOVE REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the 2 bolts and separate the rear disc brake caliper assy LH.
HINT:
Do not disconnect the flexible hose from the brake caliper.
3305M-03
Contract
3.
REMOVE REAR DISC
(a) Release the parking brake, and remove the rear disc.
HINT:
Put matchmarks on the disc and the axle hub.
If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely.
C64523
4.
INSPECT BRAKE DISC INSIDE DIAMETER
(a) Using a brake drum gauge or equivalent, measure the inside diameter of the disc.
Standard inside diameter: 170 mm (6.69 in.)
Maximum inside diameter: 171 mm (6.73 in.)
F06409
5.
REMOVE PARKING BRAKE SHOE RETURN TENSION
SPRING
(a) Using a needle-nose pliers, remove the 2 return tension springs.
F40318
6.
REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING
(a) Slide out the front shoe and remove the compression spring.
7.
REMOVE PARKING BRAKE SHOE STRUT LH
Author: Date: 2512
33-17
PARKING BRAKE PARKING BRAKE ASSY
8.
REMOVE PARKING BRAKE SHOE
(a) Release the cup claw and remove the front and rear parking brake shoe.
(b) Disconnect the parking brake cable from the shoe lever.
(c) Remove the tension spring and shoe adjuster screw set from the front and rear shoe.
(d) Remove the 2 shoe hold-down springs, 4 cups and 2 pins.
F40319
(e) Using a screwdriver, remove the C-washer.
(f) Remove the shim and shoe lever from the parking brake shoe.
F40320
9.
INSPECT PARKING BRAKE SHOE LINING
THICKNESS
(a) Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 2.0 mm (0.079 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or if there is severe, uneven wear, replace the brake shoe.
BR5332
10.
INSPECT BRAKE DISC AND PARKING BRAKE SHOE
LINING FOR PROPER CONTACT
(a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit.
If the contact between the brake disc and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly.
BR0828
11.
APPLICATION HIGH TEMPERATURE GREASE
(a) Apply the high temperature grease to the shoe attached surface of backing plate.
Author: Date:
2513
33-18
PARKING BRAKE PARKING BRAKE ASSY
12.
INSTALL PARKING BRAKE SHOE
(a) Install the shoe lever and shim to the rear shoe with a new
C-washer .
(b) Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 mm (0.0138 in.)
If the clearance is not within the specification, replace the shim with one of the correct size.
Shim Thickness
0.3 mm (0.012 in.)
0.6 mm (0.024 in.)
Shim Thickness
0.9 mm (0.035 in.)
-
R00343
(c) Apply the high temperature grease to the adjusting bolt.
(d) Install the shoe adjusting screw set and tension spring to the front and rear shoe.
(e) Install the 2 pins, 4 cups and 2 shoe hold-down springs.
(f) Connect the parking brake cable to the shoe lever.
(g) Install the front and rear parking brake shoe.
C80705
13.
INSTALL PARKING BRAKE SHOE STRUT LH
14.
INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING
15.
INSTALL PARKING BRAKE SHOE RETURN TENSION
SPRING
(a) Using a needle nose pliers, install the 2 return tension springs.
F40318
Author: Date: 2514
PARKING BRAKE PARKING BRAKE ASSY
16.
CHECK PARKING BRAKE INSTALLATION
(a) Check that each part is installed properly.
NOTICE:
There should be no oil or grease adhering to the friction surface of the shoe lining and disc.
33-19
LH RH
Front
17.
INSTALL REAR DISC(See page 32-41 )
Front
F40322
Expand
Contract
F40026
18.
ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug, and turn the adjuster and expand the shoes until the disc locks.
(c) Contract the shoe adjuster until the disc can rotate smoothly.
Standard : Return 8 notches
(d) Check shoe is no brake drag.
(e) Install the hole plug.
19.
INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper with the 2 bolts.
Torque: 47 N
⋅ m (480 kgf
⋅ cm, 35 ft
⋅ lbf)
20.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
21.
INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2 )
Author: Date:
2515
33-1
PARKING BRAKE PARKING BRAKE SYSTEM
3305F-02
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.
Symptom See page Suspect Area
1. Parking brake pedal or lever travel (Out of adjustment)
2. Parking brake wire (Sticking)
Brake drag
3. Parking brake shoe clearance (Out of adjustment)
4. Parking brake shoe lining (Cracked or distorted)
5. Tension or return spring (Damaged)
33-2
33-8
33-1 1
33-14
33-16
33-16
33-16
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2497
33-2
PARKING BRAKE PARKING BRAKE SYSTEM
ADJUSTMENT
1.
REMOVE REAR WHEEL
2.
ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16 )
3.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
4.
INSPECT PARKING BRAKE PEDAL TRAVEL
(a) Slowly depress the parking brake pedal all the way, and count the number of clicks.
Parking brake pedal travel: 3 - 6 clicks at 300 N (31 kgf, 68.3 lbf)
Lock Nut
3305G-02
Adjusting Nut
F41011
5.
ADJUST PARKING BRAKE PEDAL TRAVEL
(a) Depress the parking brake pedal 3 notches to make a room for the procedure, and loosen the lock nut.
(b) Return the parking brake pedal to the original position.
(c) Turn the adjusting nut until the parking brake pedal travel is correct.
(d) Depress the parking brake pedal 3 notches to make a room for the procedure, and tighten the lock nut.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
(e) Return the parking brake pedal to the original position.
(f) Check whether parking brake drags or not.
(g) When operating the parking brake pedal, check that the parking brake pedal indicator light lights up.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2498
COMPONENTS
Parking Brake Control Pedal Assy:
PARKING BRAKE PARKING BRAKE
Adjusting Nut
Lock Nut
5.4 (55, 48 in.
⋅ lbf)
Parking Pedal Pad
39 (398, 29)
Parking Brake Control Pedal Assy
39 (398, 29) 39 (398, 29)
Parking Brake Switch Assy
Return Spring Damper
Tension Spring
Parking Brake Cable Assy No.1
Clip
33-3
3305H-02
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
F41008
2499
33-4
PARKING BRAKE PARKING BRAKE
Parking Brake Cable:
Parking Brake Control Pedal Models:
Parking Brake Cable Assy No.4
12.5 (128, 9)
Consol Box Mounting Bracket No.2
12.5 (128, 9)
12.5 (128, 9)
12.5 (128, 9)
Parking Brake Equalizer
5.4 (55, 48 in.
⋅ lbf)
Parking Brake Cable Assy No.3
5.4 (55, 48 in.
⋅ lbf)
5.4 (55, 48 in.
⋅ lbf)
5.4 (55, 48 in.
⋅ lbf)
Parking Brake Cable Heat Insulator
7.8 (80, 69 in.
⋅ lbf)
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
C90467 F41686
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2500
33-5
PARKING BRAKE PARKING BRAKE
Parking Brake Assy:
Rear Disc Brake Caliper Assy LH
47 (480, 35)
Shoe Hold-down Spring Pin
Parking Brake Shoe
C-W asher
Shim
Parking Brake Shoe Return
Tension Spring
Parking Brake
Shoe Strut
Compression
Spring Parking Brake
Shoe Lever
Parking Brake Shoe Strut LH
Parking Brake Shoe
Return Tension Spring
Parking Brake Shoe
Adjusting Bolt
Shoe Hold-down Spring
Adjusting Bolt
Shoe Adjusting Screw Set
Shoe Hold-down Spring Cup
Rear Disc
Hole Plug
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
C90458
High Temperature grease
F41967
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2501
33-6
PARKING BRAKE PARKING BRAKE CONTROL PEDAL ASSY
OVERHAUL
HINT:
COMPONENTS: See page 71-8 and 33-3
1.
REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY(See page 71-1 1 )
2.
REMOVE COMBINATION METER ASSY(See page 71-1 1 )
3.
REMOVE FRONT DOOR SCUFF PLATE LH(See page 71-1 1 )
4.
REMOVE INSTRUMENT PANEL SUB-ASSY UPPER(See page 71-1 1 )
5.
REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH(See page 71-1 1 )
3305I-02
6.
REMOVE PARKING BRAKE CONTROL PEDAL ASSY
(a) Disconnect the parking brake switch connector.
(b) Remove the 2 bolts, nut and parking brake control pedal assy.
F41009
7.
DISCONNECT PARKING BRAKE CABLE ASSY NO.1
(a) Remove the lock nut, adjusting nut and clip, then disconnect the parking brake cable assy No.1 from the parking brake control pedal assy.
F41010
8.
REMOVE PARKING BRAKE SWITCH ASSY
(a) Remove the screw and parking brake switch assy.
9.
REMOVE TENSION SPRING
10.
REMOVE RETURN SPRING DAMPER
11.
REMOVE PARKING PEDAL PAD
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2502
33-7
PARKING BRAKE PARKING BRAKE CONTROL PEDAL ASSY
12.
INSTALL PARKING PEDAL PAD
13.
INSTALL RETURN SPRING DAMPER
14.
INSTALL TENSION SPRING
15.
INSTALL PARKING BRAKE SWITCH ASSY
(a) Install the parking brake switch assy with the screw.
16.
CONNECT PARKING BRAKE CABLE ASSY NO.1
(a) Connect the parking brake cable assy No.1 with the clip, adjusting nut and lock nut.
F41010
17.
INSTALL PARKING BRAKE CONTROL PEDAL ASSY
(a) Install the parking brake control pedal assy with the 2 bolts and nut.
Torque: 39 N
⋅ m (398 kgf
⋅ cm, 29 ft
⋅ lbf)
(b) Connect the parking brake switch connector.
F41009
18.
INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
19.
INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
20.
INSTALL FRONT DOOR SCUFF PLATE LH
21.
INSTALL COMBINATION METER ASSY
22.
INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY
23.
INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2503
33-8
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.1
REPLACEMENT
HINT:
COMPONENTS: See page 71-8 and 33-3
1.
REMOVE FRONT DOOR SCUFF PLATE RH
2.
REMOVE FRONT DOOR SCUFF PLATE LH
3.
REMOVE INSTRUMENT PANEL SUB-ASSY UPPER(See page 71-1 1 )
4.
REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH(See page 71-1 1 )
5.
REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1(See page 71-1 1 )
6.
REMOVE INSTRUMENT PANEL SUB-ASSY LOWER(See page 71-1 1 )
7.
REMOVE CONSOLE PANEL UPPER REAR(See page 71-1 1 )
8.
REMOVE CONSOLE BOX CARPET
9.
REMOVE RR CONSOLE BOX(See page 71-1 1 )
10.
REMOVE INSTRUMENT PANEL FINISH PANEL END RH
11.
REMOVE INSTRUMENT PANEL FINISH PANEL END LH(See page 71-1 1 )
12.
REMOVE AIR DUCT REAR NO.1
13.
REMOVE AIR DUCT REAR NO.2
14.
REMOVE CONSOLE BOX DUCT NO.1
15.
REMOVE YAWRATE SENSOR (W/ VSC)(See page 32-59 )
3305J-02
Turn
Buckle
16.
REMOVE PARKING BRAKE CABLE ASSY NO.1
(a) Loosen the turn buckle, disconnect the parking brake cable assy No.1 from the parking brake cable assy No.4.
(b) Remove the 2 bolts and console box mounting bracket
No.2.
C90470
(c) Remove the lock nut, adjusting nut and clip, then disconnect the parking brake cable assy No.1 from the parking brake control pedal assy.
F41010
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2504
33-9
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.1
(d) Remove the 2 nuts, 2 bolts, clip and parking brake cable assy No.1.
F41687
17.
INSTALL PARKING BRAKE CABLE ASSY NO.1
(a) Install the parking brake cable assy No.1 with the 2 nuts,
2 bolts and clip.
Turn
Buckle
F41687
(b) Install the parking brake cable assy No.1 with the clip, adjusting nut and lock nut to the parking brake control pedal assy.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
(c) Install the console box mounting bracket No.2 with the 2 bolts.
Torque: 12.5 N
⋅ m (128 kgf
⋅ cm, 9 ft
⋅ lbf)
F41010
(d) Tighten the turn buckle, connect the parking brake cable assy No.1 to the parking brake cable assy No.4.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
C90470
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2505
33-10
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.1
18.
INSTALL YAWRATE SENSOR (W/ VSC)(See page 32-59 )
19.
INSTALL CONSOLE BOX DUCT NO.1
20.
INSTALL AIR DUCT REAR NO.2
21.
INSTALL AIR DUCT REAR NO.1
22.
INSTALL INSTRUMENT PANEL FINISH PANEL END LH
23.
INSTALL INSTRUMENT PANEL FINISH PANEL END RH
24.
INSTALL RR CONSOLE BOX
25.
INSTALL CONSOLE BOX CARPET
26.
INSTALL CONSOLE PANEL UPPER REAR
27.
INSTALL INSTRUMENT PANEL SUB-ASSY LOWER
28.
INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1
29.
INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
30.
INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
31.
INSTALL FRONT DOOR SCUFF PLATE LH
32.
INSTALL FRONT DOOR SCUFF PLATE RH
33.
INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2 )
34.
CHECK VSC SENSOR SIGNAL (W/ VSC)(See page 05-471 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2506
33-1 1
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
REPLACEMENT
HINT:
COMPONENTS: See page 33-3
For parking brake cable No.2, employ the same procedure to the RH side.
1.
REMOVE REAR WHEEL
2.
REMOVE REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the 2 bolts and separate the rear disc brake caliper assy LH.
HINT:
Do not the flexible hose from the brake caliper assy LH.
3.
REMOVE REAR DISC(See page 33-16 )
4.
REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING(See page 33-16 )
5.
REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING(See page 33-16 )
6.
REMOVE PARKING BRAKE SHOE STRUT LH(See page 33-16 )
7.
REMOVE PARKING BRAKE SHOE(See page 33-16 )
8.
REMOVE PARKING BRAKE CABLE HEAT INSULATOR
(a) Remove the 3 nuts and parking brake heat insulator.
3305K-02
9.
REMOVE PARKING BRAKE CABLE ASSY NO.3
(a) Remove the 2 bolts and disconnect the parking brake cable assy No.3 from the backing plate.
(b) Remove the 2 nuts, bolt and parking brake cable assy
No.3.
C90471
C90462
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
F41690
2507
33-12
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
(c) Disconnect the parking brake cable assy No.3 from the parking brake equalizer.
10.
INSTALL PARKING BRAKE CABLE ASSY NO.3
(a) Connect the parking brake cable assy No.3 to the parking brake equalizer.
(b) Install the parking brake cable assy No.3 with the 2 nuts and bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
C90462
F41690
(c) Install the parking brake cable assy No.3 with the 2 bolts to the backing plate.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
C90471
11.
INSTALL PARKING BRAKE CABLE HEAT INSULATOR
(a) Install the parking brake heat insulator with the 3 nuts.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 kgf
⋅ cm)
12.
APPLICATION HIGH TEMPERATURE GREASE(See page 33-16 )
13.
INSTALL PARKING BRAKE SHOE(See page 33-16 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2508
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
14.
INSTALL PARKING BRAKE SHOE STRUT LH(See page 33-16 )
15.
INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING(See page 33-16 )
16.
INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING(See page 33-16 )
17.
CHECK PARKING BRAKE INSTALLATION(See page 33-16 )
18.
INSTALL REAR DISC(See page 33-16 )
19.
ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16 )
20.
INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper with the 2 bolts.
Torque: 47 N
⋅ m (480 kgf
⋅ cm, 35 ft
⋅ lbf)
21.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
22.
INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2 )
33-13
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2509
33-14
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.4
REPLACEMENT
HINT:
COMPONENTS: See page 71-8 and 33-3
1.
REMOVE CONSOLE PANEL UPPER REAR(See page 71-1 1 )
2.
REMOVE CONSOLE BOX CARPET
3.
REMOVE RR CONSOLE BOX(See page 71-1 1 )
4.
REMOVE CONSOLE BOX MOUNTING BRACKET NO.2
(a) Remove the 2 bolts and console box mounting bracket No.2.
5.
REMOVE YAWRATE SENSOR (W/ VSC)(See page 32-59 )
3305L-02
Turn
Buckle
6.
REMOVE PARKING BRAKE CABLE ASSY NO.4
(a) Loosen the turn buckle, disconnect the parking brake cable assy No.4 from the parking brake cable assy No.1.
(b) Disconnect the parking brake cable assy No.4 from the parking brake equalizer.
C90470
(c) Remove the 2 bolts and parking brake cable assy No.4.
C90464
7.
INSTALL PARKING BRAKE CABLE ASSY NO.4
(a) Install the parking brake cable No.4 with the 2 bolts.
Torque: 12.5 N
⋅ m (128 kgf
⋅ cm, 9 ft
⋅ lbf)
(b) Connect the parking brake cable assy No.4 to the parking brake equalizer.
C90464
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2510
Turn
Buckle
33-15
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.4
(c) Tighten the turn buckle, connect the parking brake cable assy No.4 to the parking brake cable assy No.1.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
C90470
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 N
⋅ m (128 kgf
⋅ cm, 9 ft
⋅ lbf)
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 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2511
33-16
PARKING BRAKE PARKING BRAKE ASSY
OVERHAUL
HINT:
COMPONENTS: See page 33-3
Overhaul the RH side by the same procedures with LH side.
1.
REMOVE REAR WHEEL
2.
REMOVE REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the 2 bolts and separate the rear disc brake caliper assy LH.
HINT:
Do not disconnect the flexible hose from the brake caliper.
3305M-03
Contract
3.
REMOVE REAR DISC
(a) Release the parking brake, and remove the rear disc.
HINT:
Put matchmarks on the disc and the axle hub.
If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely.
C64523
4.
INSPECT BRAKE DISC INSIDE DIAMETER
(a) Using a brake drum gauge or equivalent, measure the inside diameter of the disc.
Standard inside diameter: 170 mm (6.69 in.)
Maximum inside diameter: 171 mm (6.73 in.)
F06409
5.
REMOVE PARKING BRAKE SHOE RETURN TENSION
SPRING
(a) Using a needle-nose pliers, remove the 2 return tension springs.
F40318
6.
REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING
(a) Slide out the front shoe and remove the compression spring.
7.
REMOVE PARKING BRAKE SHOE STRUT LH
Author: Date: 2512
33-17
PARKING BRAKE PARKING BRAKE ASSY
8.
REMOVE PARKING BRAKE SHOE
(a) Release the cup claw and remove the front and rear parking brake shoe.
(b) Disconnect the parking brake cable from the shoe lever.
(c) Remove the tension spring and shoe adjuster screw set from the front and rear shoe.
(d) Remove the 2 shoe hold-down springs, 4 cups and 2 pins.
F40319
(e) Using a screwdriver, remove the C-washer.
(f) Remove the shim and shoe lever from the parking brake shoe.
F40320
9.
INSPECT PARKING BRAKE SHOE LINING
THICKNESS
(a) Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 2.0 mm (0.079 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or if there is severe, uneven wear, replace the brake shoe.
BR5332
10.
INSPECT BRAKE DISC AND PARKING BRAKE SHOE
LINING FOR PROPER CONTACT
(a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit.
If the contact between the brake disc and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly.
BR0828
11.
APPLICATION HIGH TEMPERATURE GREASE
(a) Apply the high temperature grease to the shoe attached surface of backing plate.
Author: Date:
2513
33-18
PARKING BRAKE PARKING BRAKE ASSY
12.
INSTALL PARKING BRAKE SHOE
(a) Install the shoe lever and shim to the rear shoe with a new
C-washer .
(b) Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 mm (0.0138 in.)
If the clearance is not within the specification, replace the shim with one of the correct size.
Shim Thickness
0.3 mm (0.012 in.)
0.6 mm (0.024 in.)
Shim Thickness
0.9 mm (0.035 in.)
-
R00343
(c) Apply the high temperature grease to the adjusting bolt.
(d) Install the shoe adjusting screw set and tension spring to the front and rear shoe.
(e) Install the 2 pins, 4 cups and 2 shoe hold-down springs.
(f) Connect the parking brake cable to the shoe lever.
(g) Install the front and rear parking brake shoe.
C80705
13.
INSTALL PARKING BRAKE SHOE STRUT LH
14.
INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING
15.
INSTALL PARKING BRAKE SHOE RETURN TENSION
SPRING
(a) Using a needle nose pliers, install the 2 return tension springs.
F40318
Author: Date: 2514
PARKING BRAKE PARKING BRAKE ASSY
16.
CHECK PARKING BRAKE INSTALLATION
(a) Check that each part is installed properly.
NOTICE:
There should be no oil or grease adhering to the friction surface of the shoe lining and disc.
33-19
LH RH
Front
17.
INSTALL REAR DISC(See page 32-41 )
Front
F40322
Expand
Contract
F40026
18.
ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug, and turn the adjuster and expand the shoes until the disc locks.
(c) Contract the shoe adjuster until the disc can rotate smoothly.
Standard : Return 8 notches
(d) Check shoe is no brake drag.
(e) Install the hole plug.
19.
INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper with the 2 bolts.
Torque: 47 N
⋅ m (480 kgf
⋅ cm, 35 ft
⋅ lbf)
20.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
21.
INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2 )
Author: Date:
2515
30-1
DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July,
2003)
3001U-13
PROBLEM SYMPTOMS TABLE
Use the table below to help determine the cause of the problem. The numbers indicate the priority of the possible cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspected Area
Wander
Front wheel shimmy
Noise
1. Wheel alignment
2. Steering linkage (Loosen or worn)
3. Hub bearing (Worn)
4. Stabilizer bar
1. Wheel balance
2. Shock absorber
3. Ball joint (Worn)
4. Hub bearing (Worn)
1. Inboard joint or outboard joint (Worn)
See page
26-5
27-3
-
30-2
26-17
27-18
28-1
26-8
27-4
26-16
30-2
30-8
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2404
30-2
DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July,
2003)
ON-VEHICLE INSPECTION
1.
REMOVE FRONT WHEEL
2.
DISCONNECT FRONT DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-8 )
3.
REMOVE FRONT DISC
3001V-08
4.
INSPECT FRONT AXLE HUB BEARING BACKLASH
(a) Using a dial indicator, check the backlash near the center of the axle hub.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
NOTICE:
Ensure that the dial indicator is set at right angles to the measurement surface.
F40163
5.
INSPECT FRONT AXLE HUB DEVIATION
(a) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt.
Maximum: 0.05 mm (0.0020 in.)
If the deviation exceeds the maximum, replace the axle hub.
NOTICE:
Ensure that the dial indicator is set at right angles to the measurement surface.
F40164
6.
INSTALL FRONT DISC
7.
INSTALL FRONT DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-8 )
8.
INSTALL FRONT WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
9.
REMOVE REAR WHEEL
10.
DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-26 )
11.
REMOVE REAR DISC
C98686
12.
INSPECT REAR AXLE HUB BEARING BACKLASH
(a) Set a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the axle hub assembly.
NOTICE:
Ensure that the dial indicator is set at right angles to the measurement surface.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2405
DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July,
2003)
C98687
30-3
13.
INSPECT REAR AXLE HUB DEVIATION
(a) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt.
Maximum: 0.07 mm (0.0027 in.)
If the deviation exceeds the maximum, replace the axle hub assembly.
NOTICE:
Ensure that the dial indicator is set at right angles to the measurement surface.
14.
INSTALL REAR DISC
15.
INSTALL REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-26 )
16.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2406
30-4
COMPONENTS
DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July,
2003)
Front Drive Shaft
Assy RH
Drive Shaft Bearing
Bracket Hole Snap Ring
300AX-02
Front Drive Shaft
Assy LH
32 (330, 24)
Tie Rod Assy LH
Front Stabilizer Link Assy LH
19 (192, 14)
74 (755, 55)
Front Flexible Hose
No. 1
Front Suspension
Arm Sub-assy Lower
No.1 LH
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part 75 (765, 55)
Cotter Pin
Front Axle Assy LH
294 (2,998, 217)
49 (500, 36)
Speed Sensor Front LH
8.0 (82, 71 in.
⋅ lbf)
C91613
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2407
DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July,
2003)
30-5
Supply Parts:
Front Axle Outboard
Joint Boot RH
No.2 Clamp
Front Axle Outboard Joint
Boot RH Clamp
Front Drive Shaft
Damper RH Clamp
Front Drive Shaft
Damper RH
Outboard Joint Boot
Front Axle Inboard
Joint Boot
Front Axle Inboard
Joint Boot RH No.2 Clamp
Front Drive Outboard
Joint Shaft Assy RH
Front Axle Inboard
Joint Boot RH Clamp
LH:
Front Drive Inboard
Joint Assy RH
Front Drive
Shaft Bearing
Front Drive Inboard
Joint Assy RH
Front Drive Inner Shaft Inner
RH Shaft Snap Ring
Front Drive Shaft Hole
Snap Ring RH
Front Drive Inboard
Joint Assy LH
Front Drive Shaft
Dust Cover LH
Front Drive Shaft LH
Hole Snap Ring
Front Drive Shaft
Dust Cover Front Drive Shaft
Dust Cover RH
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
F47192
Author: Date:
2408
30-6
DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July,
2003)
Shock Absorber Assy Front LH
210 (2,141, 155)
Front Drive Shaft Assy LH
Tie Rod Assy LH
Speed Sensor Front LH
107 (1,090, 79)
8.0 (82, 71 in.
⋅ lbf)
Front Disc brake caliper assy LH
Front Axle Assy LH
Front Disc
Front Suspension Arm
Sub-assy Lower No.1 LH
75 (765, 55)
Front Axle LH
Hub Bolt
Front Axle Hub LH
Hole Snap Ring
49 (500, 36)
Cotter Pin
Front Wheel Bearing
Dust Deflector No.1 LH
Front Axle Hub
LH Bearing
Cotter Pin
123 (1,254, 91)
Steering Knuckle LH
294 (2,998, 217)
Disc Brake Dust
Cover Front LH
8.3 (85, 73 in.
⋅ lbf)
Lower Ball Joint Assy LH
8.3 (85, 73 in.
⋅ lbf)
Front Axle Hub Sub-assy LH
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
G29148
2409
DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT, PROPELLER SHAFT, AXLE (From July,
2003)
30-7
255 (2,600, 188)
Shock Absorber Assy Rear LH
Rear Suspension Arm
Assy No.1 LH
Rear Axle Carrier
Sub-assy LH
Rear Suspension Arm
Assy No.2 LH
100 (1,020, 74)
62 (630, 46)
Rear Disc Brake
Caliper Assy LH
19 (192, 14)
100 (1,020, 74)
113 (1,152, 83)
113 (1,152, 83)
62 (630, 46)
Parking Brake Assy
Strut Rod Assy Rear
80 (816, 59)
5.4 (55, 48 in.
⋅ lbf)
5.4 (55, 48 in.
⋅ lbf)
Rear Axle Hub &
Bearing Assy LH
X5
80 (816, 59)
Rear Axle LH Hub Bolt
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
Rear Disc
C91585
2410
30-8
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
OVERHAUL
HINT:
COMPONENTS: See page 30-4
Overhaul the RH side following the same procedures as for the LH side.
1.
DRAIN AUTOMATIC TRANSAXLE FLUID
2.
REMOVE FRONT WHEEL
300M5-01
SST
C91611
3.
REMOVE FRONT AXLE HUB LH NUT
(a) Using SST and a hammer, unstake the staked part of the front axle hub LH nut.
SST 09930-00010
NOTICE:
Loosen the staked part of the lock nut completely, otherwise the screw of the drive shaft may be damaged.
(b) While applying the brake, remove the front axle hub LH nut.
4.
DISCONNECT FRONT STABILIZER LINK ASSY LH
(a) Remove the nut, and separate the stabilizer link assy LH.
HINT:
If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.
F40136
5.
DISCONNECT SPEED SENSOR FRONT LH
(a) Remove the bolt and clip, and separate the sensor wire and hose from the shock absorber.
NOTICE:
Be careful not to damage the speed sensor.
C83022
(b) Remove the bolt, and separate the speed sensor front LH from the steering knuckle.
NOTICE:
Prevent foreign matter from adhering to the speed sensor.
F40147
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2411
SST
Hold
30-9
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
6.
DISCONNECT TIE ROD ASSY LH
(a) Remove the cotter pin and nut.
(b) Using SST, separate the tie rod end from the steering knuckle.
SST 09628-6201 1
Turn
C92142
7.
DISCONNECT FRONT SUSPENSION ARM
SUB-ASSY LOWER NO.1 LH
(a) Remove the bolt and 2 nuts, and disconnect the front suspension arm sub-assy lower No.1 LH from the lower ball joint.
F40142
8.
DISCONNECT FRONT AXLE ASSY LH
(a) Using a plastic hammer, separate the drive shaft from the axle hub.
NOTICE:
Be careful not to damage the boot and speed sensor rotor.
SST
D27403
9.
REMOVE FRONT DRIVE SHAFT ASSY LH
(a) Using SST, remove the front drive shaft assy LH.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
Be careful not to damage the transaxle case oil seal, inboard joint boot and drive shaft dust cover.
Be careful not to drop the drive shaft assy.
C83850
10.
REMOVE FRONT DRIVE SHAFT ASSY RH
(a) Using pliers, remove the drive shaft bearing bracket hole snap ring.
(b) Remove the bolt and front drive shaft assy RH from the drive shaft bearing bracket.
C66549
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2412
30-10
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
SST
11.
FIX FRONT AXLE ASSY LH
SST 09608-16042 (09608-02021, 09608-02041)
NOTICE:
The hub bearing could be damaged if it is subjected to the vehicle’s full weight, such as when moving the vehicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with SST.
C92143
C91598
12.
INSPECT FRONT DRIVE SHAFT ASSY LH
NOTICE:
Move the drive shaft assy keeping it level.
(a) Check that there is no remarkable play in the radial direction of the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust direction.
(c) Check that there is no remarkable play in the radial direction of the inboard joint.
(d) Check the boots for damage.
13.
REMOVE FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) One touch type
(1) Using a screwdriver, remove the front axle inboard joint boot LH clamp and front axle inboard joint boot
LH No.2 clamp, as shown in the illustration.
C67412
(b) Claw Engagement type
(1) Using pliers, remove the front axle inboard joint boot LH clamp and front axle inboard joint boot LH
No.2 clamp, as shown in the illustration.
F07391
14.
DISCONNECT FR AXLE INBOARD JOINT BOOT
(a) Separate the inboard joint boot from the inboard joint assy.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2413
Matchmarks
30-1 1
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
15.
REMOVE FRONT DRIVE INBOARD JOINT ASSY LH
(a) Put matchmarks on the inboard joint assy and outboard joint shaft.
NOTICE:
Do not use a punch for the marks.
(b) Remove the inboard joint assy from the outboard joint shaft.
C91600
(c) Using a snap ring expander, remove the front drive inner shaft inner RH shaft snap ring.
C67414 F45046
(d) Put matchmarks on the outboard joint shaft and tripod joint.
NOTICE:
Do not use a punch for the marks.
(e) Using a brass bar and hammer, remove the tripod joint from the outboard joint shaft.
NOTICE:
Do not tap the roller.
Matchmarks
N00194
16.
REMOVE FRONT DRIVE SHAFT DAMPER LH
(a) Using a screwdriver, remove the front drive shaft damper LH clamp.
(b) Remove the front drive shaft damper LH.
17.
REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP
(a) Using a screwdriver, remove the front axle outboard joint boot LH clamp and front axle outboard joint boot LH No.2 clamp.
18.
REMOVE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard joint shaft.
(b) Remove the old grease from the outboard joint.
19.
REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Using a screwdriver, remove the hole snap ring.
C57543
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2414
30-12
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
SST
20.
REMOVE FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, remove the front drive shaft dust cover LH.
SST 09950-00020
NOTICE:
Be careful not to drop the inboard joint assy.
F40647
21.
REMOVE FRONT DRIVE SHAFT DUST COVER RH
(a) Using a press, remove the front drive shaft dust cover RH.
C67101
22.
REMOVE FRONT DRIVE SHAFT DUST COVER
(a) Using SST and a press, remove the front drive shaft dust cover.
SST 09950-00020
F40648
23.
REMOVE FRONT DRIVE SHAFT BEARING
(a) Using a snap ring expander, remove the front drive shaft hole snap ring RH.
C53236
F40209
(b) Using SST and a press, remove the bearing.
SST 09527-1001 1
NOTICE:
Be careful not to drop the inboard joint assy.
SST
C68339
C92031
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2415
SST
C66790
30-13
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
24.
INSTALL FRONT DRIVE SHAFT BEARING
(a) Using SST and a steel plate, install a new front drive shaft bearing.
SST 09527-30010, 09527-10011
NOTICE:
Bearing should be completely installed.
C92032
(b) Using a snap ring expander, install a new front drive shaft hole snap ring RH.
C66605 C92033
SST
SST
SST
25.
INSTALL FRONT DRIVE SHAFT DUST COVER
(a) Using SST and a press, install a new front drive shaft dust cover until the distance from the tip of the center drive shaft to the front drive shaft dust cover meets the specification, as shown in the illustration.
SST 09527-1001 1, 09726-40010
Distance: 42.1 0.5 mm (1.7 0.02 in.)
C91586
C92422
26.
INSTALL FRONT DRIVE SHAFT DUST COVER RH
(a) Using SST and a press, install a new drive shaft dust cover RH until the distance from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification, as shown in the illustration.
SST 09527-1001 1
Distance: 110.5 0.5 mm (4.4 0.02 in.)
NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover.
27.
INSTALL FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, install a new front drive shaft dust cover LH.
SST 09527-1001 1
NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover.
F41033
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2416
30-14
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
28.
INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Install a new front drive shaft LH hole snap ring.
SST
Vinyl Tape
W01994
R10425
29.
INSTALL OUTBOARD JOINT BOOT
HINT:
Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged.
(a) Hold the drive shaft lightly in a soft vise.
(b) Temporarily install a new outboard joint boot with 2 new clamps to the drive shaft.
(c) Pack the outboard joint shaft and boot with grease.
Grease capacity:
205 - 215 g (7.2 - 7.6 oz.)
30.
INSTALL FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
(a) Hold the drive shaft lightly in a soft vise.
(b) Install the 2 outboard joint boot clamps onto the boot.
(c) Place SST onto the outboard joint large boot clamp.
SST 09521-24010
(d) Tighten the SST so that the large clamp is pinched.
NOTICE:
Do not overtighten the SST.
(e) Using SST, adjust the clearance of the large clamp.
SST 09240-00020
Clearance: 0.8 mm (0.032 in.) or less
(f) Employ the same manner to the outboard joint small boot clamp.
225.4 2.0 mm
(8.87 0.079 in.)
R10426
31.
INSTALL FRONT DRIVE SHAFT DAMPER LH
(a) Install the drive shaft damper LH to the drive shaft.
(b) Make sure that the damper is on the shaft groove.
(c) Set the distance, as described below.
Distance: 225.4 2.0 mm (8.87 0.079 in.)
(d) Install a new front drive shaft damper LH clamp to the front drive shaft damper LH.
F40646
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2417
C67414
Matchmarks
30-15
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
C67417
32.
INSTALL FRONT DRIVE INBOARD JOINT ASSY LH
(a) Temporarily install a new inboard joint boot with 2 new clamps to the drive shaft.
(b) Place the beveled side of the tripod joint axial spline toward the outboard joint shaft.
(c) Align the matchmarks.
(d) Using a brass bar and hammer, tap in the tripod joint to the outboard joint shaft.
NOTICE:
Do not tap the roller.
Be sure to install the tripod joint assy in the correct direction.
(e) Using a snap ring expander, install a new shaft snap ring.
(f) Pack the outboard joint shaft and boot with grease.
Grease capacity: 175 to 185 g (6.25 to 6.61 oz.)
F45046
(g) Aligning the matchmarks, install the inboard joint assy to the outboard joint shaft assy.
F40222
33.
INSTALL FR AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint assy.
34.
INSTALL FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) One touch type
(1) Using a screwdriver, install the front axle inboard joint boot LH clamp and front axle inboard joint boot
LH No.2 clamp, as shown in the illustration.
C83397
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2418
30-16
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
(b) Claw Engagement type
(1) Using pliers, install the front axle inboard joint boot
LH clamp and front axle inboard joint boot LH No.2
clamp, as shown in the illustration.
F07391
C91598
35.
INSPECT FRONT DRIVE SHAFT
NOTICE:
Move the drive shaft assy keeping it level.
(a) Check that there is no remarkable play in the radial direction of the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust direction.
(c) Check that there is no remarkable play in the radial direction of the inboard joint.
(d) Check the boots for damage.
(e) Make sure that the 2 boots are on the shaft groove.
(f) Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.
Drive shaft standard length: mm (in.)
LH
RH
576.9 2.0 (22.713 0.079)
896.4 2.0 (35.291 0.079)
R00764
C83851
36.
INSTALL FRONT DRIVE SHAFT ASSY LH
(a) Install a new front drive shaft LH hole snap ring.
(b) Coat the spline of the inboard joint shaft assy with ATF.
(c) Align the shaft splines and install the drive shaft assy with a brass bar and hammer.
NOTICE:
Set the snap ring with the opening side facing downward.
Be careful not to damage the oil seal, boot and dust cover.
Move the drive shaft assy while keeping it level.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2419
30-17
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
37.
INSTALL FRONT DRIVE SHAFT ASSY RH
(a) Using a screwdriver, install a new bearing bracket hole snap ring.
NOTICE:
Do not damage the oil seal and boot.
(b) Install the bolt.
Torque: 32 N
⋅ m (330 kgf
⋅ cm, 24 ft
⋅ lbf)
C66548
38.
INSTALL FRONT AXLE ASSY LH
(a) Install the front drive shaft assy LH to the front axle assy LH.
NOTICE:
Be careful not to damage the outboard joint boot.
Be careful not to damage the speed sensor rotor.
39.
INSTALL FRONT SUSPENSION ARM SUB- ASSY
LOWER NO.1 LH
(a) Install the lower ball joint to the front suspension arm subassy lower with the bolt and nuts.
Torque: 75 N
⋅ m (765 kgf
⋅ cm, 55 ft
⋅ lbf)
F40142
40.
INSTALL TIE ROD ASSY LH
(a) Install the tie rod end to the steering knuckle with the nut.
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 60 further.
C83022
41.
INSTALL SPEED SENSOR FRONT LH
(a) Install the flexible hose and the speed sensor to the shock absorber with the bolt and set the clip of sensor on knuckle.
Torque: 19 N
⋅ m (192 kgf
⋅ cm, 14 ft
⋅ lbf)
NOTICE:
Be careful not to damage the speed sensor.
Do not twist the sensor wire when installing the speed sensor.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2420
30-18
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT (From July, 2003)
(b) Install the speed sensor to the steering knuckle with the bolt.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
NOTICE:
Prevent foreign matter from adhering to the speed sensor.
F40147
42.
INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the nut.
Torque: 74 N
⋅ m (755 kgf
⋅ cm, 55 ft
⋅ lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.
F40136
43.
INSTALL FRONT AXLE HUB LH NUT
(a) Using a socket wrench (30 mm), install a new axle hub LH nut.
Torque: 294 N
⋅ m (2,998 kgf
⋅ cm, 217 ft
⋅ lbf)
(b) Using a chisel and hammer, stake the front axle hub LH nut.
F40152
44.
INSTALL FRONT WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
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 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2421
30-19
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB-ASSY LH (From July, 2003)
REPLACEMENT
HINT:
Replace the RH side using the same procedures as for the LH side.
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 )
300M6-02
4.
SEPARATE FRONT DISC BRAKE CALIPER ASSY LH
(a) Remove the 2 bolts and separate the front disc brake caliper assy LH from the steering knuckle LH.
NOTICE:
Use a string or other device to keep the brake caliper from hanging down by the flexible hose.
C91612
5.
REMOVE FRONT DISC
6.
SEPARATE TIE ROD ASSY LH (SEE PAGE 30-8 )
SST 09628-6201 1
7.
SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (SEE PAGE 30-8 )
8.
REMOVE FRONT AXLE ASSY LH
(a) Using a plastic hammer, separate the front drive shaft assy LH from the front axle hub sub-assy LH.
NOTICE:
Be careful not to damage the boot and speed sensor rotor.
(b) Remove the 2 bolts, nuts and steering knuckle with the axle hub.
C83023
SST
9.
REMOVE LOWER BALL JOINT ASSY FRONT LH
(a) Remove the cotter pin and nut.
(b) Using SST, remove the lower ball joint assy front LH.
SST 09628-6201 1
F40153
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2422
30-20
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB-ASSY LH (From July, 2003)
10.
REMOVE FRONT WHEEL BEARING DUST
DEFLECTOR NO.1 LH
(a) Using a screwdriver, remove the bearing dust deflector
No.1 LH.
F40154
11.
REMOVE FRONT AXLE HUB LH HOLE SNAP RING
(a) Using a snap ring expander, remove the front axle hub LH hole snap ring.
C83852
SST
F45465
12.
REMOVE FRONT AXLE HUB SUB-ASSY LH
(a) Using SST, remove the front axle hub sub-assy LH.
SST 09520-00031
SST
F40156
(b) Using SST and a press, remove the bearing inner race
(outside) from the front axle hub sub-assy LH.
SST 09950- 00020, 09950- 60010 (09951- 00410),
09950-70010 (09951-07100)
F02261
13.
REMOVE DISC BRAKE DUST COVER FRONT LH
(a) Using a torx
wrench (T30), remove the 4 bolts and disc brake dust cover front LH.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2423
SST
Spanner
V Block
SST
30-21
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB-ASSY LH (From July, 2003)
SST
14.
REMOVE FRONT AXLE HUB LH BEARING
(a) Place the bearing inner race (outside) on the front axle hub LH bearing.
(b) Using SST and a press, press the front axle hub LH bearing until it contacts the SST.
SST 09527- 17011, 09950- 60010 (09951- 00600),
09950-70010 (09951-07100)
SST
F40230
F11547
(c) Using a spanner to make the steering knuckle LH horizontal, fix it to the V block as shown in the illustration.
NOTICE:
Be sure that the steering knuckle is horizontally positioned.
(d) Using SST and a press, remove the front axle hub LH bearing.
SST 09950- 60010 (09951- 00600), 09950- 70010
(09951-07100)
15.
INSTALL FRONT AXLE HUB LH BEARING
(a) Using SST and a press, install a new front axle hub LH bearing to the steering knuckle LH.
SST 09950- 60020 (09951- 00790), 09950- 70010
(09951-07100)
F40231
16.
INSTALL DISC BRAKE DUST COVER FRONT LH
(a) Place the disc brake dust cover front LH and using a torx wrench (T30), torque the 4 bolts.
Torque: 8.3 N
⋅ m (85 kgf
⋅ cm, 73 in.
⋅ lbf)
SST
17.
INSTALL FRONT AXLE HUB SUB-ASSY LH
(a) Using SST and a press, install the front axle hub subassy LH.
SST 09608- 32010, 09950- 60020 (09951- 00790),
09950-70010 (09951-07100)
SST
F40157
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2424
30-22
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB-ASSY LH (From July, 2003)
18.
INSTALL FRONT AXLE HUB LH HOLE SNAP RING
(a) Using snap ring pliers, install a new front axle hub LH hole snap ring.
C83852 F45465
F45054
19.
INSTALL FRONT WHEEL BEARING DUST
DEFLECTOR NO.1 LH
(a) Using SST and a hammer, install the bearing dust deflector No.1 LH.
SST 09316- 60011 (09316- 00011, 09316- 00031),
09608-32010
HINT:
Aligh the hole for the speed sensor in the bearing dust deflector
No.1 LH with the steering knuckle.
C97690
20.
INSTALL LOWER BALL JOINT ASSY FRONT LH
(a) Install the lower ball joint assy front LH and tighten the nut.
Torque: 123 N
⋅ m (1,254 kgf
⋅ cm, 90 ft
⋅ lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 60 further.
21.
INSTALL FRONT AXLE ASSY LH
(a) Install the front axle assy LH with the 2 bolts and nuts to the shock absorber assy front LH.
Torque: 210 N
⋅ m (2,141 kgf
⋅ cm, 155 ft
⋅ lbf)
NOTICE:
C83023
Only when reusing the bolts and nuts, apply the small amount of engine oil to the screw part of the nuts.
Do not excessively push out the front axle assy LH.
Be careful not to damage the outboard joint boot.
Be careful not to damage the speed sensor rotor.
22.
INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (SEE PAGE 30-8 )
23.
INSTALL TIE ROD ASSY LH (SEE PAGE 30-8 )
24.
INSTALL FRONT DISC
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2425
30-23
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB-ASSY LH (From July, 2003)
25.
INSTALL FRONT DISC BRAKE CALIPER ASSY LH
(a) Install the front disc brake caliper assy LH with the 2 bolts to the steering knuckle LH.
Torque: 107 N
⋅ m (1,090 kgf
⋅ cm, 79 ft
⋅ lbf)
C91612
26.
INSTALL FRONT AXLE HUB LH NUT (SEE PAGE 30-8 )
(a) Using a socket wrench (30 mm), install a new axle hub LH nut.
Torque: 294 N
⋅ m (2,998 kgf
⋅ cm, 217 ft
⋅ lbf)
27.
DISCONNECT FRONT DISC BRAKE CALIPER ASSY
LH
(a) Remove the 2 bolts and separate the front disc brake caliper assy LH from the steering knuckle LH.
NOTICE:
Use a string or other device to keep the brake caliper from hanging down by the flexible hose.
C91612
28.
REMOVE FRONT DISC
29.
INSPECT BEARING BACKLASH
(a) Using a dial indicator, check the backlash near the center of the axle hub.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
F40163
30.
INSPECT AXLE HUB DEVIATION
(a) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt.
Maximum: 0.05 mm (0.0020 in.)
If the deviation exceeds the maximum, replace the axle hub.
F40164
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2426
30-24
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB-ASSY LH (From July, 2003)
31.
INSTALL FRONT DISC
32.
INSTALL FRONT DISC BRAKE CALIPER ASSY LH
(a) Install the front disc brake caliper assy LH with the 2 bolts to the steering knuckle LH.
Torque: 107 N
⋅ m (1,090 kgf
⋅ cm, 79 ft
⋅ lbf)
C91612
33.
INSTALL SPEED SENSOR FRONT LH (SEE PAGE 30-8 )
34.
INSTALL FRONT AXLE HUB LH NUT
(a) Using a socket wrench (30 mm), install a new axle hub LH nut.
Torque: 294 N
⋅ m (2,998 kgf
⋅ cm, 217 ft
⋅ lbf)
(b) Using a chisel and hammer, stake the axle hub LH nut.
C68609
35.
INSTALL FRONT WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
36.
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-5 )
37.
CHECK ABS SPEED SENSOR SIGNAL w/ VSC (SEE PAGE 05-471 ) w/o VSC (SEE PAGE 05-420 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2427
30-25
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE LH HUB BOLT
REPLACEMENT
HINT:
COMPONENTS: See page 30-4
Replace the RH side by the same procedures with LH side.
1.
REMOVE FRONT WHEEL
2.
DISCONNECT FRONT DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-19 )
3.
REMOVE FRONT DISC
SST
30020-09
4.
REMOVE FRONT AXLE LH HUB BOLT
(a) Using SST and a screwdriver or an equivalent to hold, remove the front axle LH hub bolt.
SST 09628-1001 1
F40170
5.
INSTALL FRONT AXLE LH HUB BOLT
(a) Install a washer and nut to a new front axle LH hub bolt as shown in the illustration.
(b) Using a screwdriver to hold, install the hub bolt by torquing the nut.
F40171
6.
INSTALL FRONT DISC
7.
INSTALL FRONT DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-19 )
8.
INSTALL FRONT WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2428
30-26
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE HUB & BEARING ASSY LH
REPLACEMENT
HINT:
COMPONENTS: See page 30-4
Replace the RH side by the same procedures with the LH side.
1.
REMOVE REAR WHEEL
3006I-04
2.
DISCONNECT REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the bolt and disconnect the rear flexible hose.
C83014
(b) Remove the 2 bolts and rear disc brake caliper assy LH.
(c) Support the rear disc brake caliper assy LH securely.
C83008
3.
REMOVE REAR DISC
4.
DISCONNECT SKID CONTROL SENSOR WIRE
5.
REMOVE REAR AXLE HUB & BEARING ASSY LH
(a) Remove the 4 bolts and rear axle hub & bearing assy LH.
C83035
6.
REMOVE SKID CONTROL SENSOR (SEE PAGE 32-56 )
7.
INSTALL SKID CONTROL SENSOR (SEE PAGE 32-56 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2429
30-27
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE HUB & BEARING ASSY LH
8.
INSTALL REAR AXLE HUB & BEARING ASSY LH
(a) Install the rear axle hub & bearing assy LH with the 4 bolts.
Torque: 80 N
⋅ m (816 kgf
⋅ cm, 59 ft
⋅ lbf)
C83035
9.
INSTALL SKID CONTROL SENSOR WIRE
12.
INSTALL REAR DISC
C83015
11.
INSPECT AXLE HUB DEVIATION
(a) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt.
Maximum: 0.07 mm (0.0028 in.)
If the backlash exceeds the maximum, replace the axle hub assembly.
C83016
10.
INSPECT BEARING BACKLASH
(a) Set a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the axle hub assembly.
13.
INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper assy LH with the 2 bolts.
Torque: 62 N
⋅ m (630 kgf
⋅ cm, 46 ft
⋅ lbf)
C83008
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2430
30-28
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE HUB & BEARING ASSY LH
(b) Install the rear flexible hose with the bolt.
Torque: 19 N
⋅ m (192 kgf
⋅ cm, 14 ft
⋅ lbf)
C83014
14.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
15.
INSPECT AND ADJUST REAR WHEEL ALIGNMENT (SEE PAGE 27-3 )
16.
CHECK ABS SPEED SENSOR SIGNAL w/ VSC (SEE PAGE 05-471 ) w/o VSC (SEE PAGE 05-420 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2431
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE CARRIER SUB-ASSY LH
REPLACEMENT
HINT:
COMPONENTS: See page 30-4
Replace the RH side by the same procedures with the LH side.
1.
REMOVE REAR WHEEL
2.
REMOVE STRUT ROD ASSY REAR (SEE PAGE 27-18 )
3.
DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-26 )
4.
REMOVE REAR DISC
5.
DISCONNECT SKID CONTROL SENSOR WIRE
6.
REMOVE REAR AXLE HUB & BEARING ASSY LH (SEE PAGE 30-26 )
30-29
3006J-06
7.
SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH
(a) Remove the bolt, nut and rear suspension arm assy No.2
LH from the rear axle carrier sub-assy LH.
HINT:
While fixing the nut, turn and remove the bolt.
C83017
8.
SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH
(a) Remove the bolt, nut and rear suspension arm assy No.1
LH from the rear axle carrier sub-assy LH.
HINT:
While fixing the nut, turn and remove the bolt.
C83018
9.
REMOVE REAR AXLE CARRIER SUB-ASSY LH
(a) Remove the 2 bolts, nuts and rear axle carrier sub-assy
LH from the shock absorber assy rear LH.
NOTICE:
When removing bolt, stop the bolt from rotating and loosen the nut.
C83019
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2432
30-30
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE CARRIER SUB-ASSY LH
C83019
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 N
⋅ m (2,600 kgf
⋅ cm, 188 ft
⋅ lbf)
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.
C83018
12.
TEMPORARILY TIGHTEN REAR SUSPENSION ARM
ASSY NO.2 LH
(a) Install the rear suspension arm No.2 to the rear axle carrier 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.
C83017
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 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
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 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2433
30-31
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE LH HUB BOLT
REPLACEMENT
HINT:
COMPONENTS: See page 30-4
Replace the RH side by the same procedures with the LH side.
1.
REMOVE REAR WHEEL
2.
DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-26 )
3.
REMOVE REAR DISC
30024-07
4.
REMOVE REAR AXLE LH HUB BOLT
(a) Using SST and a screwdriver or an equivalent to hold, remove the rear axle LH hub bolt.
SST 09628-1001 1
SST
C83020
5.
INSTALL REAR AXLE LH HUB BOLT
(a) Install a washer and nut to a new rear axle LH hub bolt as shown in the illustration.
(b) Using a screwdriver to hold, install the rear axle LH hub bolt by torquing the nut.
C83021
6.
INSTALL REAR DISC
7.
INSTALL REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-26 )
8.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2434
14-1
ENGINE MECHANICAL ENGINE (3MZ-FE)
INSPECTION
1.
INSPECT ENGINE COOLANT (See page 16-1 )
2.
INSPECT ENGINE OIL
3.
INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68 F)
4.
INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY
5.
INSPECT SPARK PLUG (See page 18-3 )
141C0-02
Measuring Points for Belt Deflection or Tension
Vane Pump
Crankshaft
Generator
Compressor
A82940
6.
INSPECT V-RIBBED BELT
(a) Belt deflection:
Pressing force: 98 N (10 kgf, 22 lbf)
V-ribbed Belt
(For fan and generator)
V-ribbed Belt
(For vane pump)
(b) Belt tension:
New Belt mm (in.)
9.1 to 10.5
(0.358 to 0.413)
8 to 10
(0.315 to 0.394)
Used Belt mm (in.)
11 to 13.5
(0.433 to 0.531)
11 to 14
(0.433 to 0.551)
V-ribbed Belt
(For fan and generator)
V-ribbed Belt
(For vane pump)
New Belt
N (kg , lb)
637 to 735
(65 to 75 , 143 to 165)
588 to 686
(60 to 70 , 132 to 154)
Used Belt
N (kg , lb)
392 to 588
(40 to 60 , 88 to 132)
245 to 392
(25 to 40 , 55 to 88)
NOTICE:
Check the drive belt deflection at the specified point.
When installing a new belt, set its tension value as specified.
When inspecting a belt which is used for over 5 minutes, apply the specification of ”Used belt”.
When reinstalling a belt which is used for over 5 minutes, adjust its belt deflection and tension to the intermediate value of each specification in ”Used belt”.
The V- ribbed belt tension and deflection value should be checked after 2 revolutions of engine cranking.
When using a belt tension gauge, confirm the accuracy first by using a master gauge.
7.
INSPECT IGNITION TIMING
(a) Warm up 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.
Ignition timing: 8 to 12 BTDC
HINT:
Refer to the hand-held tester or OBD II scan tool operator’s manual if you need help to select DATA LIST.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2093
14-2
TC
CG
ENGINE MECHANICAL ENGINE (3MZ-FE)
A85669
(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.
Engine Wire
Tester Terminal
A82935
(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.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2094
14-3
ENGINE MECHANICAL ENGINE (3MZ-FE)
9.
INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the intake air surge tank (see page 11-13 ).
(c) Disconnect the injector connectors.
(d) Remove the ignition coils.
(e) Remove the spark plugs.
Compression Gauge
P19471
(f) Inspect the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
SST 09992-00500
(2) Fully open the throttle.
(3) While cranking the engine, measure the compression pressure.
Compression pressure:
1.5 MPa (15.3 kgf/cm 2 , 218 psi)
Minimum pressure:
1.0 MPa (10.2 kgf/cm
2
, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm 2 , 15 psi)
NOTICE:
Always use a fully-charged battery to obtain engine speed of 250 rpm or more.
Check the other cylinder’s compression pressure in the same way.
This measurement must be done as quickly as possible.
(4) If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole, then inspect again.
HINT:
If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
If pressure stays low, the valve may be sticking or seated improperly, or there may be leakage past the gasket.
10.
INSPECT CO/HC
HINT:
The ECM properly controls the CO/HC concentration in the emission gas.
(a) Start the engine.
(b) Run the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Check the CO/HC concentration at idle and/or at 2,500 rpm.
HINT:
When doing the 2 mode (with the engine is at idle and at 2,500 rpm) tests, these measuring order are prescribed by the applicable local regulations.
If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.
(1) Check the heated oxygen sensor operation (see page 05-126 ).
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2095
14-4
ENGINE MECHANICAL ENGINE (3MZ-FE)
Normal
Low
High
(2) See the table below for possible causes, then inspect the applicable causes and repair them if necessary.
CO HC Problems
High
High
High
Rough idle
Rough idle
(Fluctuating HC reading)
Rough idle
(Black smoke from exhaust)
Causes
5. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
6. Incorrect valve clearance
7. Leaks in intake and exhaust valves
8. Leaks in cylinders
1. Vacuum leaks:
PCV hoses
Intake manifold
Throttle body
Brake booster line
2. Lean mixture causing misfire
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI systems:
Faulty pressure regulator
Defective engine coolant temperature sensor
Defective mass air flow meter
Faulty ECM
Faulty injectors
Faulty throttle body
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2096
ENGINE MECHANICAL DRIVE BELT (3MZ-FE)
REPLACEMENT
1.
REMOVE FRONT WHEEL RH
2.
REMOVE FRONT FENDER APRON SEAL RH
14-5
14193-03
B
A
C
3.
REMOVE V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Loosen bolts A and B.
(b) Loosen the adjusting bolt C, then remove the V-ribbed belt.
A
A78698
4.
REMOVE VANE PUMP V BELT
(a) Loosen bolts A and B, then remove the V-ribbed belt.
B
A78699
A
B
5.
INSTALL VANE PUMP V BELT
(a) Install the V-ribbed belt on each pulley.
(b) Using a bar, adjust the V-ribbed belt tension, then tighten bolt B.
Torque: 43 N
⋅ m (439 kgf
⋅ cm, 32 ft
⋅ lbf)
(c) Tighten bolt A.
Torque: 43 N
⋅ m (439 kgf
⋅ cm, 32 ft
⋅ lbf)
A78699
B
C
A
A78698
6.
INSTALL V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Install the V-ribbed belt on each pulley.
(b) Tighten the adjusting bolt C, then adjust the V-ribbed belt tension.
(c) First tighten bolt A, then tighten bolt B.
Torque:
18 N
⋅ m (178 kgf
⋅ cm, 13 ft
⋅ lbf) for bolt A
58 N
⋅ m (591 kgf
⋅ cm, 43 ft
⋅ lbf) for bolt B
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2097
14-6
ENGINE MECHANICAL DRIVE BELT (3MZ-FE)
7.
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
8.
INSTALL FRONT WHEEL RH
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2098
14-7
ENGINE MECHANICAL VALVE CLEARANCE (3MZ-FE)
ADJUSTMENT
1.
DISCONNECT BATTERY NEGATIVE TERMINAL
2.
DRAIN ENGINE COOLANT (See page 16-9 )
3.
REMOVE FRONT FENDER APRON SEAL RH
4.
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
5.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
6.
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
7.
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
8.
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
9.
REMOVE RADIATOR HOSE INLET
10.
REMOVE IGNITION COIL ASSY
141J7-02
(a)
(a)
(b)
(b)
(b)
11.
REMOVE CYLINDER HEAD COVER SUB-ASSY
(a) Remove the 2 engine wire harness clamps.
(b) Remove the 3 nuts, then disconnect the engine wire harness.
(c) Remove the 9 bolts and cylinder head cover.
A78541
12.
REMOVE CYLINDER HEAD COVER SUB-ASSY LH
(a) Using an E6 Torx
socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.
(b) Remove the 9 bolts and cylinder head cover.
A36719
13.
INSPECT VALVE CLEARANCE
(a) Turn the crankshaft pulley, then align the timing notch with the timing mark ”0” of the timing belt No. 1 cover.
(b) Check that the valve lifters on the intake side of the No.
1 cylinder are not pushed by the cam.
If the valve lifters are pushed, turn the crankshaft by 1 revolution
(360 ) and align the marks as above.
P18805
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2099
14-8
RH Bank:
3 3
EX
IN
LH Bank:
1 1
Front
6 6
IN
EX
ENGINE MECHANICAL VALVE CLEARANCE (3MZ-FE)
(c) Inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
2 2
A78666
RH Bank:
EX
IN
3 3
LH Bank:
2 2
Front
IN
EX
4 4
5 5
(d) Turn the crankshaft by 2/3 of a revolution (240 ), then inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
A78667
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2100
RH Bank:
1 1
EX
IN
LH Bank:
Front
5 5
4 4
14-9
ENGINE MECHANICAL VALVE CLEARANCE (3MZ-FE)
(e) Turn the crankshaft by 2/3 of a revolution (240 ), then inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
IN
EX
6 6
A78668
Upward
14.
ADJUST VALVE CLEARANCE
(a) Turn the camshaft so that the cam lobe faces upward.
(b) Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.
Notch
A78669
Front of No. 1 and No. 2 Cylinders:
SST (A)
SST (B)
Others:
7
SST (A)
(c) Using SST (A), press down the valve lifter and place SST
(B) between the camshaft and valve lifter. Remove SST
(A).
SST 09248-55040 (09248-05410, 09248-05420)
HINT:
Apply SST (B) at a slight angle on the side marked with
”9” or ”7” at the position shown in the illustration.
When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent SST (B) from getting stuck, insert it gently from the intake side at a slight angle.
SST (A)
SST (B)
09248-05410
09248-05420
SST (B)
9
A78670
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2101
14-10
SST (B)
ENGINE MECHANICAL VALVE CLEARANCE (3MZ-FE)
(d) Using a small screwdriver and magnetic finger, remove the adjusting shim.
Magnetic Finger
A78671
EM0494
(e) Using a micrometer, measure the thickness of the removed shim.
(f) Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
A
B
C
Thickness of new shim
Thickness of used shim
Measured valve clearance
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.0079 in.))
Exhaust A = B + (C - 0.30 mm (0.0118 in.))
(g) Select a new shim with a thickness which is as close to the calculated values as possible.
EXAMPLE (Intake):
Measured valve clearance = 0.45 mm (0.0177 in.)
0.45 mm (0.0177 in.) - 0.20 mm (0.0079 in.) = 0.25 mm (0.0098 in.)
(Measured - Specification = Excess clearance)
Used shim measurement = 2.80 mm (0.1102 in.)
0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) = 3.05 mm (0.1201 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 3.05 mm (0.1201 in.)
Select No. 12 shim
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm
(0.1299 in.).
Refer to New Shim Thickness table on the next 2 pages.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2102
Installed Shim Thickness mm (in.)
Measured Clearance mm (in.)
Adjusting Shim Selection Chart (Intake)
Shim
No.
New Shim Thickness mm (in.)
Thickness
Shim
No.
Thickness
Intake valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 12 shim.
HINT: New shims have the thickness in millimeters imprinted on the face.
Installed Shim Thickness mm (in.)
Measured Clearance mm (in.)
Adjusting Shim Selection Chart (Exhaust)
Shim
No.
New Shim Thickness mm (in.)
Thickness
Shim
No.
Thickness
Exhaust valve clearance (Cold):
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 10 shim.
HINT: New shims have the thickness in millimeters imprinted on the face.
SST (B)
14-13
ENGINE MECHANICAL VALVE CLEARANCE (3MZ-FE)
SST (A)
(h) Place a new adjusting shim on the valve lifter with the imprinted number facing down.
(i) Press down the valve lifter with SST (A), then remove SST
(B).
SST 09248-55040 (09248-05410, 09248-05420)
(j) Recheck the valve clearance.
A78672
: Seal Packing
Front
A78673
15.
INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after applying seal packing.
Do not start the engine within 2 hours after installing.
(b) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
(c) Install the engine wire harness with the 3 nuts.
Torque: 8.4 N
⋅ m (85 kgf
⋅ cm, 74 in.
⋅ lbf)
: Seal Packing
Front
16.
INSTALL CYLINDER HEAD COVER SUB-ASSY LH
(a) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after applying seal packing.
A78674
Do not start the engine within 2 hours after installing.
(b) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
(c) Using an E6 Torx
socket wrench, install the engine wire harness protector with the 2 bolts.
Torque: 8.4 N
⋅ m (85 kgf
⋅ cm, 74 in.
⋅ lbf)
17.
INSTALL IGNITION COIL ASSY
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
18.
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
19.
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
20.
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
21.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
22.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
23.
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
24.
ADD ENGINE COOLANT (See page 16-9 )
25.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2105
14-14
ENGINE MECHANICAL VALVE CLEARANCE (3MZ-FE)
26.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2106
14-15
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
COMPONENTS x3 7.9 (81, 70 in.
⋅ lbf)
141J8-01
V-bank Cover Sub-assy
Front Fender Apron Seal RH
Clip x7
Clip
Radiator Lower Air Deflector
Engine Under Cover No. 1
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Engine Under Cover No. 2
Author: Date:
A84923
2107
14-16
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
9.0 (92, 80 in.
⋅ lbf)
Battery Clamp
Sub-assy
Air Cleaner Hose No. 1
Vacuum Hose
VSV Connector
Battery
5.0 (51, 44 in.
⋅ lbf) x2
Air Cleaner Cap
Sub-assy
5.0 (51, 44 in.
⋅ lbf)
Vacuum Hose
Air Cleaner
Inlet Assy
Mass
Air Flow Meter
Connector
Air Cleaner
Filter Element
Sub-assy x3 5.0 (51, 44 in.
⋅ lbf)
Battery Tray
Air Cleaner Inlet
No. 1
5.0 (51, 44 in.
⋅ lbf)
5.0 (51, 44 in.
⋅ lbf)
Clip
Intake Air Resonator
Sub-assy x2
Air Cleaner Case
7.5 (76, 66 in.
⋅ lbf)
Air Cleaner Bracket
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A84924
2108
14-17
V Belt No. 1
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
64 (653, 47)
28 (286, 21)
Generator Bracket No. 2
58 (591, 43)
8.4 (85, 74 in.
⋅ lbf)
9.8 (100, 7)
23 (235, 17)
Radio Setting
Condenser
Engine Moving
Control Rod
64 (653, 47)
43 (438, 32)
18 (178, 13)
18 (184, 13)
Engine Mounting
Stay No. 2 RH
Generator Assy
Generator Belt Adjusting Bar
Fuel Vapor
Feed Hose No. 1
Oil Reservoir to Pump Hose No. 1
Radiator Hose Inlet
Fan Belt Adjusting
Bar Bracket
25 (250, 18)
25 (250, 18)
Radiator Hose Outlet
Steering Gear Outlet
Return Tube
Oil Cooler Inlet Hose
Heater Outlet
Water Hose
Oil Cooler Outlet Hose
Compressor and
Magnetic Clutch
15 (153, 11)
Heater Inlet
Water Hose
Union to Check
Valve Hose
Fuel Pipe
Sub-assy No. 1
Fuel Pipe Clamp No. 1
Transmission Control
Cable Assy
25 (250, 18)
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A84925
2109
14-18
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Steering Intermediate Shaft Assy
35 (360, 26)
35 (360, 26)
Front Stabilizer Link
Assy LH
Tie Rod Assy LH
74 (755, 55)
49 (500, 36)
Cotter Pin
Speed Sensor Front LH
Front Suspension Arm
Sub-assy Lower No. 1 LH
75 (765, 55)
75 (765, 55)
294 (2,998, 217)
Front Axle Hub LH Nut
8.0 (82, 71 in.
⋅ lbf)
62 (633, 46)
Exhaust Pipe Assy Front
Exhaust Pipe
Gasket
Exhaust Pipe
Gasket
56 (571, 41)
Exhaust Pipe Gasket
62 (633, 46)
Exhaust Pipe No. 1
Support Bracket Front
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
33 (337, 24)
33 (337, 24)
Author:
Exhaust Pipe No. 1
Support Bracket Rear
Date:
A84926
2110
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Vane Pump V Belt
43 (439, 32)
43 (439, 32)
95 (969, 70)
Vane Pump Assy
7.8 (80, 69 in.
⋅ lbf)
14-19
87 (887, 64)
95 (969, 70)
Front Frame Assy
Frame Side Rail Plate
Sub-assy RH
Frame Side Rail Plate
Sub-assy LH
32 (326, 24)
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
85 (867, 63)
Front Suspension Member
Brace Rear RH
Front Suspension Member
Brace Rear LH
85 (867, 63)
32 (326, 24)
A84927
Author: Date:
2111
14-20
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Front Drive Shaft Assy RH
Drive Shaft Bearing
Bracket Hole Snap Ring
64 (650, 47)
Drive Plate & Torque
Converter Setting Bolt
41 (420, 30)
46 (469, 34)
7.8 (80, 69 in.
⋅ lbf)
37 (379, 27)
Flywheel Housing Under Cover
Exhaust Pipe Support Bracket No. 1
32 (330, 24)
Drive Shaft Bearing Bracket x5
64 (653, 47)
21 (214, 15)
64 (653, 47)
Engine Mounting
Bracket FR
Starter Assy
Automatic Transaxle
Assy
9.8 (100, 7)
Front Drive Shaft LH Hole
Snap Ring
Front Drive
Shaft Assy LH
37 (380, 26)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A84928
2112
20 (199, 14)
20 (199, 14)
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Emission Control
Valve Bracket
8.0 (82, 71 in.
⋅ lbf)
Emission Control Valve Set
20 (199, 14)
28 (286, 21)
Surge Tank
Stay No. 2
14-21
Surge Tank Stay No. 1
Engine Hanger No. 1
15 (153, 11)
8.4 (86, 74 in.
⋅ lbf)
15 (153, 11)
15 (153, 11) x4
Water Outlet
8.0 (80, 71 in.
⋅ lbf)
Intake Air Surge Tank
28 (286, 21)
Air Surge Tank to
Intake Manifold Gasket
15 (153, 11) x5
15 (153, 11) x2
Intake Manifold
Intake Manifold to
Head Gasket No. 1
Intake Manifold to
Head Gasket No. 2
Ignition Coil Assy
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
83 (846, 61) x8
Author:
Drive Plate
Spacer Front
Drive Plate
Spacer Rear
Drive Plate & Ring Gear
Sub-assy
A86169
Date:
2113
14-22
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
8.5 (87, 75 in.
⋅ lbf) x3
Exhaust Manifold
Heat Insulator No. 1 x6
49 (500, 36)
32 (326, 24) x3
Pump Bracket
Exhaust Manifold Sub-assy RH
Exhaust Manifold to
Head Gasket
Knock Sensor
20 (199, 14)
O-ring
8.0 (82, 71 in.
⋅ lbf) x3
Water Inlet
20 (199, 14)
O-ring
Thermostat
8.5 (87, 75 in.
⋅ lbf)
Water Inlet Pipe
15 (153, 11)
Engine Oil Pressure
Switch Assy
54 (551, 40)
Engine Mounting Bracket RH
49 (500, 36)
Manifold Stay No. 2
Exhaust Manifold to
Head LH Gasket
58 (591, 43)
49 (500, 36)
Generator Bracket No. 1
25 (250, 18) x6
49 (500, 36)
Compressor Mounting Bracket No. 1
Exhaust Manifold
Heat Insulator
No. 2
8.5 (87, 75 in.
⋅ lbf)
Exhaust Manifold
Converter Sub-assy
No. 2
Manifold Converter
Insulator No. 3
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A86170
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2114
Ventilation Valve
Sub-assy
Spark Plug
25 (250, 18)
14-23
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Oil Filler Cap Sub-assy x9
8.0 (80, 71 in.
⋅ lbf)
Cylinder Head
Cover Sub-assy
8.0 (80, 71 in.
⋅ lbf) x9
Oil Filler
Cap Gasket
Cylinder Head
Cover Gasket
VVT Sensor
8.0 (82, 71 in.
⋅ lbf)
Spark Plug
Tube Gasket
O-ring
Cylinder Head
Cover
Sub-assy LH
Cylinder Head Cover
Gasket No. 2
Spark Plug
Tube Gasket LH
8.0 (82, 71 in.
⋅ lbf)
Camshaft Timing
Oil Control Valve Assy
O-ring
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
O-ring
8.0 (82, 71 in.
⋅ lbf)
Oil Level Gage Guide
Oil Level Gage
Sub-assy
Author: Date:
A78304
2115
14-24
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Timing Belt
8.5 (87, 75 in.
⋅ lbf)
Timing Belt No. 2 Cover
220 (2,250, 162)
Crankshaft Pulley
28 (286, 21)
Timing Belt No. 1 Cover
8.5 (87, 75 in.
⋅ lbf)
Timing Belt Guide No. 2
Engine Mounting Bracket RH
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78305
2116
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
8.5 (87, 75 in.
⋅ lbf)
Collar
Bushing x6
28 (286, 21)
Timing Belt
Idler Bracket
14-25
43 (438, 32)
Camshaft Timing Pulley
125 (1,275, 92)
Timing Belt Idler
Sub-assy No. 2
Water Pump Assy
Water Pump Gasket
8.0 (82, 71 in.
⋅ lbf)
8.0 (82, 71 in.
⋅ lbf)
Timing Belt Idler Sub-assy No. 1
34 (347, 25)
Crankshaft Timing Pulley
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
8.0 (82, 71 in.
⋅ lbf)
Crankshaft
Position Sensor
8.0 (80, 71 in.
⋅ lbf)
Timing Belt Plate
A78306
Author: Date:
2117
14-26
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
RH Bank:
16 (163, 12) x10
Camshaft Bearing
Cap No. 2
Camshaft Bearing
Cap No. 4 Camshaft Timing Gear Bolt Washer
Camshaft Sub Gear
Camshaft Sub
Gear Wave Washer
Camshaft Bearing
Cap No. 1
16 (163, 12)
No. 2 Camshaft x10
Camshaft Sub Gear
Shaft Snap Ring
Camshaft Bearing Cap No. 5
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
150 (1,530, 111)
See page 14-40
1st: 54 (550, 40)
2st: Turn 90
Camshaft Bearing
Cap No. 2 x8
Camshaft Timing Gear Assy
Camshaft
Rear Plate Gasket
19 (189, 14)
Cylinder Head
10 (102, 7) x4
Cylinder Head
Sub-assy
Cylinder Head
Cover Rear
45 (459, 33)
Gasket
Oil Control
Valve Filter Camshaft Setting
Oil Seal
Cylinder Head
Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78307
2118
14-27
LH Bank:
16 (163, 12)
Camshaft Bearing
Cap No. 2
No. 3 Camshaft Sub-assy x10
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Camshaft Bearing
Cap No. 5
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
Camshaft Timing Gear Assy
150 (1,530, 11)
Camshaft Bearing
Cap No. 2
Camshaft Bearing
Cap No. 4
Camshaft
Sub Gear
Camshaft Sub
Gear Shaft
Snap Ring
16 (163, 12)
Camshaft Bearing
Cap No. 1
No. 4 Camshaft Sub-assy
See page 14-40
1st: 54 (550, 40)
2st: Turn 90
19 (189, 14) x10 x8
Camshaft Timing
Gear Bolt Washer
Oil Control
Valve Filter
Camshaft Sub
Gear Wave Washer
Gasket
10 (102, 7)
45 (459, 33) x4
Cylinder Head LH
Camshaft Setting
Oil Seal
Cylinder Head
Cover Rear
Cylinder Head
Rear Plate Gasket
Engine Hanger No. 2
Cylinder Head
Gasket No. 2
20 (199, 14)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
A78308
Author: Date:
2119
14-28
8.0 (82, 71 in.
⋅ lbf)
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Water Inlet Housing
Engine Rear Oil Seal Retainer
Engine Rear
Oil Seal
Cylinder Block Sub-assy
20 (199, 14)
Oil Pump Assy
43 (439, 32)
O-ring
8.0 (82, 71 in.
⋅ lbf) x6
8.0 (82, 71 in.
⋅ lbf)
30 (306, 22)
Oil Filter
Sub-assy
Oil Pan Baffle Plate
8.0 (82, 71 in.
⋅ lbf)
Oil Pump Seal
20 (199, 14)
Oil Pan Sub-assy
20 (199, 14)
8.0 (82, 71 in.
⋅ lbf)
Gasket
Oil Strainer Sub-assy
8.0 (82, 71 in.
⋅ lbf)
Gasket
45 (459, 33)
Oil Pan Drain Plug
8.0 (82, 71 in.
⋅ lbf)
20 (199, 14)
8.0 (82, 71 in.
⋅ lbf)
Oil Pan Sub-assy No. 2
8.0 (82, 71 in.
⋅ lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78309
2120
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
REPLACEMENT
1.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2.
DISCONNECT BATTERY NEGATIVE TERMINAL
3.
REMOVE FRONT WHEELS
4.
REMOVE ENGINE UNDER COVER NO.1
5.
REMOVE ENGINE UNDER COVER NO.2
6.
REMOVE FRONT FENDER APRON SEAL RH
7.
DRAIN ENGINE COOLANT (See page 16-9 )
8.
DRAIN ENGINE OIL (See page 17-20 )
9.
DRAIN AUTOMATIC TRANSAXLE FLUID (See page 30-8 )
10.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
11.
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
12.
REMOVE BATTERY
13.
REMOVE BATTERY TRAY
14.
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
15.
REMOVE AIR CLEANER ASSY (See page 19-5 )
16.
REMOVE AIR CLEANER BRACKET (See page 19-5 )
17.
REMOVE AIR CLEANER INLET NO.1 (See page 19-5 )
18.
REMOVE INTAKE AIR RESONATOR SUB-ASSY
(a) Remove the clip and bolt, then remove the intake air resonator.
19.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
20.
REMOVE GENERATOR ASSY (See page 19-21 )
21.
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
22.
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
23.
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
24.
REMOVE GENERATOR BELT ADJUSTING BAR (See page 17-9 )
25.
SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (See page 17-9 )
26.
SEPARATE TRANSMISSION CONTROL CABLE ASSY (See page 40-44 )
27.
DISCONNECT UNION TO CHECK VALVE HOSE
28.
DISCONNECT FUEL VAPOR FEED HOSE NO.1
29.
DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See page 11-1 )
30.
DISCONNECT HEATER INLET WATER HOSE
31.
DISCONNECT HEATER OUTLET WATER HOSE
32.
DISCONNECT RADIATOR HOSE INLET
33.
DISCONNECT RADIATOR HOSE OUTLET
34.
DISCONNECT OIL COOLER INLET HOSE
35.
DISCONNECT OIL COOLER OUTLET HOSE
14-29
141J9-02
36.
DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1
A60072
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2121
14-30
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
37.
DISCONNECT STEERING GEAR OUTLET RETURN
TUBE
A60073
38.
REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 10-22 )
39.
SEPARATE ENGINE WIRE
(a) Disconnect the engine wire harness from the ECM and junction block.
A59893
(b) Disconnect the engine wire harness from the engine room junction block.
(1) Remove the nut, then separate the engine wire harness.
(2) Using a screwdriver, release the engine room junction block. Separate the engine wire harness by pulling it upward.
(c) Remove the 2 nuts, then pull out the engine wire harness.
(d) Remove the body ground.
40.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
41.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
42.
REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2 )
43.
DISCONNECT FRONT STABILIZER LINK ASSY LH (See page 30-8 )
44.
DISCONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
45.
REMOVE FRONT AXLE HUB LH NUT (See page 30-8 )
SST 09930-00010
46.
REMOVE FRONT AXLE HUB RH NUT
HINT:
SST 09930-00010
Perform the same procedure as above on the opposite side.
47.
SEPARATE SPEED SENSOR FRONT LH (See page 30-8 )
48.
SEPARATE SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
49.
SEPARATE TIE ROD ASSY LH (See page 30-8 )
SST 09628-6201 1
50.
SEPARATE TIE ROD ASSY RH
SST 09628-6201 1
HINT:
Perform the same procedure as above on the opposite side.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2122
14-31
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
51.
SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-8 )
52.
SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
53.
SEPARATE FRONT AXLE ASSY LH (See page 30-8 )
54.
SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
55.
SEPARATE STEERING INTERMEDIATE SHAFT ASSY (See page 51-21 )
56.
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b) Remove the 4 bolts and 2 nuts, then remove the frame side rail plate RH and LH.
A59877
(c) Remove the 4 bolts and 2 nuts, then remove the front suspension member brace rear RH and LH.
(d) Carefully remove the engine assembly from the vehicle.
A59878
(e) Install the engine hanger No. 2 in the correct direction as shown in the illustration.
Torque: 20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf)
HINT:
Engine hanger No. 2
Bolt
12282-20020
91621-60822
(f) Attach the engine sling and hang the engine assembly with the chain block.
A36439
57.
REMOVE VANE PUMP V BELT (See page 14-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2123
14-32
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
58.
REMOVE VANE PUMP ASSY
(a) Remove the 2 nuts, then disconnect the power steering pressure tube.
A78549
(b) Remove the 2 bolts and vane pump.
RH: LH:
A52890
59.
REMOVE FRONT FRAME ASSY
(a) Remove the 2 nuts, then separate the engine mounting insulator RH and LH.
A78403
(b) Remove the bolt, then separate the engine mounting insulator FR.
A60501
60.
REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-8 )
SST 09520-01010, 09520-24010 (09520-32040)
61.
REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30-8 )
62.
REMOVE STARTER ASSY (See page 19-5 )
63.
REMOVE ENGINE MOUNTING BRACKET FR (See page 40-9 )
64.
REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9 )
65.
REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40-9 )
66.
REMOVE DRIVE SHAFT BEARING BRACKET
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2124
14-33
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
67.
REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-140 )
SST 09213-54015 (91651-60855), 09330-00021
68.
INSTALL ENGINE STAND
69.
REMOVE ENGINE HANGER NO.2
70.
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
71.
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
72.
REMOVE INTAKE MANIFOLD (See page 10-16 )
73.
REMOVE WATER OUTLET (See page 10-16 )
74.
REMOVE IGNITION COIL ASSY
75.
REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-120 )
76.
REMOVE EXHAUST MANIFOLD SUB-ASSY RH (See page 14-120 )
77.
REMOVE MANIFOLD CONVERTER INSULATOR NO.3
(a) Remove the bolt and nut, then remove the insulator.
A86565
78.
REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.2
(a) Remove the 2 bolts and insulator.
3
4 7
6 5
2
A86566
79.
REMOVE EXHAUST MANIFOLD CONVERTER
SUB-ASSY NO.2
(a) Using several steps, loosen and remove the 7 nuts in the sequence shown in the illustration.
(b) Remove the exhaust manifold converter No. 2 and gasket from the cylinder head LH.
1
A86567
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2125
14-34
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
80.
REMOVE MANIFOLD STAY NO.2
(a) Remove the 2 bolts and manifold stay.
A86568
81.
REMOVE ENGINE MOUNTING BRACKET RH (See page 17-9 )
82.
REMOVE PUMP BRACKET
(a) Remove the 3 bolts and pump bracket.
A05189
83.
REMOVE GENERATOR BRACKET NO.1
84.
REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-9 )
85.
REMOVE WATER INLET PIPE (See page 16-16 )
86.
REMOVE WATER INLET (See page 16-16 )
87.
REMOVE THERMOSTAT
88.
REMOVE ENGINE OIL PRESSURE SWITCH ASSY
(a) Using a deep socket wrench 24 mm, remove the oil pressure switch.
Oil Pressure
Switch
A80061
89.
REMOVE KNOCK SENSOR (See page 10-16 )
90.
REPLACE PARTIAL ENGINE ASSY
91.
INSTALL KNOCK SENSOR (See page 10-16 )
92.
INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080 THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 N
⋅ m (153 kgf
⋅ cm, 11 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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14-35
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
93.
INSTALL THERMOSTAT (See page 16-16 )
94.
INSTALL WATER INLET (See page 16-16 )
95.
INSTALL WATER INLET PIPE (See page 16-16 )
96.
INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (See page 17-9 )
97.
INSTALL GENERATOR BRACKET NO.1
Torque: 58 N
⋅ m (591 kgf
⋅ cm, 43 ft
⋅ lbf)
98.
INSTALL PUMP BRACKET
Torque: 32 N
⋅ m (326 kgf
⋅ cm, 24 ft
⋅ lbf)
99.
INSTALL ENGINE MOUNTING BRACKET RH (See page 17-9 )
100. INSTALL MANIFOLD STAY NO.2
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
4 1 6
5
2 3
101. INSTALL EXHAUST MANIFOLD CONVERTER
SUB-ASSY NO.2
(a) Install a new gasket and the exhaust manifold converter
No. 2 with the 7 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
(b) Retighten nuts 1 and 2 as shown in the illustration.
7
A86567
102. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 in.
⋅ lbf)
103. INSTALL MANIFOLD CONVERTER INSULATOR NO.3
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 in.
⋅ lbf)
104. INSTALL EXHAUST MANIFOLD SUB-ASSY RH (See page 14-120 )
105. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14-120 )
106. INSTALL IGNITION COIL ASSY (See page 14-7 )
107. INSTALL WATER OUTLET (See page 10-16 )
108. INSTALL INTAKE MANIFOLD (See page 10-16 )
109. INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
110. INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
111. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-140 )
SST 09213-54015 (91651-60855), 09330-00021
112. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 N
⋅ m (650 kgf
⋅ cm, 47 in.
⋅ lbf)
113. INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40-9 )
114. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9 )
115. INSTALL ENGINE MOUNTING BRACKET FR (See page 40-9 )
116. INSTALL STARTER ASSY (See page 19-5 )
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ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
117. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-8 )
118. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30-8 )
RH: LH:
119. INSTALL FRONT FRAME ASSY
(a) Install the engine mounting insulator RH and LH with the
2 nuts.
Torque: 95 N
⋅ m (969 kgf
⋅ cm, 70 ft
⋅ lbf)
A78403
(b) Install the engine mounting insulator FR with the bolt.
Torque: 87 N
⋅ m (887 kgf
⋅ cm, 64 ft
⋅ lbf)
A60501
120. INSTALL VANE PUMP ASSY
(a) Temporarily tighten the bolt.
(b) Install the adjusting strut to the engine mounting bracket
RH with the bolt.
Torque: 43 N
⋅ m (439 kgf
⋅ cm, 32 ft
⋅ lbf)
A52890
(c) Connect the power steering pressure tube with the 2 nuts.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
A78549
121. INSTALL VANE PUMP V BELT (See page 14-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2128
Nut B
A
Nut C
14-37
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
B
Nut
A
A59877
122. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with the transaxle on the engine lifter.
(b) Install the engine assembly to the vehicle.
(c) Install the frame side rail plate RH and LH with the 4 bolts and 2 nuts.
Torque:
85 N
⋅ m (867 kgf
⋅ cm, 63 ft
⋅ lbf) for bolt A
32 N
⋅ m (326 kgf
⋅ cm, 24 ft
⋅ lbf) for bolt B and nut
C
Nut
(d) Install the front suspension member brace rear RH and
LH with the 4 bolts and 2 nuts.
Torque:
85 N
⋅ m (867 kgf
⋅ cm, 63 ft
⋅ lbf) for bolt C
32 N
⋅ m (326 kgf
⋅ cm, 24 ft
⋅ lbf) for bolt D and nut
D
D
A59878
123. CONNECT STEERING INTERMEDIATE SHAFT ASSY (See page 51-21 )
124. INSTALL FRONT AXLE ASSY LH (See page 30-8 )
125. INSTALL FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
126. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page 30-8 )
127. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
128. INSTALL TIE ROD ASSY LH (See page 30-8 )
129. INSTALL TIE ROD ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
130. INSTALL SPEED SENSOR FRONT LH (See page 30-8 )
131. INSTALL SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
132. INSTALL FRONT AXLE HUB LH NUT (See page 30-8 )
133. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
134. INSTALL FRONT STABILIZER LINK ASSY LH (See page 30-8 )
135. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
136. INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 )
137. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
138. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
139. CONNECT FUEL PIPE SUB-ASSY NO.1 (See page 11-1 )
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ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
140. CONNECT TRANSMISSION CONTROL CABLE ASSY (See page 40-44 )
141. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See page 17-9 )
142. INSTALL GENERATOR BELT ADJUSTING BAR (See page 17-9 )
143. INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
144. INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
145. INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
146. INSTALL GENERATOR ASSY (See page 19-21 )
147. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
148. INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
149. INSTALL INTAKE AIR RESONATOR SUB-ASSY
Torque: 5.0 N
⋅ m (51 kgf
⋅ cm, 44 in.
⋅ lbf)
150. INSTALL AIR CLEANER INLET NO.1 (See page 19-5 )
151. INSTALL AIR CLEANER BRACKET (See page 19-5 )
152. INSTALL AIR CLEANER ASSY (See page 19-5 )
153. INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
154. CHECK CONNECTION OF VACUUM HOSE
Vacuum Hose Routing Diagram:
From Canister
Actuator
VSV for EVAP
Vacuum Surge
Tank
VSV for ACIS
Engine Mounting
Insulator FR
VSV for Active Control
Engine Mount
VSV
Cap
155. INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
156. INSTALL FRONT WHEELS (See page 14-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Vacuum Tank
Actuator
Date:
A86570
2130
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
157. ADD AUTOMATIC TRANSAXLE FLUID
158. ADD ENGINE OIL (See page 17-20 )
159. ADD COOLANT (See page 16-9 )
160. ADD POWER STEERING FLUID
161. BLEED POWER STEERING FLUID
162. INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40-1 )
163. CHECK FOR ENGINE OIL LEAKS
164. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
165. CHECK POWER STEERING FLUID LEAKAGE
166. INSPECT FOR FUEL LEAKS
167. CHECK FOR EXHAUST GAS LEAKS
168. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-5 )
169. INSPECT STEERING WHEEL CENTER POINT
170. INSPECT IGNITION TIMING (See page 14-1 )
SST 09843-18040
171. INSPECT ENGINE IDLE SPEED (See page 14-1 )
172. INSPECT CO/HC (See page 14-1 )
173. CHECK ABS SPEED SENSOR SIGNAL (See page 05-420 , 05-471 )
174. SYSTEM INITIALIZATION (See page 19-15 )
14-39
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2131
14-40
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
OVERHAUL
1.
REMOVE SPARK PLUG
2.
REMOVE OIL FILLER CAP SUB-ASSY
3.
REMOVE OIL FILLER CAP GASKET
4.
REMOVE CYLINDER HEAD COVER SUB-ASSY LH
5.
REMOVE CYLINDER HEAD COVER GASKET NO.2
6.
REMOVE CYLINDER HEAD COVER SUB-ASSY
7.
REMOVE CYLINDER HEAD COVER GASKET
8.
REMOVE VENTILATION VALVE SUB-ASSY
9.
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
10.
REMOVE VVT SENSOR
(a) Remove both the camshaft oil control valves.
(b) Remove the O-ring from each camshaft oil control valve.
11.
REMOVE OIL LEVEL GAGE SUB-ASSY
12.
REMOVE OIL LEVEL GAGE GUIDE
141CR-02
13.
REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
SST
SST
A78700
(b) Using SST and the pulley bolt, remove the pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05031)
NOTICE:
Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.
A78701
14.
REMOVE TIMING BELT NO.1 COVER
15.
REMOVE TIMING BELT NO.2 COVER
16.
REMOVE ENGINE MOUNTING BRACKET RH
17.
REMOVE TIMING BELT GUIDE NO.2
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2132
Approximately 60
Turn
14-41
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
18.
REMOVE TIMING BELT
(a) Set the No. 1 cylinder to the TDC/compression.
(1) Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
(2) Turn the crankshaft clockwise, then align the timing mark of the crankshaft timing pulley with the oil pump body.
A78326
(3) Check that the timing marks of the camshaft timing pulleys and the timing belt No. 3 cover are aligned.
If not, turn the crankshaft by 1 revolution (360 ).
(4) Remove the crankshaft pulley bolt.
A05052
(b) If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.
(1) If the installation marks have disappeared, put new installation marks on the timing belt before removing.
A52840
Turn
A78327
(c) Set the No. 1 cylinder to approximately 60 BTDC/compression.
(1) Turn the crankshaft counterclockwise by approximately 60 .
NOTICE:
If the timing belt is disengaged, having the crankshaft pulley set at the wrong angle can cause contact of the piston head with the valve head when removing the camshaft timing pulley and camshaft, which causes damage. So always set the crankshaft pulley at the correct angle.
(d) Remove the timing belt tensioner.
NOTICE:
Do not reinstall the tensioner with its plunger extended.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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2133
14-42
(2)
(1)
(3)
(5)
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(4)
(e) Remove the timing belt in this order.
1st
2nd
3rd
4th
5th
6th
No. 1 idler pulley
RH camshaft timing pulley
No. 2 idler pulley
LH camshaft timing pulley
Water pump pulley
Crankshaft timing pulley
(6)
A78702
19.
REMOVE TIMING BELT IDLER SUB-ASSY NO.1
(a) Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
20.
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
21.
REMOVE CRANKSHAFT POSITION SENSOR
22.
REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the bolt and RH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
SST
SST
A78703
(b) Using SST, remove the bolt and LH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
HINT:
Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling.
A78704
23.
REMOVE TIMING BELT NO.3 COVER
24.
REMOVE TIMING BELT IDLER BRACKET
25.
REMOVE CRANKSHAFT TIMING PULLEY
(a) Remove the bolt and timing belt plate.
SST
A78705
(b) Install the pulley bolt to the crankshaft.
(c) Using SST, remove the crankshaft timing pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05011)
NOTICE:
Do not scratch the sensor part of the crankshaft timing pulley.
Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2134
14-43
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
A78535
26.
REMOVE WATER PUMP ASSY
(a) Remove the 3 bolts and 3 nuts, then remove the water pump and gasket.
27.
REMOVE CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being removed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
Main Gear
Align
A78706
Sub Gear
Service Bolt
A78707
(b) Secure the exhaust camshaft sub gear to the main gear with a service bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
Recommended service bolt
Thread diameter
Thread pitch
Bolt length
6 mm
1.0 mm
16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
4
3
8
7
10
6
5
9
2
1
(c) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
A78708
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Author: Date:
2135
14-44
3
4
7
8
9
10
5
6
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
1
2
A78709
28.
REMOVE NO.2 CAMSHAFT
(a) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 2 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 2 camshaft.
29.
REMOVE NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being removed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Align the timing marks (1 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
Main Gear
Sub Gear
Align
A78710
Service Bolt
A78711
(b) Secure the exhaust camshaft sub gear to the main gear with a service bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
Recommended service bolt
Thread diameter
Thread pitch
6 mm
1.0 mm
Bolt length 16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2136
3
4
7
8
9
5
10
1
6
14-45
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
2
(c) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 3 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
A78712
4
3
8
7
10
9
6
5
2
1
A78713
30.
REMOVE NO.4 CAMSHAFT SUB-ASSY
(a) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 4 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 4 camshaft.
31.
INSPECT CAMSHAFT TIMING GEAR ASSY
(a) Clamp the camshaft in a vise on the hexagonal lobe.
(b) Check that the VVT-i will not turn.
A05739
Convex Portion
A78714
(c) Cover all the oil ports with vinyl tape except the port on the advance angle side (nearest to the convex portion) shown in the illustration.
(d) Using the air gun, apply about 100 kPa (1 kgf/cm
2
, 14 psi) of air pressure to the port on the advance angle side.
NOTICE:
Some oil spraying will occur. Be prepared to catch the spray with a shop rag.
HINT:
This operation releases the lock pin for the most retard angle lock.
(e) Under the condition above, turn the VVT-i to the advance angle side (the direction of the white arrow in the illustration) by hand.
Standard: Must turn
HINT:
Depending on the air pressure, the VVT-i will turn to the advance angle side without applying force by hand. Also, if the pressure can be hardly applied because of the air leakage from the port, the lock pin might not be released easily.
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2137
14-46
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(f) Check that the VVT-i moves freely within about 30 range. Avoid moving the VVT-i unit to the most retard angle position as the lock pin will engage again.
Standard: Smooth movable range is about 30
(g) Turn the VVT-i by hand, then lock it at the most retard angle position.
32.
REMOVE CAMSHAFT TIMING GEAR ASSY
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i) unless you are replacing the VVT-i or camshaft.
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
A05739
A05740
(b) Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.
NOTICE:
Remove it with the lock pin engaged and locked at the most retard angle position.
The lock nut has LH threads.
Never use any tools other than the socket wrench.
Other tools will deform the cam angle rotor.
(c) Remove the camshaft VVT-i.
NOTICE:
Never remove the 3 bolts on the gear.
If it is difficult to remove VVT-i, tap it lightly using a plastic-faced hammer, then remove it.
33.
REMOVE CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12596
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2138
14-47
SST
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(b) Using SST, turn the sub gear counterclockwise, then remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
A78715
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, camshaft sub gear and camshaft gear bolt washer.
HINT:
Arrange the camshaft sub gears and gear bolt washers (RH and
LH sides) so that they can be returned to the original locations when reassembling.
A52353
34.
REMOVE ENGINE HANGER NO.2
35.
REMOVE CYLINDER HEAD COVER REAR
36.
REMOVE OIL CONTROL VALVE FILTER
(a) Remove the plug, gasket and valve filter.
Front
A05275
37.
REMOVE CYLINDER HEAD SUB-ASSY
(a) Using a socket hexagon wrench 8, remove the hexagon bolt.
A78716
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2139
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4
2
Front
7
6
5
8
3
1
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(b) Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the washers into the cylinder head.
Head warpage or cracking could result from removing the bolts in an incorrect order.
A78717
38.
REMOVE CYLINDER HEAD GASKET
Front
39.
REMOVE CYLINDER HEAD LH
(a) Using a socket hexagon wrench 8, remove the hexagon bolt.
A78718
4
Front
6
2 7
8
5
1
3
(b) Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the washers into the cylinder head.
Head warpage or cracking could result from removing the bolts in an incorrect order.
A78719
40.
REMOVE CYLINDER HEAD GASKET NO.2
8
2
10
5
3
6
4
1
7
9
A78314
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
41.
REMOVE WATER INLET HOUSING
(a) Remove the 8 bolts and 2 nuts, then remove the water inlet housing.
Author: Date: 2140
SST
14-49
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
42.
REMOVE OIL FILTER SUB-ASSY
(a) Using SST, remove the oil filter.
SST 09228-07501
(b) Using a socket hexagon wrench 12, remove the oil filter union.
A78720
43.
REMOVE OIL PAN DRAIN PLUG
44.
REMOVE OIL PAN SUB-ASSY NO.2
(a) Remove the 10 bolts and 2 nuts.
SST
A36750
SST
A00019
(b) Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, then cut off the sealer and remove the oil pan
No. 2.
SST 09032-00100
NOTICE:
Be careful not to damage the contact surface of the oil pan No. 1 where the oil pan No. 2 is mounted.
Do not damage the flange portion of the oil pan No. 2 when removing.
45.
REMOVE OIL STRAINER SUB-ASSY
(a) Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
46.
REMOVE OIL PAN SUB-ASSY
(a) Loosen and remove the 15 bolts and 2 nuts uniformly.
B04136
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2141
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ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(b) Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the oil pan and cylinder block.
B04137
47.
REMOVE OIL PAN BAFFLE PLATE
48.
REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and bearing cap.
P12508
49.
REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal.
P12589
50.
REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Using a screwdriver, remove the oil pump by prying between the oil pump and bearing cap.
(c) Remove the O-ring.
A51990
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2142
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
51.
REMOVE OIL PUMP SEAL
(a) Using a screwdriver, pry out the oil seal.
14-51
A62375
52.
REMOVE SPARK PLUG TUBE GASKET
(a) Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out.
NOTICE:
Be careful not to damage the baffle plate of the cylinder head cover.
(b) Using a screwdriver and hammer, tap out the gasket.
A05245
(c) Using needle-nose pliers, pry out the gasket.
NOTICE:
Be careful not to damage the cylinder head cover.
A05243
EM3336
53.
INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow contact of the timing belt with oil, water or steam.
Do not use the timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.
Check the belt for any defects as shown in the illustrations.
Also, check these points below.
(a) If the belt tears in a short time:
Check if the belt is installed properly.
Check if the timing cover gasket is damaged and if it is installed properly.
(b) If the belt teeth are cracked or damaged, check if either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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2143
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ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(d) If there is wear or damage on only one side of the belt, check the belt guide and alignment of each pulley.
(e) If there is noticeable wear on the belt teeth:
Check the timing cover for damage.
Check that the gasket has been installed correctly.
Check for foreign objects on the pulley teeth.
If there is any doubt about the belt condition, replace the timing belt.
54.
INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the runout is greater than maximum, replace the camshaft.
EM1628
A51428
(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
43.132 to 43.232 mm (1.6981 to 1.7020 in.) for intake
43.010 to 43.110 mm (1.6933 to 1.6972 in.) for exhaust
Minimum cam lobe height:
42.98 mm (1.6921 in.) for intake
42.86 mm (1.6874 in.) for exhaust
If the cam lobe height is less than minimum, replace the camshaft.
(c) Inspect the camshaft journals.
26.959 to 26.975 mm (1.0614 to 1.0620 in.)
If the journal diameter is not as specified, check the oil clearance.
(1) Using a micrometer, measure the journal diameter.
Journal diameter:
Tension Portion
A51429
55.
INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter:
8.95 to 9.05 mm (0.3524 to 0.3563 in.)
Minimum outside diameter: 8.75 mm (0.3445 in.)
If the diameter is less than minimum, replace the bolt.
A78721
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2144
SST
SST
14-53
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
A78722
56.
INSTALL SPARK PLUG TUBE GASKET
(a) Using SST and a hammer, tap in the new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950- 60010 (09951- 00430), 09950- 70010
(09951-07100)
(b) Return the ventilation plate tab to its original position.
(c) Apply a light coat of multi-purpose grease to the gasket lip.
A78723
57.
INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, tap in the new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.
58.
INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing material from the contact surface.
Seal Width 2 to 3 mm (0.08 to 0.12 in.)
A
A
B
B
A78724
(b) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the oil seal retainer within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
(c) Install the oil seal retainer with the 6 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
SST
A78754
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
59.
INSTALL OIL PUMP SEAL
(a) Using SST and a hammer, tap in the new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010
NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.
Author: Date:
2145
14-54
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
60.
INSTALL OIL PUMP ASSY
(a) Remove any old packing material from the contact surface.
(b) Apply a light coat of engine oil to a new O-ring, then place it on the cylinder block.
A
A
B
C
B
Seal Packing
A36784
C
(c) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pump within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
Seal Width
2 to 3 mm
(0.08 to 0.12 in.)
A78725
(d) Align the key of the oil pump drive gear with the keyway located on the crankshaft, then slide the oil pump into place.
A36785
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2146
C
B
A
B
A
14-55
A
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
A
(e) Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf) for bolt A
20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf) for bolt B
43 N
⋅ m (439 kgf
⋅ cm, 32 ft
⋅ lbf) for bolt C
A
A
A51990
61.
INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
62.
INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
63.
INSTALL OIL PAN SUB-ASSY
(a) Remove any old seal packing from the contact surface.
Region ”X” Region ”Y”
A
A
Seal Packing
B
B
Seal Width
3 to 4 mm
(0.12 to 0.16 in.)
A78726
(b) Apply a continuous bead of seal packing (Diameter 3 to
4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the outer side of the bolt holes in the region ”X”.
Apply seal packing to the inner side of the bolt holes in the region ”Y”.
Install the oil pan within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
(c) Install the oil pan with the 15 bolts and 2 nuts. Tighten the bolts uniformly in several steps.
Torque:
8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf) for 10 mm head
20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf) for 12 mm head
64.
INSTALL OIL STRAINER SUB-ASSY
(a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
65.
INSTALL OIL PAN SUB-ASSY NO.2
(a) Remove any old seal packing from the contact surface.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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2147
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Seal Packing
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(b) Apply a continuous bead of seal packing (Diameter 4 to
5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pan within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
A B
A
Seal Width
4 to 5 mm
(0.16 to 0.20 in.)
B
A78727
66.
INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 45 N
⋅ m (459 kgf
⋅ cm, 33 ft
⋅ lbf)
67.
INSTALL WATER INLET HOUSING
(a) Remove any old packing material from the contact surface.
Seal Width 3 to 5 mm
(0.12 to 0.20 in.)
Seal Packing
A78728
(b) Apply a continuous bead of seal packing (Diameter 3 to
5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the water inlet housing within 3 minutes after applying seal packing.
Do not expose the seal packing to coolant within 2 hours after installing.
3
9
1
6
8
5
7
10
4
2
A78314
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Install the water inlet housing with the 8 bolts and 2 nuts.
Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
Author: Date: 2148
Front
14-57
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
A78324
68.
INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block with the R mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
69.
INSTALL CYLINDER HEAD SUB-ASSY
NOTICE:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.
7
Front
2 4 6
5 3 1 8
90
Front
Painted Mark
Front
(c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 N
⋅ m (550 kgf
⋅ cm, 40 ft
⋅ lbf)
A78717
(d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90 in the same sequence as step (c).
(f) Check that each painted mark is now at a 90 angle to the front.
A78730
(g) Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 N
⋅ m (189 kgf
⋅ cm, 14 ft
⋅ lbf)
A78716
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2149
14-58
Front
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
A79822
70.
INSTALL CYLINDER HEAD GASKET NO.2
(a) Place a new cylinder head gasket on the cylinder block with the L mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
71.
INSTALL CYLINDER HEAD LH
NOTICE:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.
5
Front
3 1 8
7 2 4 6
90
Front
Painted Mark
Front
(c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 N
⋅ m (550 kgf
⋅ cm, 40 ft
⋅ lbf)
A78719
(d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90 in the same sequence as step (c).
(f) Check that each painted mark is now at a 90 angle to the front.
A78730
(g) Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 N
⋅ m (189 kgf
⋅ cm, 14 ft
⋅ lbf)
A78718
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2150
14-59
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
72.
INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign object is on the mesh part of the filter.
(b) Assemble the valve filter and plug.
(c) Install the plug with a new gasket.
Torque: 45 N
⋅ m (459 kgf
⋅ cm, 33 ft
⋅ lbf)
A05418
73.
INSTALL CYLINDER HEAD COVER REAR
(a) Install the rear cover and a new gasket.
Torque: 10 N
⋅ m (102 kgf
⋅ cm, 7 ft
⋅ lbf)
74.
INSTALL CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12595
Wave Washer
Camshaft
Sub Gear
Camshaft Gear
Bolt Washer
A78732
(b) Install the camshaft gear bolt washer and camshaft sub gear.
HINT:
Attach the pins on the gears to the gear bolt washer ends.
(c) Install the wave washer.
(d) Using snap ring pliers, install the snap ring.
A52353
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2151
14-60
Align
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
SST
A78733
(e) Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, then temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(f) Align the gear teeth of the main gear and sub gear, then tighten the service bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
NOTICE:
Be careful not to damage the camshaft journals.
HINT:
When installing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
A78734
75.
INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Align the alignment pin with the alignment pin groove, then install the VVT-i into the camshaft.
NOTICE:
Install it with the lock pin engaged and locked at the most retard angle position.
(b) Apply engine oil to the nut, mounting surface of the VVT-i and screw threads.
NOTICE:
Be sure to apply the oil, otherwise the specified torque cannot be obtained.
New nuts must be used when replacing the VVT-i unit.
A05738
(c) Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.
Torque: 150 N
⋅ m (1,530 kgf
⋅ cm, 111 ft
⋅ lbf)
NOTICE:
The lock nut has LH threads.
Never use any tools other than the socket wrench.
Other tools will deform the cam angle rotor.
76.
INSTALL NO.2 CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2152
90
14-61
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(b) Place the No. 2 camshaft at a 90 angle of the timing mark
(2 dot marks) on the cylinder head.
(c) Apply multi-purpose grease to a new oil seal lip.
Seal Packing
Front
A78735
(d) Install the oil seal to the camshaft.
NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops.
(e) Remove any old packing material from the contact surface.
A78736
A78737
(f) Apply seal packing to the bearing cap No. 1 as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the bearing cap No. 1 within 5 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil to the threads of the bearing cap bolts.
A05283
10
6
2 9
4 5
8
1
3
7
A78738
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(i) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N
⋅ m (163 kgf
⋅ cm, 12 ft
⋅ lbf)
Author: Date:
2153
14-62
Align
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
77.
INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
(b) Align the timing marks (2 dot marks) of the camshaft drive and driven gears.
(c) Place the camshaft on the cylinder head.
A78739
(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.
7
8
A05204
3
4
1
2
5
6
9
10
A78740
(f) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N
⋅ m (163 kgf
⋅ cm, 12 ft
⋅ lbf)
(g) Remove the service bolt.
78.
INSTALL NO.4 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2154
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ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(b) Place the No. 4 camshaft at a 90 angle of the timing mark
(1 dot marks) on the cylinder head.
(c) Apply multi-purpose grease to a new oil seal lip.
90
Seal Packing
Front
A78741
(d) Install the oil seal to the camshaft.
NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops.
(e) Remove any old packing material from the contact surface.
A78742
A78737
(f) Apply seal packing to the bearing cap No. 1 as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the bearing cap No. 1 within 5 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil to the threads of the bearing cap bolts.
A05209
9
5 10
1
6
3
2
7 4
8
A78743
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(i) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N
⋅ m (163 kgf
⋅ cm, 12 ft
⋅ lbf)
Author: Date:
2155
14-64
Align
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
79.
INSTALL NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
(b) Align the timing marks (1 dot marks) of the camshaft drive and driven gears.
(c) Place the camshaft on the cylinder head.
A78744
(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.
A05214
4
3
2
6
10
5
1
9
(f) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N
⋅ m (163 kgf
⋅ cm, 12 ft
⋅ lbf)
(g) Remove the service bolt.
8
7
A78745
Inward
Sensor
A78746
80.
INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the timing pulley with the key located on the crankshaft, then slide the timing pulley into place.
NOTICE:
Do not scratch the sensor area of the crankshaft timing pulley.
(b) Install the timing belt plate with the bolt.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2156
14-65
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
81.
INSTALL WATER PUMP ASSY
(a) Install a new gasket and the water pump with the 3 bolts and 3 nuts.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
A78535
82.
INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to a new O-ring, then install it to the level gage guide.
(b) Install the level gage guide.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
83.
INSTALL OIL FILTER SUB-ASSY
(a) Using a socket hexagon wrench 12, install the oil filter union.
Torque: 30 N
⋅ m (306 kgf
⋅ cm, 22 ft
⋅ lbf)
(b) Check and clean the oil filter installation surface.
(c) Apply clean engine oil to the gasket of a new oil filter.
(d) Lightly screw the oil filter into place, then tighten it until the gasket contacts the seat.
SST
(e) Using SST, tighten it by an additional 3/4 turn.
SST 09228-07501
Additional
3/4 Turn
A78747
84.
INSTALL TIMING BELT IDLER BRACKET
Torque: 28 N
⋅ m (286 kgf
⋅ cm, 21 ft
⋅ lbf)
85.
INSTALL TIMING BELT NO.3 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
HINT:
If there is a trace of water intrusion when checking visually, repair the gasket with seal packing when the crack length is within
2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) or longer.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2157
14-66
Seal Packing
E
Front
Belt
Guide
F
Joining
D
Line
Joining Portion:
Gasket
Seal Packing
Front
Gasket
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
A78748
(b) If the timing belt cover gasket is needed to repair, follow the procedure below.
(1) Repair the cracks and breaks by applying seal packing to the damaged area.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high as the gasket.
(c) If the timing belt cover gasket is needed to replace, follow the procedure below.
(1) Using a screwdriver and gasket scraper, remove the remaining gasket.
NOTICE:
Be careful not to damage the timing belt cover.
E
G
Joining
Line
A78749
(2) Remove the backing paper from a new gasket, then affix the gasket along the groove of the timing belt cover as shown in the illustration.
NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform.
HINT:
Gasket
Length
D
335 mm
(13.19 in.)
E
180 mm
(7.09 in.)
F
133 mm
(5.24 in.)
G
72 mm
(2.83 in.)
(3) If there is a gap between the ends of the gasket, apply seal packing to close the gap.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high as the gasket.
(d) Install the timing belt cover with the 6 bolts.
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 in.
⋅ lbf)
Belt
Guide
A78750
86.
INSTALL CAMSHAFT TIMING PULLEY
(a) Pay attention to the orientation of the belt guide. Install the camshaft timing pulley with the belt guide properly oriented, then tighten the bolt temporarily.
HINT:
Align the belt guide of the RH timing pulley so it faces the front of the engine as illustrated.
Align the belt guide of the LH timing pulley so it faces the rear of the engine as illustrated.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2158
14-67
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(b) Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 N
⋅ m (1,275 kgf
⋅ cm, 92 ft
⋅ lbf)
SST
A78703
(c) Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 N
⋅ m (1,275 kgf
⋅ cm, 92 ft
⋅ lbf)
SST
A78704
87.
INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 N
⋅ m (438 kgf
⋅ cm, 32 ft
⋅ lbf)
88.
INSTALL TIMING BELT IDLER SUB-ASSY NO.1
(a) Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot bolt.
Torque: 34 N
⋅ m (347 kgf
⋅ cm, 25 ft
⋅ lbf)
89.
INSTALL TIMING BELT
(a) Remove any oil or water on the pulleys, then keep them clean.
NOTICE:
If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
Only wipe the pulleys; do not use any cleaning agent.
(b) Check the idler pulleys.
(1) Check that the idler pulley turns smoothly.
(2) Visually check the seal portion of the idler pulley for oil leakage.
(c) Check the water pump.
(1) Turn the pulley, then check that water pump bearing moves smoothly and does not make a noise.
(2) Visually check the drain hole for coolant leakage.
(d) Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2159
14-68
Approximately 60
SST
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
Turn
(e) Turn the crankshaft counterclockwise by approximately
60 .
NOTICE:
To prevent contact of the piston head with the valve head, set the crankshaft pulley at the 60 BTDC/compression position.
A82349
(f) Using SST, turn the crankshaft pulley, then align the timing marks of the timing pulley with the timing belt No. 3 cover.
SST 09960-10010 (09962-01000, 09963-01000)
A78751
(g) Turn the crankshaft, then align the timing mark of the crankshaft timing pulley with the oil pump body.
A05062
(h) Align the front mark on the timing belt so it faces forward.
(i) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
(j) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
A52840
(4)
(2)
(5)
(3)
(6)
(1)
A78702
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(k) Install the timing belt in this order.
1st
2nd
3rd
4th
5th
6th
Crankshaft timing pulley
Water pump pulley
LH camshaft timing pulley
No. 2 idler pulley
RH camshaft timing pulley
No. 1 idler pulley
Author: Date: 2160
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
90.
INSTALL TIMING BELT TENSIONER ASSY
(a) Set the timing belt tensioner upright on the press.
14-69
A36238
(b) Slowly press in the push rod.
NOTICE:
Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.
(c) Align the holes of the push rod and housing, then pass a
1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
(d) Release the press.
(e) Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
Torque: 27 N
⋅ m (280 kgf
⋅ cm, 20 ft
⋅ lbf)
NOTICE:
Be sure to tighten the bolts uniformly. Installing the tensioner at an angle may cause failure of its proper operation.
(f) Remove the 1.5 mm hexagon wrench from the tensioner.
(g) Turn the crankshaft 2 revolutions slowly, then align the timing mark of the crankshaft timing pulley with the oil pump body.
NOTICE:
Always turn the crankshaft clockwise.
Turn
A78326
(h) Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the timing belt
No. 3 cover as shown in the illustration.
If the marks are not aligned, remove the timing belt and reinstall it.
(i) Remove the crankshaft pulley bolt.
A05052
91.
INSTALL TIMING BELT GUIDE NO.2
(a) Install the timing belt guide with the cup side facing the engine front.
A36239
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2161
14-70
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
92.
INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 N
⋅ m (286 kgf
⋅ cm, 21 ft
⋅ lbf)
93.
INSTALL TIMING BELT NO.2 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 in.
⋅ lbf)
94.
INSTALL TIMING BELT NO.1 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 in.
⋅ lbf)
95.
INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the crankshaft, then slide the pulley into place.
(b) Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 N
⋅ m (2,250 kgf
⋅ cm, 162 ft
⋅ lbf)
SST
A78753
96.
INSTALL VVT SENSOR
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
97.
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
98.
INSTALL ENGINE HANGER NO.2
Torque: 20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf)
A52345
99.
INSPECT VALVE CLEARANCE
(a) Turn the crankshaft pulley, then align the timing notch with the timing mark ”0” of the timing belt No. 1 cover.
(b) Check that the valve lifters on the intake side of the No.
1 cylinder are not pushed by the cam.
If the valve lifters are pushed, turn the crankshaft 1 revolution
(360 ) and align the marks as above.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2162
RH Bank:
3 3
EX
IN
LH Bank:
1 1
Front
6 6
IN
EX
14-71
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(c) Inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
2 2
A78666
RH Bank:
EX
IN
3 3
LH Bank:
2 2
Front
IN
EX
4 4
5 5
(d) Turn the crankshaft by 2/3 of a revolution (240 ), then inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
A78667
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2163
14-72
RH Bank:
1 1
EX
IN
LH Bank:
Front
5 5
4 4
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(e) Turn the crankshaft by 2/3 of a revolution (240 ), then inspect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(2) Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
IN
EX
6 6
A78668
Upward
100. ADJUST VALVE CLEARANCE
(a) Turn the camshaft so that the cam lobe faces upward.
(b) Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.
Notch
A78669
Front of No. 1 and No. 2 Cylinders:
SST (A)
SST (B)
Others:
7
SST (A)
(c) Using SST (A), press down the valve lifter and place SST
(B) between the camshaft and valve lifter. Remove SST
(A).
SST 09248-55040 (09248-05410, 09248-05420)
HINT:
Apply SST (B) at a slight angle on the side marked with
”9” or ”7” at the position shown in the illustration.
When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent SST(B) from getting stuck, insert it gently from the intake side at a slight angle.
SST (A)
SST (B)
09248-05410
09248-05420
SST (B)
9
A78670
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2164
SST (B)
14-73
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
(d) Using a small screwdriver and magnetic finger, remove the adjusting shim.
Magnetic Finger
A78671
EM0494
(e) Using a micrometer, measure the thickness of the removed shim.
(f) Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
A
B
C
Thickness of new shim
Thickness of used shim
Measured valve clearance
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.0079 in.))
Exhaust A = B + (C - 0.30 mm (0.0118 in.))
(g) Select a new shim with a thickness which is as close to the calculated values as possible.
EXAMPLE (Intake):
Measured valve clearance = 0.45 mm (0.0177 in.)
0.45 mm (0.0177 in.) - 0.20 mm (0.0079 in.) = 0.25 mm (0.0098 in.)
(Measured - Specification = Excess clearance)
Used shim measurement = 2.80 mm (0.1102 in.)
0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) = 3.05 mm (0.1201 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 3.05 mm (0.1201 in.)
Select No. 12 shim
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm
(0.1299 in.).
Refer to New Shim Thickness table on the next 2 pages.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2165
Installed Shim Thickness mm (in.)
Measured Clearance mm (in.)
Adjusting Shim Selection Chart (Intake)
Shim
No.
New Shim Thickness mm (in.)
Thickness
Shim
No.
Thickness
Intake valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 12 shim.
HINT: New shims have the thickness in millimeters imprinted on the face.
Installed Shim Thickness mm (in.)
Measured Clearance mm (in.)
Adjusting Shim Selection Chart (Exhaust)
Shim
No.
New Shim Thickness mm (in.)
Thickness
Shim
No.
Thickness
Exhaust valve clearance (Cold):
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 10 shim.
HINT: New shims have the thickness in millimeters imprinted on the face.
14-76
SST (B)
: Seal Packing
Front
ENGINE MECHANICAL PARTIAL ENGINE ASSY (3MZ-FE)
SST (A)
(h) Place a new adjusting shim on the valve lifter with the imprinted number facing down.
(i) Press down the valve lifter with SST (A), then remove SST
(B).
SST 09248-55040 (09248-05410, 09248-05420)
(j) Recheck the valve clearance.
101. INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) Install the gasket to the cylinder head cover.
A78672
A78673
(b) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after applying seal packing.
Do not start the engine within 2 hours after installing.
(c) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
102. INSTALL CYLINDER HEAD COVER SUB-ASSY LH
(a) Install the gasket to the cylinder head cover.
: Seal Packing
Front
(b) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after applying seal packing.
Do not start the engine within 2 hours after installing.
A78674
(c) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
103. INSTALL SPARK PLUG
Torque: 25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2168
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
COMPONENTS
58 (591, 43)
28 (286, 21)
Front Fender Apron
Seal RH
Vane Pump V Belt
64 (653, 47)
V Belt No. 1
64 (653, 47)
23 (235, 17)
Radio Setting Condenser
Engine Moving Control Rod
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
14-77
141JA-01
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A84916
2169
14-78
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
8.5 (87, 75 in.
⋅ lbf)
Timing Belt
Timing Belt No. 2 Cover
220 (2,250, 162)
Crankshaft Pulley
28 (286, 21)
Timing Belt No. 1 Cover
8.5 (87, 75 in.
⋅ lbf)
Engine Wire
Protector
Timing Belt Guide No. 2
Engine Mounting Bracket RH
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78353
2170
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
REPLACEMENT
1.
REMOVE FRONT WHEEL RH
2.
REMOVE FRONT FENDER APRON SEAL RH
3.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
4.
REMOVE VANE PUMP V BELT (See page 14-5 )
14-79
141JB-01
5.
REMOVE ENGINE MOVING CONTROL ROD
(a) Remove the reserve tank cap.
(b) Remove the 4 bolts, engine moving control rod and bracket.
A78546
6.
REMOVE ENGINE MOUNTING STAY NO.2 RH
(a) Remove the bolt, engine mounting stay No. 2 and engine mounting bracket No. 2.
A52344
7.
REMOVE GENERATOR BRACKET NO.2
(a) Remove the nut and generator bracket.
P18816
8.
REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
SST
A78755
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2171
14-80
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
SST
(b) Using SST and the pulley bolt, remove the pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05031)
NOTICE:
Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.
A78756
9.
REMOVE TIMING BELT NO.1 COVER
Clamp
Clamp
10.
REMOVE TIMING BELT NO.2 COVER
(a) Disconnect the 2 engine wire protector clamps from the timing belt No. 3 cover.
(b) Remove the 5 bolts and timing belt cover.
A78759
11.
REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the 2 bolts, nut and engine mounting bracket
RH.
P18814
12.
REMOVE TIMING BELT GUIDE NO.2
Turn
A78326
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13.
REMOVE TIMING BELT
(a) Set the No. 1 cylinder to the TDC/compression.
(1) Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
(2) Turn the crankshaft clockwise, then align the timing mark of the crankshaft timing pulley with the oil pump body.
Author: Date: 2172
14-81
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
(3) Check that the timing marks of the camshaft timing pulleys and the timing belt No. 3 cover are aligned.
If not, turn the crankshaft by 1 revolution (360 ).
(4) Remove the crankshaft pulley bolt.
A05052
(b) If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.
(1) If the installation marks have disappeared, put new installation marks on the timing belt before removing.
Approximately 60
(2)
(1)
A52840
Turn
A78327
(c) Set the No. 1 cylinder to approximately 60 BTDC/compression.
(1) Turn the crankshaft counterclockwise by approximately 60 .
NOTICE:
If the timing belt is disengaged, having the crankshaft pulley set at the wrong angle can cause contact of the piston head with the valve head when removing the camshaft timing pulley and camshaft, which causes damage. So always set the crankshaft pulley at the correct angle.
(d) Remove the timing belt tensioner.
NOTICE:
Do not reinstall the tensioner with its plunger extended.
(3)
(5)
(4)
(6)
A78702
(e) Remove the timing belt in this order.
1st
2nd
3rd
4th
5th
6th
No. 1 idler pulley
RH camshaft timing pulley
No. 2 idler pulley
LH camshaft timing pulley
Water pump pulley
Crankshaft timing pulley
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2173
14-82
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
EM3336
14.
INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow contact of the timing belt with oil, water or steam.
Do not use the timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.
Check the belt for any defects as shown in the illustrations.
Also, check these points below.
(a) If the belt tears in a short time:
Check if the belt is installed properly.
Check if the timing cover gasket is damaged and if it is installed properly.
(b) If the belt teeth are cracked or damaged, check if either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.
(d) If there is wear or damage on only one side of the belt, check the belt guide and alignment of each pulley.
(e) If there is noticeable wear on the belt teeth:
Check the timing cover for damage.
Check that the gasket has been installed correctly.
Check for foreign objects on the pulley teeth.
If there is any doubt about the belt condition, replace the timing belt.
15.
INSTALL TIMING BELT
(a) Remove any oil or water on the pulleys, then keep them clean.
NOTICE:
If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
Only wipe the pulleys; do not use any cleaning agent.
(b) Check the idler pulleys.
(1) Check that the idler pulley turns smoothly.
(2) Visually check the seal portion of the idler pulley for oil leakage.
(c) Check the water pump.
(1) Turn the pulley, then check that water pump bearing moves smoothly and does not make a noise.
(2) Visually check the drain hole for coolant leakage.
(d) Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2174
Approximately 60
14-83
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
Turn
(e) Turn the crankshaft counterclockwise by approximately
60 .
NOTICE:
To prevent contact of the piston head with the valve head, set the crankshaft pulley at the 60 BTDC/compression position.
A82349
(f) Using SST, turn the timing pulleys, then align the timing marks of the timing pulleys with the timing belt No. 3 cover.
SST 09960-10010 (09962-01000, 09963-01000)
SST
A78751
(g) Turn the crankshaft, then align the timing mark of the crankshaft timing pulley with the oil pump body.
A05062
(h) Align the front mark on the timing belt so it faces forward.
(i) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
(j) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
A52840
(4)
(2)
(5)
(3)
(6)
(1)
A78702
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(k) Install the timing belt in this order.
1st
2nd
3rd
4th
5th
6th
Crankshaft timing pulley
Water pump pulley
LH camshaft timing pulley
No. 2 idler pulley
RH camshaft timing pulley
No. 1 idler pulley
Author: Date:
2175
14-84
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
16.
INSTALL TIMING BELT TENSIONER ASSY
(a) Set the timing belt tensioner upright on the press.
A36238
(b) Slowly press in the push rod.
NOTICE:
Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.
(c) Align the holes of the push rod and housing, then pass a
1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
(d) Release the press.
(e) Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
Torque: 27 N
⋅ m (280 kgf
⋅ cm, 20 ft
⋅ lbf)
NOTICE:
Be sure to tighten the bolts uniformly. Installing the tensioner at an angle may cause failure of its proper operation.
(f) Remove the 1.5 mm hexagon wrench from the tensioner.
(g) Turn the crankshaft 2 revolutions slowly, then align the timing mark of the crankshaft timing pulley with the oil pump body.
NOTICE:
Always turn the crankshaft clockwise.
Turn
A78326
(h) Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the timing belt
No. 3 cover as shown in the illustration.
If the marks are not aligned, remove the timing belt and reinstall it.
(i) Remove the crankshaft pulley bolt.
A05052
17.
INSTALL TIMING BELT GUIDE NO.2
(a) Install the timing belt guide with the cup side facing the engine front.
A36239
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2176
14-85
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
18.
INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH with the 2 bolts and nut.
Torque: 28 N
⋅ m (286 kgf
⋅ cm, 21 ft
⋅ lbf)
P18814
19.
INSTALL TIMING BELT NO.2 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 in.
⋅ lbf)
20.
INSTALL TIMING BELT NO.1 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
(b) Install the timing belt cover.
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 in.
⋅ lbf)
(c) Install the 2 engine wire protector clamps to the timing belt No. 3 cover.
SST
A78760
22.
INSTALL GENERATOR BRACKET NO.2
Torque: 28 N
⋅ m (286 kgf
⋅ cm, 21 ft
⋅ lbf)
21.
INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the crankshaft, then slide the pulley into place.
(b) Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 N
⋅ m (2250 kgf
⋅ cm, 162 ft
⋅ lbf)
23.
INSTALL ENGINE MOUNTING STAY NO.2 RH
(a) Install the engine mounting stay No. 2 and engine mounting bracket No. 2 with the bolt.
Torque: 64 N
⋅ m (653 kgf
⋅ cm, 47 ft
⋅ lbf)
A52344
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2177
14-86
A
B
ENGINE MECHANICAL TIMING BELT (3MZ-FE)
A
24.
INSTALL ENGINE MOVING CONTROL ROD
(a) Install the engine moving control rod and bracket with the
4 bolts.
Torque:
64 N
⋅ m (653 kgf
⋅ cm, 47 ft
⋅ lbf) for bolt A
23 N
⋅ m (235 kgf
⋅ cm, 17 ft
⋅ lbf) for bolt B
A
A78546
25.
INSTALL VANE PUMP V BELT (See page 14-5 )
26.
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
27.
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
28.
INSTALL FRONT WHEEL RH (See page 14-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2178
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
COMPONENTS x2
80 (816, 59)
Spacer
7.9 (81, 70 in.
⋅ lbf) x3
W/O TEMS:
Front Suspension Upper Brace Center
14-87
141JC-01
V-bank Cover Sub-assy x2
80 (816, 59)
Spacer
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Vacuum Hose
Vacuum Hose
5.0 (51, 44 in.
⋅ lbf)
Author:
Fuel Vapor Feed Hose
Assy
Mass Air Flow
Meter Connector
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
A86358
Date:
2179
14-88
VSV Connector
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE) x2
8.0 (82, 71 in.
⋅ lbf)
7.8 (80, 69 in.
⋅ lbf)
Pressure Feed
Tube Assy x2
Emission
Control Valve Set
Fuel Vapor Feed Hose
Bond Cable No. 1
Connector
Emission Control Valve Bracket
28 (286, 21)
28 (286, 21) x3 x2
Engine Hunger No. 1
20 (199, 14) x2
20 (199, 14) x2
Surge Tank Stay
No. 1 x2
20 (199, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86260
2180
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
58 (591, 43)
28 (286, 21)
Front Fender Apron
Seal RH
Vane Pump V Belt
64 (653, 47)
V Belt No. 1
64 (653, 47)
23 (235, 17)
Radio Setting Condenser
Engine Moving Control Rod
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
14-89
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
A84916
Author: Date:
2181
14-90
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
8.5 (87, 75 in.
⋅ lbf)
Timing Belt
Timing Belt No. 2 Cover
8.5 (87, 75 in.
⋅ lbf)
220 (2,250, 162)
Crankshaft Pulley
Engine Wire
Protector
28 (286, 21)
Timing Belt No. 1 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78383
2182
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
14-91
Timing Belt No. 3 Cover
Gasket
Camshaft Timing Pulley
8.5 (87, 75 in.
⋅ lbf)
Collar
Bushing x6
125 (1,275, 92)
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Engine Wire
Author: Date:
A78384
2183
14-92
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
8.4 (85, 74 in.
⋅ lbf)
Engine Wire
8.0 (80, 71 in.
⋅ lbf)
Ignition Coil Assy
Engine Wire
Cylinder Head
Cover Gasket
16 (163, 12)
8.0 (80, 71 in.
⋅ lbf) x9 x10
Cap No. 2
Cylinder Head Cover Sub-assy
Camshaft Bearing
Cap No. 4
Camshaft Bearing
Camshaft Timing Gear
Bolt Washer
Camshaft Sub Gear
Camshaft Sub Gear
Wave Washer
Camshaft Sub Gear
Shaft Snap Ring
Camshaft Bearing
Cap No. 1
No. 2 Camshaft
Camshaft Bearing Cap No. 2
16 (163, 12) x10
Camshaft Bearing Cap No. 5
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
150 (1,530, 111)
Camshaft Timing Gear Assy
Camshaft
Camshaft Setting
Oil Seal
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78385
2184
14-93
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
141JD-01
REPLACEMENT
1.
DISCONNECT BATTERY NEGATIVE TERMINAL
2.
DRAIN ENGINE COOLANT (See page 16-9 )
3.
REMOVE FRONT WHEEL RH
4.
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
5.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
6.
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
7.
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
8.
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
9.
REMOVE IGNITION COIL ASSY
10.
REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-7 )
11.
REMOVE FRONT FENDER APRON SEAL RH
12.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
13.
REMOVE VANE PUMP V BELT (See page 14-5 )
14.
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
15.
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
16.
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
17.
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
18.
REMOVE TIMING BELT NO.1 COVER
19.
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
20.
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
21.
REMOVE TIMING BELT GUIDE NO.2
22.
REMOVE TIMING BELT (See page 14-79 )
23.
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
RH:
24.
REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the bolt and RH timing pulley.
SST 09960- 10010 (09962- 01000, 09963- 01000),
09249-63010
SST
LH:
SST
A78761
(b) Using SST, remove the bolt and LH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
HINT:
Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling.
A78762
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2185
14-94
Clamp
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
Clamp
Clamp
A05077
25.
REMOVE TIMING BELT NO.3 COVER
(a) Disconnect the 3 engine wire harness clamps from the timing belt No. 3 cover.
(b) Remove the 6 bolts and timing belt cover.
26.
REMOVE CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being removed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
Main Gear
Align
A78706
Sub Gear
Service Bolt
A78707
(b) Secure the exhaust camshaft sub gear to the main gear with a service bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
Recommended service bolt
Thread diameter
Thread pitch
Bolt length
6 mm
1.0 mm
16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
4
8
7
10
6
5
9
2
1
(c) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
3
A78708
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2186
3
4
7
8
9
10
5
6
14-95
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
1
2
A78709
27.
REMOVE NO.2 CAMSHAFT
(a) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 2 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 2 camshaft.
28.
REMOVE CAMSHAFT TIMING GEAR ASSY
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i) unless you are replacing the VVT-i or camshaft.
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
A05739
A05740
(b) Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.
NOTICE:
Remove it with the lock pin engaged and locked at the most retard angle position.
The lock nut has LH threads.
Never use any tools other than the socket wrench.
Other tools will deform the cam angle rotor.
(c) Remove the camshaft VVT-i.
NOTICE:
Never remove the 3 bolts on the gear.
If it is difficult to remove VVT-i, tap it lightly using a plastic-faced hammer, then remove it.
29.
REMOVE CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12596
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2187
14-96
SST
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
(b) Using SST, turn the sub gear counterclockwise, then remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
A78715
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, camshaft sub gear and camshaft gear bolt washer.
A52353
30.
INSTALL CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE:
Be careful not to damage the camshaft.
P12595
Wave Washer
Camshaft
Sub Gear
Camshaft Gear
Bolt Washer
A78732
(b) Install the camshaft gear bolt washer and camshaft sub gear.
HINT:
Attach the pins on the gears to the gear bolt washer ends.
(c) Install the wave washer.
(d) Using snap ring pliers, install the snap ring.
A52353
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2188
Align
14-97
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
SST
A78733
(e) Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, then temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(f) Align the gear teeth of the main gear and sub gear, then tighten the service bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
NOTICE:
Be careful not to damage the camshaft journals.
HINT:
When installing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
A78734
31.
INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Align the alignment pin with the alignment pin groove, then install the VVT-i on the camshaft.
NOTICE:
Install it with the lock pin engaged and locked at the most retard angle position.
(b) Apply engine oil to the nut, mounting surface of the VVT-i and screw threads.
NOTICE:
Be sure to apply the oil, otherwise the specified torque cannot be obtained.
New nut must be used when replacing the VVT-i unit.
A05738
(c) Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.
Torque: 150 N
⋅ m (1,530 kgf
⋅ cm, 111 ft
⋅ lbf)
NOTICE:
The lock nut has LH threads.
Never use any tools other than the socket wrench.
Other tools will deform the cam angle rotor.
32.
INSTALL NO.2 CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2189
14-98
90
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
(b) Place the No. 2 camshaft at a 90 angle of the timing mark
(2 dot marks) on the cylinder head.
(c) Apply multi-purpose grease to a new oil seal lip.
Seal Packing
Front
A78735
(d) Install the oil seal to the camshaft.
NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops.
(e) Remove any old packing material from the contact surface.
A78736
A78737
(f) Apply seal packing to the bearing cap No. 1 as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the bearing cap No. 1 within 5 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil to the threads of the bearing cap bolts.
A05283
10
6
2 9
4 5
8
1
3
7
A78738
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(i) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N
⋅ m (163 kgf
⋅ cm, 12 ft
⋅ lbf)
Author: Date: 2190
Align
14-99
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
33.
INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
(b) Align the timing marks (2 dot marks) of the camshaft drive and driven gears.
(c) Place the camshaft on the cylinder head.
A78739
(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.
7
8
A05204
3
4
1
2
5
6
9
10
A78740
(f) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N
⋅ m (163 kgf
⋅ cm, 12 ft
⋅ lbf)
(g) Remove the service bolt.
34.
INSTALL TIMING BELT NO.3 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
HINT:
If there is a trace of water intrusion when checking visually, repair the gasket with seal packing when the crack length is within
2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) or longer.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2191
14-100
Seal Packing
E
Front
Belt
Guide
F
Joining
D
Line
Joining Portion:
Gasket
Seal Packing
Front
Gasket
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
A78748
(b) If the timing belt cover gasket is needed to repair, follow the procedure below.
(1) Repair the cracks and breaks by applying seal packing to the damaged area.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high as the gasket.
(c) If the timing belt cover gasket is needed to replace, follow the procedure below.
(1) Using a screwdriver and gasket scraper, remove the remaining gasket.
NOTICE:
Be careful not to damage the timing belt cover.
E
G
Joining
Line
A78749
(2) Remove the backing paper from a new gasket, then affix the gasket along the groove of the timing belt cover as shown in the illustration.
NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform.
HINT:
Gasket
Length
D
335 mm
(13.19 in.)
E
180 mm
(7.09 in.)
F
133 mm
(5.24 in.)
G
72 mm
(2.83 in.)
(3) If there is a gap between the ends of the gasket, apply seal packing to close the gap.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
When applying the seal packing, apply it as wide and high as the gasket.
(d) Install the timing belt cover with the 6 bolts.
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 in.
⋅ lbf)
Belt
Guide
A78750
35.
INSTALL CAMSHAFT TIMING PULLEY
(a) Pay attention to the orientation of the belt guide. Install the camshaft timing pulley with the belt guide properly oriented, then tighten the bolt temporarily.
HINT:
Align the belt guide of the RH timing pulley so it faces the front of the engine as illustrated.
Align the belt guide of the LH timing pulley so it faces the rear of the engine as illustrated.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2192
RH:
150 mm
(5.91 in.)
SST
14-101
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
A78763
(b) Using SST, tighten the RH pulley bolt.
SST 09960- 10010 (09962- 01000, 09963- 01000),
09249-63010
Torque: 125 N
⋅ m (1,275 kgf
⋅ cm, 92 ft
⋅ lbf)
NOTICE:
The torque indicated above is used without SST on the extension tool. If you are using the extension tool, find the reading of the torque wrench by the formula (see page
01-5 ).
Extended length:
SST (09249-63010) 150mm (5.91 in.)
LH:
SST
(c) Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 N
⋅ m (1275 kgf
⋅ cm, 92 ft
⋅ lbf)
A78762
36.
INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 N
⋅ m (438 kgf
⋅ cm, 32 ft
⋅ lbf)
37.
INSPECT TIMING BELT (See page 14-79 )
38.
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
39.
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
40.
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
41.
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
42.
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
43.
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
44.
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
45.
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
46.
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
47.
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
48.
INSPECT VALVE CLEARANCE (See page 14-7 )
49.
ADJUST VALVE CLEARANCE (See page 14-7 )
SST 09248-55040 (09248-05410, 09248-05420)
50.
INSTALL VANE PUMP V BELT (See page 14-5 )
51.
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
52.
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
53.
INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-7 )
54.
INSTALL IGNITION COIL ASSY (See page 14-7 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2193
14-102
ENGINE MECHANICAL CAMSHAFT (RH BANK) (3MZ-FE)
55.
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
56.
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
57.
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
58.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
59.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
60.
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
61.
INSTALL FRONT WHEEL RH (See page 14-5 )
62.
ADD ENGINE COOLANT (See page 16-9 )
63.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
64.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2194
ENGINE MECHANICAL CAMSHAFT (LH BANK) (3MZ-FE)
COMPONENTS
58 (591, 43)
28 (286, 21)
Front Fender Apron
Seal RH
Vane Pump V Belt
64 (653, 47)
V Belt No. 1
64 (653, 47)
23 (235, 17)
Radio Setting Condenser
Engine Moving Control Rod
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
14-103
141JE-01
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A84916
2195
14-104
ENGINE MECHANICAL CAMSHAFT (LH BANK) (3MZ-FE)
8.5 (87, 75 in.
⋅ lbf)
Timing Belt
Timing Belt No. 2 Cover
220 (2,250, 162)
Crankshaft Pulley
28 (286, 21)
Timing Belt No. 1 Cover
8.5 (87, 75 in.
⋅ lbf)
Engine Wire
Protector
Timing Belt Guide No. 2
Engine Mounting Bracket RH
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78353
2196
ENGINE MECHANICAL CAMSHAFT (LH BANK) (3MZ-FE)
14-105
Timing Belt No. 3 Cover
Gasket
Camshaft Timing Pulley
8.5 (87, 75 in.
⋅ lbf)
Collar
Bushing x6
125 (1,275, 92)
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Engine Wire
Author: Date:
A78384
2197
14-106
ENGINE MECHANICAL CAMSHAFT (LH BANK) (3MZ-FE)
V-bank Cover Sub-assy
8.0 (80, 71 in.
⋅ lbf)
7.9 (81, 70 in.
⋅ lbf) x3 x9
8.0 (80, 71 in.
⋅ lbf)
Ignition Coil Assy
Cylinder Head Cover
Sub-assy LH
8.4 (85, 74 in.
⋅ lbf)
Cylinder Head Cover Gasket No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 5
16 (163, 12) x10
Camshaft Bearing Cap No. 2
No. 4 Camshaft Sub-assy
Camshaft Bearing Cap No. 6
150 (1,530, 111)
Engine Wire
No. 3 Camshaft
Sub-assy
16 (163, 12)
Camshaft Bearing Cap No. 1 x10
Camshaft Timing Gear Assy
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 4
Camshaft Sub Gear
Shaft Snap Ring
Camshaft Sub Gear
Wave Washer
Camshaft Sub Gear
Camshaft Timing Gear
Bolt Washer
Camshaft Setting
Oil Seal
Radiator Hose Inlet
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78386
2198
14-107
ENGINE MECHANICAL CAMSHAFT (LH BANK) (3MZ-FE)
141JF-01
REPLACEMENT
1.
DISCONNECT BATTERY NEGATIVE TERMINAL
2.
DRAIN ENGINE COOLANT (See page 16-9 )
3.
REMOVE FRONT WHEEL RH
4.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
5.
REMOVE RADIATOR HOSE INLET
6.
REMOVE IGNITION COIL ASSY
7.
REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7 )
8.
REMOVE FRONT FENDER APRON SEAL RH
9.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
10.
REMOVE VANE PUMP V BELT (See page 14-5 )
11.
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
12.
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
13.
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
14.
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
15.
REMOVE TIMING BELT NO.1 COVER
16.
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
17.
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
18.
REMOVE TIMING BELT GUIDE NO.2
19.
REMOVE TIMING BELT (See page 14-79 )
20.
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
21.
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
22.
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
23.
REMOVE NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being removed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Align the timing marks (1 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
Align
A78710
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2199
14-108
Main Gear
Sub Gear
ENGINE MECHANICAL CAMSHAFT (LH BANK) (3MZ-FE)
Service Bolt
A78711
(b) Secure the exhaust camshaft sub gear to the main gear with a service bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
Recommended service bolt
Thread diameter
Thread pitch
Bolt length
6 mm
1.0 mm
16 to 20 mm
HINT:
When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
3
7
8
9
5
1
6
10
2
(c) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 3 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
4
A78712
4
3
8
7
10
9
6
5
2
1
A78713
24.
REMOVE NO.4 CAMSHAFT SUB-ASSY
(a) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 4 camshaft.
NOTICE:
Do not pry out the camshaft.
Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
(b) Remove the oil seal from the No. 4 camshaft.
25.
REMOVE CAMSHAFT TIMING GEAR ASSY (See page 14-93 )
26.
REMOVE CAMSHAFT SUB GEAR NO.3 (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-00500)
27.
INSTALL CAMSHAFT SUB GEAR NO.3 (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-00500)
28.
INSTALL CAMSHAFT TIMING GEAR ASSY (See page 14-93 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2200
14-109
ENGINE MECHANICAL CAMSHAFT (LH BANK) (3MZ-FE)
29.
INSTALL NO.4 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
(b) Place the No. 4 camshaft at a 90 angle of the timing mark
(1 dot marks) on the cylinder head.
(c) Apply multi-purpose grease to a new oil seal lip.
90
Seal Packing
Front
A78741
(d) Install the oil seal to the camshaft.
NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops.
(e) Remove any old packing material from the contact surface.
A78742
A78737
(f) Apply seal packing to the bearing cap No. 1 as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the bearing cap No. 1 within 5 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil to the threads of the bearing cap bolts.
A05209
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2201
14-1 10
7
8
3
4
1
2
5
6
ENGINE MECHANICAL CAMSHAFT (LH BANK) (3MZ-FE)
9
10
A78743
(i) Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N
⋅ m (163 kgf
⋅ cm, 12 ft
⋅ lbf)
30.
INSTALL NO.3 CAMSHAFT SUB-ASSY
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
(b) Align the timing marks (1 dot marks) of the camshaft drive and driven gears.
(c) Place the camshaft to the cylinder head.
Align
A78744
(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.
A05214
4
3
2
6
10
5
1
9
(f) Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N
⋅ m (163 kgf
⋅ cm, 12 ft
⋅ lbf)
(g) Remove the service bolt.
8
7
A78745
31.
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
32.
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
33.
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2202
ENGINE MECHANICAL CAMSHAFT (LH BANK) (3MZ-FE)
34.
INSPECT TIMING BELT (See page 14-79 )
35.
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
36.
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
37.
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
38.
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
39.
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
40.
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
41.
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
42.
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
43.
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
44.
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
45.
INSPECT VALVE CLEARANCE (See page 14-7 )
46.
ADJUST VALVE CLEARANCE (See page 14-7 )
SST 09248-55040 (09248-05410, 09248-05420)
47.
INSTALL VANE PUMP V BELT (See page 14-5 )
48.
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
49.
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
50.
INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7 )
51.
INSTALL IGNITION COIL ASSY (See page 14-7 )
52.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
53.
INSTALL FRONT WHEEL RH (See page 14-5 )
54.
ADD ENGINE COOLANT (See page 16-9 )
55.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
56.
SYSTEM INITIALIZATION (See page 19-15 )
14-1 11
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2203
14-1 12
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
COMPONENTS x2
80 (816, 59)
Spacer
7.9 (81, 70 in.
⋅ lbf) x3
W/O TEMS:
Front Suspension Upper Brace Center
141JG-01
V-bank Cover Sub-assy x2
80 (816, 59)
Spacer
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Vacuum Hose
Vacuum Hose
5.0 (51, 44 in.
⋅ lbf)
Author:
Fuel Vapor Feed Hose
Assy
Mass Air Flow
Meter Connector
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
A86358
Date: 2204
14-1 13
VSV Connector
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE) x2
8.0 (82, 71 in.
⋅ lbf)
7.8 (80, 69 in.
⋅ lbf)
Pressure Feed
Tube Assy x2
Emission
Control Valve Set
Fuel Vapor Feed Hose
Bond Cable No. 1
Connector
Emission Control Valve Bracket
28 (286, 21)
28 (286, 21) x3 x2
Engine Hunger No. 1
20 (199, 14) x2
20 (199, 14) x2
Surge Tank Stay
No. 1 x2
20 (199, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86260
2205
14-1 14
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
15 (153, 11) x2
Engine Coolant
Temperature Sensor
Connector
8.4 (86, 74 in.
⋅ lbf)
Ground Cable x9 x2 x2
15 (153, 11)
Washer
Bond Cable No. 1
Connector
Pipe
Radiator Hose Inlet
Water Outlet
Intake Manifold
Fuel Injector Connector
Clamp
Intake Manifold
to Head Gasket No. 1
15 (153, 11)
Washer
Fuel Injector
Connector
Fuel Pipe
Clamp
Heater Inlet
Water Hose
Intake Manifold
to Head Gasket No. 2
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86583
2206
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
Front Fender Apron
Seal RH
Vane Pump V Belt
64 (653, 47)
23 (235, 17)
Radio Setting Condenser
V Belt No. 1
Engine Moving Control Rod
64 (653, 47)
28 (286, 21)
Engine Mounting Stay No. 2 RH
58 (591, 43)
Generator Bracket No. 2
14-1 15
56 (571, 41)
Exhaust Pipe
Gasket
62 (633, 46)
Exhaust Pipe Gasket
Exhaust Pipe Gasket
Exhaust Pipe
Assy Front
62 (633, 46)
Exhaust Pipe No. 1
Support Bracket Front
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
33 (337, 24)
33 (337, 24)
Author:
Exhaust Pipe No. 1
Support Bracket Rear
Date:
A84917
2207
14-1 16
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
8.5 (87, 75 in.
⋅ lbf)
Timing Belt
Timing Belt No. 2 Cover
8.5 (87, 75 in.
⋅ lbf)
220 (2,250, 162)
Crankshaft Pulley
Engine Wire
Protector
28 (286, 21)
Timing Belt No. 1 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78383
2208
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
14-1 17
Timing Belt No. 3 Cover
Gasket
Camshaft Timing Pulley
8.5 (87, 75 in.
⋅ lbf)
Collar
Bushing x6
125 (1,275, 92)
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Engine Wire
Author: Date:
A78384
2209
14-1 18
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
8.5 (87, 75 in.
⋅ lbf) x3
Exhaust Manifold Heat Insulator No. 1
49 (500, 36) x6
Exhaust Manifold Sub-assy RH
Exhaust Manifold to Head Gasket
43 (439, 32)
43 (439, 32)
Vane Pump Assy
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A84918
2210
14-1 19
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
8.4 (85, 74 in.
⋅ lbf)
Engine Wire
8.0 (80, 71 in.
⋅ lbf)
Ignition Coil Assy
Engine Wire x9
8.0 (80, 71 in.
⋅ lbf)
Cylinder Head Cover Sub-assy
16 (163, 12)
Camshaft Bearing Cap No. 1 x10
Cylinder Head Cover Gasket
Camshaft Bearing
Cap No. 2
Camshaft Bearing Cap No. 4
No. 2 Camshaft
16 (163, 12) x10
Camshaft Bearing Cap No. 5
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 6
Camshaft Bearing Cap No. 2 Camshaft
See page 14-120
1st: 54 (550, 40)
2st: Turn 90 x8
19 (189, 14)
Cylinder Head Sub-assy
Camshaft Setting
Oil Seal
Cylinder Head Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78390
2211
14-120
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
141JH-01
REPLACEMENT
1.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2.
DISCONNECT BATTERY NEGATIVE TERMINAL
3.
DRAIN ENGINE COOLANT (See page 16-9 )
4.
DRAIN ENGINE OIL (See page 17-20 )
5.
REMOVE FRONT WHEEL RH
6.
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
7.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
8.
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
9.
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
10.
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
11.
REMOVE INTAKE MANIFOLD (See page 10-16 )
12.
REMOVE WATER OUTLET (See page 10-16 )
13.
REMOVE FRONT FENDER APRON SEAL RH
14.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
15.
REMOVE VANE PUMP V BELT (See page 14-5 )
16.
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
17.
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
18.
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
19.
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
20.
REMOVE TIMING BELT NO.1 COVER
21.
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
22.
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
23.
REMOVE TIMING BELT GUIDE NO.2
24.
REMOVE TIMING BELT (See page 14-79 )
25.
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
26.
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
27.
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
28.
SEPARATE VANE PUMP ASSY
29.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
30.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
31.
REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2 )
32.
REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the 3 bolts and exhaust manifold heat insulator.
A86571
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2212
3 6
14-121
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
1
33.
REMOVE EXHAUST MANIFOLD SUB-ASSY RH
(a) Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration.
(b) Remove the exhaust manifold RH and gasket from the cylinder head RH.
2 5 4
A86572
34.
REMOVE IGNITION COIL ASSY
35.
REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-7 )
36.
REMOVE CAMSHAFT (See page 14-93 )
37.
REMOVE NO.2 CAMSHAFT (See page 14-93 )
38.
REMOVE CYLINDER HEAD SUB-ASSY
(a) Disconnect the VVT sensor connector.
(b) Disconnect the camshaft timing oil control valve connector.
(c) Remove the nut, then disconnect the engine wire harness clamp.
A78401
(d) Using a socket hexagon wrench 8, remove the hexagon bolt.
Front
A78716
4
2
Front
7
6
5
8
3
1
A78717
39.
REMOVE CYLINDER HEAD GASKET
(e) Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the washers into the cylinder head.
Head warpage or cracking could result from removing the bolts in an incorrect order.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2213
14-122
Tension Portion
Front
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
40.
INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter:
8.95 to 9.05 mm (0.3524 to 0.3563 in.)
Minimum outside diameter: 8.75 mm (0.3445 in.)
If the diameter is less than minimum, replace the bolt.
A78721
A78324
41.
INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block with the R mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
42.
INSTALL CYLINDER HEAD SUB-ASSY
NOTICE:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.
7
Front
2 4 6
(c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 N
⋅ m (550 kgf
⋅ cm, 40 ft
⋅ lbf)
5 3 1 8
A78717
90
Front
Painted Mark
A78730
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90 in the same sequence as step (c).
(f) Check that each painted mark is now at a 90 angle to the front.
Author: Date: 2214
Front
14-123
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
(g) Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 N
⋅ m (189 kgf
⋅ cm, 14 ft
⋅ lbf)
(h) Connect the engine wire harness clamp with the nut.
Torque: 8.4 N
⋅ m (85 kgf
⋅ cm, 74 in.
⋅ lbf)
A78716
43.
INSTALL NO.2 CAMSHAFT (See page 14-93 )
44.
INSTALL CAMSHAFT (See page 14-93 )
45.
INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-7 )
46.
INSTALL IGNITION COIL ASSY (See page 14-7 )
4 1 6
47.
INSTALL EXHAUST MANIFOLD SUB-ASSY RH
(a) Install a new gasket and the exhaust manifold RH with the
6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
(b) Retighten nuts 1 and 2 shown in the illustration.
5 2 3
A86572
48.
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 ft
⋅ lbf)
49.
INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 )
50.
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
51.
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
52.
INSTALL VANE PUMP ASSY (See page 14-29 )
53.
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
54.
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
55.
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
56.
INSPECT TIMING BELT (See page 14-79 )
57.
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
58.
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
59.
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
60.
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
61.
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
62.
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
63.
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
64.
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
65.
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
66.
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
67.
INSTALL VANE PUMP V BELT (See page 14-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2215
14-124
ENGINE MECHANICAL CYLINDER HEAD GASKET (3MZ-FE)
68.
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
69.
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
70.
INSTALL WATER OUTLET (See page 10-16 )
71.
INSTALL INTAKE MANIFOLD (See page 10-16 )
72.
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
73.
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
74.
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
75.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
76.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
77.
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
78.
INSTALL FRONT WHEEL RH (See page 14-5 )
79.
ADD ENGINE OIL (See page 17-20 )
80.
ADD ENGINE COOLANT (See page 16-9 )
81.
CHECK FOR ENGINE OIL LEAKS
82.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
83.
INSPECT FOR FUEL LEAKS
84.
CHECK FOR EXHAUST GAS LEAKS
85.
INSPECT IGNITION TIMING (See page 14-1 )
SST 09843-18040
86.
INSPECT ENGINE IDLE SPEED (See page 14-1 )
87.
INSPECT COMPRESSION (See page 14-1 )
SST 09992-00500
88.
INSPECT CO/HC (See page 14-1 )
89.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2216
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
COMPONENTS
80 (816, 59) x2
Spacer
7.9 (81, 70 in.
⋅ lbf) x3
W/O TEMS:
Front Suspension Upper Brace Center
14-125
141JI-01
80 (816, 59)
V-bank Cover Sub-assy
Fuel Vapor Feed
Hose No. 1
Spacer x2
Vacuum Hose x7
Vacuum Hose
5.0 (51, 44 in.
⋅ lbf)
Clip
Air Cleaner
Inlet Assy x2
Air Cleaner Cap
Sub-assy
5.0 (51, 44 in.
⋅ lbf)
5.0 (51, 44 in.
⋅ lbf) x3
Mass Air Flow
Meter Connector
Air Cleaner Filter
Element Sub-assy
VSV Connector
Clip
N·m (kgf·cm, ft·lbf) : Specified torque
Radiator Lower
Air Deflector
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Air Cleaner Case
A84919
Author: Date:
2217
14-126
VSV Connector
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE) x2
8.0 (82, 71 in.
⋅ lbf)
7.8 (80, 69 in.
⋅ lbf)
Pressure Feed
Tube Assy x2
Emission
Control Valve Set
Fuel Vapor Feed Hose
Bond Cable No. 1
Connector
Emission Control Valve Bracket
28 (286, 21)
28 (286, 21) x3 x2
Engine Hunger No. 1
20 (199, 14) x2
20 (199, 14) x2
Surge Tank Stay
No. 1 x2
20 (199, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86260
2218
14-127
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
15 (153, 11) x2
Engine Coolant
Temperature Sensor
Connector
8.4 (86, 74 in.
⋅ lbf)
Ground Cable x9 x2 x2
15 (153, 11)
Washer
Bond Cable No. 1
Connector
Pipe
Radiator Hose Inlet
Water Outlet
Intake Manifold
Fuel Injector Connector
Clamp
Intake Manifold
to Head Gasket No. 1
15 (153, 11)
Washer
Fuel Injector
Connector
Fuel Pipe
Clamp
Heater Inlet
Water Hose
Intake Manifold
to Head Gasket No. 2
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86583
2219
14-128
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
58 (591, 43)
28 (286, 21)
Front Fender Apron
Seal RH
Vane Pump V Belt
64 (653, 47)
V Belt No. 1
64 (653, 47)
23 (235, 17)
Radio Setting Condenser
Engine Moving Control Rod
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
A84916
Author: Date: 2220
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
8.5 (87, 75 in.
⋅ lbf)
Timing Belt
14-129
Timing Belt No. 2 Cover
8.5 (87, 75 in.
⋅ lbf)
220 (2,250, 162)
Crankshaft Pulley
Engine Wire
Protector
28 (286, 21)
Timing Belt No. 1 Cover
Timing Belt Guide No. 2
Engine Mounting Bracket RH
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78383
2221
14-130
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
Camshaft Timing Pulley
8.5 (87, 75 in.
⋅ lbf)
Collar
Bushing x6
125 (1,275, 92)
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Engine Wire
Author: Date:
A78384
2222
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
14-131
Exhaust Pipe
Assy Front
Gasket
Oil Level Gage Guide
8.0 (82, 71 in.
⋅ lbf)
Oil Level Gage
Sub-assy
Manifold Stay No. 2
O-ring
49 (500, 36)
49 (500, 36)
62 (633, 46)
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
A84920
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2223
14-132
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
8.0 (80, 71 in.
⋅ lbf)
8.0 (80, 71 in.
⋅ lbf) x9
Ignition Coil Assy
8.4 (85, 74 in.
⋅ lbf)
Cylinder Head Cover Sub-assy LH
Cylinder Head Cover Gasket No. 2
Camshaft Bearing Cap No. 3
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 5
16 (163, 12) x10
Camshaft Bearing
Cap No. 2
16 (163, 12) x10
Camshaft Bearing Cap No. 1
Camshaft Bearing
Cap No. 6
Engine Wire
No. 3 Camshaft Sub-assy
Camshaft Bearing Cap No. 2
Camshaft Bearing Cap No. 4
No. 4 Camshaft Sub-assy
5.4 (55, 48 in.
⋅ lbf) See page 14-133
1st: 54 (550, 40)
2st: Turn 90
5.4 (55, 48 in.
⋅ lbf)
19 (189, 14) x8
Camshaft Setting
Oil Seal
O-ring
20 (199, 14)
Water Inlet Pipe
Cylinder Head LH
Cylinder Head
Gasket No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Non-reusable part
Author: Date:
A86599
2224
14-133
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
141JJ-01
REPLACEMENT
1.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2.
DISCONNECT BATTERY NEGATIVE TERMINAL
3.
DRAIN ENGINE COOLANT (See page 16-9 )
4.
DRAIN ENGINE OIL (See page 17-20 )
5.
REMOVE FRONT WHEEL RH
6.
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
7.
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
8.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
9.
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
10.
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
11.
REMOVE AIR CLEANER CASE (See page 19-5 )
12.
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
13.
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
14.
REMOVE INTAKE MANIFOLD (See page 10-16 )
15.
REMOVE WATER OUTLET (See page 10-16 )
16.
REMOVE FRONT FENDER APRON SEAL RH
17.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
18.
REMOVE VANE PUMP V BELT (See page 14-5 )
19.
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
20.
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
21.
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
22.
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
23.
REMOVE TIMING BELT NO.1 COVER
24.
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
25.
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
26.
REMOVE TIMING BELT GUIDE NO.2
27.
REMOVE TIMING BELT (See page 14-79 )
28.
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
29.
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
30.
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
31.
REMOVE MANIFOLD STAY NO.2 (See page 14-29 )
32.
SEPARATE EXHAUST PIPE ASSY FRONT (See page 15-2 )
33.
REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt which secures the oil level gage guide from the cylinder head LH.
(b) Pull out the oil level gage guide and oil level gage together from the cylinder block.
(c) Remove the O-ring from the oil level gage guide.
A86574
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2225
14-134
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
34.
REMOVE WATER INLET PIPE (See page 16-16 )
35.
REMOVE IGNITION COIL ASSY
36.
REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7 )
37.
REMOVE NO.3 CAMSHAFT SUB-ASSY (See page 14-107 )
38.
REMOVE NO.4 CAMSHAFT SUB-ASSY (See page 14-107 )
39.
REMOVE CYLINDER HEAD LH
(a) Disconnect the VVT sensor connector.
(b) Disconnect the camshaft timing oil control valve connector.
(c) Disconnect the air fuel ratio sensor connector.
(d) Remove the bolt, then disconnect the ground cable.
(e) Remove the bolt and wire harness clamp bracket.
A86575
(f) Using a socket hexagon wrench 8, remove the hexagon bolt.
Front
A78718
4
Front
6
2 7
8
5
1
3
(g) Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the washers into the cylinder head.
Head warpage or cracking could result from removing the bolts in an incorrect order.
A78719
40.
REMOVE CYLINDER HEAD GASKET NO.2
41.
INSPECT CYLINDER HEAD SET BOLT (See page 14-120 )
Front
A79822
42.
INSTALL CYLINDER HEAD GASKET NO.2
(a) Place a new cylinder head gasket on the cylinder block with the L mark upward.
NOTICE:
Remove any oil from the contact surface.
Be careful of the installing orientation.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2226
14-135
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
43.
INSTALL CYLINDER HEAD LH
NOTICE:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washer to the cylinder head bolt.
5
Front
3 1 8
(c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 N
⋅ m (550 kgf
⋅ cm, 40 ft
⋅ lbf)
7 2 4 6
A78719
Front
90
(d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90 in the same sequence as step (c).
(f) Check that each painted mark is now at a 90 angle to the front.
Painted Mark
A78730
Front
(g) Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 N
⋅ m (189 kgf
⋅ cm, 14 ft
⋅ lbf)
(h) Install the wire harness clamp bracket with the bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
(i) Connect the ground cable with the bolt.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
A78718
44.
INSTALL NO.4 CAMSHAFT SUB-ASSY (See page 14-107 )
45.
INSTALL NO.3 CAMSHAFT SUB-ASSY (See page 14-107 )
46.
INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See page 14-7 )
47.
INSTALL IGNITION COIL ASSY (See page 14-7 )
48.
INSTALL WATER INLET PIPE (See page 16-16 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2227
14-136
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
O-ring
A86573
49.
INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O-ring to the oil level gage guide.
(b) Apply soapy water to the O-ring.
(c) Push in the oil level gage guide end into the guide hole of the cylinder block.
(d) Install the oil level gage guide with the bolt.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
(e) Install the oil level gage.
50.
INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 )
51.
INSTALL MANIFOLD STAY NO.2 (See page 14-29 )
52.
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
53.
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
54.
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
55.
INSPECT TIMING BELT (See page 14-79 )
56.
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
57.
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
58.
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
59.
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
60.
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
61.
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
62.
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
63.
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
64.
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
65.
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
66.
INSTALL VANE PUMP V BELT (See page 14-5 )
67.
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
68.
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
69.
INSTALL WATER OUTLET (See page 10-16 )
70.
INSTALL INTAKE MANIFOLD (See page 10-16 )
71.
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
72.
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
73.
INSTALL AIR CLEANER CASE (See page 19-5 )
74.
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
75.
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
76.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
77.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
78.
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
79.
INSTALL FRONT WHEEL RH (See page 14-5 )
80.
ADD ENGINE OIL (See page 17-20 )
81.
ADD ENGINE COOLANT (See page 16-9 )
82.
CHECK FOR ENGINE OIL LEAKS
83.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
84.
INSPECT FOR FUEL LEAKS
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2228
ENGINE MECHANICAL CYLINDER HEAD GASKET NO.2 (3MZ-FE)
85.
CHECK FOR EXHAUST GAS LEAKS
86.
INSPECT IGNITION TIMING (See page 14-1 )
SST 09843-18040
87.
INSPECT ENGINE IDLE SPEED (See page 14-1 )
88.
INSPECT COMPRESSION (See page 14-1 )
SST 09992-00500
89.
INSPECT CO/HC (See page 14-1 )
90.
SYSTEM INITIALIZATION (See page 19-15 )
14-137
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2229
14-138
ENGINE MECHANICAL OIL PUMP SEAL (3MZ-FE)
141JK-01
REPLACEMENT
1.
REMOVE FRONT WHEEL RH
2.
REMOVE FRONT FENDER APRON SEAL RH
3.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
4.
REMOVE VANE PUMP V BELT (See page 14-5 )
5.
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
6.
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
7.
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
8.
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
9.
REMOVE TIMING BELT NO.1 COVER
10.
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
11.
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
12.
REMOVE TIMING BELT GUIDE NO.2
13.
REMOVE TIMING BELT (See page 14-79 )
14.
REMOVE CRANKSHAFT TIMING PULLEY
(a) Remove the bolt and timing belt plate.
SST
A78764
(b) Install the pulley bolt to the crankshaft.
(c) Using SST, remove the crankshaft timing pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05011)
NOTICE:
Do not scratch the sensor part of the crankshaft timing pulley.
Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.
Cut Position
15.
REMOVE OIL PUMP SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out the oil seal.
NOTICE:
After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
A78765
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2230
SST
ENGINE MECHANICAL OIL PUMP SEAL (3MZ-FE)
16.
INSTALL OIL PUMP SEAL
(a) Apply multi-purpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
14-139
(b) Using SST and a hammer, tap in the new oil seal until its surface is flush with the oil pump edge.
SST 09223-00010
NOTICE:
Be careful not to tap the oil seal at an angle.
Wipe off extra grease on the crankshaft.
A78766
Inward
Sensor
A78746
17.
INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the pulley with the key located on the crankshaft, then slide the pulley into place.
NOTICE:
Do not scratch the sensor area of the crankshaft timing pulley.
(b) Install the timing belt plate with the bolt.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
18.
INSPECT TIMING BELT (See page 14-79 )
19.
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
20.
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
21.
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
22.
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
23.
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
24.
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
25.
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
26.
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
27.
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
28.
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
29.
INSTALL VANE PUMP V BELT (See page 14-5 )
30.
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
31.
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
32.
INSTALL FRONT WHEEL RH (See page 14-5 )
33.
CHECK FOR ENGINE OIL LEAKS
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2231
14-140
ENGINE MECHANICAL ENGINE REAR OIL SEAL (3MZ-FE)
REPLACEMENT
1.
REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40-9 )
141JL-02
2.
REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
(b) Remove the 8 bolts, rear spacer, drive plate and front spacer.
SST
A78767
Cut Position
SST
Cut Position
3.
REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out the oil seal.
NOTICE:
After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
A78768
SST
A78769
A78767
4.
INSTALL ENGINE REAR OIL SEAL
(a) Apply multi-purpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign materials.
(b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
Be careful not to tap the oil seal at an angle.
Wipe off extra grease on the crankshaft.
5.
INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
(b) Clean the 8 bolts and 8 bolt holes.
(c) Apply adhesive to 2 or 3 threads of the 8 bolts.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
(d) Install the front spacer, drive plate and rear spacer on the crankshaft.
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3
5
1
14-141
ENGINE MECHANICAL ENGINE REAR OIL SEAL (3MZ-FE)
7
4
(e) Using several steps, install and tighten the 8 bolts uniformly in the sequence shown in the illustration.
Torque: 83 N
⋅ m (846 kgf
⋅ cm, 61 ft
⋅ lbf)
NOTICE:
Do not start the engine within 1 hour after installing.
8
2
6
A78771
6.
INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40-9 )
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2233
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ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
COMPONENTS
Valve Adjusting Shim
Valve Lifter
Valve Spring Retainer Lock
Valve Spring Retainer
Inner Compression Spring
Valve Stem Oil O Seal or Ring
Valve Spring Seat
Exhaust Valve Guide Bush
Intake Valve Guide Bush
RH Cylinder:
W/ Head Straight Screw
Plug No. 1
LH Cylinder:
W/ Head Straight Screw
Plug No. 2
Gasket
Semicircular Plug
1419J-03
44 (449, 32)
Intake Valve
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Exhaust Valve
Author: Date:
A78310
2234
14-143
ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
1419K-03
OVERHAUL
1.
REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
(a) Using a straight hexagon wrench 14, remove the 2 screw plugs.
2.
REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
(a) Using a straight hexagon wrench 14, remove the 2 screw plugs.
3.
REMOVE VALVE LIFTER
HINT:
Store the lifters in the correct order so that they can be returned to the original locations when reassembling.
SST
A78770
4.
REMOVE INTAKE VALVE
(a) Using SST, compress the spring, then remove the 2 retainer locks, retainer, spring and valve.
SST 09202-70020 (09202-00010)
HINT:
Store the valves, springs, seats and retainers in the correct order so that they can be returned to the original locations when reassembling.
SST
5.
REMOVE EXHAUST VALVE
(a) Using SST, compress the spring, then remove the 2 retainer locks, retainer, spring and valve.
SST 09202-70020 (09202-00010)
HINT:
Store the valves, springs, seats and retainers in the correct order so that they can be returned to the original locations when reassembling.
A78772
6.
REMOVE VALVE STEM OIL O SEAL OR RING
(a) Using needle-nose pliers, remove the oil seal.
7.
REMOVE VALVE SPRING SEAT
8.
REMOVE SEMICIRCULAR PLUG
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Cylinder Block Surface:
ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
9.
INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, measure the warpage on the surfaces which contacts the cylinder block and manifolds.
Maximum warpage:
0.05 mm (0.0020 in.) for cylinder block surface
0.10 mm (0.0039 in.) for intake manifold surface
0.10 mm (0.0039 in.) for exhaust manifold surface
If the warpage is greater than maximum, replace the cylinder head.
Intake Manifold Surface:
Exhaust Manifold Surface:
A78773
10.
INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
A05227
Overall Length
11.
INSPECT INTAKE VALVE
(a) Inspect the valve overall length.
Standard overall length: 95.45 mm (3.7579 in.)
Minimum overall length: 94.95 mm (3.7382 in.)
If the overall length is less than minimum, replace the valve.
EM2534
(b) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter:
5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Z00052
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ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
(c) Inspect the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.
Margin
Thickness
A78774
Overall Length
12.
INSPECT EXHAUST VALVE
(a) Inspect the valve overall length.
Standard overall length: 95.40 mm (3.7559 in.)
Minimum overall length: 94.90 mm (3.7362 in.)
If the overall length is less than minimum, replace the valve.
EM2534
(b) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter:
5.465 to 5.480 mm (0.2152 to 0.2157 in.)
Z00052
(c) Inspect the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.
Margin
Thickness
A78774
13.
INSPECT INNER COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the spring.
Free length: 45.50 mm (1.7913 in.)
If the free length is not as specified, replace the spring.
EM0801
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Deviation
ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
(b) Using a steel square, measure the deviation of the spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the spring.
A78775
(c) Using a spring tester, measure the tension of the spring when the spring is the specified installed length.
Installed tension:
186 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at 33.8 mm (1.331 in.)
If the installed tension is not as specified, replace the spring.
EM0281
P12754
14.
INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the valve guide bush.
Bush inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the valve guide bush inside diameter measurement.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0024 in.) for intake
0.030 to 0.065 mm (0.0012 to 0.0026 in.) for exhaust
Maximum oil clearance:
0.08 mm (0.0031 in.) for intake
0.10 mm (0.0039 in.) for exhaust
If the clearance is greater than maximum, replace the valve and valve guide bush.
15.
REMOVE VALVE GUIDE BUSH
(a) Heat the cylinder head up to 80 to 100 C (176 to 212 F).
A05234
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2238
SST
14-147
ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
(b) Using SST and a hammer, tap out the valve guide bush.
SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
A78776
Intake:
34.5 mm
(1.358 in.)
Exhaust:
P12956
40.5 mm
(1.594 in.)
16.
INSTALL VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Diameter: 10.295 to 10.313 mm (0.4053 to 0.4060 in.)
If the bush bore diameter of the cylinder head is greater than
10.313 mm (0.4060 in.), machine the bush bore to the dimension of 10.345 to 10.363 mm (0.4073 to 0.4080 in.).
HINT:
Bush diameter:
STD
O/S
Bush length:
10.333 to 10.344 mm (0.4068 to 0.4072 in.)
10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Intake 34.5 mm (1.358 in.)
Exhaust 40.5 mm (1.594 in.)
(b) Heat the cylinder head up to 80 to 100 C (176 to 212 F).
SST
A78777
(c) Using SST and a hammer, tap in a new valve guide bush to the specified protrusion height.
SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
Protrusion height:
11.1 to 11.5 mm (0.437 to 0.453 in.) for intake
8.9 to 9.3 mm (0.350 to 0.366 in.) for exhaust
A78778
(d) Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance between the valve guide bush and valve stem.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0024 in.) for intake
0.030 to 0.065 mm (0.0012 to 0.0026 in.) for exhaust
Z09124
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ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
17.
INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the valve face.
(b) Lightly press the valve against the seat.
NOTICE:
Do not rotate the valve.
1.0 to 1.4 mm
(0.039 to 0.055 in.)
Width
A78779
45
30
(c) Check the valve face and seat according to the following procedure.
(1) If blue appears 360 around the face, the valve is concentric. If not, replace the valve.
(2) If blue appears 360 around the valve seat, the guide and face are concentric. If not, resurface the seat.
(3) Check that the seat contact is in the middle of the valve face with the width between 1.0 and 1.4 mm
(0.039 to 0.055 in.).
18.
REPAIR VALVE SEATS
NOTICE:
Releasing the seat cutter pressure gradually helps to make smoother valve seat faces.
(a) If the seating is too high on the valve face, use the 30 and
45 cutters to correct the seat.
A78780
60
45
(b) If the seating is too low on the valve face, use the 60 and
45 cutters to correct the seat.
(c) Lap the valve and valve seat by hand with an abrasive compound.
(d) Recheck the valve seating position.
1.0 to 1.4 mm
(0.039 to 0.055 in.)
A78781
19.
INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
EM6368
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ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
P12685
20.
INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter:
31.009 to 31.025 mm (1.2208 to 1.2215 in.)
(b) Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance:
0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the valve lifter.
If necessary, replace the cylinder head.
21.
INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshaft timing gear.
(b) Install the camshafts to the cylinder head.
NOTICE:
Install the camshafts with the valves and sub gear removed.
Install the camshafts with their timing marks matched.
A33264
(c) Set the dial indicator to the teeth of the intake camshaft at a right angle (90 ).
(d) Measure the backlash of the camshaft timing gear at least
4 positions.
Standard backlash:
0.020 to 0.200 mm (0.0008 to 0.0079 in.)
Maximum backlash: 0.30 mm (0.0118 in.)
22.
INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts.
A05238
(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance:
0.040 to 0.090 mm (0.0016 to 0.0035 in.)
Maximum thrust clearance: 0.12 mm (0.0047 in.)
If the thrust clearance is greater than maximum, replace the camshaft.
If necessary, replace the bearing caps and cylinder head together.
23.
INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Clean the camshafts.
(c) Place the camshafts on the cylinder head.
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2241
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ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
(d) Lay a strip of Plastigage across each of the camshaft journals.
(e) Install the bearing caps.
Torque: 16 N
⋅ m (163 kgf
⋅ cm, 12 ft
⋅ lbf)
NOTICE:
Do not turn the camshaft.
(f) Remove the bearing caps.
A05239
A05240
(g) Measure the Plastigage at its widest point.
Standard oil clearance:
Intake #4, #5 journals
0.025 to 0.057 mm (0.0010 to 0.0022 in.)
Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum oil clearance 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the camshaft.
If necessary, replace the bearing caps and cylinder head together.
NOTICE:
Completely remove the Plastigage.
RH Cylinder:
10 mm (0.39 in.)
8 mm (0.31 in.)
24.
INSTALL RING W/HEAD PIN (RH CYLINDER)
(a) Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height.
Protrusion height: 3 mm (0.12 in.)
A78782
LH Cylinder: 10 mm (0.39 in.)
8 mm (0.31 in.)
25.
INSTALL RING PIN (LH CYLINDER)
(a) Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height.
Protrusion height: 3 mm (0.12 in.)
A78783
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2242
Protrusion Height
14-151
Mark
ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
A78784
26.
INSTALL SPARK PLUG TUBE
(a) Using paint, mark the standard height from the edge.
Standard protrusion height:
42.4 to 43.4 mm (1.669 to 1.709 in.)
HINT:
Use either end of the spark plug tube.
(b) Apply adhesive to the end of the spark plug tube which will be pressed into the cylinder head.
Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
NOTICE:
Install the spark plug tube within 3 minutes after applying adhesive.
Do not deform the spark plug tube.
Do not expose the spark plug tube to coolant within
1 hour after installing.
Wooden
Block
Press
Protrusion
Height
(c) Using a press and wooden block, install the spark plug tube to the required protrusion height.
NOTICE:
Be careful not to drip the adhesive.
Wooden
Block
A78785
27.
INSTALL PCV PIPE (RH CYLINDER)
(a) Using a wooden block and hammer, tap in 2 new PCV pipes until their top edges are flush with the cylinder head edge.
NOTICE:
Be careful not to damage the cylinder head edge.
Flush
A78786
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Author: Date:
2243
14-152
RH Cylinder:
M8
ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
28.
INSTALL STUD BOLT
(a) Install the stud bolts on the intake side.
Torque: 7.5 N
⋅ m (76 kgf
⋅ cm, 66 in.
⋅ lbf)
49 mm
(1.93 in.)
A78787
LH Cylinder:
49 mm
(1.93 in.)
M8
A78788
29.
INSTALL STUD BOLT
(a) Install the stud bolts on the exhaust side.
Torque: 15 N
⋅ m (153 kgf
⋅ cm, 11 ft
⋅ lbf)
Intake:
Light Brown
SST
Gray
Exhaust:
A78789
30.
INSTALL VALVE STEM OIL O SEAL OR RING
(a) Apply a light coat of engine oil to the valve stem.
NOTICE:
Installing the oil seals for intake and exhaust to the opposite valve guide bush may cause an improper installation.
HINT:
The intake valve oil seal is light brown and the exhaust valve oil seal is gray.
(b) Using SST, push in a new oil seal.
SST 09201-41020
NOTICE:
Failure to use SST will cause the seal to be damaged or improperly seated.
A78790
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14-153
ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
31.
INSTALL INTAKE VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the original locations.
P12668
(b) Using SST, compress the spring and place the 2 retainer locks around the valve stem.
SST 09202-70020 (09202-00010)
SST
A78770
(c) Using a plastic-faced hammer and discarded valve (the tip is wrapped with tape), lightly tap the installed valve to fit into place.
NOTICE:
Be careful not to damage the installed valve stem tip.
A05246
32.
INSTALL EXHAUST VALVE
(a) Install the valve, seat, spring, and retainer.
NOTICE:
Install the same parts in the same combination to the original locations.
A52900
(b) Using SST, compress the spring and place the 2 retainer locks around the valve stem.
SST 09202-70020 (09202-00010)
SST
A78772
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2245
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ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
(c) Using a plastic-faced hammer and discarded valve (the tip is wrapped with tape), lightly tap the installed valve to fit into place.
NOTICE:
Be careful not to damage the installed valve stem tip.
A05246
33.
INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil to the valve lifter.
NOTICE:
Install the same parts in the same combination to the original locations.
(b) Install the valve lifter.
(c) Check that the valve lifter is rotated smoothly by hand.
34.
INSTALL SEMICIRCULAR PLUG
(a) Remove any old seal packing material.
(b) Apply seal packing to the plug grooves.
Seal packing: Part No. 08826-00080 or equivalent
Seal Packing
: Semicircular Plug
RH Cylinder:
A78791
(c) Install the 2 plugs to the cylinder heads.
NOTICE:
Install the plugs so that they are flush with the top of the cylinder head.
Install the plugs within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
Front
LH Cylinder:
A78792
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ENGINE MECHANICAL CYLINDER HEAD ASSY (3MZ-FE)
35.
INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
(a) Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 N
⋅ m (449 kgf
⋅ cm, 32 ft
⋅ lbf)
36.
INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
(a) Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 N
⋅ m (449 kgf
⋅ cm, 32 ft
⋅ lbf)
14-155
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Author: Date:
2247
14-156
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
COMPONENTS
Piston Ring (No. 1 Compression Ring)
Piston Ring (No. 2 Compression Ring)
Piston Ring (Side Rail)
Piston
Piston Pin Hole Snap Ring
Connecting Rod Sub-assy
1419L-03
Piston Ring (Expander)
Piston Pin Hole
Snap Ring
Piston Pin
Connecting Rod Small
End Bush
Connecting Rod Bearing
Connecting Rod Cap
See page ( 14-158 )
1st: 25 (250, 18)
2st: Turn 90
Cylinder Block Sub-assy
Gasket
50 (510, 37)
Cylinder Block w/ Head
Straight Screw No. 3 Plug
39 (398, 29)
Cylinder Block Water
Drain Cock Sub-assy
30 (306, 22)
Cylinder Block w/ Head
Straight Screw No. 1 Plug
Gasket
Gasket
30 (306, 22)
Cylinder Block w/ Head
Straight Screw No. 2 Plug
Water Seal Plate
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
39 (398, 29)
Cylinder Block Water Drain Cock
Sub-assy
18 (184, 13)
A78311
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2248
27 (275, 20)
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
Cylinder Block Sub-assy
14-157
Crankshaft Bearing
Upper Crankshaft Thrust Washer
Crankshaft
Lower Crankshaft Thrust Washer
Crankshaft Bearing Cap
Crankshaft Bearing
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
See page ( 14-158 )
1st: 22 (224, 16)
2st: Turn 90
27 (275, 20)
Author: Date:
A78312
2249
14-158
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
OVERHAUL
1.
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
2.
REMOVE WATER SEAL PLATE
3.
REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
(a) Using a socket hexagon wrench 10, remove the screw plug.
4.
REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
(a) Using a socket hexagon wrench 10, remove the screw plug.
5.
REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
(a) Using a socket hexagon wrench 10, remove the screw plug.
1419M-03
P12695
6.
INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the connecting rod.
If necessary, replace the crankshaft.
7.
INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(b) Remove the cap bolts.
(c) Clean the crank pin, bearing and connecting rod.
(d) Check the crank pin and bearing for pitting and scratches.
(e) Lay a strip of Plastigage across the crank pin.
Plastigage
Front
Protrusion
A78793
(f) Check that the protrusion of the cap is facing the correct direction.
(g) Apply a light coat of engine oil to the threads of the cap bolts.
A78794
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
(h) Tighten the cap bolts in several steps by the specified torque.
Torque: 25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
90
Front
90
Painted Mark
P12697
(i) Mark the front side of each cap bolt with paint.
(j) Retighten the cap bolts by 90 as shown in the illustration.
NOTICE:
Do not turn the crankshaft.
(k) Remove the cap bolts, cap and lower bearing.
Number Mark
A78795
P12698
A79803
(l) Measure the Plastigage at its widest point.
Standard oil clearance:
0.038 to 0.066 mm (0.0015 to 0.0026 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
NOTICE:
Completely remove the Plastigage.
If the oil clearance is greater than maximum, replace the bearing.
If necessary, grind or replace the crankshaft.
HINT:
If replacing the bearing, replace it with one having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked ”1 ”, ”2”, ”3” and ”4” accordingly.
Reference:
Standard bearing center wall thickness:
Mark
”1”
”2”
”3”
”4” mm (in.)
1.484 to 1.487 (0.0584 to 0.0585)
1.487 to 1.490 (0.0585 to 0.0587)
1.490 to 1.493 (0.0587 to 0.0588)
1.493 to 1.496 (0.0588 to 0.0589)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
A05258
8.
REMOVE PISTON SUB-ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Push out the piston and connecting rod assembly from the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in the correct order so they can be returned to the original locations when reassembling.
9.
REMOVE CONNECTING ROD BEARING
10.
REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the 2 side rails and expander by hand.
A78315
11.
REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
80 C (176 F)
P12403
12.
REMOVE W/PIN PISTON SUB-ASSY
(a) Gradually heat the piston up to approximately 80 C
(176 F).
A78797
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
(b) Using a plastic-faced hammer and brass bar, lightly tap out the piston pin, then remove the connecting rod.
HINT:
The piston and piston pin are a matched set.
Store the pistons, piston pins, rings, connecting rods and bearings in the correct order so that they can be returned to the original locations when reassembling.
P12415
P12799
13.
INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
HINT:
The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to
0.0780 in.).
7
8
5
14.
REMOVE CRANKSHAFT
(a) Using several steps, loosen and remove the 8 bearing cap bolts and 8 seal washers uniformly in the sequence shown in the illustration.
6 2
3
4
1
A78798
2
10
9
6
14
13
8
16
15
4
12
7
5
11
3
1
A78799
(b) Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence shown in the illustration.
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
(c) Using a screwdriver, pry out the bearing caps. Remove the 4 bearing caps and 4 lower bearings.
NOTICE:
Carefully pry out the main bearing cap by alternately lifting each end of the bearing cap little by little.
Be careful not to damage the joint surface of the cylinder block and bearing cap.
P12603
Joint Surface
A78800
15.
REMOVE CRANKSHAFT THRUST WASHER SET
16.
REMOVE CRANKSHAFT BEARING
17.
INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, measure the warpage on the surface which contacts the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than maximum, replace the cylinder block.
Z09222
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
18.
INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter:
92.000 to 92.012 mm (3.6220 to 3.6225 in.)
Maximum diameter: 92.132 mm (3.6272 in.)
If the average diameter of 4 positions is greater than maximum, replace the cylinder block.
Thrust Direction
Axial Direction
A
B
10 mm (0.39 in.)
A88633
13.0 mm
(0.512 in.)
19.
INSPECT W/PIN PISTON SUB-ASSY
(a) Using a micrometer, measure the diameter of the piston.
Align the micrometer so it is 13.0 mm (0.512 in.) from the bottom of the piston and at a right angle (90 ) to the piston pin holes as illustrated.
Piston diameter:
91.953 to 91.967 mm (3.6202 to 3.6207 in.)
A78316
20.
INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than maximum, replace all the 6 pistons.
If necessary, replace the cylinder block.
21.
INSPECT CONNECTING ROD SUB-ASSY
(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.
(1) Inspect for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If misalignment is greater than maximum, replace the connecting rod assembly.
Z00064
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SST
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
(2) Inspect for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than maximum, replace the connecting rod assembly.
Z00065
22.
INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the bush.
Bush inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
EM6525
EM0227
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the bush inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush.
If necessary, replace the piston and piston pin together.
23.
REMOVE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bush.
SST 09222-30010
A78803
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
24.
INSTALL CONNECTING ROD SMALL END BUSH
(a) Align the oil holes of a new bush and the connecting rod.
Oil Hole
A78804
(b) Using SST and a press, press in the bushing.
SST 09222-30010
SST
A78803
(c) Using a pin hole grinder, hone the bush to obtain the standard specified clearance between the bush and piston pin.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
EM6535
(d) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, then push it into the connecting rod with your thumb.
P00326
A78317
25.
INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between the new piston ring and wall of the ring groove.
Ring groove clearance:
0.03 to 0.08 mm (0.0012 to 0.0031 in.) for No. 1 ring
0.02 to 0.06 mm (0.0008 to 0.0024 in.) for No. 2 ring
0.03 to 0.11 mm (0.0012 to 0.0043 in.) for oil ring
If the groove clearance is not as specified, replace the piston ring.
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110 mm
(4.33 in.)
EM6347
EM6347
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
26.
INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring which it is a little below the bottom of the ring travel, where is 110 mm (4.33 in.) from the top of the cylinder block.
A78805
A37355
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
0.30 to 0.40 mm (0.0118 to 0.0157 in.) for No. 1 ring
0.50 to 0.60 mm (0.0197 to 0.0236 in.) for No. 2 ring
0.15 to 0.40 mm (0.0059 to 0.0157 in.) for oil (side rail) ring
Maximum end gap:
0.95 mm (0.0374 in.) for No. 1 ring
1.05 mm (0.0413 in.) for No. 2 ring
1.00 mm (0.0394 in.) for oil (side rail) ring
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.
27.
INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than minimum, replace the bolt.
A15065
28.
INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than minimum, replace the bolt.
A15065
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29.
INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crankshaft.
P12406
A37157
(b) Using a micrometer, measure the diameter of each main journal.
Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
If the diameter is not as specified, check the crankshaft oil clearance
(c) Check each main journal for taper and out-of-round as shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than maximum, replace the crankshaft.
ZF6928
(d) Using a micrometer, measure the diameter of each crank pin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
If the diameter is not as specified, check the connecting rod oil clearance.
(e) Check each crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than maximum, replace the crankshaft.
No. 1 and No. 4:
Upper
Lower
No. 2 and No. 3:
22.4 mm (0.882 in.) 19.0 mm (0.748 in.)
A78806
30.
INSPECT CRANKSHAFT OIL CLEARANCE
HINT:
Crankshaft bearings come in widths of 22.4 mm (0.882 in.) and
19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the bearing caps. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
(a) Clean each main journal and bearing.
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Mark
1, 2, 3 or 4
Plastigage
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
(b) Align the key of the bearing with the keyway of the cylinder block, then push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact surface.
P12599
A78807
(c) Align the key of the bearing with the keyway of the bearing cap, then push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact surface.
HINT:
A number is marked on each bearing cap to indicate the installation position.
(d) Place the crankshaft on the cylinder block.
(e) Lay a strip of Plastigage across each journal.
A78808
(f) Examine the front marks and numbers, then install the bearing caps on the cylinder block.
(g) Apply a light coat of engine oil to the threads of the bearing cap bolts.
A10530
(h) Temporarily install the 8 bearing cap bolts to the inside positions.
(i) Install the bearing cap by hand using the inner bolt as a guide. Stop when the bearing cap is about 6 mm (0.23 in.) away from contact with the cylinder block.
Less than 6 mm (0.23 in.)
A78809
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
(j) Using a plastic-faced hammer, lightly tap the bearing cap to ensure proper fit.
(k) Apply a light coat of engine oil to the threads of the bearing cap bolts.
A10529
15
7
8
11
3
4
16
9
13
2
1
5
12
6
10
14
A78810
(l) Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 22 N
⋅ m (224 kgf
⋅ cm, 16 ft
⋅ lbf)
90
Front 90
Painted Mark
(m) Mark the front side of the bearing cap bolts with paint.
(n) Retighten the bearing cap bolts by 90 in the same sequence as step (l).
(o) Check that each painted mark is now at a 90 angle to the front.
NOTICE:
Do not turn the crankshaft.
A78811
3
2
1
4
5
6
7
(p) Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 27 N
⋅ m (275 kgf
⋅ cm, 20 ft
⋅ lbf)
HINT:
Use the short bolt for the position marked with the arrow.
(q) Remove the bearing caps.
8
A78812
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
P12993
(r) Measure the Plastigage at its widest point.
Standard oil clearance:
0.014 to 0.034 mm (0.0006 to 0.0013 in.) for No. 1 and
No. 2 journals
0.026 to 0.046 mm (0.0010 to 0.0018 in.) for No. 3 and
No. 4 journals
Maximum clearance:
0.05 mm (0.0020 in.) for No. 1 and No. 2 journals
0.06 mm (0.0024 in.) for No. 3 and No. 4 journals
If the oil clearance is greater than maximum, replace the bearings.
If necessary, replace the crankshaft.
NOTICE:
Completely remove the Plastigage.
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No. 1
Number
Mark
No. 2
Number Mark
14-171
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
No. 3
No. 4
No. 1
No. 2
No. 3
No. 4
Number Mark
A78813
(s) If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. The No. 1 and No. 2 journal bearing come in 5 sizes, marked ”3”, ”4”, ”5”, ”6” and ”7”. The No. 3 and No.
4 journal bearings come in 5 standard bearing sizes, marked ”1”, ”2”, ”3”, ”4” and ”5”.
No. 1 and No. 2 journal bearings:
Cylinder block
+
Crankshaft
=
Replacement
Bearing
0 to 5
”3”
6 to 11
”4”
12 to 17
”5”
18 to 23
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked ”5”
No. 3 and No. 4 journal bearings:
”6”
Cylinder block
+
Crankshaft
=
0 to 5 6 to 11 12 to 17 18 to 23
Replacement
Bearing
”1” ”2” ”3”
HINT:
EXAMPLE
Imprinted number on the cylinder block is 06
Imprinted number on the crankshaft is 08
6 + 8 = 14
Select the bearing marked ”3”
”4”
24 to 28
”7”
24 to 28
”5”
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Item
Cylinder block main journal bore diameter (A)
Crankshaft main journal diameter (B)
Standard bearing center wall thickness
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
Mark
”00”
”01”
”02”
”03”
”04”
”05”
”06”
”07”
”08”
”09”
”10”
”11”
”12”
”1”
”2”
”3”
”4”
”5”
”6”
”7”
”09”
”10”
”11”
”12”
”13”
”14”
”15”
”16”
”00”
”01”
”02”
”03”
”04”
”05”
”06”
”07”
”08” mm (in.)
66.000 (2.5984)
66.001 (2.5985)
66.002 (2.5985)
66.003 (2.5985)
66.004 (2.5986)
66.005 (2.5986)
66.006 (2.5987)
66.007 (2.5987)
66.008 (2.5987)
66.009 (2.5988)
66.010 (2.5988)
66.011 (2.5989)
66.012 (2.5989)
66.013 (2.5989)
66.014 (2.5990)
66.015 (2.5990)
66.016 (2.5990)
61.000 (2.4016)
60.999 (2.4015)
60.998 (2.4015)
60.997 (2.4015)
60.996 (2.4014)
60.995 (2.4014)
60.994 (2.4013)
60.993 (2.4012)
60.992 (2.4012)
60.991 (2.4012)
60.990 (2.4012)
60.989 (2.4011)
60.988 (2.4011)
2.486 to 2.489 (0.0979 to 0.0980)
2.489 to 2.492 (0.0980 to 0.0981)
2.492 to 2.495 (0.0981 to 0.0982)
2.495 to 2.498 (0.0982 to 0.0983)
2.498 to 2.501 (0.0983 to 0.0985)
2.501 to 2.504 (0.0985 to 0.0986)
2.504 to 2.507 (0.0986 to 0.0987)
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31.
INSTALL STUD BOLT
Front Side: Front Side:
M6
Torque: 6.0 N
⋅ m (60 kgf
⋅ cm, 53 in.
⋅ lbf)
29 mm
(1.14 in.)
M8
Torque: 15 N
⋅ m (145 kgf
⋅ cm, 11 ft
⋅ lbf)
99 mm
(3.90 in.)
Front Side: Left Side:
M10
Torque: 21 N
⋅ m (220 kgf
⋅ cm, 15 ft
⋅ lbf)
80 mm
(3.15 in.)
M8
Torque: 7.0 N
⋅ m (70 kgf
⋅ cm, 62 in.
⋅ lbf)
28.5mm
(1.12 in.)
Upper Side: Upper Side:
M6
Torque: 4.0 N
⋅ m (40 kgf
⋅ cm, 35 in.
⋅ lbf)
27.5 mm
(1.08 in.)
Torque: 12 N
⋅ m (122 kgf
⋅ cm, 9 ft
⋅ lbf)
52.5 mm
(2.07 in.)
A78318
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
32.
INSTALL STRAIGHT PIN
Front Side:
4 mm
(0.16 in)
12 mm
(0.47 in.)
Protrusion Height: 6 mm (0.24 in.)
Right Side:
4 mm
(0.16 in)
12 mm
(0.47 in.)
Protrusion Height: 6 mm (0.24 in.)
Upper Side:
4 mm
(0.16 in)
12 mm
(0.47 in.)
Protrusion Height: 6 mm (0.24 in.)
Lower Side:
4 mm
(0.16 in)
Protrusion Height: 6 mm (0.24 in.)
12 mm
(0.47 in.)
Back Side:
4 mm
(0.16 in)
Protrusion Height: 6 mm (0.24 in.)
12 mm
(0.47 in.)
Back Side:
10 mm
(0.39 in.)
22 mm
(0.87 in.)
Protrusion Height: 11 mm (0.43 in.)
A78319
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
33.
INSTALL RING PIN
Upper Side:
16 mm
(0.63 in.)
Protrusion Height: 10 mm (0.39 in.)
20 mm
(0.79 in.)
11 mm
(0.43 in.)
Protrusion Height: 4 mm (0.16 in.)
8 mm
(0.31 in.)
A78816
P12418
80 C (176 F)
34.
INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not aligned with the pin hole cutout of the piston.
A32958
35.
INSTALL W/PIN PISTON SUB-ASSY
(a) Gradually heat the piston up to approximately 80 C
(176 F).
Front Mark
Front Mark
(Mold Mark)
A78376
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
A78817
(b) Coat the piston pin with engine oil.
(c) Align the front marks of the piston and connecting rod, then push in the piston pin with your thumb until the pin contacts the snap ring.
Author: Date:
2267
14-176
P12418
No. 1:
No. 2:
2A
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
36.
INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
HINT:
Be sure that the end of gap of the snap ring is not aligned with the pin hole cutout of the piston.
37.
INSTALL PISTON RING SET
(a) Install the expander and 2 side rails by hand.
A32958
(b)
HINT:
Using a piston ring expander, install the 2 compression rings.
The No. 2 compression ring is installed with the code mark ”2A” facing upward as shown in the illustration.
No. 1
Compression
Expander
Front Mark
A78320
Lower Side
Rail
(c) Position the piston rings so that the ring ends are arranged as shown in the illustration.
NOTICE:
Do not align the ring ends.
Upper Side
Rail
No. 2
Compression
A86598
38.
INSTALL CONNECTING ROD BEARING
(a) Align the key of the bearing with the keyway of the connecting rod or cap.
NOTICE:
Clean the backside of the bearing and bearing surface of the connecting rod. The surface should be free of dust and oils.
P12402
No. 1 and No. 4:
Upper
Lower
No. 2 and No. 3:
22.4 mm (0.882 in.) 19.0 mm (0.748 in.)
A78806
39.
INSTALL CRANKSHAFT BEARING
HINT:
Crankshaft bearings come in widths of 22.4 mm (0.882 in.) and
19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing caps. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.
(a) Clean each main journal and the bearing.
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1, 2, 3 or 4
14-177
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
(b) Align the key of the bearing with the keyway of the cylinder block, then push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact surface.
P12599
A78807
(c) Align the key of the bearing with the keyway of the bearing cap, then push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact surface.
HINT:
A number is marked on each bearing cap to indicate the installation position.
40.
INSTALL CRANKSHAFT THRUST WASHER SET
(a) Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
P12600
(b) Install the 2 thrust washers on the No. 2 bearing cap with the grooves facing outward.
41.
INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, then install the crankshaft on the cylinder block.
A05264
(b) Examine the front marks and numbers, then install the bearing caps on the cylinder block.
(c) Apply a light coat of engine oil to the threads of the bearing cap bolts.
A10530
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ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
(d) Temporarily install the 8 bearing cap bolts to the inside positions.
(e) Install the bearing cap by hand using the inner bolt as a guide. Stop when the bearing cap is about 6 mm (0.23 in.) away from contact with the cylinder block.
Less than 6 mm (0.23 in.)
A78809
(f) Using a plastic-faced hammer, lightly tap the bearing cap to ensure proper fit.
(g) Apply a light coat of engine oil to the threads of the bearing cap bolts.
90
Front 90
Painted Mark
A10529
15
7
8
11
3
4
16
9
13
2
1
5
12
6
10
14
A78810
(h) Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 22 N
⋅ m (224 kgf
⋅ cm, 16 ft
⋅ lbf)
(i) Mark the front side of the bearing cap bolts with paint.
(j) Retighten the bearing cap bolts by 90 in the same sequence as step (h).
(k) Check that each painted mark is now at a 90 angle to the front.
(l) Check that the crankshaft turns smoothly.
A78811
3
2
1
4
7
6
5
8
A78812
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(m) Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 27 N
⋅ m (275 kgf
⋅ cm, 20 ft
⋅ lbf)
HINT:
Use the short bolt for the position marked with the arrow.
Author: Date: 2270
Front Mark (Cavity)
Front
Front
Protrusion
14-179
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
A78322
42.
INSTALL PISTON SUB-ASSY W/CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the numbered piston and connecting rod assemblies correctly into each cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connecting rod.
(d) Check that the protrusion of the cap is facing the correct direction.
(e) Apply a light coat of engine oil to the threads of the cap bolts.
A78794
(f) Tighten the cap bolts in several steps by the specified torque.
Torque: 25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
90
Front
90
Painted Mark
P12697
(g) Mark the front side of each cap bolt with paint.
(h) Retighten the cap bolts by 90 as shown in the illustration.
(i) Check that the crankshaft turns smoothly.
Front Side:
A78795
43.
INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.1 PLUG
(a) Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 30 N
⋅ m (306 kgf
⋅ cm, 22 ft
⋅ lbf)
A78822
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2271
14-180
Left Side:
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
44.
INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.2 PLUG
(a) Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 30 N
⋅ m (306 kgf
⋅ cm, 22 ft
⋅ lbf)
A78823
Back Side :
45.
INSTALL CYLINDER BLOCK W/HEAD STRAIGHT
SCREW NO.3 PLUG
(a) Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 50 N
⋅ m (510 kgf
⋅ cm, 37 ft
⋅ lbf)
46.
INSTALL WATER SEAL PLATE
(a) Remove any old seal packing from the contact surface.
A78824
A
A
B
B
Seal Width
3 to 5 mm (0.12 to 0.20 in.)
A62377
(b) Apply a continuous bead of seal packing (Diameter 3 to
5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the seal plate within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
(c) Install the seal plate with the 2 nuts.
Torque: 18 N
⋅ m (184 kgf
⋅ cm, 13 ft
⋅ lbf)
47.
INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSY
(a) Apply adhesive to 2 or 3 threads of the drain cock end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2272
10
45
14-181
ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE)
(b) After applying the specified torque, rotate the drain cock clockwise as shown in the illustration.
Torque: 39 N
⋅ m (398 kgf
⋅ cm, 29 ft
⋅ lbf)
NOTICE:
Install the drain cock within 3 minutes after applying adhesive.
Do not expose the drain cock to coolant within 1 hour after installing.
Do not rotate the drain cock by more than 1 revolution
(360 ) after tightening the drain cock with the specified torque.
Do not loosen the drain cock after setting it correctly.
A78323
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2273
10-1
ENGINE CONTROL SYSTEM SFI SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
100IZ-01
DLC3
Hand-held Tester
A86347
1.
INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Check the operation.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Start the engine and allow it to warm up.
(4) Connect the hand-held tester, then select VVT from the ACTIVE TEST menu.
(5) Check the engine speed when the OCV is operated with the hand-held tester.
Standard:
Tester Operation
OCV is OFF
OCV is ON
Specified Condition
Normal engine speed
Rough idle or engine stall
If the operation is not as specified, inspect the camshaft timing oil control valve (see page 10-2 ).
2.
INSPECT THROTTLE BODY ASSY
(a) Check the operation (throttle control motor).
(1) Turn the ignition switch ON.
(2) When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound.
If the operation is not as specified, inspect the throttle body (see page 10-2 ).
Hand-held Tester
(b) Check the operation (throttle position sensor).
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Check that the check engine warning light does not light up.
(4) Check that the throttle valve opening percentage
(THROTTLE POS) of CURRENT DATA showns the
DLC3
A86347 standard value.
Standard throttle valve opening percentage:
60 % or more
NOTICE:
When checking the standard throttle valve opening percentage, the transmission is in the neutral position.
3.
INSPECT ACCELERATOR PEDAL POSITION SENSOR
(a) Inspect the voltage.
(1) After turning the ignition switch ON, check CURRENT DATA, then verify that the throttle position sensor voltage is within the standard value.
Standard voltage: 0.6 to 1.0 V
If the voltage is not as specified, inspect the accelerator pedal (see page 10-2 ).
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2006
10-2
INSPECTION
ENGINE CONTROL SYSTEM SFI SYSTEM (3MZ-FE)
100J0-01
Spool Valve
Ohmmeter
A86282
Battery
A86283
1.
INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 (-) - 2 (+)
Specified Condition
6.9 to 7.9
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the camshaft timing oil control valve.
(b) Check the operation.
(1) Connect the positive (+) lead from the battery to terminal 2 (+) and negative (-) lead to terminal 1 (-), then check the movement of the spool valve.
NOTICE:
Confirm that the spool valve moves freely and does not get stuck in any position.
HINT:
Bad returning of the spool valve resulted from catching foreign objects causes subtle pressure leak to the advanced direction.
In that case, DTC can be detected.
Air
Voltmeter
Battery
A84676
2.
INSPECT MASS AIR FLOW METER
(a) Check the operation.
(1) Apply battery voltage across terminals 1 (+B) and 2
(E2G).
(2) Using voltmeter, connect the positive (+) tester probe to terminal 3 (VC), and negative (-) tester probe to terminal 2 (E2G).
(3) Blow air into the mass air flow sensor, then check that the voltage fluctuates.
If the operation is not as specified, replace the mass air flow sensor.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2007
10-3
ENGINE CONTROL SYSTEM SFI SYSTEM (3MZ-FE)
Ohmmeter
(b) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
4 (THA) - 5 (E2)
4 (THA) - 5 (E2)
4 (THA) - 5 (E2)
Specified Condition
13.6 to 18.4 k
Ω
at -20 C (-4 F)
2.21 to 2.69 k
Ω
at 20 C (68 F)
0.493 to 0.667 k
Ω
at 60 C (140 F)
If the resistance is not as specified, replace the mass air flow sensor.
30
20
10
5
1
0.5
0.2
-20 0 20 40 60 80
(-4) (32)(68)(104)(140)(176)
Temperature C ( F)
A84677
Ohmmeter
30
20
10
5
1
0.5
0.2
-20 0 20 40 60 80
(-4) (32)(68)(104)(140)(176)
Temperature C ( F)
A84678
3.
INSPECT ENGINE COOLANT TEMPERATURE
SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 (E2) - 2 (THW)
1 (E2) - 2 (THW)
Specified Condition
2.32 to 2.59 k
Ω
at 20 C (68 F)
0.310 to 0.326 k
Ω
at 80 C (176 F)
NOTICE:
When checking the engine coolant temperature sensor in water, be careful not to allow water to intrude into the terminals. Then dry the engine coolant temperature sensor after checking.
If the resistance is not as specified, replace the engine coolant temperature sensor.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2008
10-4
Ohmmeter
ENGINE CONTROL SYSTEM SFI SYSTEM (3MZ-FE)
Ohmmeter
4.
INSPECT THROTTLE BODY ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 (M-) - 2 (M+)
3 (E2) - 5 (VC)
Specified Condition
0.3 to 100
Ω
at 20 C (68 F)
1.2 to 3.2 k
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the throttle body.
A86281
A84680
5.
INSPECT KNOCK SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 (Output)- 2 (Ground)
Specified Condition
120 to 280
Ω
at 20 C (68 F)
If the resistance is not specified, replace the knock sensor.
Ohmmeter
6.
INSPECT ACCELERATOR PEDAL ASSY (NORMAL
PEDAL)
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
2 (VPA2) - 3 (EP1)
1 (EP2) - 5 (VPA1)
3 (EP1) - 6 (VCP1)
1 (EP2) - 4 (VCP2)
Specified Condition
5.0 k
Ω
or less
5.0 k
Ω
or less
2.25 to 4.75 k
Ω
2.25 to 4.75 k
Ω
If the resistance is not specified, replace the accelerator pedal.
A86284
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2009
Battery
Ohmmeter
Battery
Ohmmeter
10-5
ENGINE CONTROL SYSTEM SFI SYSTEM (3MZ-FE)
Ohmmeter
7.
INSPECT ACCELERATOR & BRAKE PEDAL ASSY
(POWER PEDAL)
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
3 (EP1) - 5 (VPA1)
1 (EP2) - 2 (VPA2)
3 (EP1) - 6 (VCP1)
1 (EP2) - 4 (VCP2)
Specified Condition
5.0 k
Ω
or less
5.0 k
Ω
or less
2.25 to 4.75 k
Ω
2.25 to 4.75 k
Ω
If the resistance is not specified, replace the accelerator & brake pedal.
A86285
A84683
A84683
8.
INSPECT MAIN RELAY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
3 - 5
3 - 5
Specified Condition
10 k
Ω
or higher
Below 1
Ω
(Apply battery voltage to terminals 1 and 2
If the result is not as specified, replace the main relay.
9.
INSPECT CIRCUIT OPENING RELAY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
3 - 5
3 - 5
Specified Condition
10 k
Ω
or higher
Below 1
Ω
(Apply battery voltage to terminals 1 and 2
If the result is not as specified, replace the circuit opening relay.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2010
10-6
ENGINE CONTROL SYSTEM CAMSHAFT TIMING OIL CONTROL VALVE
ASSY (3MZ-FE)
100J1-01
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
RH Bank:
(b)
(a)
A86244
3.
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Disconnect the 2 camshaft timing oil control valve connectors.
(b) Remove the 2 bolts, then remove the 2 camshaft timing oil control valves.
HINT:
The camshaft timing oil control valve is installed with the bolt.
LH Bank:
(b)
(a)
A86306
4.
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Apply a light coat of engine oil to the O-ring on each camshaft timing oil control valve.
(b) Install the 2 camshaft timing oil control valves with the 2 bolts.
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
NOTICE:
Be careful not to twist the O-ring.
(c) Connect the 2 camshaft timing oil control valve connectors.
5.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
6.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
7.
CHECK FOR ENGINE OIL LEAKS
8.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2011
10-7
ENGINE CONTROL SYSTEM MASS AIR FLOW METER (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
(b)
(a)
100J2-02
2.
REMOVE MASS AIR FLOW METER
(a) Disconnect the mass air flow meter connector.
(b) Remove the 2 screws, then remove the mass air flow meter.
(b)
A86246
3.
INSTALL MASS AIR FLOW METER
4.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
5.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2012
10-8
ENGINE CONTROL SYSTEM ENGINE COOLANT TEMPERATURE
SENSOR (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
3.
DRAIN ENGINE COOLANT (See page 16-9 )
100J3-02
(a)
Deep Socket
Wrench 19
4.
REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Disconnect the engine coolant temperature sensor connector.
(b) Using a deep socket wrench 19, remove the engine coolant temperature sensor and gasket.
(b)
A86247
5.
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Using a deep socket wrench 19, install a new gasket and the engine coolant temperature sensor.
Torque: 20 N
⋅ m (200 kgf
⋅ cm, 14 ft
⋅ lbf)
(b) Connect the engine coolant temperature sensor connector.
6.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
7.
ADD ENGINE COOLANT (See page 16-9 )
8.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
9.
INSTALL RADIATOR LOWER AIR DEFLECTOR
10.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2013
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (3MZ-FE)
COMPONENTS x2
80 (816, 59)
Spacer
7.9 (81, 70 in.
⋅ lbf) x3
W/O TEMS:
Front Suspension Upper Brace Center
10-9
100J4-01
V-bank Cover Sub-assy x2
80 (816, 59)
Spacer
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Vacuum Hose
Vacuum Hose
5.0 (51, 44 in.
⋅ lbf)
Author:
Fuel Vapor Feed Hose
Assy
Mass Air Flow
Meter Connector
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
A86358
Date:
2014
10-10
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (3MZ-FE)
Intake Air Connector
Gasket
Throttle Body Assy
11 (112, 8) x4
Water By-pass Hose No. 2
Water By-pass Hose No. 3
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Throttle Motor Connector
A86249
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2015
10-1 1
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
3.
DRAIN ENGINE COOLANT (See page 19-5 )
100J5-01
4.
REMOVE FRONT SUSPENSION UPPER BRACE
CENTER (W/O TEMS)
(a) Remove the 4 nuts, then remove the front suspension upper brace center and 4 spacers.
(b) Temporarily tighten the 4 nuts.
A86250
Socket Hexagon
Wrench 5
5.
REMOVE V-BANK COVER SUB-ASSY
(a) Using a socket hexagon wrench 5, remove the 3 nuts.
(b) Unfasten the 2 retainers, then remove the V-bank cover.
(a)
(a)
(b) 2 Retainers
(a)
A86251
(b)
(c)
(b)
(b)
(f)
(d)
(a)
(d)
(e)
6.
REMOVE AIR CLEANER CAP SUB-ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the 4 vacuum hoses.
(c) Disconnect the ventilation hose No. 2.
(d) Disconnect the fuel vapor feed hose from the 2 hose clamps.
(e) Loosen the 2 air cleaner cap bolts.
(f) Loosen the air cleaner hose clamp bolt, then remove the air cleaner cap.
(g) Remove the air cleaner filter element.
(b)
(e)
(b)
(c)
A86253
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
A86252
(a)
7.
REMOVE THROTTLE BODY ASSY
(a) Disconnect the throttle motor connector.
(b) Disconnect the water by-pass hose No. 2.
(c) Disconnect the water by-pass hose No. 3.
Author: Date:
2016
10-12
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (3MZ-FE)
(d)
(d) Remove the 4 bolts, then remove the throttle body.
(e) Remove the gasket from the intake air connector.
(d)
(d)
(d)
A86254
8.
INSTALL THROTTLE BODY ASSY
(a) Install a new gasket to the intake air connector.
(b) Install the throttle body with the 4 bolts.
Torque: 11 N
⋅ m (112 kgf
⋅ cm, 8 ft
⋅ lbf)
(c) Connect the water by-pass hose No. 3.
(d) Connect the water by-pass hose No. 2.
(e) Connect the throttle motor connector.
9.
INSTALL AIR CLEANER CAP SUB-ASSY
Torque: 5.0 N
⋅ m (51 kgf
⋅ cm, 44 in.
⋅ lbf)
10.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
11.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
12.
ADD ENGINE COOLANT (See page 16-9 )
13.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
14.
INSTALL V-BANK COVER SUB-ASSY
(a) Fit the 2 retainers, then install the V-bank cover.
(b) Using a socket hexagon wrench 5, tighten the 3 nuts.
Torque: 7.9 N
⋅ m (81 kgf
⋅ cm, 70 in.
⋅ lbf)
15.
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS)
Torque: 80 N
⋅ m (816 kgf
⋅ cm, 59 ft
⋅ lbf)
16.
INSTALL RADIATOR LOWER AIR DEFLECTOR
17.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2017
ENGINE CONTROL SYSTEM KNOCK SENSOR (3MZ-FE)
COMPONENTS x2
80 (816, 59)
Spacer
7.9 (81, 70 in.
⋅ lbf) x3
W/O TEMS:
Front Suspension Upper Brace Center
10-13
100J6-02
V-bank Cover Sub-assy x2
80 (816, 59)
Spacer
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Vacuum Hose
Vacuum Hose
5.0 (51, 44 in.
⋅ lbf)
Author:
Fuel Vapor Feed Hose
Assy
Mass Air Flow
Meter Connector
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
A86358
Date:
2018
10-14
VSV Connector
ENGINE CONTROL SYSTEM KNOCK SENSOR (3MZ-FE) x2
8.0 (82, 71 in.
⋅ lbf)
7.8 (80, 69 in.
⋅ lbf)
Pressure Feed
Tube Assy x2
Emission
Control Valve Set
Fuel Vapor Feed Hose
Bond Cable No. 1
Connector
Emission Control Valve Bracket
28 (286, 21)
28 (286, 21) x3 x2
Engine Hunger No. 1
20 (204, 14) x2
20 (204, 14) x2
Surge Tank Stay
No. 1 x2
20 (204, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86260
2019
10-15
ENGINE CONTROL SYSTEM KNOCK SENSOR (3MZ-FE)
64 (653, 47)
64 (653, 47) x2
Engine Moving
Control Rod
15 (153, 11) x2
23 (235, 17)
8.4 (86, 74 in.
⋅ lbf)
Radio Setting
Condenser
Ground Cable x9 x2
Engine Coolant
Temperature Sensor
Connector x2
15 (153, 11)
Washer
Bond Cable No. 1
Connector
Pipe
Radiator Hose Inlet
Water Outlet
Intake Manifold
Fuel Injector Connector
Clamp
Intake Manifold
to Head Gasket No. 1
15 (153, 11)
Washer
Fuel Injector
Connector
Fuel Pipe
Clamp
Heater Inlet
Water Hose
Intake Manifold
to Head Gasket No. 2
Knock Sensor Connector
Knock Sensor
20 (204, 14)
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86261
2020
10-16
ENGINE CONTROL SYSTEM KNOCK SENSOR (3MZ-FE)
REPLACEMENT
1.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3.
DRAIN ENGINE COOLANT (See page 16-9 )
4.
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
5.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
6.
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
7.
REMOVE EMISSION CONTROL VALVE SET (See page 11-13 )
8.
REMOVE INTAKE AIR SURGE TANK (See page 11-13 )
100J7-02
(b)
(b)
(a) (b)
9.
REMOVE ENGINE MOVING CONTROL ROD
(a) Remove the pipe from the clamp.
(b) Remove the 4 bolts, then remove the engine moving control rod and radio setting condenser.
(b)
A86262
Pull Out
Fuel Pipe
Clamp
Pinch
Nylon Tube
Pinch
A86263
Tube Connector
10.
REMOVE INTAKE MANIFOLD
(a) Disconnect the fuel pipe No. 1.
(1) Remove the fuel pipe clamp.
(2) Pinch the tube connector, then pull out the fuel pipe
No. 1.
NOTICE:
Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
Be careful of mud because the quick connector has an O-ring which seals the pipe and quick connector that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the quick connector by covering it with a vinyl or plastic bag.
When the pipe and quick connector are stuck, push and pull the quick connector to release and pull the quick connector out carefully.
O-ring
Quick Connector
Pipe
A75650
(b) Disconnect the heater inlet water hose.
(b)
A86264
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2021
(c)
(d)
(d)
(d)
(d)
10-17
(d)
ENGINE CONTROL SYSTEM KNOCK SENSOR (3MZ-FE)
(c) Remove the nut, then disconnect the ground cable.
(d) Disconnect the 6 fuel injector connectors.
(d)
A86265
(e) In order to remove the intake manifold, using several steps, remove the 9 bolts and 2 nuts in the sequence shown in the illustration.
4
3
(a)
8
7
(b)
10
6
2
11
9
5
1
A86266
(c)
11.
REMOVE WATER OUTLET
(a) Disconnect the bond cable No. 1 connector.
(b) Disconnect the pipe of the radiator reserve tank.
(c) Lock the hose clamp as shown in the illustration, then disconnect the radiator hose inlet.
A86267
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2022
10-18
(f)
(f)
(f)
(d)
(f)
ENGINE CONTROL SYSTEM KNOCK SENSOR (3MZ-FE)
(d) Disconnect the engine coolant temperature sensor connector.
(e) Remove the clamp.
(f) Remove the 2 bolts, 2 nuts and 2 washers.
(g) Lock the hose clamp as shown in the illustration. Then remove the water outlet together with water by-pass hose
No. 1.
(h) Remove the 2 gaskets from the 2 cylinder heads.
(e)
(g)
(a)
A86268
12.
REMOVE KNOCK SENSOR
(a) Disconnect the 2 knock sensor connectors.
(b) Remove the 2 nuts, then remove the 2 knock sensors.
(b)
(b)
(a)
A79749
0 to 5
Engine
Front
Upper
13.
INSTALL KNOCK SENSOR
(a) Install the 2 knock sensors with the 2 nuts as shown in the
(b) illustration.
Torque: 20 N
⋅ m (204 kgf
⋅ cm, 14 ft
⋅ lbf)
Connect the 2 knock sensor connectors.
A79750
14.
INSTALL WATER OUTLET
(a) Install 2 new gaskets to the 2 cylinder heads.
(b) Install the water outlet together with water by-pass hose No. 1, then unlock the hose clamp.
(c) Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 N
⋅ m (153 kgf
⋅ cm, 11 ft
⋅ lbf)
(d) Install the clamp.
(e) Connect the engine coolant temperature sensor connector.
(f) Connect the bond cable No. 3 connector.
(g) Connect the pipe of the radiator reserve tank.
(h) Connect the radiator hose inlet, then unlock the hose clamp.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2023
8
10-19
ENGINE CONTROL SYSTEM KNOCK SENSOR (3MZ-FE)
15.
INSTALL INTAKE MANIFOLD
(a) Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps, tighten the 9 bolts and 2 nuts uniformly in the sequence shown in the illustration.
Torque: 15 N
⋅ m (153 kgf
⋅ cm, 11 ft
⋅ lbf)
(b) Retighten the 9 water outlet mounting bolts and 2 nuts.
Torque: 15 N
⋅ m (153 kgf
⋅ cm, 11 ft
⋅ lbf)
(c) Install the ground cable with the nut.
Torque: 8.4 N
⋅ m (86 kgf
⋅ cm, 74 in.
⋅ lbf)
(d) Connect the heater inlet water hose.
2
6
10
4
1
9
B
5
B
Push
3
7
11
A86266
A
Fuel Pipe
Clamp
A86269
(e) Connect the fuel pipe No. 1.
(1) Push in the quick connector to the pipe until it makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the quick connector and pipe are securely connected by pulling them.
(2) Install the fuel pipe clamp.
16.
INSTALL ENGINE MOVING CONTROL ROD
Torque:
23 N
⋅ m (235 kgf
⋅ cm, 17 ft
⋅ lbf) for bolt A
64 N
⋅ m (653 kgf
⋅ cm, 47 ft
⋅ lbf) for bolt B
B
A86262
17.
INSTALL INTAKE AIR SURGE TANK (See page 11-13 )
18.
INSTALL EMISSION CONTROL VALVE SET (See page 11-13 )
19.
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
20.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
21.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
22.
ADD ENGINE COOLANT (See page 16-9 )
23.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
24.
CHECK FOR FUEL LEAKS (See page 11-5 )
25.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2024
10-20
ENGINE CONTROL SYSTEM KNOCK SENSOR (3MZ-FE)
26.
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
27.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2025
10-21
ENGINE CONTROL SYSTEM ACCELERATOR PEDAL ASSY (3MZ-FE (NORMAL
PEDAL))
100J8-01
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
(a)
(b)
2.
REMOVE ACCELERATOR PEDAL ASSY
(a) Disconnect the accelerator position sensor connector.
(b) Remove the 2 bolts, then remove the accelerator pedal rod.
(b)
A86338
3.
INSTALL ACCELERATOR PEDAL ASSY
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
4.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
5.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2026
10-22
ENGINE CONTROL SYSTEM ECM (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
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 )
100J9-02
(b)
5.
REMOVE STEREO COMPONENT AMPLIFIER ASSY
(a) Disconnect the 3 stereo component amplifier connectors.
(b) Remove the 2 nuts, then remove the stereo component amplifier.
(a)
(c)
(b)
(b)
(b)
(b)
(b)
(c)
(a)
(a)
(a) (b)
A86255
A86256
6.
REMOVE ECM
(a) Remove the wire harness clamp.
(b) Disconnect the 5 ECM connectors.
(c) Remove the 2 nuts, then remove the ECM.
7.
REMOVE ECM BRACKET
(a) Remove the 2 screws, then remove the ECM bracket.
(a)
(a)
A86257
8.
REMOVE ECM BRACKET NO.2
(a) Remove the 2 screws, then remove the ECM bracket No.
2.
(a)
(a)
A86258
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2027
10-23
ENGINE CONTROL SYSTEM ECM (3MZ-FE)
9.
REMOVE ECM BRACKET NO.3
(a) Remove the 2 screws, then remove the ECM bracket No
3.
(a)
(a)
A86259
10.
INSTALL ECM BRACKET NO.3
11.
INSTALL ECM BRACKET NO.2
12.
INSTALL ECM BRACKET
13.
INSTALL ECM
Torque: 5.5 N
⋅ m (56 kgf
⋅ cm, 49 in.
⋅ lbf)
14.
INSTALL STEREO COMPONENT AMPLIFIER ASSY
Torque: 5.5 N
⋅ m (56 kgf
⋅ cm, 49 in.
⋅ lbf)
15.
INSTALL INSTRUMENT PANEL SUB-ASSY LOWER
16.
INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1
17.
INSTALL FRONT DOOR SCUFF PLATE RH
18.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
19.
RESET MEMORY (See page 05-604 )
20.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2028
11-1
FUEL FUEL SYSTEM (3MZ-FE)
110XR-01
PRECAUTION
1.
PRECAUTION
(a) Before working on the fuel system, disconnect the engine wire No. 3 (battery negative terminal) from battery.
(b) Do not smoke or work near open flame when working on the fuel system.
(c) Keep gasoline away from the rubber or leather parts.
2.
DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
Do not disconnect any parts of the fuel system pressure until you have discharging the fuel system pressure.
Even after discharge the fuel pressure, place a shop rag over fittings as you separate them in order to reduce risk of fuel spray on yourself or in the engine compartment.
(a) Disconnect the engine wire No. 3 (battery negative terminal).
Circuit Opening Relay
A62391
(b) Remove the circuit opening relay from the engine room relay block.
(c) Connect the engine wire No. 3 (battery negative terminal).
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
(d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
HINT:
There is a case that DTC P0171 (system to lean) is output.
(e) Check that the engine does not start.
(f) Remove the fuel tank cap, then let the air out of the fuel tank.
(g) Disconnect battery negative terminal.
(h) Reinstall the circuit opening relay.
3.
FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. So observe these procedures.
(1) Work in order to prevent gasoline from spilling out.
(2) Disconnect the fuel pump tube (see page 11-20 ).
(3) Drain the fuel remaining inside the fuel pump tube.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2029
11-2
FUEL FUEL SYSTEM (3MZ-FE)
(4) In order to prevent the disconnected fuel pump tube from being damaged and foreign objects from being introduced, cover the disconnected fuel pump tube with a vinyl or plastic bag.
(5) Place a tray under the vehicle or point of disconnection to catch any fuel that may spill.
B00679
(6) Put a container under the connection.
New O-ring
Grommet Delivery Pipe
Injector
CORRECT
WRONG
FI6372
(b) Take the following precautions when removing and installing the fuel injectors.
NOTICE:
Never reuse the O-ring.
(1) When installing a new O-ring on the fuel injector, be careful not to damage it.
(2) Coat a new O-ring with spindle oil or gasoline before installing. Never use engine oil, gear oil or brake oil.
Delivery Pipe
B00347
O-ring
Grommet
Spacer
(c) Install the fuel injector to the fuel delivery pipe and intake manifold as shown in the illustration. Before installing the fuel injector, be sure to apply spindle oil or gasoline to the place where the fuel delivery pipe or intake manifold touches the O-ring of the fuel injector.
Insulator
A62371
(d) Take the following precautions when disconnecting the quick connector.
(1) Remove the fuel pipe clamp.
(2) Check the pipe and around the quick connector for dirt or mud before disconnecting them. Remove the dirt if necessary.
Fuel Pipe
Clamp
A60083
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2030
A
11-3
FUEL FUEL SYSTEM (3MZ-FE)
(3) Disconnect the quick connector from the pipe while pinching portion A with your fingers as shown in the illustration.
A
Vinyl Bag
B12941
B12944
(4) If the quick connector and pipe are stuck, pinch the pipe, then push and pull the quick connector to release and pull it out.
NOTICE:
Do not use any tools.
(5) If there is dirt or any other substances on the sealing surface that might interfere with the seal, clean the area thoroughly before assembling.
(6) In order to prevent the disconnected pipe and quick connector from damage or dirt, cover them with a vinyl or plastic bag.
Push
Pull
A52581
A71366
(e) Take the following precautions when connecting the quick connector.
(1) Check the connected part of the pipe for damage or foreign objects.
(2) Align the axis of the quick connector with the axis of the pipe, then push into the quick connector until the quick connector makes a ”click” sound. In case that the connection is tight, apply a little amount of fresh engine oil to the tip of the pipe.
(3) After connecting, check if the pipe and quick connector are securely connected by pulling on them.
(4) Install the fuel pipe clamp.
(5) Check if there is any leakage.
A71366
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2031
11-4
FUEL FUEL SYSTEM (3MZ-FE)
4.
CHECK FOR FUEL LEAKS
(a) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system (see page
11-5 ).
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2032
ON-VEHICLE INSPECTION
FUEL FUEL SYSTEM (3MZ-FE)
11-5
110XS-01
Fuel Tube Connector
A50710
1.
CHECK FUEL PRESSURE
(a) Discharge the fuel pressure and take precautions against possible fuel spillage (see page 11-1 ).
(b) Check that tha battery voltage is above 12 V.
(c) Disconnect the engine wire No. 3 (battery negative terminal).
(d) Pull out the fuel tube connector from a new fuel tube.
HINT:
Part No. 23801-20190
(e) Remove the fuel pipe clamp.
Fuel Pipe
Clamp
A
A
A60083
B12941
(f) Disconnect the quick connector from the fuel pipe by pinching portion A with your fingers as shown in the illustration.
CAUTION:
After taking the precautions, disconnect the quick connector.
As pressure remains in the fuel line, prevent it from splashing inside the engine compartment.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2033
11-6
SST
(T-joint)
SST
(Hose)
SST
(Hose)
SST
FUEL FUEL SYSTEM (3MZ-FE)
(g) Install SST (a pressure gauge) and fuel tube connector using SST as shown in the illustration.
SST 09268-41047 (95336-08070), 09268-45014
(09268-41250, 09268-41200, 09268-41220)
(h) Wipe up any gasoline.
(i) Reconnect the engine wire No. 3 (battery negative terminal).
Fuel Inlet Tube
Fuel Tube
Connector
Hand-held Tester
DLC3
A71359
A86347
(j) Connect the hand-hand tester to the DLC3.
(k) Measure the fuel pressure.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2
, 44 to 50 psi)
If the pressure is high, replace the fuel pressure regulator.
If the pressure is low, check the fuel hose connections, fuel pump, fuel filter and fuel pressure regulator.
(l) Disconnect the hand-held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2
, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/cm
2
, 21 psi) or more
If the pressure is not as specified, check the fuel pump, pressure regulator and/or fuel injectors.
(q) After checking the fuel pressure, disconnect the battery negative terminal and carefully remove SST and the fuel tube connector to prevent gasoline splash.
(r) Reconnect the No. 1 fuel pipe (the fuel tube connector).
CAUTION:
After taking the precautions, connect the quick connector.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2034
DLC3
Hand-held Tester
FP
+B
A86347
11-7
FUEL FUEL SYSTEM (3MZ-FE)
2.
CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand-held tester.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON and the hand-held tester ON.
NOTICE:
Do not start the engine.
(3) Select the ACTIVE TEST mode on the hand-held tester.
(4) If you need help to select the ACTIVE TEST mode on the hand-held tester, refer to the hand-held tester operator’s manual.
A62390
(b) When not using the hand-held tester.
(1) Remove the circuit opening relay.
(2) Using a service wire, connect terminals FP and +B of the engine room relay block.
NOTICE:
Pay due attention to the terminal connecting position to avoid a malfunction.
(3) Turn the ignition switch ON, and check that the fuel pump operates.
NOTICE:
Do not start the engine.
(c) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2035
11-8
INSPECTION
Fuel Tube Connector
FUEL FUEL SYSTEM (3MZ-FE)
110XT-02
1.
INSPECT FUEL INJECTOR ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 - 2
Specified Condition
13.4 to 14.2
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the fuel injector.
(b) Check the operation.
CAUTION:
This test involves high-pressure fuel and electricity.
Keep the injector free of sparks during the test.
Take every precaution regarding safe handling of both the fuel and electricity.
Perform this test in a safe area, and avoid any sparks or flame.
Do not smoke.
(1) Pull out the fuel tube connector from a new fuel tube.
HINT:
Part No. 23801 - 20190
Fuel Tube Connector
SST
(Hose)
A50710
(2) Connect SST and the fuel tube connector to the fuel
SST
CAUTION: pipe.
09268-41047 (95336-08070)
After taking the precautions, connect the quick connector.
B12947
SST
(Union)
O-ring
Vinyl Tube
SST
(Hose)
SST
(Clamp)
A86391
(3) Install the grommet and O-ring to the fuel injector.
(4) Connect SST (a union and hose) to the fuel injector, then hold the fuel injector and union with SST (a clamp).
SST 09268- 41047 (09268- 41110, 09268- 41300,
95336-08070)
(5) Put the fuel injector into a graduated cylinder.
HINT:
Install a suitable vinyl tube to the fuel injector to contain the gasoline spray.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2036
FUEL FUEL SYSTEM (3MZ-FE)
(6) Operate the fuel pump (see page 11-5 ).
11-9
SST
A86390
(7) Connect SST (a wire) to the fuel injector and battery for 15 seconds, then measure the injection volume with the graduated cylinder. Test each fuel injector
2 or 3 times.
SST 09842-30070
Standard:
Injection Volume
60 to 73 cm 3 (3.7 to 4.5 cu in.) per 15 seconds
Difference between Cylenders
13 cm 3 (0.8 cu in.) or less
NOTICE:
Always do the switching at the battery side.
If the injection volume is not as specified, replace the fuel injector.
(c) Inspect the leakage.
(1) In the condition of step (7), disconnect the test probes of SST (a wire) from the battery, then check the fuel leakage from the fuel injector.
Fuel drop: 1 drop or less per 12 minutes
If the fuel drop is not as specified, replace the fuel injector.
B05331
Ohmmeter
2.
INSPECT FUEL PUMP
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 - 2
Specified Condition
0.2 to 3.0
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the fuel pump.
A84685
Battery
A84686
(b) Check the operation.
(1) Apply battery positive voltage across the terminals.
(2) Check that the fuel pump operates.
NOTICE:
These tests must be performed quickly (within 10 seconds) to prevent burnout of the coil.
Keep the fuel pump as far away from the battery as possible.
Always do the switching at the battery side.
If the operation is not as specified, replace the fuel pump.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2037
11-10
FUEL FUEL INJECTOR ASSY (3MZ-FE)
COMPONENTS x2
80 (816, 59)
Spacer
7.9 (81, 70 in.
⋅ lbf) x3
W/O TEMS:
Front Suspension Upper Brace Center
110XU-01
V-bank Cover Sub-assy x2
80 (816, 59)
Spacer
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Vacuum Hose
Vacuum Hose
5.0 (51, 44 in.
⋅ lbf)
Author:
Fuel Vapor Feed Hose
Assy
Mass Air Flow
Meter Connector
Air Cleaner Cap
Sub-assy
Air Cleaner Filter
Element Sub-assy
A86358
Date: 2038
11-1 1
FUEL FUEL INJECTOR ASSY (3MZ-FE)
VSV Connector x2
8.0 (82, 71 in.
⋅ lbf)
7.8 (80, 69 in.
⋅ lbf)
Pressure Feed
Tube Assy x2
Emission
Control Valve Set
Fuel Vapor Feed Hose
Bond Cable No. 1
Connector
Emission Control Valve Bracket
28 (286, 21)
28 (286, 21) x3 x2
Engine Hunger No. 1
20 (199, 14) x2
20 (199, 14) x2
Surge Tank Stay
No. 1 x2
20 (199, 14)
Intake Air Surge Tank
Surge Tank Stay
No. 2
Union to Check Valve Hose
Throttle Motor Connector
Air Surge Tank
to Intake Manifold
Gasket
Water By-pass Hose No. 3
Water By-pass Hose No. 2
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86260
2039
11-12
FUEL FUEL INJECTOR ASSY (3MZ-FE)
Fuel Injector O-ring
Fuel Injector Grommet
Fuel Injector Assy
10 (102, 7)
Connector
Fuel Delivery Pipe
Sub-assy
Fuel Injector
Injector Vibration Insulator
Delivery Pipe No. 1 Spacer
Fuel Delivery Pipe No. 2
10 (102, 7)
Injector
Vibration Insulator
Fuel Injector
Connector
Fuel Pipe
No. 2 Gasket
Delivery Pipe No. 1 Spacer
20 (199, 14)
Fuel Pump Hose Gasket
Fuel Pressure
Pulsation Damper Assy
33 (331, 24)
Fuel Pipe Sub-assy No. 1
33 (331, 24)
Fuel Pipe No. 2 Union Bolt
N·m (kgf·cm, ft·lbf)
Non-reusable part
: Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86296
2040
11-13
FUEL FUEL INJECTOR ASSY (3MZ-FE)
REPLACEMENT
1.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3.
DRAIN ENGINE COOLANT (See page 16-9 )
4.
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
5.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
6.
REMOVE AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
110XV-01
7.
REMOVE EMISSION CONTROL VALVE SET
(a) Disconnect the 2 VSV connectors.
(b) Remove the wire harness clamp.
(a)
(a)
(b)
(e)
(g)
(c)
(e)
(d)
A79751
(f)
(c) Disconnect the fuel vapor feed hose No. 1.
(d) Disconnect the fuel vapor feed hose No. 2.
(e) Disconnect the 2 vacuum hoses.
(f) Remove the clamp.
(g) Remove the 2 nuts, then remove the emission control valve set.
(g)
(c)
A86300
(d)
(a)
8.
REMOVE INTAKE AIR SURGE TANK
(a) Disconnect the throttle motor connector.
(b) Disconnect the water by-pass hose No. 3.
(c) Disconnect the water by-pass hose No. 2.
(d) Disconnect the union to check valve hose.
(b)
A86297
(e) Disconnect the ventilation hose.
(e)
A79706
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2041
11-14
FUEL FUEL INJECTOR ASSY (3MZ-FE)
(f) Remove the 2 nuts, then remove the pressure feed tube.
(f)
(i)
(h)
(f)
A86298
(g)
(g) Remove the 2 bolts, then remove the engine hunger No.
1.
(h) Remove the 2 bolts, then remove the surge tank stay No.
1.
(i) Remove the 2 bolts, then remove the surge tank stay No.
2.
(i) (h)
(i)
(k)
(l)
(k) (k)
(k)
(l)
(g)
A86299
(j) Disconnect the bond cable No. 1 connector.
(k) Using a socket hexagon wrench 8, remove the 4 bolts.
(l) Remove the 2 nuts, then remove the emission control
(m) valve bracket and intake air surge tank.
Remove the gasket from the intake air surge tank.
(a)
A86301
9.
SEPARATE FUEL PIPE SUB-ASSY NO.1
(a) Remove the fuel pressure pulsation damper and 2 gaskets.
(b) Remove the fuel pipe No. 2 union bolt and 2 gaskets.
(c) Remove the bolt, then separate the fuel pipe No. 1.
(b) (c)
A79710
(a)
(a)
(a)
(a)
(a)
(a)
A86302
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10.
REMOVE FUEL INJECTOR ASSY
(a) Disconnect the 6 fuel injector connectors.
Author: Date: 2042
(b)
(b)
(b)
(b)
11-15
FUEL FUEL INJECTOR ASSY (3MZ-FE)
(b) Remove the 4 bolts, then remove the 2 fuel delivery pipes together with the 6 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
(d)
(d)
(c)
(d)
(c)
(d)
(c)
(c)
(d)
(d)
A86303
(c) Remove the 4 delivery pipe No. 1 spacers from the intake manifold.
(d) Remove the 6 insulators from the intake manifold.
A86304
(e) Pull out the fuel injector from the fuel delivery pipe.
A81137
New O-ring
11.
INSTALL FUEL INJECTOR ASSY
(a) Install new grommets to each fuel injector.
(b) Apply a light coat of spindle oil or gasoline to new O-rings, then install them to each fuel injector.
New Grommet
A79762
Push
Turn
A81139
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Apply a light coat of spindle oil or gasoline to the place where the fuel delivery pipe contacts the O-ring.
(d) Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe.
NOTICE:
Be careful not to twist the O-ring.
After installing the fuel injectors, check that they turn smoothly. If not, replace O-ring with a new O-ring.
Author: Date:
2043
11-16
FUEL FUEL INJECTOR ASSY (3MZ-FE)
(e) Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold.
(f) Place the 2 fuel delivery pipes together with the 6 fuel injectors to the intake manifold.
NOTICE:
Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
(g) Temporarily install the 4 bolts which attach the fuel delivery pipe to the intake manifold.
Turn
(h) Check that the fuel injectors rotate smoothly.
If the fuel injectors do not rotate smoothly, the probable cause
A86305 is incorrect installation of the O-ring. Replace it with a new one.
(i) Tighten the 4 bolts.
Torque: 10 N
⋅ m (102 kgf
⋅ cm, 7 ft
⋅ lbf)
(j) Connect the 6 fuel injector connectors.
12.
INSTALL FUEL PIPE SUB-ASSY NO.1
(a) Install 2 new gaskets and fuel pipe No. 2 union bolt.
Torque: 33 N
⋅ m (331 kgf
⋅ cm, 24 ft
⋅ lbf)
(b) Install 2 new gaskets and fuel pressure pulsation damper.
Torque: 33 N
⋅ m (331 kgf
⋅ cm, 24 ft
⋅ lbf)
(c) Install the fuel pipe No. 1 with the bolt.
Torque: 20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf)
13.
INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket to the intake air surge tank.
(b) Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 N
⋅ m (286 kgf
⋅ cm, 21 ft
⋅ lbf)
(c) Using a socket hexagon wrench 8, tighten the 4 bolts.
Torque: 28 N
⋅ m (286 kgf
⋅ cm, 21 ft
⋅ lbf)
(d) Install the surge tank stay No. 2 with the 2 bolts.
Torque: 20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf)
(e) Install the surge tank stay No. 1 with the 2 bolts.
Torque: 20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf)
(f) Install the engine hunger No. 1 with the 2 bolts.
Torque: 20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf)
(g) Install the pressure feed tube with the 2 nuts.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
(h) Connect the ventilation hose.
(i) Connect the union to check valve hose.
(j) Connect the water by-pass hose No. 2.
(k) Connect the water by-pass hose No. 3.
(l) Connect the throttle motor connector.
14.
INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
15.
INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-1 1 )
16.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
17.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2044
FUEL FUEL INJECTOR ASSY (3MZ-FE)
18.
ADD ENGINE COOLANT (See page 16-9 )
19.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
20.
CHECK FOR FUEL LEAKS (See page 11-5 )
21.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
22.
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See page 10-1 1 )
23.
SYSTEM INITIALIZATION (See page 19-15 )
11-17
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2045
11-18
FUEL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
110XW-02
COMPONENTS
Rear Seat Cushion Assy
Fuel Pump Connector
5.9 (60, 52 in.
⋅ lbf) x8
Fuel Tank Bent Tube Set Plate
Fuel Suction w/ Pump & Gauge Tube Assy
Rear Floor Service Hole Cover
Vapor Pressure Sensor Connector
Fuel Pump Tube Sub-assy
Tube Joint Clip
Fuel Suction Tube Set Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2046
Fuel Suction Plate Sub-assy
FUEL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
11-19
Vapor Pressure Sensor Assy
Tube Joint Clip
Fuel Pump Harness
Fuel Sender Gauge Assy
Fuel Pressure Regulator
O-ring
Fuel Pressure Regulator Assy
Fuel Tank Fuel Filter
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Fuel Pump Assy
Fuel Pump Filter
Fuel Pump Filter Clip
Fuel Pump Cushion Rubber
Fuel Suction Support No. 2
Author: Date:
2047
11-20
FUEL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
Removal & Installation and Disassembly & Reassembly
1.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3.
REMOVE REAR SEAT CUSHION ASSY (See page 72-39 )
(c)
110XX-02
4.
REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Remove the rear floor service hole cover.
(b) Disconnect the vapor pressure sensor connector.
(c) Disconnect the fuel pump connector.
(b)
Fuel Tube Joint
Tube Joint Clip
(b)
A79487
Tube Joint Clip
Nylon Tube
A79488
5.
REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY
(a) Remove the tube joint clip, then pull out the fuel pump tube.
NOTICE:
Check around the connector for dirt or mud before this operation. Remove the dirt if necessary.
Be careful of mud because the fuel tube joint has an
O-ring which seals the pipe and connector that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull the connector to release. Pull the connector carefully.
O-ring
Fuel Suction Plate
A91017
(b)
(b)
(b) Remove the 8 bolts, then remove the fuel tank vent tube set plate.
(b)
(b)
(b)
(b)
(b)
A79489
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2048
Tape
FUEL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
11-21
(c) Remove the fuel suction tube w/ pump & gauge from the fuel tank.
NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gauge.
(d) Remove the gasket from the fuel suction tube w/ pump & gauge.
A79490
Cover
Tube Joint Clip
6.
REMOVE VAPOR PRESSURE SENSOR ASSY
(a) Remove the cover.
(b) Remove the tube joint clip, then pull out the vapor pressure sensor.
A79491
7.
REMOVE FUEL SUCTION SUPPORT NO.2
(a) Using a screwdriver with the tip wrapped in tape, unfasten the 5 claws. Then remove the fuel suction support No. 2.
NOTICE:
Do not damage the fuel suction support No. 2.
A77832
8.
REMOVE FUEL PUMP CUSHION RUBBER
Tape
A79492
(a)
Slide
9.
REMOVE FUEL SENDER GAUGE ASSY
(a) Disconnect the fuel sender gauge connector.
(b) Using a screwdriver with the tip wrapped in tape, unfasten the clamp to release the fuel sender gauge. Then slide the fuel sender gauge to remove it from the fuel pump.
A79494
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2049
11-22
Tape
(a)
(b)
FUEL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
10.
REMOVE FUEL SUCTION PLATE SUB-ASSY
(a) Disconnect the fuel pump connector.
(b) Using a screwdriver with the tip wrapped in tape, unfasten the 4 claws. Then pull out the fuel suction plate.
NOTICE:
Do not damage the fuel suction plate.
A79493
11.
REMOVE FUEL PUMP HARNESS
(a) Disconnect the connector.
(b) Using a small screwdriver, pry out the fuel pump harness.
(a)
(b)
A79495
12.
REMOVE FUEL PUMP
(a) Pull out the fuel pump from the fuel tank fuel filter.
A79496
13.
REMOVE FUEL PUMP FILTER
(a) Using a small screwdriver, pry out the clip.
(b) Pull out the fuel pump filter from the fuel pump.
A79497
14.
REMOVE FUEL PRESSURE REGULATOR ASSY
(a) Pull out the fuel pressure regulator from the fuel tank fuel filter.
(b) Remove the O-ring from the fuel pressure regulator.
A65037
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2050
New O-ring
FUEL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
11-23
15.
INSTALL FUEL PRESSURE REGULATOR ASSY
(a) Apply a light coat of spindle oil or gasoline to a new Oring, then install it to the fuel pressure regulator.
(b) Push in the fuel pressure regulator to the fuel tank fuel filter.
A65038
16.
INSTALL FUEL PUMP FILTER
(a) Install the fuel pump filter with a new clip.
O-ring
17.
INSTALL FUEL PUMP
(a) Apply a light coat of gasoline or spindle oil to the O-ring on the fuel pump.
(b) Push in the fuel pump to the fuel tank fuel filter.
A65040
18.
INSTALL FUEL PUMP HARNESS
19.
INSTALL FUEL SUCTION PLATE SUB-ASSY
20.
INSTALL FUEL SENDER GAUGE ASSY
21.
INSTALL FUEL PUMP CUSHION RUBBER
22.
INSTALL FUEL SUCTION SUPPORT NO.2
Cover
23.
INSTALL VAPOR PRESSURE SENSOR ASSY
(a) Install the vapor pressure sensor with the tube joint clip.
NOTICE:
Tube Joint Clip
A86272
Check the connected part for scratch or foreign objects.
Check that the vapor pressure sensor is inserted securely.
Check that the tube joint clip is on the collar of the vapor pressure sensor.
After installing the tube joint clip, check that the vapor pressure sensor has not been pulled off.
(b) Install the cover.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2051
11-24
Mark
A79489
FUEL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (3MZ-FE)
24.
INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY
(a) Install a new gasket to the fuel suction tube w/ pump & gauge.
(b) Install the fuel suction tube w/ pump & gauge to the fuel tank.
NOTICE:
Do not damage the fuel pump filter.
Do not bend the arm of the fuel sender gauge.
(c) Align the mark of the fuel tank vent tube set plate with the fuel suction tube w/ pump & gauge.
(d) Install the fuel tank bent tube set plate with the 8 bolts.
Torque: 5.9 N
⋅ m (60 kgf
⋅ cm, 52 in.
⋅ lbf)
Collar
Tube Joint Clip
A81595
(e) Install the fuel pump tube with the tube joint clip.
NOTICE:
Check the connected part for scratch or foreign objects.
Check that the fuel tube joint is inserted securely.
Check that the tube joint clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel tube joint has not been pulled off.
25.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
26.
CHECK FOR FUEL LEAKS (See page 11-5 )
27.
INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the fuel pump connector.
(b) Connect the vapor pressure sensor connector.
(c) Using new butyl tape, install the rear floor service hole cover.
New Butyl Tape
A79487
28.
INSTALL REAR SEAT CUSHION ASSY
29.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2052
FUEL FUEL TANK ASSY (3MZ-FE)
COMPONENTS
11-25
110XY-01
Rear Seat Cushion Assy
Fuel Pump Connector
5.9 (60, 52 in.
⋅ lbf) x8
Fuel Tank Bent Tube Set Plate
Fuel Suction w/ Pump & Gauge Tube Assy
Rear Floor Service Hole Cover
Vapor Pressure Sensor Connector
Fuel Pump Tube Sub-assy
Tube Joint Clip
Fuel Suction Tube Set Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2053
11-26
FUEL FUEL TANK ASSY (3MZ-FE)
Fuel Tube No. 1
Fuel Tank Inlet Pipe
Sub-assy
Fuel Tank Assy
Fuel Tank Protector Lower Center
5.4 (55, 48 in.
⋅ lbf) x4
Fuel Tank Band Sub-assy No. 1 RH
Pin
39 (400, 29) 39 (400, 29)
Fuel Tank Band Sub-assy No. 1 LH
5.4 (55, 48 in.
⋅ lbf)
Parking Brake Cable Assy No. 2
Pin
5.4 (55, 48 in.
⋅ lbf)
Exhaust Pipe Gasket
5.4 (55, 48 in.
⋅ lbf)
Parking Brake Cable Assy No. 3
5.4 (55, 48 in.
⋅ lbf)
Exhaust Pipe Assy Center x2
56 (571, 41)
Exhaust Pipe Gasket x2
Floor Panel Brace Rear
20 (199, 14) x2
56 (571, 41)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86273
2054
Fuel Tank Cushion
No. 2 x7
Clip Nut x4
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
11-27
FUEL FUEL TANK ASSY (3MZ-FE)
Fuel Pump Tube Sub-assy
Fuel Tank Vent Hose
Fuel Tank Assy
5.4 (55, 48 in.
⋅ lbf)
Fuel Main Tube Support
A79483
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2055
11-28
FUEL FUEL TANK ASSY (3MZ-FE)
110XZ-01
Removal & Installation and Disassembly & Reassembly
1.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3.
REMOVE REAR SEAT CUSHION ASSY (See page 72-39 )
4.
REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
5.
REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20 )
6.
DRAIN FUEL
7.
REMOVE FLOOR PANEL BRACE REAR (See page 15-2 )
8.
REMOVE EXHAUST PIPE ASSY CENTER
(a) Remove the 2 bolts and 4 nuts.
(b) Remove the exhaust pipe center and 2 gaskets from the
2 exhaust pipe supports.
(b)
(b)
(a)
(a)
(a)
(a)
A86274
9.
DISCONNECT PARKING BRAKE CABLE ASSY NO.2
(a) Remove the bolt and nut, then disconnect the parking brake cable No. 2.
A79472
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2056
11-29
FUEL FUEL TANK ASSY (3MZ-FE)
10.
DISCONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Remove the bolt and nut, then disconnect the parking brake cable No. 3.
A79473
11.
REMOVE FUEL TANK PROTECTOR LOWER CENTER
(a) Remove the 4 bolts, then remove the fuel tank protector lower center.
Pull Out
Pinch
Pinch
Quick Connector
Nylon Tube
O-ring
A79476
Retainer
Retainer
A79474
Pipe
12.
REMOVE FUEL TANK ASSY
(a) Disconnect the fuel pump tube.
(1) Pinch the projection of the retainer to remove the lock claws, then pull it down as shown in the illustration.
(2) Pull out the fuel pump tube.
NOTICE:
Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
Be careful of mud because the quick connector has an O-ring which seals the pipe and quick connector that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the quick connector by covering it with a vinyl or plastic bag.
When the pipe and quick connector are stuck, push and pull the quick connector to release. Pull out the quick connector from the pipe.
A81596
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2057
11-30
Pinch
Nylon Tube
Pull Out
Pinch
A86275
Tube Connector
FUEL FUEL TANK ASSY (3MZ-FE)
(b) Disconnect the fuel tube No. 1.
(1) Pinch the tube connector, then pull out the fuel tube
No. 1.
NOTICE:
Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
Be careful of mud because the quick connector has an O-ring which seals the pipe and quick connector that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the quick connector by covering it with a vinyl or plastic bag.
When the pipe and quick connector are stuck, push and pull the quick connector to release. Pull out the quick connector carefully.
Quick Connector
O-ring
(d)
Pinch
(d)
Pipe
A75650
(e)
(c) Set up a transmission jack underneath the fuel tank.
(d) Remove the 2 bolts which hold the fuel tank bands.
(e) Loosen the clamp bolt.
(f) Operate the transmission jack, then disconnect the fuel tank inlet pipe.
(g) Disconnect the fuel tank vent hose from the charcoal canister.
(1) Deeply push the quick connector to release the lock pin.
(2) Pinch portion A.
(3) Pull out the fuel tank vent hose.
(h) Operate the transmission jack, then remove the fuel tank.
A
Push
Pinch
A
A86276
(i) Remove the 2 pins, then remove the 2 fuel tank bands as shown in the illustration.
A79478
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2058
11-31
(j) (j)
FUEL FUEL TANK ASSY (3MZ-FE)
(j) Remove the 4 clip nuts.
(j)
Pinch
Push A
Pinch
A
(j)
A79482
13.
REMOVE FUEL TANK VENT HOSE
(a) Deeply push the quick connector to release the lock pin.
(b) Pinch portion A.
(c) Pull out the fuel tank vent hose.
A86277
14.
REMOVE FUEL PUMP TUBE SUB-ASSY
(a) Remove the fuel pump tube from the fuel main tube support.
A79480
15.
REMOVE FUEL MAIN TUBE SUPPORT
(a) Remove the bolt, then remove the fuel main tube support.
A79481
16.
REMOVE FUEL TANK CUSHION NO.2
(a) Remove the 7 fuel tank cushions from the fuel tank.
A79484
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2059
11-32
FUEL FUEL TANK ASSY (3MZ-FE)
17.
INSTALL FUEL TANK CUSHION NO.2
(a) Install 7 new fuel tank cushions to the fuel tank.
18.
INSTALL FUEL MAIN TUBE SUPPORT
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
19.
INSTALL FUEL PUMP TUBE SUB-ASSY
Push
Push
Push
A86279
20.
INSTALL FUEL TANK VENT HOSE
(a) Push in the quick connector to the pipe until the quick connector makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the quick connector and pipe are securely connected by pulling on them.
21.
INSTALL FUEL TANK ASSY
(a) Install the 4 clip nuts.
(b) Install the 2 fuel tank bands with the 2 pins.
(c) Set up the fuel tank to the transmission jack.
(d) Connect the fuel tank vent hose to the charcoal canister.
(1) Push in the quick connector to the pipe until the quick connector makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the connector and pipe are securely connected by pulling on them.
(e) Operate the transmission jack, then connect the fuel tank filler pipe.
(f) Tighten the clamp bolt.
(g) Tighten the 2 bolts which hold the fuel tank bands.
Torque: 39 N
⋅ m (400 kgf
⋅ cm, 29 ft
⋅ lbf)
A86339
(h) Connect the fuel tube No. 1.
(1) Push in the quick connector to the pipe until the quick connector makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the quick connector and pipe are securely connected by pulling on them.
A86280
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2060
Push
Retainer
A81598
11-33
FUEL FUEL TANK ASSY (3MZ-FE)
(i) Connect the fuel pump tube.
(1) Push in the quick connector to the pipe until the quick connector makes a ”click” sound, then push up the retainer until the claws lock.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the connector and pipe are securely connected by pulling on them.
22.
INSTALL FUEL TANK PROTECTOR LOWER CENTER
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
23.
INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
24.
INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
25.
INSTALL EXHAUST PIPE ASSY CENTER
(a) Install 2 new gaskets and the exhaust pipe center to the 2 exhaust pipe supports.
(b) Tighten the 2 bolts and 4 new nuts.
Torque: 56 N
⋅ m (571 kgf
⋅ cm, 41 ft
⋅ lbf)
26.
INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20 )
27.
ADD FUEL
28.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
29.
CHECK FOR FUEL LEAKS (See page 11-5 )
30.
CHECK FOR EXHAUST GAS LEAKS
31.
INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
32.
INSTALL REAR SEAT CUSHION ASSY
33.
INSTALL FLOOR PANEL BRACE REAR (See page 15-2 )
34.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2061
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
LOCATION
Ventilation Valve Sub-assy
Vacuum Surge Tank
EVAP Service Port
12-1
120C0-01
VSV for EVAP
Air Fuel Ratio Sensor
(Bank 2 Sensor 1)
Air Fuel Ratio Sensor
(Bank 1 Sensor 1)
Charcoal Canister Assy
Heated Oxygen Sensor
(Bank 2 Sensor 2)
Heated Oxygen Sensor
(Bank 1 Sensor 2)
Fuel Tank Cap Assy
VSV for CCV
Charcoal Canister Filter
Sub-assy
Vapor Pressure Sensor Assy
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86341
2062
12-2
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
Air Cleaner Assy
Ventilation Valve Assy
Air Fuel Ratio Sensor
(Bank 2 Sensor 1)
Vacuum
Surge Tank
VSV for EVAP
EVAP
Service Port
Heated Oxygen Sensor
(Bank 1 Sensor 2)
Purge Line
Heated Oxygen Sensor
(Bank 2 Sensor 2)
Fuel Tank Cap
Assy
Vapor Pressure Sensor
Assy
Air Fuel Ratio Sensor
(Bank 1 Sensor 1)
Vent Line
Fuel Tank Assy
Charcoal Canister Assy
VSV for CCV
Air Inlet Line
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Charcoal Canister Filter
Sub-assy
Date:
A86342
2063
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
12-3
120C1-02
E9
Voltmeter
E8
1.
INSPECT AIR FUEL RATIO COMPENSATION SYSTEM
(a) Inspect the voltage.
(1) Turn the ignition switch ON.
(2) Using a voltmeter, measure the voltage between the terminals of the ECM.
Standard:
Tester Connection
A1A+ (E9-22) - E1 (E8-1)
A1A- (E9-30) - E1 (E8-1)
A2A+ (E9-23) - E1 (E8-1)
A2A- (E9-31) - E1 (E8-1)
Specified Condition
3.3 V
3.0 V
3.3 V
3.0 V
CAUTION:
Connect the test leads from the back side of the ECM connector to the terminals.
HINT:
The voltage between the terminals of the ECM is constant regardless of the voltage output from the air fuel ratio sensor (A/F sensor).
G37992
Hand-held Tester
(b) Check the operation.
(1) Connect the hand-held tester to the DLC3.
(2) Enter ”DIAGNOSIS/ENHANCED OBD II/DATA
LIST”, then select ”AFS B1 S1” and ”AFS B2 S1” to display the monitor.
(3) Warm up the A/F sensor with the engine speed at
2,500 rpm for approximately 2 minutes.
DLC3
A86347
3.3 V
Keep the engine speed
Time
Lean
14.7
Air
Fuel
Rich
Ratio
A86385
(4) Keep the engine speed at 2,500 rpm, then confirm that the waveform of ”AFS B1 S1” and ”AFS B2 S1” are similar as shown in the illustration.
HINT:
The waveform in the illustration is a sample.
Only the hand-held tester displays the waveform of the
A/F sensor.
(c) Confirm that the display of ”DATA LIST” - ”O2S B1 S2” and ”O2S B2 S2” fluctuates up and down between 0 V and 1 V with the engine speed at 2,500 rpm.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2064
12-4
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
2.
INSPECT FUEL CUT OFF RPM
(a) Check the operation.
(1) Increase the engine speed to at least 3,500 rpm.
(2) Use a sound scope to check the fuel injector operating noise.
(3) Check that when the throttle lever is released, the fuel injector operation noise stops momentarily at 2,500 rpm and then resumes at 1,200 rpm.
2,500 rpm: Fuel cut off rpm
1,200 rpm: Fuel return rpm
A86346
3.
VISUALLY INSPECT HOSES, CONNECTIONS AND
GASKETS
(a) Check the appearance.
(1) Check the engine assembly to see if the indicated portions by the arrows have cracks, leaks or damage.
HINT:
Separation of the engine oil level gauge, oil filler cap, PCV hose, etc. may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly.
If necessary, repair the engine assembly.
Vacuum Gauge
4.
INSPECT EVAP SYSTEM LINE
(a) Warm up the engine to the normal operating temperature.
(b) Connect the vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. Then stop the engine.
DLC3
Hand-held Tester
A59499
(c) If you have the hand-held tester:
Force the VSV for EVAP to operate.
(1) Connect the hand-held tester to the DLC3.
(2) Start the engine.
(3) Turn the hand-held tester ON.
(4) Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for EVAP.
A86347
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2065
Battery
Vacuum Gauge
Pressure Gauge
12-5
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
(d) If you have no hand-held tester:
Force the VSV for EVAP to operate.
(1) Disconnect the VSV for EVAP connector.
(2) Connect the positive (+) and negative (-) leads of the battery to the VSV for EVAP terminals.
(3) Start the engine.
A86348
A59500
(e) Check the vacuum at idle.
Vacuum:
Maintain at 0.368 to 19.713 in.Hg (5 to 268 in.Aq) for over 5 seconds.
HINT:
If the vacuum does not change, it can be concluded that the hose which connects the VSV to the service port is loose or blocked, or the VSV is malfunctioning.
(f) If you have the hand-held tester:
Return to the normal VSV for EVAP.
(1) Stop the engine.
(2) Disconnect the hand-held tester from the DLC3.
(g) If you have no hand-held tester:
Return to the normal VSV for EVAP.
(1) Stop the engine.
(2) Disconnect the positive (+) and negative (-) leads of the battery from the VSV for EVAP terminals.
(3) Reconnect the VSV for EVAP connector.
(h) Disconnect the vacuum gauge from the EVAP service port on the purge line.
(i) Connect a pressure gauge to the EVAP service port on the purge line.
A72589
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2066
12-6
DLC3
Hand-held Tester
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
A86347
(j) If you have the hand-held tester:
Force the VSV for CCV to operate.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Turn the hand-held tester ON.
(4) Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for CCV.
NOTICE:
Do not start the engine during this operation.
HINT:
If the check is not completed within 10 minutes, the forced close of the VSV for CCV will be tested.
(k) If you have no hand-held tester:
Force the VSV for CCV to operate.
(1) Disconnect the VSV for CCV connector.
(2) Connect the positive (+) and negative (-) leads of the battery to the VSV for CCV terminals.
Battery
A86349
Fuel Tank Cap
Pressure Gauge
Pressure
A59501
Pressure Gauge
A52634
(l) Check the pressure.
(1) Add the pressure (13.5 to 15.5 in.Aq) from the
EVAP service port.
Pressure:
2 minutes after the pressure is added, the gauge should be over 7.7 to 8.8 in.Aq.
HINT:
If you cannot add the pressure, it can be concluded that the hose which connects the VSV for EVAP canister fuel tank is slipped off or the VSV is open.
(2) Check if the pressure decreases when the fuel tank cap is removed while adding the pressure.
HINT:
If the pressure does not decrease when the filler cap is removed, it can be concluded that the hose which connects the service port to the fuel tank is blocked, etc.
(m) If you have the hand-held tester:
Return to the normal VSV for CCV operation.
(1) Turn the ignition switch ON.
(2) Disconnect the hand-held tester from the DLC3.
(n) If you have no hand-held tester:
Return to the normal VSV for CCV operation.
(1) Disconnect the positive (+) and negative (-) leads of the battery to the VSV for CCV terminals.
(2) Reconnect the VSV for CCV connector.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2067
Pressure Gauge
12-7
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
(o) Disconnect the pressure gauge from the EVAP service port on the purge line.
A86387
5.
CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER
PIPE
(a) Check the operation.
(1) Remove the fuel tank (see page 11-28 ).
(2) Remove the fuel tank vent hose from the fuel tank
(see page 11-28 ).
(3) Connect the pressure gauge to the fuel tank vent hose port of the fuel tank.
(4) Apply pressure to the fuel tank, so that the internal pressure of the fuel tank is 4 kPa (41 gf/cm
2
, 0.58
psi).
(5) Check that the internal fuel tank pressure is maintained for 1 minute.
(6) Check the connected portions of each hose and pipe.
(7) Check the installed parts on the fuel tank.
If there is no abnormality, replace the fuel tank and fuel tank filler pipe.
(8) Reinstall the fuel tank vent hose to the fuel tank (see page 11-28 ).
(9) Reinstall fuel tank (see page 11-28 ).
Pressure Gauge
A86386
6.
INSPECT FUEL CUT OFF VALVE AND FILL CHECK
VALVE
(a) Check the operation.
(1) Remove the fuel tank (see page 11-28 ).
(2) Remove the fuel tank vent hose from the fuel tank
(see page 11-28 ).
(3) Connect the pressure gauge to the fuel tank vent hose port of the fuel tank.
(4) Fully fill the fuel tank with fuel.
HINT:
In the condition that the fuel is full, there is no ventilation as the float valve of the fill check valve is closed.
(5) Install the fuel suction w/ pump & gauge tube (see page 11-20 ).
(6) Securely cover the fuel pump tube, fuel tube No. 1 port and fuel tank to filler pipe port with vinyl or plastic bags to perform the accurate pressure test.
(7) Apply 4 kPa (41 gf/cm
2
, 0.58 psi) of pressure to the fuel tank vent hose port of the fuel tank.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2068
12-8
Air
Voltmeter
E10
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
(8) Remove the vinyl or plastic bag from the fuel tank to filler pipe port, then check that the pressure drops.
If the pressure does not drop, replace the fuel tank.
(9) Drain fuel from the fuel tank.
(10) Reinstall the fuel tank vent hose to the fuel tank (see page 11-28 ).
(11) Reinstall the fuel tank (see page 11-28 ).
7.
CHECK AIR INLET LINE
(a) Disconnect the fuel tank vent hose (see page 12-18 ).
(b) Check that there is ventilation in fuel tank vent hose.
If necessary, replace the charcoal canister filter.
(c) Reconnect the fuel tank vent hose (see page 12-18 ).
A86352
8.
INSPECT VAPOR PRESSURE SENSOR
(a) Inspect the voltage (power source).
(1) Turn the ignition switch ON.
(2) Using a voltmeter, measure the voltage between the terminals of the ECM.
Voltage:
Tester Connection
VC (E10-18) - E2 (E10-28)
Specified Condition
4.5 to 5.5 V
CAUTION:
Connect the test leads from the back side of the ECM connector to the terminals.
(3) Turn the ignition switch OFF.
A86344
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2069
E10
Voltmeter
E6
12-9
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
(b) Inspect the voltage (power output).
(1) Turn the ignition switch ON.
(2) Remove the fuel tank cap.
(3) Using a voltmeter, measure the voltage between the terminals of the ECM.
Voltage:
Tester Connection Specified Condition
PTNK (E6-21) - E2 (E10-28) 3.0 to 3.6 V
CAUTION:
Connect the test leads from the back side of the ECM connector to the terminals.
(4) Reinstall the fuel tank cap.
(5) Turn the ignition switch OFF.
G37993
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2070
12-10
INSPECTION
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
120C2-01
Cylinder Head Side:
Clean Hose
A59511
1.
INSPECT VENTILATION VALVE SUB-ASSY
(a) Check the operation.
(1) Install a clean hose as shown in the illustration.
(2) Blow air into the cylinder head side, then check that air passes through easily.
CAUTION:
Do not suck air through the ventilation valve. Petroleum substances inside the ventilation valve are harmful.
Intake Manifold Side:
(3) Blow air into the intake manifold side, then check that air passes through with difficulty.
If the operation is not as specified, replace the ventilation valve.
Clean Hose
A59512
2.
INSPECT FUEL TANK CAP ASSY
(a) Check the appearance.
(1) Visually check if the fuel tank cap and gasket are deformed or damaged.
If necessary, replace the fuel tank cap.
Gasket
A76682
3.
INSPECT CHARCOAL CANISTER ASSY
(a) Check the appearance.
(1) Visually check the charcoal canister to see if the indicated portions by the arrows are cracked or damaged.
If necessary, replace the charcoal canister.
A86329
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2071
Purge Port
Air Inlet Port
12-1 1
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
(b) Check the operation.
(1) While holding the purge port closed, blow air (0.39
kPa (4.0 gf/cm
2
, 0.06 psi)) into the vent port, then check that the air flows from the air inlet port.
If the operation is not as specified, replace the charcoal canister.
Vent Port
Air
A86330
Air Inlet Port check that the air flows from the purge port.
If the operation is not as specified, replace the charcoal canister.
(2) While holding the air inlet port closed, blow air (0.39
kPa (4.0 gf/cm
2
, 0.06 psi)) into the vent port, then
Purge Port
Vent Port
Purge Port
Air
A86331
Air Inlet Port
(3) While holding the air inlet port closed, apply vacuum
(3.43 kPa (25.7 mm/Hg, 1.01 in.Hg)) to the vent port, then check that the air is sucked from the purge port.
If the operation is not as specified, replace the charcoal canister.
Vent Port
Vacuum
A86332
Purge Port
Vent Port
Air Inlet Port
Vacuum
A86333
(c) Check the air tightness.
(1) While holding the vent and air inlet ports closed, apply vacuum (3.43 kPa (25.7 mmHg, 1.01 in.Hg)) to the purge port, then check that the vacuum is maintained for 1 minute.
HINT:
In order to maintain air tightness, the check should be performed with the VSV (for CCV) terminal port held closed by your finger.
If the operation is not as specified, replace the charcoal canister.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2072
12-12
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
(d) Inspect the diaphragm.
(1) Remove the air hose.
A86334
A
Vacuum
Purge Port
B
Air Inlet Port
(2) While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa (11 mmHg, 0.42
in.Hg)) into port A, then check that the air is sucked from port B.
If the operation is not as specified, replace the charcoal canister.
Vent Port
A86335
A
Vacuum
Purge Port
B Air Inlet Port
(3) While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa (11 mmHg, 0.42
in.Hg)) into port A, then measure how long it takes for vacuum to drop.
Vacuum drop time: 10 seconds or longer
If the operation is not as specified, replace the charcoal canister.
(4) Reinstall the air hose.
Vent Port
A86336
(e) Disconnect the air hose.
(f) Remove the 2 bolts, then remove the VSV.
(f)
(f)
(e)
A86337
Ohmmeter
A86286
(g) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 - 2
1 - 2
Specified Condition
25 to 30
Ω
at 20 C (68 F)
32 to 40
Ω
at 100 C (212 F)
If the resistance is not as specified, replace the charcoal canister.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2073
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
(h) Check the operation.
(1) Check that air flows from port A to B and C.
12-13
B
C
A
Valve
Closed
Air
A86287
(2) Apply battery voltage across the terminals.
(3) Check that the valve is closed.
B
C
A
Battery
A86288
(4) Check that air does not flow from port A to B.
(5) Check that air flows from port A to C.
If the operation is not as specified, replace the charcoal canister.
(i) Install the VSV with the 2 bolts.
(j) Connect the air hose.
Air
Battery
A86289
Air
Ohmmeter
A86290
4.
INSPECT VACUUM SWITCHING VALVE ASSY NO.1
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 - 2
Specified Condition
26 to 30
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the vacuum switching valve No. 1.
(b) Check the operation.
(1) Check that air does not flow from port E to F.
E
F
A86292
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2074
12-14
Air
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to F.
If the operation is not as specified, replace the vacuum switching valve No. 1.
E
F
Battery
A86293
Ohmmeter
A86294
5.
INSPECT AIR FUEL RATIO SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 (HT) - 2 (+B)
Specified Condition
1.8 to 3.4
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the air fuel ratio sensor.
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between terminals 2 (+B) and 4 (AF-).
If there is continuity, replace the air fuel ratio sensor.
Ohmmeter
Bank 1 Sensor 2 Bank 2 Sensor 2
6.
INSPECT HEATED OXYGEN SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
1 (HT) - 2 (+B)
Specified Condition
11 to 16
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the heated oxygen sensor.
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between terminals 1 (HT) and 4 (E).
If there is continuity, replace the heated oxygen sensor.
A86295
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2075
Battery
Ohmmeter
12-15
EMISSION CONTROL EMISSION CONTROL SYSTEM (3MZ-FE)
A84683
7.
INSPECT AIR FUEL RATIO SENSOR HEATER RELAY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
3 - 5
3 - 5
Specified Condition
10 k
Ω
or higher
Below 1
Ω
(Apply battery voltage to terminals 1 and 2
If the result is not as specified, replace the air fuel ratio sensor heater relay.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2076
12-16
EMISSION CONTROL CHARCOAL CANISTER ASSY (3MZ-FE)
REPLACEMENT
1.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3.
REMOVE REAR SEAT CUSHION ASSY (See page 72-39 )
4.
REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
5.
REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20 )
6.
DRAIN FUEL
7.
REMOVE FLOOR PANEL BRACE REAR (See page 15-2 )
8.
REMOVE EXHAUST PIPE ASSY CENTER (See page 11-28 )
9.
DISCONNECT PARKING BRAKE CABLE ASSY NO.2 (See page 11-28 )
10.
DISCONNECT PARKING BRAKE CABLE ASSY NO.3 (See page 11-28 )
11.
REMOVE FUEL TANK PROTECTOR LOWER CENTER (See page 11-28 )
12.
REMOVE FUEL TANK ASSY (See page 11-28 )
120BT-01
(b)
(b)
(c)
13.
REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the VSV connector.
(b) Remove the 2 wire harness clamps.
(c) Disconnect the fuel hose No. 1.
(a)
A86270
A
Push
Pinch
A
Pinch
A86393
(d) Disconnect the fuel tank vent hose.
(1) Deeply push the quick connector to release the lock pin.
(2) Pinch portion A.
(3) Pull out the fuel tank vent hose.
(e) Remove the 2 bolts.
(f) Unfasten the claw, then remove the charcoal canister.
(f)
(e)
(e)
A86360
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2077
EMISSION CONTROL CHARCOAL CANISTER ASSY (3MZ-FE)
14.
REMOVE FUEL EMISSION TUBE FUEL HOSE
(a) Remove the fuel emission tube fuel hose.
12-17
A87557
15.
INSTALL FUEL EMISSION TUBE FUEL HOSE
Push
A86389
16.
INSTALL CHARCOAL CANISTER ASSY
(a) Install the charcoal canister with the 2 bolts.
Torque: 40 N
⋅ m (400 kgf
⋅ cm, 29 ft
⋅ lbf)
(b) Connect the fuel tank vent hose.
(1) Push in the quick connector to the pipe until the quick connector makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the quick connector and pipe are securely connected by pulling on them.
(c) Connect the fuel hose No. 1.
(d) Install the 3 wire harness clamps.
(e) Connect the VSV connector.
17.
INSTALL FUEL TANK ASSY (See page 11-28 )
18.
INSTALL FUEL TANK PROTECTOR LOWER CENTER (See page 11-28 )
19.
INSTALL PARKING BRAKE CABLE ASSY NO.3 (See page 11-28 )
20.
INSTALL PARKING BRAKE CABLE ASSY NO.2 (See page 11-28 )
21.
INSTALL EXHAUST PIPE ASSY CENTER (See page 11-28 )
22.
INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See page 11-20 )
23.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
24.
ADD FUEL
25.
CHECK FOR FUEL LEAKS (See page 11-5 )
26.
CHECK FOR EXHAUST GAS LEAKS
27.
INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
28.
INSTALL REAR SEAT CUSHION ASSY
29.
INSTALL FLOOR PANEL BRACE REAR (See page 15-2 )
30.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2078
12-18
EMISSION CONTROL CHARCOAL CANISTER FILTER SUB-ASSY (3MZ-FE)
REPLACEMENT
120BW-01
Pinch
Pinch
A
Push
A
1.
REMOVE CHARCOAL CANISTER FILTER SUB-ASSY
(a) Disconnect the 2 fuel tank vent hoses.
(1) Deeply push the quick connector to release the lock pin.
(2) Pinch portion A.
(3) Pull out the 2 fuel tank vent hoses.
(b) Remove the bolt, then remove the charcoal canister filter.
(b)
Push
Pinch
Pinch
A86357
Push
2.
INSTALL CHARCOAL CANISTER FILTER SUB-ASSY
(a) Install the charcoal canister filter with the bolt.
Torque: 7.5 N
⋅ m (76 kgf
⋅ cm, 66 in.
⋅ lbf)
(b) Connect the 2 fuel tank vent hoses.
(1) Push in the quick connector to the pipe until the quick connector makes a ”click” sound.
NOTICE:
Check the connected part for damage or foreign objects.
After connecting, check if the quick connector and pipe are securely connected by pulling on them.
Push
A86388
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2079
EMISSION CONTROL DUTY VACUUM SWITCHING VALVE (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
12-19
120BU-01
3.
REMOVE EMISSION CONTROL VALVE SET
(a) Disconnect the 2 VSV connectors.
(b) Remove the wire harness clamp.
(a)
(a)
(b)
A79751
(e)
(g)
(d)
(f)
(c) Disconnect the fuel vapor feed hose No. 1.
(d) Disconnect the fuel vapor feed hose No. 2.
(e) Disconnect the vacuum hose.
(f) Remove the vacuum hose from the clamp.
(g) Remove the 2 nuts, then remove the emission control valve set.
(g)
(c)
A86217
(a)
4.
REMOVE DUTY VACUUM SWITCHING VALVE
(a) Disconnect the 2 vacuum hoses.
(b) Remove the screw, then remove the duty vacuum switching valve.
(a)
(b)
A86278
5.
INSTALL DUTY VACUUM SWITCHING VALVE
6.
INSTALL EMISSION CONTROL VALVE SET
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
7.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
8.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
9.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
10.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2080
12-20
EMISSION CONTROL VAPOR PRESSURE SENSOR ASSY (3MZ-FE)
REPLACEMENT
1.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
3.
REMOVE REAR SEAT CUSHION ASSY (See page 72-39 )
4.
REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
120BV-02
Fuel Tube Joint
Tube Joint Clip
Tube Joint Clip
Nylon Tube
A79488
5.
DISCONNECT FUEL PUMP TUBE SUB-ASSY
(a) Remove the tube joint clip, then pull out the fuel pump tube.
NOTICE:
Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
Be careful of mud because the quick connector has an O-ring which seals the pipe and quick connector that can be contaminated.
Do not use any tools in this operation.
Do not bend or twist the nylon tube. Protect the quick connector by covering it with a vinyl or plastic bag.
When the pipe and quick connector are stuck, push and pull the quick connector to release. Pull the quick connector carefully.
O-ring
Fuel Suction Plate
A91017
6.
REMOVE FUEL TANK VENT TUBE SET PLATE
(a) Remove the 8 bolts, then remove the fuel tank vent tube set plate.
A79489
Cover
Tube Joint Clip
7.
REMOVE VAPOR PRESSURE SENSOR ASSY
(a) Remove the cover.
(b) Remove the tube joint clip, then pull out the vapor pressure sensor.
A79491
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2081
12-21
EMISSION CONTROL VAPOR PRESSURE SENSOR ASSY (3MZ-FE)
Cover
Tube Joint Clip
A86272
8.
INSTALL VAPOR PRESSURE SENSOR ASSY
(a) Install the vapor pressure sensor with the tube joint clip.
NOTICE:
Check the connected part for scratch or foreign objects.
Check that the vapor pressure sensor is inserted securely.
Check that the tube joint clip is on the collar of the vapor pressure sensor.
After installing the tube joint clip, check that the vapor pressure sensor has not been pulled off.
(b) Install the cover.
9.
INSTALL FUEL TANK VENT TUBE SET PLATE
(a) Align the mark of the fuel tank vent tube set plate with the fuel suction tube w/ pump & gauge.
(b) Install the fuel tank vent tube set plate with the 8 bolts.
Torque: 5.9 N
⋅ m (60 kgf
⋅ cm, 52 in.
⋅ lbf)
Mark
A79489
Collar
Tube Joint Clip
10.
CONNECT FUEL PUMP TUBE SUB-ASSY
(a) Install the fuel pump tube with the tube joint clip.
NOTICE:
Check the connected part for scratch or foreign objects.
Check that the fuel tube joint is inserted securely.
Check that the tube joint clip is on the collar of the fuel tube joint.
A81595
After installing the tube joint clip, check that the fuel tube joint has not been pulled off.
11.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
12.
CHECK FOR FUEL LEAKS (See page 11-5 )
13.
INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-20 )
14.
INSTALL REAR SEAT CUSHION ASSY
15.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2082
12-22
EMISSION CONTROL AIR FUEL RATIO SENSOR (3MZ-FE (RH BANK))
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
3.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
4.
REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2 )
120BY-01
(b)
(a)
(b)
5.
REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the 3 bolts, then remove the exhaust manifold heat insulator No. 1.
(b)
A86340
6.
REMOVE AIR FUEL RATIO SENSOR
(a) Using SST, remove the air fuel ratio sensor.
SST 09224-00010
SST
SST
A86354
7.
INSTALL AIR FUEL RATIO SENSOR
(a) Using SST, install the air fuel ratio sensor.
SST 09224-00010
Torque: 44 N
⋅ m (449 kgf
⋅ cm, 32 ft
⋅ lbf)
A86354
8.
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 8.5 N
⋅ m (87 kgf
⋅ cm, 75 in.
⋅ lbf)
9.
INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 )
10.
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
11.
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
12.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
13.
CHECK FOR EXHAUST GAS LEAKS
14.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2083
12-23
EMISSION CONTROL AIR FUEL RATIO SENSOR (3MZ-FE (LH BANK))
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE AIR FUEL RATIO SENSOR
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the wire harness clamp.
(a)
120BZ-01
(b)
A86359
(c) Using SST, remove the air fuel ratio sensor.
SST 09224-00010
SST
(c)
SST
A86353
3.
INSTALL AIR FUEL RATIO SENSOR
(a) Using SST, install the air fuel ratio sensor.
SST 09224-00010
Torque: 44 N
⋅ m (449 kgf
⋅ cm, 32 ft
⋅ lbf)
(b) Install the wire harness clamp.
(c) Connect the air fuel ratio sensor connector.
A86353
4.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
5.
CHECK FOR EXHAUST GAS LEAKS
6.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2084
12-23
EMISSION CONTROL AIR FUEL RATIO SENSOR (3MZ-FE (LH BANK))
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE AIR FUEL RATIO SENSOR
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the wire harness clamp.
(a)
120BZ-01
(b)
A86359
(c) Using SST, remove the air fuel ratio sensor.
SST 09224-00010
SST
(c)
SST
A86353
3.
INSTALL AIR FUEL RATIO SENSOR
(a) Using SST, install the air fuel ratio sensor.
SST 09224-00010
Torque: 44 N
⋅ m (449 kgf
⋅ cm, 32 ft
⋅ lbf)
(b) Install the wire harness clamp.
(c) Connect the air fuel ratio sensor connector.
A86353
4.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
5.
CHECK FOR EXHAUST GAS LEAKS
6.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2084
13-1
INTAKE INTAKE AIR CONTROL SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
Vacuum Gauge
3-way
Connector
1307V-01
1.
INSPECT INTAKE CONTROL VALVE ASSY NO. 2
(a) Check the operation.
(1) Using a 3-way connector, connect the vacuum gauge to the actuator hose as shown in the illustration.
DLC3
Hand-held Tester
A82242
A86347
(2) Connect the hand-held tester to the DLC3.
(3) Start the engine.
(4) Turn the hand-held tester switch ON.
(5) Select the item ”DIAGNOSIS/ENHANCED OBD II/
ACTIVE TEST/INTAKE CTL VSV1” and operate the VSV for AICS.
Vacuum:
Tester Operation
VSV is ON
VSV is OFF
Specified Condition
Approximately 27.6 kpa (200 mmHg, 7.9 in.Hg)
0 kPa (0 mmHg, 0 in.Hg)
If the operation is not as specified, replace the intake air control valve No. 2.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2086
13-2
INSPECTION
INTAKE INTAKE AIR CONTROL SYSTEM (3MZ-FE)
1307W-01
Hand-held
Vacuum Pump
Hand-held
Vacuum Pump
Ohmmeter
Ohmmeter
Body
Valve
Valve
A82243
1.
INSPECT INTAKE AIR CONTROL VALVE ASSY NO.2
(a) Check the operation.
(1) With vacuum of 26.7 kPa (200 mmHg, 7.9 in.Hg) applied to the actuator, check that the valve closes.
(2) 1 minute after applying the vacuum, check that the valve remains closed.
NOTICE:
Do not adjust the adjust screw.
If the operation is not as specified, replace the intake air control valve No. 2.
2.
INSPECT INTAKE AIR CONTROL VALVE ASSY NO.3
(a) Check the operation.
(1) With vacuum of 26.7 kPa (200 mmHg, 7.9 in.Hg) applied to the actuator, check that the valve opens.
(2) 1 minute after applying the vacuum, check that the valve remains opened.
If the operation is not as specified, replace the intake air control valve No. 3.
A86222
(b) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance:
Tester Connection
1 - 2
Specified Condition
37 to 44
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the intake air control valve No. 3.
A86223
(c) Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between each terminal and the body.
If there is continuity, replace the intake air control valve No. 3.
A86224
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2087
Air
F
E
Air
E
INTAKE INTAKE AIR CONTROL SYSTEM (3MZ-FE)
(d) Check the operation.
(1) Check that air flows from port E to the filter.
13-3
Filter
A86225
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to F.
If the operation is not as specified, replace the intake air control valve No. 3.
Battery
A86226
Ohmmeter
A86227
3.
INSPECT VACUUM SWITCHING VALVE ASSY NO.1
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance:
Tester Connection
1 - 2
Specified Condition
33 to 39
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the vacuum switching valve No. 1.
Ohmmeter
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between each terminal and the body.
If there is continuity, replace the vacuum switching valve No. 1.
Body
Air
A86228
E
Filter
A86229
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Check the operation.
(1) Check that air flows from port E to the filter.
Author: Date:
2088
13-4
Battery
A
B
C
Air
E
F
INTAKE INTAKE AIR CONTROL SYSTEM (3MZ-FE)
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to F.
If the operation is not as specified, replace the vacuum switching valve No. 1.
A86230
A86231
4.
INSPECT AIR CLEANER CAP SUB-ASSY
(a) Check the operation.
(1) Cover port C with your finger, then check that the air flow from port B to A.
(2) Cover port C with your finger, then check that the air does not flow from port A to B.
(3) Cover ports A and C with your fingers, then apply 60 kPa (450 mmHg, 18 in.Hg) of vacuum to port B.
Check that there is no vacuum change after 1 minute.
If the operation is not as specified, replace the air cleaner cap.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2089
13-5
INTAKE INTAKE AIR CONTROL VALVE ASSY NO.2 (3MZ-FE)
REPLACEMENT
1307X-01
(a)
1.
REMOVE INTAKE AIR CONTROL VALVE ASSY NO.2
(a) Remove the wire harness clamp.
A79700
(b) Disconnect the vacuum hose.
(c)
Lever
(c)
(b)
(c)
A79701
(c) Remove the 3 bolts and nut.
(d) Rotate the lever to the closed position as shown in the illustration, then pull out the intake air control valve No. 2.
(e) Remove the gasket from the intake air surge tank.
(c)
A79702
2.
INSTALL INTAKE AIR CONTROL VALVE ASSY NO.2
(a) Install a new gasket to the intake air surge tank.
(b) Install the intake air control valve No. 2 with the 3 bolts and nut.
Torque: 10 N
⋅ m (102 kgf
⋅ cm, 7 ft
⋅ lbf)
(c) Connect the vacuum hose.
(d) Install the wire harness clamp.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2090
13-6
INTAKE INTAKE AIR CONTROL VALVE ASSY NO.3 (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
3.
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
1307Y-01
(b)
(b)
(b)
(c)
(a)
(b)
(d)
(d)
(a)
(b)
4.
REMOVE AIR CLEANER CAP SUB-ASSY
(a)
(b)
(c)
(d)
(e)
Disconnect the mass air flow meter connector.
Disconnect the 4 vacuum hoses.
Loosen the hose clamp bolt.
Loosen the 2 bolts, then remove the air cleaner cap.
Remove the air cleaner filter element.
A86220
(c)
(c)
5.
REMOVE INTAKE AIR CONTROL VALVE ASSY NO.3
(a) Disconnect the VSV connector.
(b) Disconnect the vacuum hose.
(c) Unfasten the 2 claws, then remove the intake air control valve No. 3.
A86221
6.
INSTALL INTAKE AIR CONTROL VALVE ASSY NO.3
7.
INSTALL AIR CLEANER CAP SUB-ASSY
Torque: 5.0 N
⋅ m (51 kgf
⋅ cm, 44 in.
⋅ lbf)
8.
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
9.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
10.
INSTALL RADIATOR LOWER AIR DEFLECTOR
11.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
12.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2091
13-7
INTAKE VACUUM SWITCHING VALVE ASSY NO.1 (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE V-BANK COVER SUB-ASSY (See page 10-1 1 )
3.
REMOVE EMISSION CONTROL VALVE SET (See page 12-19 )
1307Z-01
(a)
4.
REMOVE VACUUM SWITCHING VALVE ASSY NO.1
(a) Remove the 2 screws, then remove the vacuum surge tank.
(a)
(b)
(c)
A86218
(b) Disconnect the vacuum hose.
(c) Remove the vacuum hose.
(d) Remove the screw, then remove the vacuum switching valve No. 1.
(d)
A86219
5.
INSTALL VACUUM SWITCHING VALVE ASSY NO.1
6.
INSTALL EMISSION CONTROL VALVE SET (See page 12-19 )
7.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
8.
INSTALL V-BANK COVER SUB-ASSY (See page 10-1 1 )
9.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
10.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2092
15-1
EXHAUST EXHAUST PIPE ASSY (3MZ-FE)
COMPONENTS
Heated Oxygen Sensor
44 (450, 33)
Exhaust Pipe
Gasket
62 (633, 46)
Exhaust Pipe
Gasket x2
Exhaust Pipe Gasket
Exhaust Pipe Assy Front
44 (450, 33)
Heated Oxygen Sensor
62 (633, 46)
Exhaust Pipe No. 1
Support Bracket Front x2 x2
33 (337, 24) x2
Exhaust Pipe No. 1
Support Bracket Rear
33 (337, 24)
Exhaust Pipe Assy Tail
Tail Pipe Baffle
150B7-01
Exhaust Pipe Gasket
Exhaust Pipe Assy Center x2
Floor Panel Brace Rear
20 (199, 14) x2
56 (574, 41)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: x2
56 (574, 41)
A86208
2274
15-2
EXHAUST EXHAUST PIPE ASSY (3MZ-FE)
Removal & Installation and Disassembly & Reassembly
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE HEATED OXYGEN SENSOR (See page 12-24 )
SST 09224-00010
150B8-01
3.
REMOVE FLOOR PANEL BRACE REAR
(a) Remove the 2 bolts, then remove the floor panel brace rear.
A86209
4.
REMOVE EXHAUST PIPE ASSY TAIL
(a) Remove the 2 nuts.
(b) Remove the exhaust pipe tail and gasket from the 3 exhaust pipe supports.
(b)
(b)
Plastic-faced Hammer
(a)
(b)
(a)
A86210
5.
REMOVE TAIL PIPE BAFFLE
(a) Using a plastic-faced hammer, uniformly tap the tail pipe baffle to remove.
A86211
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2275
(b)
15-3
EXHAUST EXHAUST PIPE ASSY (3MZ-FE)
6.
REMOVE EXHAUST PIPE ASSY CENTER
(a) Remove the 2 bolts and 2 nuts.
(b) Remove the exhaust pipe center and gasket from the 2 exhaust pipe supports.
(b)
(a)
(a)
A86212
7.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
FRONT
(a) Remove the 2 nuts, then remove the exhaust pipe No. 1 support bracket front.
(a)
(b)
(a)
A86213
8.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
REAR
(a) Remove the 2 bolts.
(b) Remove the exhaust pipe No. 1 support bracket rear from the exhaust pipe front.
A86214
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2276
15-4
EXHAUST EXHAUST PIPE ASSY (3MZ-FE)
9.
REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 nuts, then remove the exhaust pipe front and 2 gaskets.
(a)
(a)
(a)
(a)
A86215
10.
INSTALL EXHAUST PIPE ASSY FRONT
(a) Install 2 new gaskets and the exhaust pipe front with the 2 bolts.
Torque: 62 N
⋅ m (633 kgf
⋅ cm, 46 ft
⋅ lbf)
(b) Tighten 2 new nuts.
Torque: 62 N
⋅ m (633 kgf
⋅ cm, 46 ft
⋅ lbf)
11.
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
REAR
Torque: 33 N
⋅ m (337 kgf
⋅ cm, 24 ft
⋅ lbf)
HINT:
Be careful not to install the exhaust pipe No. 1 support bracket rear in the wrong direction.
Exhaust Pipe
No. 1 Support Bracket
A60823
12.
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT
Torque: 33 N
⋅ m (337 kgf
⋅ cm, 24 ft
⋅ lbf)
13.
INSTALL EXHAUST PIPE ASSY CENTER
(a) Install a new gasket and the exhaust pipe center to the 2 exhaust pipe supports.
(b) Tighten the 2 bolts and 2 new nuts.
Torque: 56 N
⋅ m (574 kgf
⋅ cm, 41 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2277
Keyway
15-5
EXHAUST EXHAUST PIPE ASSY (3MZ-FE)
14.
INSTALL TAIL PIPE BAFFLE
(a) Align the keyway of the tail pipe baffle with the key on the exhaust pipe tail.
(b) Using a plastic-faced hammer, tap the tail pipe baffle to install.
Plastic-faced
Hammer
Key
A86216
15.
INSTALL EXHAUST PIPE ASSY TAIL
(a) Install a new gasket and the exhaust pipe tail to the 3 exhaust pipe supports.
(b) Tighten the 2 new nuts.
Torque: 56 N
⋅ m (574 kgf
⋅ cm, 41 ft
⋅ lbf)
16.
INSTALL HEATED OXYGEN SENSOR (See page 12-24 )
SST 09224-00010
17.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
18.
CHECK FOR EXHAUST GAS LEAKS
19.
INSTALL FLOOR PANEL BRACE REAR
Torque: 20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf)
20.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2278
16-1
COOLING COOLING SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
160QB-01
Radiator Cap
Tester
A60522
1.
INSPECT COOLING SYSTEM FOR LEAKS
(a) Remove the water outlet cap.
CAUTION:
To avoid the danger of being burned, do not remove the water outlet cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Fill the radiator with coolant, then attach a radiator cap tester.
(c) Warm up the engine.
(d) Pump it to 118 kPa (1.2 kgf/cm
2
, 17.1 psi), then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leaks. If there are no signs or traces of external coolant leaks, check the heater core, cylinder block and head.
(e) Reinstall the water outlet cap.
2.
CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ”LOW” and ”FULL” lines when the engine is cold.
If low, check for leaks and add ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the ”FULL” line.
3.
CHECK ENGINE COOLANT QUALITY
(a) Remove the water outlet cap.
CAUTION:
To avoid the danger of being burned, do not remove the water outlet cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there are any excessive deposits of rust or scale around the water outlet cap and water outlet filler hole; the coolant should free of oil.
If excessively dirty, replace the coolant.
(c) Reinstall the water outlet cap.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2279
16-2
A73603
COOLING COOLING SYSTEM (3MZ-FE)
4.
INSPECT FIN BLOCKAGE
(a) If the fins are clogged, wash them with water or a steam cleaner, then dry with compressed air.
NOTICE:
If the distance between the steam cleaner and core is too close, there is a possibility of damaging the fins, so keep the following injection distance.
Injection Pressure kPa (kgf/cm 2 , psi)
2,942 to 4,903
(30 to 50, 427 to 711)
4,903 to 7,845
(50 to 80, 711 to 1,138)
Injection Distance mm (in.)
300 (11.811)
500 (19.685)
If the fins are bent, straighten them with a screwdriver or pliers.
Be careful not to expose electronic components to water.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2280
16-5
COOLING COOLING FAN SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
160QD-01
1.
CHECK COOLING FAN OPERATION AT LOW TEM-
PERATURE (Below 83 C (181 F))
(a) Turn the ignition switch ON.
(b) Check that the fan and fan No. 2 stops.
If not, check the cooling fan relays and temperature detect switches.
(c) Disconnect the temperature detect switch connector.
A86555
(d) Connect the terminals of the temperature detect switch wire connector.
A86554
(e) Check that the fan rotates at high speed.
If not, check the cooling fan relay and fan.
(f) Reconnect the temperature detect switch connector.
(g) Disconnect the temperature detect switch No. 2 connector.
A86556
(h) Ground the terminal on the temperature detect switch No.
2 wire harness side connector.
B09432
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2283
16-6
Ammeter
Battery
COOLING COOLING FAN SYSTEM (3MZ-FE)
(i) Check that the fan and fan No. 2 rotates at low speed.
If not, check the cooling fan relay No. 2, cooling fan relay No.
3 and No. 2 fan.
(j) Reconnect the temperature detect switch No. 2 connector.
A86557
Ammeter
2.
INSPECT FAN
(a) Disconnect the fan connector.
(b) Connect battery and ammeter to the fan connector.
(c) Check that the fan rotates smoothly, then check the reading on the ammeter.
Standard amperage: 10.2 to 16.2 A at 20 C (68 F)
(d) Reconnect the fan connector.
Battery
A86558
3.
INSPECT NO. 2 FAN
(a) Disconnect the No. 2 fan connector.
(b) Connect the battery and ammeter to the No. 2 fan connector.
(c) Check that the No. 2 fan rotates smoothly, then check the reading on the ammeter.
Standard amperage: 10.2 to 16.2 A at 20 C (68 F)
(d) Reconnect the No. 2 fan connector.
A86559
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2284
INSPECTION
COOLING COOLING SYSTEM (3MZ-FE)
16-3
160QC-01
1.
INSPECT THERMOSTAT
HINT:
The thermostat is inscribed with the valve opening temperature.
P13560
(a) Immerse the thermostat in water, then gradually heat the water.
(b) Inspect the valve opening temperature of the thermostat.
Valve opening temperature:
80 to 84 C (176 to 183 F)
If the valve opening temperature is not as specified, replace the thermostat.
P00436
10 mm
(0.39 in.)
A85445
(c) Inspect the valve lift.
Valve lift: 10 mm (0.39 in.) or more at 95 C (203 F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat is at low temperature (below 77 C (171 F)).
If not fully closed, replace the thermostat.
2.
INSPECT WATER OUTLET CAP SUB-ASSY
NOTICE:
If the water outlet cap is contaminated, rinse it with water.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
When performing the following steps (a) and (b), keep the tester at an angle of over 30 above horizontal.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2281
16-4
30 or more
Water Outlet Cap
Radiator Cap Tester
A85446
COOLING COOLING SYSTEM (3MZ-FE)
(a) Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve.
Pump speed: 1 push / 3 seconds or more
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the water outlet cap.
(b) Pump the tester, then measure the relief valve opening pressure.
Pump speed: 1 push within 1 second
NOTICE:
The above pump speed is for the first pump only (in order to close the vacuum valve). After the first pump, the pump speed can be reduced.
Standard opening pressure:
83 to 113 kPa (0.85 to 1.15 kgf/cm 2 , 12.1 to 16.4 psi)
Minimum opening pressure:
69 kPa (0.7 kgf/cm
2
, 10.0 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the water outlet cap.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2282
COOLING COOLING FAN SYSTEM (3MZ-FE)
16-7
160QE-01
INSPECTION
Ohmmeter
Battery
Ohmmeter
Ohmmeter
A86576
1.
INSPECT COOLING FAN RELAY
(a) Check the continuity.
(1) Using an ohmmeter, check for continuity between the terminals.
Standard:
Tester Connection
1 - 2
3 - 5
Specified Condition
Continuity
No continuity
If the result is not as specified, replace the cooling fan relay.
(b) Check the operation.
(1) Apply battery positive voltage across terminals 1 and 2.
(2) Using an ohmmeter, check that there is continuity between terminals 3 and 5.
If there is no continuity, replace the cooling fan relay.
A86577
Ohmmeter
2.
INSPECT COOLING FAN RELAY NO.2
(a) Check the continuity.
(1) Using an ohmmeter, check for continuity between the terminals.
Standard:
Tester Connection
1 - 2
Specified Condition
Continuity
3 - 4
3 - 5
Continuity
No continuity
If the result is not as specified, replace the cooling fan relay.
A86578
Battery
Ohmmeter Ohmmeter
A86579
(b) Check the operation.
(1) Apply battery positive voltage across terminals 1 and 2.
(2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4.
If there is continuity, replace the cooling fan relay.
(3) Using an ohmmeter, check that there is continuity between terminals 3 and 5.
If there is no continuity, replace the cooling fan relay.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2285
16-8
Ohmmeter
Battery
Ohmmeter
A86576
COOLING COOLING FAN SYSTEM (3MZ-FE)
3.
INSPECT COOLING FAN RELAY NO.3
(a) Check the continuity.
(1) Using an ohmmeter, check for continuity between the terminals.
Standard:
Tester Connection
1 - 2
3 - 5
Specified Condition
Continuity
No continuity
If the result is not as specified, replace the cooling fan relay.
(b) Check the operation.
(1) Apply battery positive voltage across terminals 1 and 2.
(2) Using an ohmmeter, check that there is continuity between terminals 3 and 5.
If there is no continuity, replace the cooling fan relay.
A86577
Ohmmeter
A86580
4.
INSPECT TEMPERATURE DETECT SWITCH
(a) Check the continuity.
(1) Using an ohmmeter, check for continuity between the terminals.
Standard:
Coolant Temperature
Above 98 C (208 F)
Below 88 C (190 F)
Specified Condition
Continuity
No continuity
If the result is not as specified, replace the temperature detect switch.
Ohmmeter
A86581
5.
INSPECT TEMPERATURE DETECT SWITCH NO.2
(a) Check the continuity.
(1) Using an ohmmeter, check for continuity between the terminals.
Standard:
Coolant Temperature
Above 93 C (199 F)
Specified Condition
Continuity
Below 83 C (181 F) No continuity
If the result is not as specified, replace the temperature detect switch.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2286
16-9
COOLING ENGINE COOLANT (3MZ-FE)
REPLACEMENT
160QF-01
Water Outlet Cap
Drain Cock Plug
Drain Cock Plug
1.
DRAIN ENGINE COOLANT
(a) Remove the water outlet cap from the water outlet.
CAUTION:
To avoid the danger of being burned, do not remove the water outlet cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
Radiator Drain Plug (b) Loosen the radiator drain plug and 2 drain cock plugs, then drain the coolant.
A86582
(c) Close the radiator drain plug.
(d) Tighten the 2 drain cock plugs.
Torque: 13 N
⋅ m (130 kgf
⋅ cm, 9 ft
⋅ lbf)
2.
ADD ENGINE COOLANT
(a) Slowly fill the cooling system with coolant.
Capacity: 9.2 liters (9.7 US qts, 8.1 lmp. qts)
HINT:
Use of improper coolants may damage the engine cooling system.
Use ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non-silicate, nonamine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology.
New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethyleneglycol concentration is approximately 50% and freezing temperature is -35 C (-31 F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended.
Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.
NOTICE:
Do not use plain water alone.
3.
CHECK FOR ENGINE COOLANT LEAKS
(a) Fill the radiator with coolant, then attach a radiator cap tester.
(b) Pump it to 118 kPa (1.2
kgf/cm 2 17.1 psi), then check for leakage.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2287
16-10
COOLING WATER PUMP ASSY (3MZ-FE)
COMPONENTS
58 (591, 43)
28 (286, 21)
Front Fender Apron
Seal RH
Vane Pump V Belt
64 (653, 47)
V Belt No. 1
64 (653, 47)
23 (235, 17)
Radio Setting Condenser
Engine Moving Control Rod
Engine Mounting Stay No. 2 RH
Generator Bracket No. 2
160QG-01
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A84916
2288
8.5 (87, 75 in.
⋅ lbf)
COOLING WATER PUMP ASSY (3MZ-FE)
Timing Belt
16-1 1
Timing Belt No. 2 Cover
220 (2,250, 162)
Crankshaft Pulley
28 (286, 21)
Timing Belt No. 1 Cover
8.5 (87, 75 in.
⋅ lbf)
Engine Wire
Protector
Timing Belt Guide No. 2
Engine Mounting Bracket RH
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78353
2289
16-12
COOLING WATER PUMP ASSY (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
8.5 (87, 75 in.
⋅ lbf)
Collar
Bushing x6
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
Camshaft Timing
Pulley
125 (1,275, 92)
8.0 (82, 71 in.
⋅ lbf)
Engine Wire
Water Pump Assy
Water Pump Gasket
8.0 (82, 71 in.
⋅ lbf)
Timing Belt Idler Sub-assy No. 1
34 (347, 25)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78394
2290
16-13
COOLING WATER PUMP ASSY (3MZ-FE)
160QH-01
REPLACEMENT
1.
DRAIN ENGINE COOLANT (See page 16-9 )
2.
REMOVE FRONT WHEEL RH
3.
REMOVE FRONT FENDER APRON SEAL RH
4.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
5.
REMOVE VANE PUMP V BELT (See page 14-5 )
6.
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
7.
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
8.
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
9.
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
10.
REMOVE TIMING BELT NO.1 COVER
11.
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
12.
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
13.
REMOVE TIMING BELT GUIDE NO.2
14.
REMOVE TIMING BELT (See page 14-79 )
15.
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
16.
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
17.
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
18.
REMOVE TIMING BELT IDLER SUB-ASSY NO.1
(a) Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
19.
REMOVE WATER PUMP ASSY
(a) Remove the 3 bolts and 3 nuts, then remove the water pump and gasket.
A78535
20.
INSTALL WATER PUMP ASSY
(a) Install a new gasket and the water pump with the 3 bolts and 3 nuts.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
21.
INSTALL TIMING BELT IDLER SUB-ASSY NO.1
(a) Using a socket hexagon wrench 10, install the plate washer and timing belt idler No.1 with the pivot bolt.
Torque: 34 N
⋅ m (347 kgf
⋅ cm, 25 ft
⋅ lbf)
22.
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
23.
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
24.
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
25.
INSPECT TIMING BELT (See page 14-79 )
26.
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2291
16-14
COOLING WATER PUMP ASSY (3MZ-FE)
27.
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
28.
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
29.
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
30.
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
31.
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
32.
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
33.
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
34.
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
35.
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
36.
INSTALL VANE PUMP V BELT (See page 14-5 )
37.
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
38.
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
39.
INSTALL FRONT WHEEL RH (See page 14-5 )
40.
ADD ENGINE COOLANT (See page 16-9 )
41.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2292
INSPECTION
COOLING WATER PUMP ASSY (3MZ-FE)
16-15
160LM-03
P12487
1.
INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
(b) Turn the pulley, then check that the water pump bearing moves smoothly without making a niose.
If not, replace the water pump.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2293
16-16
COOLING THERMOSTAT (3MZ-FE)
REPLACEMENT
1.
DISCONNECT BATTERY NEGATIVE TERMINAL
2.
DRAIN ENGINE COOLANT (See page 16-9 )
3.
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
4.
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
5.
REMOVE AIR CLEANER ASSY (See page 19-5 )
6.
REMOVE WATER INLET PIPE
(a) Remove the bolt and water inlet pipe.
(b) Remove the O-ring from the water inlet pipe.
160QI-01
A80823
7.
REMOVE WATER INLET
(a) Disconnect the wire harness clamp.
(b) Remove the 3 nuts and water inlet.
8.
REMOVE THERMOSTAT
A80824
15
15
Jiggle Valve
A80298
10.
INSTALL WATER INLET
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
9.
INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Align the thermostat jiggle valve with the upper stud bolt, then insert the thermostat in the water inlet housing.
HINT:
The jiggle valve may be set within 15 of either side of the prescribed position.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2294
COOLING THERMOSTAT (3MZ-FE)
11.
INSTALL WATER INLET PIPE
(a) Install a new O-ring to the water inlet pipe.
(b) Apply soapy water to the O-ring.
(c) Connect the water inlet pipe to the water inlet.
(d) Install the bolt which is used to fixes the water inlet pipe to the cylinder head.
Torque: 20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf)
12.
INSTALL AIR CLEANER ASSY (See page 19-5 )
13.
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
14.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
15.
ADD ENGINE COOLANT (See page 16-9 )
16.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
16-17
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2295
16-18
COOLING RADIATOR ASSY (3MZ-FE)
COMPONENTS
160QJ-01
5.5 (56, 49 in.
⋅ lbf)
Battery Clamp
Sub-assy
Battery
Clip x7
Clip
Radiator Lower Air Deflector
Air Cleaner Hose No. 1
Vacuum Hose
Mass
Air Flow Sensor
Connector
VSV Connector
5.0 (51, 44 in.
⋅ lbf) x2
Vacuum Hose
5.0 (51, 44 in.
⋅ lbf) x3
Air Cleaner Cap
Sub-assy
Air Cleaner
Filter Element
Sub-assy
5.0 (51, 44 in.
⋅ lbf)
Air Cleaner
Inlet Assy
5.0 (51, 44 in.
⋅ lbf)
Battery Tray
Air Cleaner Inlet
No. 1
Engine Under Cover No. 1
Air Cleaner Case x2
7.5 (76, 66 in.
⋅ lbf)
Air Cleaner Bracket
Engine Under Cover No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86584
2296
16-19
Hood Lock Assy
8.0 (82, 71 in.
⋅ lbf) x3
COOLING RADIATOR ASSY (3MZ-FE) x5
14 (142, 10)
Radiator Support Upper
Hood Lock Release
Lever Protector
Radiator Support
Cushion
Radiator Hose Inlet
5.0 (51, 44 in.
⋅ lbf) x3
Fan Shroud
Sub-assy
Radiator Assy
Oil Cooler
Inlet Hose
Oil Cooler
Outlet Hose
Temperature Detect
Switch
Radiator Support
Lower
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Radiator Hose Outlet
Author: Date:
A86585
2297
16-20
COOLING RADIATOR ASSY (3MZ-FE)
Radiator Tank Upper
O-ring
Radiator Core Sub-assy
ATM Oil Cooler
Radiator Tank Lower
O-ring
O-ring
O-ring
8.3 (85, 74 in.
⋅ lbf)
Washer
15 (150, 11)
Inlet No. 1
Radiator Drain
Cock Plug
O-ring
Washer
8.3 (85, 74 in.
⋅ lbf)
15 (150, 11)
Inlet No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86586
2298
COOLING RADIATOR ASSY (3MZ-FE)
REPLACEMENT
1.
DISCONNECT BATTERY NEGATIVE TERMINAL
2.
DRAIN ENGINE COOLANT (See page 16-9 )
3.
REMOVE ENGINE UNDER COVER NO.1
4.
REMOVE ENGINE UNDER COVER NO.2
5.
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
6.
REMOVE BATTERY
7.
REMOVE BATTERY TRAY
8.
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
9.
REMOVE AIR CLEANER ASSY (See page 19-5 )
10.
REMOVE AIR CLEANER BRACKET (See page 19-5 )
11.
REMOVE AIR CLEANER INLET NO.1 (See page 19-5 )
12.
DISCONNECT RADIATOR HOSE INLET
13.
DISCONNECT RADIATOR HOSE OUTLET
14.
DISCONNECT OIL COOLER INLET HOSE
15.
DISCONNECT OIL COOLER OUTLET HOSE
Clip
16-21
160QK-01
A61350
16.
REMOVE HOOD LOCK RELEASE LEVER
PROTECTOR
(a) Using a screwdriver with the tip wrapped in tape, remove the protector.
NOTICE:
Removing the protector damages the clips inside the protector, therefore it is necessary to use a new protector when installing.
17.
SEPARATE HOOD LOCK ASSY
(a) Disconnect the hood switch connector.
(b) Remove the 3 bolts, then separate the hood lock.
A86560
18.
REMOVE RADIATOR SUPPORT UPPER
(a) Disconnect the horn connectors.
(b) Remove the 5 bolts, then remove the radiator support upper.
A86561
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2299
16-22
COOLING RADIATOR ASSY (3MZ-FE)
19.
REMOVE RADIATOR ASSY
(a) Disconnect the 2 wire harness connectors.
(b) Remove the radiator from the vehicle.
A86562
20.
REMOVE RADIATOR SUPPORT CUSHION
(a) Remove the 2 radiator support cushions from the radiator.
21.
REMOVE RADIATOR SUPPORT LOWER
(a) Remove the 2 radiator support lowers from the radiator.
22.
REMOVE FAN SHROUD SUB-ASSY
(a) Disconnect the temperature detect switch connector.
(b) Remove the 3 bolts, then remove the fan shroud with motor.
A86563
23.
REMOVE TEMPERATURE DETECT SWITCH
24.
REPLACE RADIATOR ASSY
25.
INSTALL FAN SHROUD SUB-ASSY
Torque: 5.0 N
⋅ m (51 kgf
⋅ cm, 44 in.
⋅ lbf)
26.
INSTALL RADIATOR SUPPORT UPPER
Torque: 14 N
⋅ m (142 kgf
⋅ cm, 10 ft
⋅ lbf)
27.
INSTALL HOOD LOCK ASSY
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
28.
INSTALL AIR CLEANER INLET NO.1 (See page 19-5 )
29.
INSTALL AIR CLEANER BRACKET (See page 19-5 )
30.
INSTALL AIR CLEANER ASSY (See page 19-5 )
31.
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
32.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
33.
ADD ENGINE COOLANT (See page 16-9 )
34.
CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2300
16-23
COOLING RADIATOR ASSY (3MZ-FE)
OVERHAUL
1.
REMOVE RADIATOR DRAIN COCK PLUG
(a) Remove the drain cock plug.
(b) Remove the O-ring from the drain cock plug.
160QL-01
Dimension ”B”
SST
Claw
Part ”A”
Stopper Bolt
Overhaul Handle
A87082
Radiator Tank
2.
ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01030)
(a) Install hole in part ”A” as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that dimension ”B” is as shown in the illustration.
Dimension ”B”: 0.2 to 0.3 mm (0.008 to 0.012 in)
NOTICE:
If the stopper bolt is not adjusted, the claw may be damaged.
3.
UNCAULK CORE PLATE
(a) Using SST to release the core plate, grip the handle until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)
Core Plate
SST
Stopper Bolt
A86587
4.
REMOVE RADIATOR TANK UPPER
(a) Lightly tap the bracket of the radiator tank (or radiator tank pipe) with a soft-faced hammer, then remove the radiator tank.
(b) Remove the O-ring.
Tap
A86588
5.
REMOVE RADIATOR TANK LOWER
HINT:
Perform the same procedures as the radiator tank upper.
6.
REMOVE INLET NO.1
(a) Remove the bolt.
(b) Remove the nut and inlet No. 1.
A86589
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2301
16-24
COOLING RADIATOR ASSY (3MZ-FE)
7.
REMOVE INLET NO.2
(a) Remove the nut and inlet No. 2.
A86590
8.
REMOVE ATM OIL COOLER
(a) Remove the 2 nuts and 2 washers, then remove the oil cooler from the radiator tank.
(b) Remove the 2 O-rings from the oil cooler.
Core Plate
A86591
Core Plate
A87087
9.
INSPECT RADIATOR CORE SUB-ASSY
Check the core plate for damage.
HINT:
If the sides of the core plate groove are deformed, it will be impossible to reassemble the radiator tank. Therefore, first correct any deformation with pliers or a similar tool.
Water leakage will result if the bottom of the core plate groove is damaged or dented. Repair or replace if necessary.
NOTICE:
The radiator can only be recaulked 2 times. After being recaulked 2 times, the radiator core must be replaced.
10.
INSTALL ATM OIL COOLER
(a) Install the 2 new O-rings to the oil cooler.
(b) Install the oil cooler to the radiator tank.
(c) Install the 2 nuts and 2 washers.
Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf)
A86592
11.
INSTALL INLET NO.2
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
12.
INSTALL INLET NO.1
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2302
Normal X Twisted
O-ring
Radiator Tank
X Twisted
A87088
CORRECT
Core
Plate
WRONG
(b) Install the radiator tank without damaging the O-ring.
(c) Tap the core plate with a soft-faced hammer so that there is no gap between the core plate and radiator tank.
Tap
16-25
COOLING RADIATOR ASSY (3MZ-FE)
13.
INSTALL RADIATOR TANK UPPER
(a) After checking that there are no foreign objects in the core plate groove, install a new O-ring without twisting it.
HINT:
When cleaning the core plate groove, lightly rub it with sandpaper without scratching it.
A86593
14.
INSTALL RADIATOR TANK LOWER
HINT:
Perform the same procedures as the radiator tank upper.
Part ”A”
Dimension ”B”
SST
Stopper Bolt
Punch Assembly Overhaul Handle
A87090
15.
ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01020)
(a) Install the punch assembly to the overhaul handle by inserting it in the hole in part ”A” as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that dimension ”B” is as shown in the illustration.
Dimension ”B”: 8.4 mm (0.341 in.)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2303
16-26
1
SST
Stopper
Bolt
5 3 7
6 4 8
2
COOLING RADIATOR ASSY (3MZ-FE)
16.
CAULK CORE PLATE
(a) Lightly press SST against the core plate in the order shown in the illustration. After repeating this a few times, fully caulk the core plate by gripping the handle until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01020)
Rib
Radiator
Tank
Core
Plate
A86594
HINT:
Do not tap the areas protruding around the pipes, brackets or tank ribs.
Bracket
A86595
The points shown in the illustration and oil cooler near here cannot be tapped with the SST. Use pliers or a similar tool and be careful not to damage the core plate.
A86596
H
A86597
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Check the core plate height (H) after completing the caulking.
Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.)
If the height is not as specified, adjust the stopper bolt of the handle again, then caulk again.
Author: Date: 2304
COOLING RADIATOR ASSY (3MZ-FE)
17.
INSTALL RADIATOR DRAIN COCK PLUG
(a) Install a new O-ring to the drain cock plug.
(b) Install the drain cock plug.
16-27
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2305
17-1
LUBRICATION LUBRICATION SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1.
CHECK ENGINE OIL LEVEL
(a) Warm up the engine, then stop the engine and wait for 5 minutes.
(b) Check that the engine oil level is between the low and full level marks on the level gage.
If low, check for leakage and add oil up to the full level mark.
NOTICE:
Do not fill with engine oil above the full level mark.
170FZ-02
Recommended Viscosity (SAE)
5W-30
C -29 -18 -7 4 16 27 38
F -20 0 20 40 60 80 100
A66623
2.
CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, water intrusion, discoloring or thinning.
If the quality is visibly poor, replace the oil.
Oil grade:
Use API grade SL ”Energy-Conserving”, or ILSAC multigrade engine oil.
SAE 5W-30 is the best choice for good fuel economy, and good starting in cold weather.
If SAE 5W-30 is not available, SAE 10W-30 may be used.
However, it should be replaced with SAE 5W-30 at the next oil replacement.
3.
INSPECT OIL PRESSURE
(a) Disconnect the oil pressure switch connector.
(b) Using a deep socket wrench 24 mm, remove the oil pressure switch.
Oil Pressure
Switch
Oil Pressure Gauge
A90353
(c) Install the oil pressure gauge.
(d) Warm up the engine.
(e) Inspect the oil pressure.
Oil pressure:
At idle
At 3,000 rpm
29 kPa (0.3 kgf/cm 2 , 4.3 psi) or more
245 to 539 kPa (2.5 to 5.5 kgf/cm 2 , 36 to 78 psi)
A90354
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2306
17-2
Adhesive
LUBRICATION LUBRICATION SYSTEM (3MZ-FE)
A85603
(f) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(g) Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 N
⋅ m (153 kgf
⋅ cm, 11 ft
⋅ lbf)
NOTICE:
Do not start the engine within 1 hour of installation.
(h) Connect the oil pressure switch connector.
(i) Check for the engine oil leaks.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2307
17-3
LUBRICATION OIL PUMP ASSY (3MZ-FE)
COMPONENTS
V Belt No. 1
28 (286, 21)
Front Fender Apron
Seal RH
Vane Pump V Belt
64 (653, 47)
64 (653, 47)
23 (235, 17)
Radio Setting Condenser
Engine Moving Control Rod
58 (591, 43)
Generator Bracket No. 2
9.8 (100, 7)
Engine Mounting Stay No. 2 RH
18 (178, 13)
Generator Assy
170HM-01
Engine Under Cover No. 1
Engine Under Cover No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A84921
2308
17-4
LUBRICATION OIL PUMP ASSY (3MZ-FE)
8.5 (87, 75 in.
⋅ lbf)
Timing Belt
Timing Belt No. 2 Cover
220 (2,250, 162)
Crankshaft Pulley
28 (286, 21)
Timing Belt No. 1 Cover
8.5 (87, 75 in.
⋅ lbf)
Engine Wire
Protector
Timing Belt Guide No. 2
Engine Mounting Bracket RH
27 (280, 20)
Timing Belt Tensioner Assy
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A78353
2309
17-5
LUBRICATION OIL PUMP ASSY (3MZ-FE)
Timing Belt No. 3 Cover
Gasket
8.5 (87, 75 in.
⋅ lbf)
Collar
Bushing x6
43 (438, 32)
Timing Belt Idler
Sub-assy No. 2
Camshaft Timing
Pulley
125 (1,275, 92)
Engine Wire
Timing Belt Idler Sub-assy No. 1
34 (347, 25)
Crankshaft Timing Pulley
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Timing Belt Plate
8.0 (82, 71 in.
⋅ lbf)
Author: Date:
A78396
2310
17-6
95 (969, 70)
54 (551, 40)
LUBRICATION OIL PUMP ASSY (3MZ-FE)
54 (551, 40)
43 (439, 32)
54 (551, 40)
Engine Mounting Bracket RH
Engine Mounting Insulator RH
87 (887, 64)
8.4 (85, 74 in.
⋅ lbf)
87 (887, 64)
43 (438, 32)
Generator Belt
Adjusting Bar
Engine Mounting
Insulator FR
52 (530, 38)
18 (184, 13)
25 (250, 18)
Compressor Mounting
Bracket No. 1
Compressor and Magnetic Clutch
25 (250, 18)
26 (260, 19)
Oil Level Gage
Sub-assy
8.0 (82, 71 in.
⋅ lbf)
Oil Level Gage Guide
O-ring
25 (250, 18)
25 (250, 18) 21 (214, 15)
Fan Belt Adjusting
Bar Bracket
62 (633, 46)
Exhaust Pipe
Gasket
62 (633, 46)
Exhaust Pipe No. 1 Support Bracket Front
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Exhaust Pipe Support
Bracket No. 1
56 (571, 41)
Exhaust Pipe Assy Front
Exhaust Pipe
Gasket
Exhaust Pipe
Gasket
Exhaust Pipe No. 1
Support Bracket Rear
33 (337, 24)
33 (337, 24)
A84922
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2311
LUBRICATION OIL PUMP ASSY (3MZ-FE)
17-7
43 (439, 32)
Oil Pump Assy
20 (199, 14)
8.0 (82, 71 in.
⋅ lbf)
Oil Pump Seal
20 (199, 14)
20 (199, 14)
20 (199, 14)
8.0 (82, 71 in.
⋅ lbf)
20 (199, 14)
Gasket
Oil Strainer Sub-assy
8.0 (82, 71 in.
⋅ lbf)
Gasket
45 (459, 33)
Oil Pan Drain Plug
O-ring
Crankshaft Position Sensor
8.0 (80, 71 in.
⋅ lbf)
Oil Pan Sub-assy
8.0 (82, 71 in.
⋅ lbf)
20 (199, 14)
20 (199, 14)
8.0 (82, 71 in.
⋅ lbf)
37 (379, 27)
Flywheel Housing
Under Cover
7.8 (80, 69 in.
⋅ lbf)
8.0 (82, 71 in.
⋅ lbf)
Oil Pan Sub-assy No. 2
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86564
2312
17-8
LUBRICATION OIL PUMP ASSY (3MZ-FE)
Driven Rotor
Drive Rotor
Oil Pump Assy
Oil Pump Cover
10 (105, 8) x10
Oil Pump Relief Valve
Oil Pump Relief Valve Spring
N·m (kgf·cm, ft·lbf) : Specified torque
49 (500, 36)
Oil Pump Relief Valve Plug
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
A80109
Author: Date: 2313
17-9
LUBRICATION OIL PUMP ASSY (3MZ-FE)
170HN-02
REPLACEMENT
1.
DISCONNECT BATTERY NEGATIVE TERMINAL
2.
DRAIN ENGINE OIL (See page 17-20 )
3.
REMOVE FRONT WHEEL RH
4.
REMOVE ENGINE UNDER COVER NO.1
5.
REMOVE ENGINE UNDER COVER NO.2
6.
REMOVE FRONT FENDER APRON SEAL RH
7.
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
8.
REMOVE GENERATOR ASSY (See page 19-21 )
9.
REMOVE VANE PUMP V BELT (See page 14-5 )
10.
REMOVE ENGINE MOVING CONTROL ROD (See page 14-79 )
11.
REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
12.
REMOVE GENERATOR BRACKET NO.2 (See page 14-79 )
13.
REMOVE CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
14.
REMOVE TIMING BELT NO.1 COVER
15.
REMOVE TIMING BELT NO.2 COVER (See page 14-79 )
16.
REMOVE ENGINE MOUNTING BRACKET RH (See page 14-79 )
17.
REMOVE TIMING BELT GUIDE NO.2
18.
REMOVE TIMING BELT (See page 14-79 )
19.
REMOVE TIMING BELT IDLER SUB-ASSY NO.2
20.
REMOVE CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
21.
REMOVE TIMING BELT NO.3 COVER (See page 14-93 )
22.
REMOVE TIMING BELT IDLER SUB-ASSY NO.1 (See page 16-13 )
23.
REMOVE CRANKSHAFT TIMING PULLEY (See page 14-138 )
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)
24.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
25.
REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
26.
REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2 )
27.
REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9 )
28.
REMOVE OIL LEVEL GAGE GUIDE (See page 14-133 )
29.
REMOVE GENERATOR BELT ADJUSTING BAR
(a) Remove the 2 bolts and 2 nuts, then remove the adjusting bar.
A52889
Author: Date:
2314
17-10
(b)
(b)
(a)
Adjusting Bar Bracket
(a)
(b)
A78827
LUBRICATION OIL PUMP ASSY (3MZ-FE)
30.
SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
(a) Remove the bolt and nut, then remove the adjusting bar bracket.
(b) Remove the 3 bolts and compressor.
HINT:
Secure the hoses off to the side instead of detaching.
31.
REMOVE COMPRESSOR MOUNTING BRACKET
NO.1
(a) Remove the 2 bolts and compressor mounting bracket.
A36749
32.
SEPARATE ENGINE MOUNTING INSULATOR FR
(a) Remove the 3 nuts and bolt, then separate the engine mounting insulator FR.
NOTICE:
Do not remove the engine mounting insulator FR.
33.
REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the bolt, then disconnect the power steering return hose clamp from the frame.
A60523
(b) Remove the 4 nuts.
(c) Place a wooden block on a jack underneath the engine.
(d) Jack up the engine, then remove the engine mounting insulator RH.
NOTICE:
Be careful not to damage the oil pan.
A86600
Author: Date: 2315
17-1 1
LUBRICATION OIL PUMP ASSY (3MZ-FE)
34.
REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the 4 bolts and nut, then remove the bracket.
A52015
35.
REMOVE OIL PAN SUB-ASSY NO.2
(a) Remove the 10 bolts and 2 nuts.
SST
A36750
SST
A00019
(b) Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, then cut off the sealer and remove the oil pan
No. 2.
SST 09032-00100
NOTICE:
Be careful not to damage the contact surface of the oil pan No. 1 where the oil pan No. 2 is mounted.
Do not damage the flange portion of the oil pan No. 2 when removing.
36.
REMOVE OIL STRAINER SUB-ASSY
(a) Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
37.
REMOVE OIL PAN SUB-ASSY
(a) Remove the 2 bolts and nut, then disconnect the engine oil level sensor connector.
(b) Remove the 2 bolts and flywheel housing under cover.
A78379
Author: Date:
2316
17-12
LUBRICATION OIL PUMP ASSY (3MZ-FE)
(c) Loosen and remove the 17 bolts and 2 nuts uniformly.
A36754
(d) Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the oil pan and cylinder block.
B04137
38.
REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the crankshaft position sensor connector.
(b) Remove the bolt and crankshaft position sensor.
39.
REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Using a screwdriver, remove the oil pump by prying between the oil pump and bearing cap.
(c) Remove the O-ring.
SST
A51990
A78754
40.
INSTALL OIL PUMP SEAL
(a) Using SST and a hammer, tap in the new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010
NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the lip free of foreign objects.
(b) Apply multi-purpose grease to the oil seal lip.
Author: Date: 2317
17-13
LUBRICATION OIL PUMP ASSY (3MZ-FE)
41.
INSTALL OIL PUMP ASSY
(a) Remove any old seal packing material from the contact surface.
(b) Apply a light coat of engine oil to a new O-ring, then place it on the cylinder block.
A
A
B
C
B
Seal Packing
A36784
C
(c) Apply a continuous bead of seal packing (Diameter 2 to
3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pump within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
Seal Width
2 to 3 mm
(0.08 to 0.12 in.)
A78725
(d) Align the key of the oil pump drive gear with the keyway located on the crankshaft, then slide the oil pump into place.
A36785
Author: Date:
2318
17-14
C
A
B
B
A
A
A
A
A
LUBRICATION OIL PUMP ASSY (3MZ-FE)
(e) Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf) for bolt A
20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf) for bolt B
43 N
⋅ m (439 kgf
⋅ cm, 32 ft
⋅ lbf) for bolt C
A51990
42.
INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
43.
INSTALL OIL PAN SUB-ASSY
(a) Remove any old seal packing from the contact surface.
Region ”X”
A
Region ”Y”
B
(b) Apply a continuous bead of seal packing (Diameter 3 to
4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the outer side of the bolt holes in the region ”X”.
Apply seal packing to the inner side of the bolt holes in the region ”Y”.
Install the oil pan within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2
A
Seal Packing
B
Seal Width
3 to 4 mm
(0.12 to 0.16 in.)
A78726 hours after installing.
(c) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts uniformly in several steps.
Torque:
8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf) for 10 mm head
20 N
⋅ m (199 kgf
⋅ cm, 14 ft
⋅ lbf) for 12 mm head
37 N
⋅ m (379 kgf
⋅ cm, 27 ft
⋅ lbf) for 14 mm head
(d) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
(e) Install the engine oil level sensor connector with the 2 bolts and nut.
Torque: 8.4 N
⋅ m (85 kgf
⋅ cm, 74 in.
⋅ lbf)
44.
INSTALL OIL STRAINER SUB-ASSY
(a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
Author: Date: 2319
B
17-15
LUBRICATION OIL PUMP ASSY (3MZ-FE)
45.
INSTALL OIL PAN SUB-ASSY NO.2
(a) Remove any old seal packing from the contact surface.
C
A
A
Seal Packing
A B
Seal Width
4 to 5 mm
(0.16 to 0.20 in.)
(b) Apply a continuous bead of seal packing (Diameter 4 to
5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pan within 3 minutes after applying seal packing.
Do not expose the seal packing to engine oil within 2 hours after installing.
(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 N
⋅ m (82 kgf
⋅ cm, 71 in.
⋅ lbf)
B
A78727
A
B
46.
INSTALL ENGINE MOUNTING BRACKET RH
Torque:
54 N
⋅ m (551 kgf
⋅ cm, 40 ft
⋅ lbf) for bolt A
54 N
⋅ m (551 kgf
⋅ cm, 40 ft
⋅ lbf) for nut B
43 N
⋅ m (439 kgf
⋅ cm, 32 ft
⋅ lbf) for bolt C
A
A78825
A
47.
INSTALL ENGINE MOUNTING INSULATOR RH
Torque:
95 N
⋅ m (969 kgf
⋅ cm, 70 ft
⋅ lbf) for nut A
87 N
⋅ m (887 kgf
⋅ cm, 64 ft
⋅ lbf) for nut B
B B
A86600
Author: Date:
2320
17-16
A
LUBRICATION OIL PUMP ASSY (3MZ-FE)
48.
INSTALL ENGINE MOUNTING INSULATOR FR
Torque:
87 N
⋅ m (887 kgf
⋅ cm, 64 ft
⋅ lbf) for bolt A
52 N
⋅ m (530 kgf
⋅ cm, 38 ft
⋅ lbf) for nut B
B
B
B
A60523
49.
INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
(a)
(b)
(a)
(a)
50.
INSTALL COMPRESSOR AND MAGNETIC CLUTCH
(a) Install the compressor with the 3 bolts.
Torque: 25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
(b) Install the adjusting bar bracket with the bolt and nut.
Torque:
25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf) for bolt
26 N
⋅ m (260 kgf
⋅ cm, 19 ft
⋅ lbf) for nut
Adjusting Bar Bracket
(b)
A78827
A
51.
INSTALL GENERATOR BELT ADJUSTING BAR
(a) Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
43 N
⋅ m (438 kgf
⋅ cm, 32 ft
⋅ lbf) for nut A
18 N
⋅ m (184 kgf
⋅ cm, 13 ft
⋅ lbf) for bolt B
8.4
N
⋅ m (85 kgf
⋅ cm, 74 in.
⋅ lbf) for bolt C
C
B
A78828
52.
INSTALL OIL LEVEL GAGE GUIDE (See page 14-133 )
53.
INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 40-9 )
54.
INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 )
55.
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR (See page 15-2 )
Author: Date: 2321
LUBRICATION OIL PUMP ASSY (3MZ-FE)
56.
INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT (See page 15-2 )
57.
INSTALL CRANKSHAFT TIMING PULLEY (See page 14-138 )
58.
INSTALL TIMING BELT IDLER SUB-ASSY NO.1 (See page 16-13 )
59.
INSTALL TIMING BELT NO.3 COVER (See page 14-93 )
60.
INSTALL CAMSHAFT TIMING PULLEY (See page 14-93 )
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
61.
INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See page 14-93 )
62.
INSPECT TIMING BELT (See page 14-79 )
63.
INSTALL TIMING BELT (See page 14-79 )
SST 09960-10010 (09962-01000, 09963-01000)
64.
INSTALL TIMING BELT TENSIONER ASSY (See page 14-79 )
65.
INSTALL TIMING BELT GUIDE NO.2 (See page 14-79 )
66.
INSTALL ENGINE MOUNTING BRACKET RH (See page 14-79 )
67.
INSTALL TIMING BELT NO.2 COVER (See page 14-79 )
68.
INSTALL TIMING BELT NO.1 COVER (See page 14-79 )
69.
INSTALL CRANKSHAFT PULLEY (See page 14-79 )
SST 09213-54015 (91651-60855), 09330-00021
70.
INSTALL GENERATOR BRACKET NO.2 (See page 14-79 )
71.
INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-79 )
72.
INSTALL ENGINE MOVING CONTROL ROD (See page 14-79 )
73.
INSTALL VANE PUMP V BELT (See page 14-5 )
74.
INSTALL GENERATOR ASSY (See page 19-21 )
75.
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14-5 )
76.
INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14-1 )
77.
INSTALL FRONT WHEEL RH (See page 14-5 )
78.
ADD ENGINE OIL (See page 17-20 )
79.
CHECK FOR ENGINE OIL LEAKS
80.
CHECK FOR EXHAUST GAS LEAKS
81.
SYSTEM INITIALIZATION (See page 19-15 )
17-17
Author: Date:
2322
17-18
LUBRICATION OIL PUMP ASSY (3MZ-FE)
OVERHAUL
1.
REMOVE OIL PUMP RELIEF VALVE
(a) Remove the plug, spring and relief valve.
170F4-03
A33002
2.
INSPECT OIL PUMP RELIEF VALVE
(a) Apply a light coat of engine oil to the relief valve.
(b) Check that the relief valve falls smoothly into the valve hole by its own weight.
3.
INSPECT OIL PUMP ASSY
(a) Remove the oil pump cover.
(1) Remove the 10 screws and oil pump cover.
(b) Remove the oil pump rotor set.
NOTICE:
Do not change the combination or turn over the 2 removed rotors.
(c) Inspect the oil pump rotor set.
(1) Apply a light coat of engine oil to the oil pump rotor set, then place them into the oil pump body. Check that the rotors revolve smoothly.
(d) Inspect the tip clearance.
(1) Using a feeler gauge, measure the clearance between the drive and driven rotor tips.
Standard tip clearance:
0.06 to 0.18 mm (0.0024 to 0.0071 in.)
Maximum tip clearance: 0.35 mm (0.0138 in.)
A33003
(e) Inspect the body clearance.
(1) Using a feeler gauge, measure the clearance between the driven rotor and body.
Standard body clearance:
0.250 to 0.325 mm (0.0098 to 0.0128 in.)
Maximum body clearance: 0.30 mm (0.0118 in.)
A33004
(f) Inspect the side clearance.
(1) Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.
Standard side clearance:
0.03 to 0.09 mm (0.0012 to 0.0035 in.)
Maximum side clearance: 0.15 mm (0.0059 in.)
A33005
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2323
Marks
17-19
LUBRICATION OIL PUMP ASSY (3MZ-FE)
(g) Install the oil pump rotor set.
(1) Apply a light coat of engine oil to the oil pump gear set, then place it into the pump body with the marks facing the pump body cover side.
(h) Install the oil pump cover.
(1) Install the 10 screws and oil pump cover.
Torque: 10 N
⋅ m (105 kgf
⋅ cm, 8 ft
⋅ lbf)
A78905
4.
INSTALL OIL PUMP RELIEF VALVE
(a) Apply a light coat of engine oil to the relief valve, then insert the relief valve and spring into the pump body hole.
(b) Install the oil pump relief valve plug.
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2324
17-20
LUBRICATION OIL FILTER SUB-ASSY (3MZ-FE)
170F5-03
REPLACEMENT
CAUTION:
Prolonged and repeated contact with engine oil will cause removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or solvents.
For environmental protection used oil and used oil filter must be disposed of at designated disposal sites.
1.
REMOVE ENGINE UNDER COVER NO.1
2.
DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, then drain the oil into a container.
(c) Clean and install the oil drain plug with a new gasket.
Torque: 45 N
⋅ m (459 kgf
⋅ cm, 33 ft
⋅ lbf)
SST
3.
REMOVE OIL FILTER SUB-ASSY
(a) Using SST, remove the oil filter.
SST 09228-07501
4.
INSTALL OIL FILTER SUB-ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, then tighten it until the gasket contacts the seat.
A78720
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228-07501
SST
Additional
3/4 Turn
P12582
5.
ADD ENGINE OIL
(a) Fill with fresh engine oil.
Capacity:
Drain and refill with oil filter change
Drain and refill without oil filter change
Dry fill
6.
CHECK FOR ENGINE OIL LEAKS
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
4.7 liters (5.0 US qts, 4.1 lmp. qts)
4.5 liters (4.8 US qts, 4.0 lmp. qts)
5.5 liters (5.8 US qts, 4.8 lmp. qts)
Author: Date: 2325
18-1
IGNITION IGNITION SYSTEM (3MZ-FE)
1809A-01
ON-VEHICLE INSPECTION
NOTICE:
”Cold” and ”Hot” in this section mean temperature of the coils themselves. ”Cold” is from -10 C
(14 F) to 50 C (122 F) and ”Hot” is from 50 C (122 F) to 100 C (212 F).
1.
INSPECT IGNITION COIL AND SPARK TEST
(a) Check the DTCs.
NOTICE:
If a DTC is present, perform troubleshooting in accordance with a procedure for that DTC.
(b) Check that a spark occurs.
(1) Remove the 6 ignition coils (see page 18-7 ).
(2) Using a spark plug wrench 16 mm, remove the 6 spark plugs.
Torque: 25 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
(3) Install the spark plugs to each ignition coil, then connect the ignition coil connectors.
(4) Disconnect the 6 fuel injector connectors.
(5) Ground the spark plugs.
(6) Check that the spark plug occurs at each spark plug while the engine is being cranked.
NOTICE:
Be sure to ground the spark plugs when checking.
Replace the ignition coil if physical impact is felt.
Do not crank the engine for more than 2 seconds.
If a spark does not occur, perform the following test.
NG
NG CONNECT SECURELY
OK
OK REPLACE IGNITION COIL ASSY
(See page 18-7 )
NG
(a) Turn the ignition switch ON.
(b) Check that there is battery voltage at the ignition coil positive (+) terminal.
NG CHECK WIRE HARNESS (BETWEEN IGNITION
(START) SWITCH ASSY AND IGNITION COIL
ASSY)
OK
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2326
18-2
IGNITION IGNITION SYSTEM (3MZ-FE)
18-3
NG REPLACE VVT SENSOR (See page 18-5 )
OK
18-3
NG REPLACE CRANKSHAFT POSITION SENSOR
(See page 18-6 )
OK
05-34
NG
OK
REPAIR WIRE HARNESS (BETWEEN IGNI-
TION COIL ASSY AND IGNITION (START)
SWITCH ASSY)
REPLACE ECM (See page 10-22 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2327
INSPECTION
IGNITION IGNITION SYSTEM (3MZ-FE)
18-3
1809B-01
1.
INSPECT SPARK PLUG
NOTICE:
Do not use a wire brush to clean the spark plug.
Do not try to adjust the electrode gap of a used spark plug.
Ohmmeter
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the insulation and body ground.
Resistance: 10 M
Ω
or more
If the resistance is not as specified, check the electrode gap.
Ground
IG0147
(b) Alternative inspection method.
(1) Quickly accelerate the engine speed to 4,000 rpm
5 times.
(2) Remove the spark plug.
(3) Visually check the spark plug.
(4) If the electrode is dry...OK.
(5) If the electrode is wet...Proceed to step (c).
(6) Reinstall the spark plug.
B01301
(c) Check the appearance.
(1) Check the thread and insulator of the spark plug for damage.
If damaged, replace the spark plug.
Recommended spark plug:
Supplier
DENSO
NGK
Type
SK20R11
IFR6A11
IG0316
Spark Plug Gauge
1.0 to 1.1 mm
(0.039 to 0.043 in.)
B02101
(d) Inspect the electrode gap.
(1) Using a spark plug gauge, measure the electrode gap.
Maximum electrode gap of used spark plug:
1.3 mm (0.051 in.)
If the electrode gap is greater than maximum, replace the spark plug.
Electrode gap of new spark plug:
1.0 to 1.1 mm (0.039 to 0.043 in.)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2328
18-4
IGNITION IGNITION SYSTEM (3MZ-FE)
(e) Clean the spark plugs.
If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner, then dry it.
Air pressure: Blow 588 kPa (6 kgf/cm 2 , 85 psi)
Duration: 20 seconds or shorter
If there are traces of oil, remove it with gasoline before using the spark plug cleaner.
B62019
Ohmmeter
A84690
2.
INSPECT VVT SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance:
Tester Connection
1 (G+) - 2 (G-)
1 (G+) - 2 (G-)
Specified Condition
835 to 1,400
Ω at cold
1,060 to 1,645
Ω at hot
NOTICE:
”Cold” and ”Hot” mean temperature of the coils themselves. ”Cold” is from -10 C (14 F) to 50 C (122 F) and
”Hot” is from 50 C (122 F) to 100 C (212 F).
If the resistance is not as specified, replace the VVT sensor.
Ohmmeter
A84688
3.
INSPECT CRANKSHAFT POSITION SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance:
Tester Connection
1 (NE+) - 2 (NE-)
1 (NE+) - 2 (NE-)
Specified Condition
1,630 to 2,740
Ω at cold
2,065 to 3,225
Ω at hot
NOTICE:
”Cold” and ”Hot” mean temperature of the coils themselves. ”Cold” is from -10 C (14 F) to 50 C (122 F) and
”Hot” is from 50 C (122 F) to 100 C (212 F).
If the resistance is not as specified, replace the crankshaft position sensor.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2329
IGNITION VVT SENSOR (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5 )
3.
REMOVE AIR CLEANER INLET ASSY (See page 19-5 )
4.
REMOVE AIR CLEANER ASSY (See page 19-5 )
RH Bank:
LH Bank:
(b)
(a)
A79541
5.
REMOVE VVT SENSOR
(a) Remove the 2 VVT sensor connectors.
(b) Remove the 2 bolts, then remove the 2 VVT sensors.
HINT:
The VVT sensor is installed with the bolt.
18-5
1809C-01
(b)
(a)
A78529
6.
INSTALL VVT SENSOR
(a) Apply a light coat of engine oil to the O-ring on each VVT sensor.
(b) Install the 2 VVT sensors with the 2 bolts.
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
NOTICE:
Be careful not to twist the O-ring.
(c) Connect the 2 VVT sensor connectors.
7.
INSTALL AIR CLEANER ASSY (See page 19-5 )
8.
INSTALL AIR CLEANER INLET ASSY (See page 19-5 )
9.
INSTALL RADIATOR LOWER AIR DEFLECTOR
10.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
11.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
12.
CHECK FOR ENGINE OIL LEAKS
13.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2330
18-6
IGNITION CRANKSHAFT POSITION SENSOR (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
1809D-01
2.
REMOVE ENGINE UNDER COVER NO.1
(a) Remove the 3 clips and 5 screws, then remove the engine under cover No. 1.
A86232
3.
REMOVE FRONT FENDER APRON SEAL RH
(a) Remove the clip and 2 bolts, then remove the front fender apron seal.
(a)
A86233
4.
REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the crankshaft position sensor connector.
(b) Remove the bolt, then remove the crankshaft position sensor.
(b)
A79763
5.
INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
6.
INSTALL FRONT FENDER APRON SEAL RH
7.
INSTALL ENGINE UNDER COVER NO.1
8.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
9.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2331
18-7
IGNITION IGNITION COIL ASSY (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2.
DRAIN ENGINE COOLANT (RH BANK) (See page 10-1 1 )
3.
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS, RH BANK)
(See page 16-9 )
4.
REMOVE V-BANK COVER SUB-ASSY (See page 16-9 )
5.
REMOVE AIR CLEANER CAP SUB-ASSY (RH BANK) (See page 16-9 )
6.
REMOVE EMISSION CONTROL VALVE SET (RH BANK) (See page 11-13 )
7.
REMOVE INTAKE AIR SURGE TANK (RH BANK) (See page 11-13 )
1809E-02
RH Bank: (b)
(a)
(b)
(a)
(b)
(a)
8.
REMOVE IGNITION COIL ASSY
(a) Disconnect the 6 connectors.
(b) Remove the 6 bolts, then remove the 6 ignition coils.
HINT:
The ignition coil is installed with the bolt.
LH Bank:
(a)
A86234
(b)
(a)
(b)
(a) (b)
A86235
9.
INSTALL IGNITION COIL ASSY
Torque: 8.0 N
⋅ m (80 kgf
⋅ cm, 71 in.
⋅ lbf)
10.
INSTALL INTAKE AIR SURGE TANK (RH BANK) (See page 11-13 )
11.
INSTALL EMISSION CONTROL VALVE SET (RH BANK) (See page 11-13 )
12.
INSTALL AIR CLEANER CAP SUB-ASSY (RH BANK) (See page 16-9 )
13.
CHECK CONNECTION OF VACUUM HOSE (RH BANK) (See page 14-29 )
14.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
15.
ADD ENGINE COOLANT (RH BANK) (See page 10-1 1 )
16.
CHECK FOR ENGINE COOLANT LEAKS (RH BANK) (See page 16-1 )
17.
INSTALL V-BANK COVER SUB-ASSY (See page 16-9 )
18.
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS, RH BANK)
(See page 16-9 )
19.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2332
26-1
FRONT SUSPENSION FRONT SUSPENSION SYSTEM
2601D-09
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.
Symptom
Bottoming
Sways/pitches
Front wheel shimmy
Abnormal tire wear
Suspect Area
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Ball joint (Worn)
6. Hub bearing (Worn)
7. Steering linkage (Loose or worn)
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)
See page
-
26-8
26-8
28-1
26-8
26-8
28-1
28-1
26-8
26-5
27-3
26-16
30-2
-
28-1
26-5
27-3
26-8
-
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2364
26-2
FRONT SUSPENSION FRONT SUSPENSION SYSTEM
REPAIR
HINT:
This is the repair procedure for vehicle pull.
START
Preliminary Check
Tire pressure
Vehicle height
Brake dragging
Does the vehicle lead/pull?
YES
NO Is there steering off center?
YES
NO
COMPLETE
Adjust front tie rods.
YES
Are the tires uni-directional type?
NO
Cross switch front tire & wheel assemblies (left & right).
Choose the position of front tire & wheel assemblies where there is least amount of pull.
Check front wheel alignment.
Is it within specification?
NO
Adjust front wheel alignment.
YES
NO
ROAD TEST
Does the vehicle still lead/pull?
YES
YES
Does the vehicle lead/pull in same direction as before?
NO
NO Is the lead/pull stronger than before?
YES
Reverse the front left side tire and rebalance it.
COMPLETE
ROAD TEST
Does the vehicle still lead/pull?
NO YES
ROAD TEST
Does the vehicle still lead/pull?
YES
NO
Does the vehicle lead/pull to the left?
YES NO
NOTICE : Do not exceed 1 ° of cross camber.
Do not exceed adjustment range.
Increase right front camber and decrease left front camber until lead/pull is eliminated.
Increase left front camber and decrease right front camber until lead/pull is eliminated.
NO ROAD TEST
Does the vehicle still lead/pull?
YES
Contact your local retail tire distributor.
2606R-02
of 35mph. Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in
a straight line for 100 meters at a constant speed of 35mph without holding the steering wheel.
(1) The vehicle can keep straight but the steering wheel has some angle.
STEERING OFF CENTER (See page 50-4 )
(2) The vehicle cannot keep straight.
STEERING PULL
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2365
FRONT SUSPENSION FRONT SUSPENSION (From July, 2003)
COMPONENTS
26-3
2601C-06 w/ H-TEMS: 14 (143, 10)
80 (816, 59)
Front Suspension
Upper Brace Center
80 (816, 59)
Front Shock Absorber
Cap LH
80 (816, 59)
Washer
49 (500, 36)
Front Suspension
Support Sub-assy LH
Front Suspension
Support Bearing LH
Front Coil Spring
Seat Upper LH
Front Coil Spring
Insulator Upper
LH
Front Stabilizer
Link Assy LH
Front Flexible Hose
No. 1
Front Axle Assy LH
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
74 (755, 55)
210 (2,141, 155)
18.8 (192, 14)
Speed Sensor
Front LH
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author:
Front Coil Spring LH
Front Spring Bumper LH
Front Coil Spring
Insulator Lower LH w/ H-TEMS:
Shock Absorber Assy
Front LH
Date:
C93850
2366
26-4
74 (755, 55)
Front Stabilizer
Link Assy RH
FRONT SUSPENSION FRONT SUSPENSION (From July, 2003)
19 (194, 14)
Stabilizer Bar Front
Front Stabilizer Bracket No. 1 RH
Front Stabilizer Bar Bush No. 1
19 (194, 14)
Front Stabilizer Bracket No. 1 LH
Rack & Pinion Power
Steering Gear Assy
74 (755, 55)
Front Stabilizer Link Assy LH
70 (714, 52)
95 (969, 70)
70 (714, 52)
Transverse Engine
Engine Mounting
Insulator
Front Frame Assy
Speed Sensor
Front LH
8.0 (82, 71 in.
⋅ lbf)
74 (755, 55)
200 (2,039, 148)
Front Lower Arm
Bush Stopper
200 (2,039, 148)
Lower Ball Joint
Assy Front LH
123 (1,254 91)
Cotter Pin
106.9 (1,090, 79)
206 (2,101, 152)
87 (887, 64)
106.9 (1,090, 79)
Front Axle Assy LH
Front Suspension
Arm Sub-assy
Lower No. 1 LH
75 (765, 55)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Front Brake
Caliper Assy
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Cotter Pin
49 (500, 36)
Author: Date:
210 (2,141, 155)
Front Disc
294 (2,998, 217)
C93097
2367
26-5
FRONT SUSPENSION FRONT WHEEL ALIGNMENT (From July, 2003)
ADJUSTMENT
1.
INSPECT TIRE (See page
Front:
Rear:
C
A
2605T-05
D
B
C91608
2.
MEASURE VEHICLE HEIGHT
Vehicle height:
Front
Rear
A - B: 120 mm (4.72 in.)
D - C: 52 mm (2.05 in.)
Measuring points:
A: Ground clearance of front wheel center
B: Ground clearance of lower suspension arm No. 2 set bolt center
C: Ground clearance of strut rod set bolt center
D: Ground clearance of rear wheel center
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle height to the specified value.
HINT:
Bounce the vehicle at the corners up and down to stabilize the suspension and inspect the vehicle height.
C91609
A
D
Front
C
B
SA3213
3.
INSPECT TOE-IN
Toe-in:
Toe-in
(total)
A + B: 0
° ±
12’ (0
° ±
0.2
°
)
C - D: 0
±
2 mm (0
±
0.08 in.)
If the toe-in is not within the specified value, adjust it at the rack ends.
4.
ADJUST TOE-IN
(a) Remove the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to adjust the toe-in.
HINT:
Try to adjust the toe-in to the center of the specified value.
F40165
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Make sure that the lengths of the right and left rack ends are the same.
(e) Torque the tie rod end lock nuts.
Torque: 74 N·m (755 kgf·cm, 55 ft·lbf)
(f) Place the boots on the seats and install the clips.
HINT:
Make sure that the boots are not twisted.
(g) Perform VSC system calibration. (See page 05-471 )
Author: Date:
2368
26-6
A B
Alignment
Tester
Front
A: Inside
B: Outside
B A
FRONT SUSPENSION FRONT WHEEL ALIGNMENT (From July, 2003)
5.
INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully left and right, and measure the turning angle.
Wheel turning angle:
Inside wheel
Outside wheel: Reference
36°39
’
±
2
° (36.65° ± 2°)
32°
11’
(32.18°)
If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths.
SA0028
Gauge
Z03382
6.
INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
(a) Put the front wheel on the center of the alignment tester.
(b) Set the camber - caster - kingpin gauge at the center of the axle hub or drive shaft.
Camber, caster and steering axis inclination:
Camber
Caster
Steering axis inclination
Left-right error
Left-right error
-0
°
43’
±
45’ (-0.72
° ±
0.75
°
)
45’ (0.75
°
) or less
2°
46’
±
45’ (2.77
° ±
0.75
°
)
45’ (0.75
°
) or less
11°
27’ (11.45
°
)
If the caster and steering axis inclination are not within the specification, after the camber has been correctly adjusted, recheck the suspension parts for damage and/or worn out parts.
7.
ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheel.
C93871
(b) Remove the 2 nuts on the lower side of the shock absorber.
HINT:
When removing nuts, stop the bolt from rotating and loosen the nut.
(c) Clean the installation surfaces of the shock absorber and the steering knuckle.
(d) Temporarily install the 2 nuts.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2369
1
2
26-7
FRONT SUSPENSION FRONT WHEEL ALIGNMENT (From July, 2003)
C93869
(e) Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required.
(f) Tighten the nuts.
Torque: 210 N
⋅ m (2,141 kgf
⋅ cm, 155 ft
⋅ lbf)
NOTICE:
When installing the nuts, keep the bolts from rotating and then torque the nut.
(g) Install the front wheel.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
(h) Check the camber.
HINT:
Try to adjust the camber to the center of the specified value.
Adjusting value for the set bolts is 6’ to 30’ (0.1
°
to 0.5
°
).
If the camber is not within the specified valve, estimate how much additional camber adjustment will be required, and select the camber adjusting bolt.
NOTICE:
Tighten the adjusting bolt with a new nut.
Bolt
Set Bolt Adjusting Bolt
90105-17008 90105-17009 90105-17010 90105-17011
1 Dot 2 Dots 3 Dots
Adjusting
Value
1 2 1 2 1 2 1 2
15’
30’
45’
1 00’
1 15’
1 30’
(i) Do the steps mentioned above again. At step (b), replace
1 or 2 selected bolts.
HINT:
When replacing the 2 bolts, replace 1 bolt for each time.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2370
26-8
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
OVERHAUL
HINT:
COMPONENTS: See page 26-3 .
1.
REMOVE FRONT WHEEL
2606S-02
2.
DISCONNECT FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the front stabilizer link assy LH from the shock absorber assy front LH.
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.
F40136
3.
REMOVE FRONT SHOCK ABSORBER CAP LH
(H-TEMS SUSPENSION)
(a) Disconnect the connector.
(b) Remove the 3 nuts, harness clamp and the front shock absorber cap LH.
SST
C91030
C93102
4.
REMOVE FRONT SHOCK ABSORBER WITH COIL
SPRING
(a) w/ H-TEMS:
Using SST, loosen the lock nut.
SST 09817-33190
(b) w/o H-TEMS:
Loosen the lock nut.
NOTICE:
Do not loosen except for the case with disassembling the shock absorber assy front LH with coil spring.
Do not remove the lock nut.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2371
26-9
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
(c) Remove the bolt, disconnect the front flexible hose No. 1 and speed sensor front LH.
C65925
(d) Remove the 2 nuts and 2 bolts on the lower side of front shock absorber with coil spring.
NOTICE:
When removing bolt, stop the bolt from rotating and loosen the nut.
C93871
(e) Remove the 3 nuts on the upper side of the front shock absorber with coil spring.
(f) Remove the front shock absorber with the coil spring.
NOTICE:
Be careful not to drop the 2 washers in the case that there is front suspension upper brace center.
SST
F40140
5.
FIX FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower side of the front shock absorber with coil spring and secure it in a vise.
SST
F03956
6.
REMOVE SHOCK ABSORBER ASSY FRONT LH
(a) Using SST, compress the front coil spring LH.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
HINT:
Use 2 of the same type of SST.
(b) Remove the front suspension support sub-assy LH, front suspension support bearing LH, front coil spring seat upper LH, front coil spring insulator upper LH, front coil spring LH, front spring bumper LH and front coil spring insulator upper LH.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2372
26-10
Outside
SST
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
W03646
7.
INSPECT SHOCK ABSORBER ASSY FRONT LH
(a) Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during operation.
If there is any abnormality, replace the shock absorber assy front LH with a new one.
NOTICE:
When disposing of the shock absorber assy front LH, see
DISPOSAL on page 26-13 .
8.
INSTALL SHOCK ABSORBER ASSY FRONT LH
(a) Install the front coil spring insulator lower LH onto the shock absorber assy front LH.
(b) Install the front spring bumper LH to the piston rod.
SST
F40160
(c) Using SST, compress the front coil spring LH.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
HINT:
Use 2 of the same type of SST.
(d) Install the front coil spring LH to the shock absorber assy front LH.
HINT:
Fit the lower end of the front coil spring LH into the gap of the spring lower seat.
5
Outside
5
(e) Install the front coil spring insulator upper LH as shown in the illustration.
Outside
5 5
F40168
(f) Install the front coil spring seat upper LH to the shock absorber assy front LH with the mark facing to the outside of the vehicle.
F40161
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2373
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
(g) Install a new front suspension support bearing LH.
26-1 1
Outside
F40162
Outside
(h) Install the front suspension support sub-assy LH with the mark facing to the outside of the vehicle.
(i) Temporarily tighten the new lock nut.
9.
INSTALL FRONT SHOCK ABSORBER WITH COIL
SPRING
(a) Install the front shock absorber with coil spring as shown in the illustration.
F40169
(b) Install the 3 nuts to the upper side of front shock absorber with coil spring.
Torque: 80 N
⋅ m (816 kgf
⋅ cm, 59 ft
⋅ lbf)
NOTICE:
Be careful not to drop the 2 washers in the case that there is front suspension upper brace center.
F40140
(c) Install the 2 bolts and 2 nuts to the lower side of front shock absorber with coil spring.
Torque: 210 N
⋅ m (2,141 kgf
⋅ cm, 155 ft
⋅ lbf)
NOTICE:
When installing bolt, stop the bolt from rotating and torque the nut.
C93871
SST
C93102
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) w/ H-TEMS:
Using SST, fully tighten the lock nut.
SST 09817-33190
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
(e) w/o H-TEMS:
Fully tighten the lock nut.
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
Author: Date:
2374
26-12
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
(f) Install the front flexible hose No. 1 and speed sensor front
LH with the bolt.
Torque: 18.8 N
⋅ m (192 kgf
⋅ cm, 14 ft
⋅ lbf)
C65925
10.
INSTALL FRONT SHOCK ABSORBER CAP LH
(H-TEMS SUSPENSION)
(a) Install the front shock absorber cap LH with the 3 nuts.
Torque: 14 N
⋅ m (143 kgf
⋅ cm, 10 ft
⋅ lbf)
(b) Disconnect the connector, install the harness clamp.
C91030
11.
INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the nut.
Torque: 74 N
⋅ m (755 kgf
⋅ cm, 55 ft
⋅ lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.
F40136
12.
INSTALL FRONT WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
13.
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-5 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2375
26-13
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
N00204
DISPOSAL
HINT:
Dispose the RH side by the same procedures with the LH side.
1.
DISPOSE OF SHOCK ABSORBER ASSY FRONT LH
(a) Fully extend the shock absorber rod.
2601G-11
(b) Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside.
CAUTION:
When drilling, chips may fly out, work carefully.
The gas is colorless, odorless and non-poisonous.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2376
26-14
FRONT SUSPENSION FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1
LH (From July, 2003)
REPLACEMENT
HINT:
COMPONENTS: See page 26-3 .
1.
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See page 14-29 )
2601H-09
2.
REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 3 nuts and the transverse engine engine mounting insulator.
C83387
3.
REMOVE FRONT SUSPENSION ARM SUB- ASSY
LOWER NO.1 LH
(a) Remove the 2 bolts on the front side of the front suspension arm sub-assy lower No. 1 LH.
C91606
(b) Remove the bolt and nut on the rear side of the front suspension arm sub-assy lower No. 1 LH.
(c) Remove the front suspension arm sub-assy lower No. 1
LH.
(d) Remove the front lower arm bush stopper from the front suspension arm sub-assy lower No. 1 LH.
F02227
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2377
FRONT SUSPENSION FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1
LH (From July, 2003)
26-15
4.
INSTALL FRONT SUSPENSION ARM SUB- ASSY
LOWER NO.1 LH
(a) Install the front lower arm bush stopper to the front suspension arm sub-assy lower No. 1 LH.
(b) Install the front suspension arm sub-assy lower No. 1 LH with the 2 bolts to the front side.
Torque: 200 N
⋅ m (2,039 kgf
⋅ cm, 148 ft
⋅ lbf)
C91606
(c) Install the front suspension arm sub-assy lower No. 1 LH with the bolt and nut to the rear side.
Torque: 206 N
⋅ m (2,101 kgf
⋅ cm, 152 ft
⋅ lbf)
F02227
5.
INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
INSULATOR
(a) Install the transverse engine engine mounting insulator with the 3 nuts.
Torque: 87 N
⋅ m (887 kgf
⋅ cm, 64 ft
⋅ lbf)
C83387
6.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See page 14-29 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2378
26-16
FRONT SUSPENSION 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
2601I-09
ZX1712
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 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
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 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2379
FRONT SUSPENSION STABILIZER BAR FRONT
REPLACEMENT
HINT:
COMPONENTS: See page 26-3 .
1.
REMOVE FRONT WHEEL
26-17
2601J-17
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.
F40143
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.
C91607
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 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2380
26-18
FRONT SUSPENSION STABILIZER BAR FRONT
12.
REMOVE STABILIZER BAR FRONT
13.
REMOVE FRONT STABILIZER BAR BUSH NO.1
Inner side
C66721
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.
Rear side
C81547 F40197
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 N
⋅ m (194 kgf
⋅ cm, 14 ft
⋅ lbf)
C91607
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2381
26-19
FRONT SUSPENSION STABILIZER BAR FRONT
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 N
⋅ m (755 kgf
⋅ cm, 55 ft
⋅ lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.
F40143
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 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
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 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2382
51-1
POWER STEERING POWER STEERING SYSTEM
PRECAUTION
TYPE A VANE PUMP
Pulley
51067-03
1.
HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Care must be taken to when replacing parts. Incorrect replacement could affect the performance of the steering system and result in a driving hazard.
(b) 1MZ-FE engine has 2 types of vane pump assy.
HINT:
TYPE A VANE PUMP
Vane pump pulley can be removed from the vane pump shaft
(See page 51-7 ).
TYPE B VANE PUMP
Vane pump pulley cannot be removed from the vane pump shaft (See page 51-7 ).
TYPE B VANE PUMP
Pulley
F41916
2.
HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The LEXUS ES330 is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in correct sequence could cause the
SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing
(including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint system (See page 60-1 ).
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2576
51-2
POWER STEERING POWER STEERING SYSTEM
51017-12
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.
Symptom
Hard steering
Poor return
Excessive play
Abnormal noise
Suspect Area
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 assy
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Rack & pinion power steering gear assy
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
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Vane pump assy
4. Rack & pinion power steering gear assy
-
26-16
-
-
30-2
51-21
51-3
-
51-9
51-21
See page
28-1
51-3
14-1
26-5
-
26-16
-
51-9
51-21
28-1
26-5
-
51-21
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2577
POWER STEERING POWER STEERING SYSTEM
ON-VEHICLE INSPECTION
Normal
51-3
51018-15
Abnormal
F40449
1.
INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords, etc.
If any defect is found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the missing chunks from the ribs are found on the belt, it should be replaced.
2.
BLEED POWER STEERING SYSTEM
(a) Check the fluid level.
(b) Jack up the front of the vehicle and support it with the stands.
(c) Turn the steering wheel.
(1) With the engine stopped, turn the wheel slowly from lock to lock several times.
(d) Lower the vehicle.
(e) Start the engine.
(1) Run the engine at idle for a few minutes.
(f) Turn the steering wheel.
(1) With the engine idling, turn the wheel to left or right full lock position and keep it there for 2 - 3 seconds, then turn the wheel to the opposite full lock position and keep it there for 2 - 3 seconds.
(2) Repeat (1) several times.
(g) Stop the engine.
(h) Check for forming or emulsification.
Especially, if the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system.
(i) Check the fluid level.
F40897
F40898
3.
CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON
®
II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the reservoir cap. If the fluid is cold, check that it is within the COLD
LEVEL range.
Author: Date:
2578
51-4
Normal Abnormal
POWER STEERING POWER STEERING SYSTEM
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to raise fluid temperature.
Fluid temperature: 75 - 80
°
C (167 - 176
°
F)
(e) Check for foaming or emulsification.
If foaming or emulsification is identified, bleed the power steering system.
F40897
Engine Idling
5 mm (0.20 in.) or less
Engine Stopped
R11786
(f) With the engine idling, measure the fluid level in the oil reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed the power steering system.
(i) Check the fluid level.
4.
CHECK STEERING FLUID PRESSURE
(a) Disconnect the pressure feed tube assy from the rack & pinion power steering gear assy (See page 51-21 ).
(b) Connect SST, as shown in the illustration.
SST 09640-10010 (09641-01010, 09641-01020,
09641-01030)
NOTICE:
Check that the valve of the SST is in the open position.
(c) Bleed the power steering system.
(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to raise fluid temperature.
Fluid temperature: 75 - 80
°
C (167 - 176
°
F)
Author: Date: 2579
Attachment
POWER STEERING POWER STEERING SYSTEM
Attachment
Pressure Feed
Tube Assy
SST
51-5
IN
OUT
PS Gear
Closed
SST
PS Gear
Open
SST
PS Gear
Lock Position
Open
SST
F41520
Oil
Reservoir
PS Vane
Pump
Z15498
(f) With the engine idling, close the valve of the SST and observe the reading on the SST.
Fluid pressure:
7,800 - 8,300 kPa (80 - 85 kgf/cm
2
, 1,138 - 1,209 psi)
NOTICE:
Do not keep the valve closed for more than 10 seconds.
Do not let the fluid temperature become too high.
Oil
Reservoir
PS Vane
Pump
Z15499
(g) With the engine idling, open the valve fully.
(h) Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm.
Fluid pressure difference:
490 kPa (5 kgf/cm 2 , 71 psi) or less
NOTICE:
Do not turn the steering wheel.
Oil
Reservoir
PS Vane
Pump
Z15500
(i) With the engine idling and valve fully opened, turn the steering wheel to full lock position.
Fluid pressure:
7,800 - 8,300 kPa (80 - 85 kgf/cm
2
, 1,138 - 1,209 psi)
NOTICE:
Do not maintain lock position for more than 10 seconds.
Do not let the fluid temperature become too high.
Author: Date:
2580
51-6
POWER STEERING POWER STEERING SYSTEM
(j) Disconnect the SST.
SST 09640- 10010 (09641- 01010, 09641- 01020,
09641-01030)
(k) Connect the pressure feed tube assy to the rack & pinion power steering gear assy (See page 51-21 ).
(l) Bleed the power steering system.
F41590
5.
CHECK STEERING EFFORT
(a) Center the steering wheel assy.
(b) Remove the horn button assy (See page 60-22 ).
(c) Start the engine and run it at idle.
(d) Using a torque wrench, measure the steering effort in both directions.
Steering effort (Reference):
6 N·m (60 kgf·cm, 53 in.·lbf) or less
HINT:
Take the tire type, pressure and contact surface into consideration before making your diagnosis.
(e) Install the steering wheel assy set nut.
Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)
(f) Install the horn button assy (See page 60-22 ).
(g) Inspect SRS warning light (See page 05-818 ).
Author: Date: 2581
51-7
COMPONENTS
TYPE A VANE PUMP:
POWER STEERING VANE PUMP ASSY
Pressure Port Union
83 (846, 61)
O-Ring
Flow Control Valve
13 (133, 10)
O-Ring
Power Steering
Suction Port Union
43 (438, 32)
Flow Control Valve
Compression Spring
Gasket
Vane Pump
Housing Rear
51068-01
Vane Pump
Bracket Rear
O-Ring
Vane Pump
Housing Front
43 (438, 32) Pump Bracket
Front
Vane Pump Rotor
24 (245, 18)
24 (245, 18)
Wave Washer
44 (449, 32)
Vane Pump Shaft
Vane Pump
Side Plate Rear
Vane Pump Cam Ring X10
Vane Pump Plate
Vane Pump Housing Oil Seal
Vane Pump Shaft Snap Ring
Vane Pump Pulley
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
Power steering fluid
F41597
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2582
51-8
TYPE B VANE PUMP:
POWER STEERING VANE PUMP ASSY
Pressure Port Union
83 (846, 61)
Vane Pump
Housing Rear
O-Ring
44 (449, 32)
Flow Control Valve
13 (133, 10)
O-Ring
Flow Control Valve
Compression Spring
Gasket
Power Steering
Suction Port Union
Vane Pump
Bracket Rear
44 (449, 32)
O-Ring
24 (245, 18)
Vane Pump
Housing Front
Pump Bracket
Front
Vane Pump Rotor
24 (245, 18)
Wave Washer
Vane Pump Housing
Oil Seal
Vane Pump
Side Plate Rear
X10
Vane Pump Cam Ring
Vane Pump Plate
W/Pulley Shaft
Sub-assy
Vane Pump Shaft Snap Ring
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
Power steering fluid
F41589
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2583
POWER STEERING VANE PUMP ASSY
OVERHAUL
NOTICE:
When using a vise, do not over tighten.
When installing, coat the parts indicated by the arrows with power steering fluid
(See page 51-7 ).
1.
REMOVE FRONT WHEEL RH
2.
DRAIN POWER STEERING FLUID
3.
REMOVE FRONT FENDER LINER RH
4.
REMOVE FRONT FENDER APRON SEAL RH
5.
DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Remove the clip and disconnect the oil reservoir to pump hose No.1.
NOTICE:
Take care not to spill fluid on the V belt.
6.
REMOVE POWER STEERING OIL PRESSURE SWITCH
(a) Disconnect the connector.
(b) Remove the oil power steering pressure switch from the union bolt.
NOTICE:
Be careful not to drop the oil power steering pressure switch.
If the oil power steering pressure switch is dropped or strongly damaged, replace it with a new one.
51-9
51069-02
7.
DISCONNECT PRESSURE FEED HOSE
(a) Using a spanner (22 mm) to hold the pressure port union, remove the union bolt and gasket.
F41598
8.
REMOVE VANE PUMP V BELT
(a) Loosen the 2 bolts and remove the vane pump V belt.
9.
REMOVE VANE PUMP ASSY
(a) Remove the 2 bolts and vane pump assy.
F41599
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2584
51-10
SST
POWER STEERING VANE PUMP ASSY
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.
F41600
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 rotor.
(b) Using a screwdriver, remove the vane pump shaft snap ring.
(c) Remove the vane pump rotor.
C65312
21.
REMOVE VANE PUMP SHAFT(TYPE A VANE PUMP)
22.
REMOVE W/PULLEY SHAFT SUB-ASSY(TYPE B VANE PUMP)
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POWER STEERING VANE PUMP ASSY
23.
REMOVE PUMP BRACKET FRONT
(a) Remove the bolt and pump bracket front from the vane pump housing front.
Caliper Gauge
SST
24.
REMOVE VANE PUMP HOUSING OIL SEAL
(a) Using SST and a hammer, tap out the vane pump housing oil seal from the vane pump housing front.
SST 09631-10030
NOTICE:
Be careful not to damage the bushing of the vane pump housing front.
F41486
25.
INSPECT OIL CLEARANCE
(a) Using a micrometer and a caliper gauge, measure the oil clearance.
Standard clearance:
0.027 - 0.054 mm (0.00106 - 0.00213 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the vane pump assy.
Micrometer
TYPE A VANE PUMP
Vane Pump
Shaft Bushing
Vane Pump Housing Front
TYPE B VANE PUMP
Bushing
W/Pulley Shaft
Sub-assy
Vane Pump
Housing Front
F41618
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Height
Length
Thickness
POWER STEERING VANE PUMP ASSY
26.
INSPECT VANE PUMP ROTOR AND VANE PUMP
PLATES
(a) Using a micrometer, measure the height, thickness and length of the vane pump plates.
Minimum height: 8.6 mm (0.339 in.)
Minimum thickness: 1.397 mm (0.05500 in.)
Minimum length: 14.991 mm (0.59020 in.)
N00372
(b) Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane pump plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the vane pump assy.
Feeler Gauge
R10282
27.
INSPECT FLOW CONTROL VALVE
(a) Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight.
Compressed Air
F41490
(b) Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392 - 490 kPa (4 - 5 kgf/cm 2 , 57 - 71 psi) into the opposite side hole, and confirm that air does not come out from the end holes.
If necessary, replace the vane pump assy.
F41491 F41622
Vernier Calipers
28.
INSPECT FLOW CONTROL VALVE COMPRESSION
SPRING
(a) Using vernier calipers, measure the free length of the flow control valve compression spring.
Minimum free length: 32.24 mm (1.2693 in.)
If it is not within the specification, replace the vane pump assy.
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POWER STEERING VANE PUMP ASSY
29.
INSPECT PRESSURE PORT UNION
If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage, replace the vane pump assy.
W03541
Press
Oil Seal
SST
F41624
31.
INSTALL PUMP BRACKET FRONT
30.
INSTALL VANE PUMP HOUSING OIL SEAL
(a) Coat a new vane pump housing oil seal lip with power steering fluid.
(b) Using SST and a press, install the new vane pump housing oil seal.
SST 09950-60010 (09951-00330),
09950-70010 (09951-07100)
NOTICE:
Make sure that the vane pump housing oil seal is installed facing the correct direction.
(a) Install the pump bracket front with the bolt.
Torque:
Type A Vane Pump: 43 N
⋅ m (438 kgf
⋅ cm, 32 ft
⋅ lbf)
Type B Vane Pump: 44 N
⋅ m (449 kgf
⋅ cm, 32 ft
⋅ lbf)
Power Steering Fluid
Power Steering Fluid
32.
INSTALL VANE PUMP SHAFT(TYPE A VANE PUMP)
(a) Coat inside bushing surface of the vane pump housing front with power steering fluid.
(b) Gradually insert the vane pump shaft from the pulley side.
NOTICE:
Do not damage the vane pump housing oil seal lip in the vane pump housing front.
F40339
33.
INSTALL W/PULLEY SHAFT SUB- ASSY(TYPE B
VANE PUMP)
F40339
(a) Coat inside bushing surface of the vane pump housing front with power steering fluid.
(b) Gradually insert the w/pulley shaft sub-assy from the pulley side.
NOTICE:
Do not damage the vane pump housing oil seal lip in the vane pump housing front.
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POWER STEERING VANE PUMP ASSY
34.
INSTALL VANE PUMP ROTOR
(a) Install the vane pump rotor.
(b) Using a snap ring expander, install a new vane pump shaft snap ring.
Inscribed
Mark
F40340
35.
INSTALL VANE PUMP CAM RING
(a) Align the holes of the vane pump cam ring with 2 straight pins, and install the vane pump cam ring with inscribed mark facing outward.
Gasket
Round End
F40341
(b) Coat 10 vane pump plates with power steering fluid.
(c) Install the vane pump plates with the round end facing outward.
(d) Install a new gasket.
Set
F04644
36.
INSTALL VANE PUMP SIDE PLATE REAR
(a) Coat a new O-ring with power steering fluid and install it to the vane pump side plate rear.
(b) Align the groove of the vane pump cam ring with that of the vane pump side plate rear, install the vane pump side plate rear.
F41480
(c) Install the wave washer so that its protrusions fit into the slots in the vane pump side plate rear.
R11292
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51-15
POWER STEERING VANE PUMP ASSY
37.
INSTALL VANE PUMP HOUSING REAR
(a) Coat a new O-ring with power steering fluid and install it to the vane pump housing rear.
(b) Install the vane pump housing rear with the 4 bolts.
Torque: 24 N
⋅ m (245 kgf
⋅ cm, 18 ft
⋅ lbf)
F41573
38.
MEASURE VANE PUMP ROTATION TORQUE(TYPE A
VANE PUMP)
(a) Check that the vane pump rotates smoothly without abnormal noise.
(b) Temporarily install the pulley set nut.
(c) Using a torque wrench, check the vane pump rotating torque.
Rotating torque:
0.27 N
⋅ m (2.8 kgf
⋅ cm, 2.4 in.
⋅ lbf) or less
39.
MEASURE VANE PUMP ROTATION TORQUE(TYPE B
VANE PUMP)
(a) Check that the vane pump rotates smoothly without abnormal noise.
(b) Temporarily install the service bolt.
Recommended service bolt:
Thread diameter: 10 mm (0.39 in.)
Thread pitch: 1.25 mm (0.0492 in.)
F41492
Bolt length: 50 mm (1.97 in.)
(c) Using a torque wrench, check the vane pump rotating torque.
Rotating torque:
0.27 N
⋅ m (2.8 kgf
⋅ cm, 2.4 in.
⋅ lbf) or less
40.
INSTALL VANE PUMP BRACKET REAR(TYPE A VANE PUMP)
(a) Install the vane pump bracket rear with the 2 bolts.
Torque: 43 N
⋅ m (438 kgf
⋅ cm, 32 ft
⋅ lbf)
41.
INSTALL VANE PUMP BRACKET REAR(TYPE B VANE PUMP)
(a) Install the vane pump bracket rear with the 2 bolts and 2 nuts.
Torque: 44 N
⋅ m (449 kgf
⋅ cm, 32 ft
⋅ lbf)
42.
INSTALL FLOW CONTROL VALVE COMPRESSION SPRING
(a) Coat the flow control valve compression spring with power steering fluid and install it.
(b) Install the flow control valve compression spring.
43.
INSTALL FLOW CONTROL VALVE
(a) Coat the flow control valve with power steering fluid.
(b) Install the flow control valve.
44.
INSTALL PRESSURE PORT UNION
(a) Coat a new O-ring with power steering fluid and install it to the pressure port union.
(b) Install the pressure port union.
Torque: 83 N
⋅ m (846 kgf
⋅ cm, 61 ft
⋅ lbf)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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POWER STEERING VANE PUMP ASSY
45.
INSTALL POWER STEERING SUCTION PORT UNION
(a) Coat a new O-ring with power steering fluid and install it to the power steering suction port union.
(b) Install the power steering suction port union with the bolt.
Torque: 13 N
⋅ m (133 kgf
⋅ cm, 10 ft
⋅ lbf)
46.
INSTALL VANE PUMP PULLEY(TYPE A VANE PUMP)
SST
(a) Install the vane pump pulley to the vane pump shaft.
(b) Using SST, stop the vane pump pulley rotation and install the nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 44 N
⋅ m (449 kgf
⋅ cm, 32 ft
⋅ lbf)
A
B
F41600
47.
INSTALL VANE PUMP ASSY
(a) Temporarily install the vane pump assy with the 2 (A and
B) bolts.
48.
INSTALL VANE PUMP V BELT
F41599
(a) Install the vane pump V belt and adjust the V belt tension
(See page 14-1 ).
(b) Torque the bolt A.
Torque: 43 N
⋅ m (438 kgf
⋅ cm, 32 ft
⋅ lbf)
(c) Torque the bolt B.
Torque: 43 N
⋅ m (438 kgf
⋅ cm, 32 ft
⋅ lbf)
Pressure
Feed
Hose
49.
CONNECT PRESSURE FEED HOSE
Stopper
(a) Using a spanner (22 mm) to hold the pressure port union,
HINT: connect the pressure feed hose with the union bolt and a new gasket.
Torque: 51.5 N
⋅ m (525 kgf
⋅ cm, 38 ft
⋅ lbf)
Make sure the stopper of the pressure feed hose touches the pump bracket front as shown in the illustration, then install the
W03441 union bolt.
50.
INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Install the power steering oil pressure switch to the union bolt.
Torque: 21 N
⋅ m (214 kgf
⋅ cm, 15 ft
⋅ lbf)
NOTICE:
Be careful not to allow oil from being attached to the connector.
(b) Connect the connector.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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POWER STEERING VANE PUMP ASSY
51.
CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Connect the oil reservoir to pump hose No.1.
(b) Install the clip.
52.
INSTALL FRONT FENDER APRON SEAL RH
53.
INSTALL FRONT FENDER LINER RH
54.
INSTALL FRONT WHEEL RH
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
55.
BLEED POWER STEERING FLUID (See page 51-3 )
56.
INSPECT FLUID LEAK
51-17
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2592
51-18
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
COMPONENTS
24.5 (250, 18)
*22.5 (229, 17)
9.8 (100, 87 in.
⋅ lbf)
Return Tube
Assy Clamp
9.8 (100, 87 in.
⋅ lbf)
Pressure
Feed Tube
35.3 (360, 26)
O-Ring
Steering Intermediate
Shaft Sub-assy
5106A-01
Return Tube
Assy
24.5 (250, 18)
*22.5 (229, 17)
Power Steering Rack
Housing Heat Insulator
74 (755, 55)
49 (500, 36)
Cotter Pin
70 (714, 52)
Rack & Pinion Power
Steering Gear Assy
Front Stabilizer
Bracket No.1 RH
19 (194, 14)
49 (500, 36)
19 (194, 14)
Front
Stabilizer Bar
Bush No.1
Front Stabilizer
Bracket No.1 LH
Front Stabilizer Bar
Bush No.1
Front Stabilizer Bar
Cotter Pin
74 (755, 55)
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
* For use with SST
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
F41605
2593
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
RACK & PINION POWER STEERING GEAR ASSY:
21 (214, 15)
12.5 (127, 9)
*11.5 (117, 8)
Steering Right Turn
Pressure Tube
12.5 (127, 9)
*11.5 (117, 8)
Dust Cover
O-Ring
51-19
Rack Housing
24.5 (250, 18)
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
Precoated part
Molybdenum disulfide lithium base grease
Power steering fluid
MP grease
* For use with SST
Steering Left Turn
Pressure Tube
Control Valve
Oil Seal
Gasket
Control Valve
Housing
Power Steering
Control Valve
Upper Oil Seal
Control Valve Upper
Bearing
Control Valve Ring
Compression
Spring
Rack Guide
Spring Cap Nut
68.5 (699, 51)
*48 (489, 35)
Rack Guide Spring Cap
Rack Guide
Rack Housing Cap
58.5 (597, 43)
F41889
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POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
RACK & PINION GEAR POWER STEERING GEAR ASSY:
Steering Rack
Boot No.1 Clamp
Steering Rack
Boot No.1
Lock Nut
74 (755, 55)
Tie Rod Assy LH
Rack Housing
Steering Rack Boot
Clip
Steering Rack End Sub-assy
83.5 (851, 62)
*58.5 (597, 43)
Claw Washer
Power Steering Rack
O-Ring
Rack Steering
Piston Ring
Steering Rack End Sub-assy
83.5 (851, 62)
*58.5 (597, 43) Claw Washer
Power Steering Cylinder
Tube Oil Seal
Cylinder End Stopper
O-Ring
Tie Rod Assy RH
Lock Nut
74 (755, 55)
Wire
Rack Bush
Oil Seal
Steering Rack
Boot No.2
Power Steering Rack Bush
Steering Rack Boot Clip
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
Molybdenum disulfide lithium base grease
Power steering fluid
* For use with SST
Steering Rack Boot No.2 Clamp
F41890
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2595
51-21
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
5106B-04
OVERHAUL
NOTICE:
When installing , coat the parts indicated by the arrow with power steering fluid or molybdenum disulfide lithium base grease (See page 51-18 ).
1.
PRECAUTION(See page 60-1 )
2.
DISCONNECT BATTERY NEGATIVE TERMINAL
3.
REMOVE HORN BUTTON ASSY
(See page 60-22 )
4.
REMOVE STEERING WHEEL ASSY
(See page 50-8 )
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
5.
REMOVE FRONT WHEEL
6.
REMOVE SPIRAL CABLE SUB-ASSY
(See page 50-8 )
SST
7.
DISCONNECT TIE ROD ASSY LH
(a) Remove the cotter pin and nut.
(b) Using SST, remove the tie rod assy LH from the steering knuckle.
SST 09628-6201 1
F40531
8.
DISCONNECT TIE ROD ASSY RH
SST 09628-6201 1
HINT:
Remove the RH side by the same procedures with LH side.
9.
DISCONNECT STEERING INTERMEDIATE SHAFT
SUB-ASSY
(a) Loosen the bolt and remove the clamp from the steering column hole cover No.1.
(b) Disconnect the steering column hole cover No.2 from the steering column hole cover No.1.
(c) Loosen the bolt.
C92274
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Matchmarks
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
(d) Place matchmarks on the steering intermediate shaft sub-assy and rack & pinion power steering gear assy.
(e) Remove the bolt and disconnect the steering intermediate shaft sub-assy.
F41595
10.
DISCONNECT FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the front stabilizer link assy LH from the shock absorber assy front LH.
HINT:
If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.
F41524
11.
DISCONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures with LH side.
12.
REMOVE FRONT STABILIZER BRACKET NO.1 LH
(a) Remove the 2 bolts and disconnect the front stabilizer bracket No.1 LH.
F41523
13.
REMOVE FRONT STABILIZER BRACKET NO.1 RH
HINT:
Remove the RH side by the same procedures with LH side.
14.
DISCONNECT PRESSURE FEED TUBE ASSY
(a) Using SST, disconnect the return tube assy from the rack
& pinion power steering gear assy.
SST 09023-12701
SST
F41578
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POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
(b) Using SST, disconnect the pressure feed tube assy from the rack & pinion power steering gear assy.
SST 09023-12701
SST
F42897
(c) Remove the nut and disconnect the return tube assy clamp.
F41602
15.
REMOVE RACK & PINION POWER STEERING GEAR
ASSY
(a) Remove the bolt and disconnect the tube clamp.
F41568
(b) Remove the 2 bolts, 2 nuts and rack & pinion power steering gear assy.
F41496
16.
REMOVE POWER STEERING RACK HOUSING HEAT INSULATOR
(a) Remove the power steering rack housing heat insulator.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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2598
51-24
SST
SST
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
F41497
17.
REMOVE STEERING LEFT TURN PRESSURE TUBE
(a) Using SST, remove the steering left turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the steering left turn pressure tube.
18.
REMOVE STEERING RIGHT TURN PRESSURE TUBE
(a) Using SST, remove the steering right turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the steering right turn pressure tube.
19.
FIX RACK & PINION POWER STEERING GEAR ASSY
(a) Using SST, secure the rack & pinion power steering gear assy.
SST 09612-00012
HINT:
Tape the SST before use.
F41498
20.
REMOVE TIE ROD ASSY LH
(a) Place matchmarks on the tie rod assy LH and steering rack end sub-assy.
(b) Loosen the lock nut, and remove the tie rod assy LH and lock nut.
Matchmarks
F40050
21.
REMOVE TIE ROD ASSY RH
HINT:
Remove the RH side by the same procedures with LH side.
22.
INSPECT TIE ROD ASSY LH
23.
INSPECT TIE ROD ASSY RH
ZK8184
(a) Secure the tie rod assy LH in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading of the 5th turn.
Turning torque:
0.83 - 3.43 N
⋅ m (8.5 - 35.0 kgf
⋅ cm, 7.3 - 30.4 in.
⋅ lbf)
HINT:
Remove the RH side by the same procedures with LH side.
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POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
24.
REMOVE STEERING RACK BOOT CLIP
(a) Remove the 2 steering rack boot clips.
25.
REMOVE STEERING RACK BOOT NO.2 CLAMP
(a) Using pliers, remove the steering rack boot No.2 clamp.
NOTICE:
Be careful not to damage the steering rack boot No.2.
26.
REMOVE STEERING RACK BOOT NO.1 CLAMP
HINT:
Remove the steering rack boot No.1 clamp by the same procedures with the steering rack boot No.2 clamp.
NOTICE:
Be careful not to damage the steering rack boot No.1.
27.
REMOVE STEERING RACK BOOT NO.2
(a) Remove the steering rack boot No.2.
28.
REMOVE STEERING RACK BOOT NO.1
HINT:
Remove the steering rack boot No.1 by the same procedures with the steering rack boot No.2.
Claw
Washer
29.
REMOVE STEERING RACK END SUB-ASSY
(a) Using a screwdriver and a hammer, unstake the claw washer.
NOTICE:
Avoid any impact to the power steering rack.
C83166
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2600
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SST
SST
SST
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
(b) Using 2 SSTs, remove the 2 steering rack ends sub-assy and 2 claw washers.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustration.
Securely hold the steering rack end sub-assy with a
SST.
SST
F41526
30.
REMOVE RACK GUIDE
(a) Using SST, remove the rack guide spring cap nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustration.
F41500
Rack Guide
Spring Cap
(b) Using SST, remove the rack guide spring cap.
SST 09631-10021
(c) Remove the compression spring and rack guide.
SST
F41501
31.
REMOVE POWER STEERING CONTROL VALVE
(a) Using a socket wrench (27 mm), remove the rack housing cap.
F41502
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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SST
51-27
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
(b) Using SST, hold the control valve and remove the nut.
SST 09616-0001 1
Vinyl Tape
F41503
(c) Wind vinyl tape around the serrated part of the control valve.
(d) Remove the dust cover from the control valve housing.
F41504
(e) Remove the 2 bolts and control valve housing.
(f) Remove the gasket.
Control Valve Ring
Vinyl Tape
F41505
(g) To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
(h) Using a plastic hammer, remove the control valve with oil seal from the control valve housing.
(i) Remove the oil seal from the control valve.
F41506
(j) Using a screwdriver, remove the 4 control valve rings.
NOTICE:
Be careful not to damage the grooves for the control valve ring.
R11572
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2602
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SST
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
32.
REMOVE POWER STEERING CONTROL VALVE
UPPER OIL SEAL
(a) Using SST and a press, remove the control valve upper bearing and power steering control valve upper oil seal from the control valve housing.
SST 09950- 70010 (09951- 07150), 09950- 60010
(09951-00250)
F40911
33.
REMOVE CYLINDER END STOPPER
(a) Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
(b) Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper.
Cylinder End
Stopper
Wire
C83179
34.
REMOVE POWER STEERING RACK
(a) Remove the power steering rack and power steering rack bush.
SST
F40542
35.
REMOVE POWER STEERING RACK BUSH
(a) Remove the power steering rack bush from the power steering rack.
(b) Using SST, remove the rack bush oil seal.
SST 09527-2101 1, 09612-24014 (09613-22011)
(c) Using a screwdriver, remove the O-ring from the power steering rack bush.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
36.
INSPECT POWER STEERING RACK
(a) Using a dial indicator, check the power steering rack for runout and for teeth wear and damage.
Maximum runout: 0.3 mm (0.012 in.)
(b) Check the back surface for wear and damage.
ZX9355
SST
37.
REMOVE POWER STEERING CYLINDER TUBE OIL
SEAL
(a) Using SST and a press, remove the power steering cylinder tube oil seal.
SST 09950- 70010 (09951- 07360), 09950- 60010
(09951-00290)
F40544
38.
REMOVE RACK STEERING PISTON RING
(a) Using a screwdriver, remove the rack steering piston ring and O-ring.
NOTICE:
Be careful not to damage the grooves for rack steering piston ring.
R10955
C03629
39.
INSTALL RACK STEERING PISTON RING
(a) Coat a new O-ring with power steering fluid and install it to the power steering rack.
(b) Expand a new rack steering piston ring with your fingers.
NOTICE:
Be careful not to over expand the rack steering piston ring.
(c) Coat the new rack steering piston ring with power steering fluid.
(d) Install the rack steering piston ring to the power steering rack, and settle it down with your fingers.
N00401
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2604
51-30
SST
Rack Teeth End
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
SST
F40545
40.
INSTALL POWER STEERING CYLINDER TUBE OIL
SEAL
(a) Coat a new power steering cylinder tube oil seal lip with power steering fluid.
SST 09950- 60010 (09951- 00420, 09951- 00250,
09952-06010), 09950-70010 (09951-07360)
(b) Using SST and a press, install the power steering cylinder tube oil seal.
NOTICE:
Make sure that the power steering cylinder tube oil seal is installed facing in the correct direction.
Take care so that the power steering cylinder tube oil seal will not be reversed as you install it.
41.
INSTALL POWER STEERING RACK
(a) Install SST to the power steering rack.
SST 09631-33010
HINT:
If necessary, scrape the burrs off the power steering rack teeth end and burnish.
(b) Coat the SST with power steering fluid.
(c) Install the power steering rack into the rack housing.
(d) Remove the SST.
SST
SST
W02101
F40543
42.
INSTALL POWER STEERING RACK BUSH
(a) Using SST and a press, install the rack bush oil seal to the power steering rack bush.
SST 09950- 60010 (09951- 00400), 09950- 70010
(09951-07100)
NOTICE:
Make sure that the rack bush oil seal is installed facing in the correct direction.
(b) Coat a new O-ring with power steering fluid and install it to the power steering rack bush.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2605
Vinyl Tape
51-31
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
(c) To prevent rack bush oil seal lip damage, wind vinyl tape around the power steering rack end, and apply power steering fluid.
(d) Install the power steering rack bush to the power steering rack.
Power
Steering
Bush
F05730
Wire
43.
INSTALL CYLINDER END STOPPER
(a) Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
(b) Install a new wire into the cylinder end stopper.
(c) Using a screwdriver, turn the cylinder end stopper clockwise by 450 50 .
Cylinder
End Stopper
SST
SST
SST
SST
F40546
44.
AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071 (09633-00010)
(b) Apply vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is a change in the vacuum, check the installation of the oil seals.
F41507
F40912
45.
INSTALL POWER STEERING CONTROL VALVE
UPPER OIL SEAL
(a) Coat a control valve upper bearing and a new power steering control valve upper oil seal with power steering fluid.
(b) Using SST and a press, install the power steering control valve upper oil seal.
SST 09950- 70010 (09951- 07150), 09950- 60010
(09951-00180, 09952-06010, 09951-00320)
(c) Using SST and a press, install the control valve upper bearing.
SST 09950- 70010 (09951- 07150), 09950- 60010
(09951-00180, 09952-06010, 09951-00340)
F40913
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2606
51-32
SST
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
46.
INSTALL POWER STEERING CONTROL VALVE
(a) Expand 4 new control valve rings with your fingers.
NOTICE:
Be careful not to over expand the control valve ring.
(b) Coat the 4 control valve rings with power steering fluid.
(c) Install the 4 control valve rings to the control valve, and settle them down with your fingers.
C03629
(d) Carefully slide the tapered end of SST over the control valve rings until they fit to the control valve.
SST 09631-20081
NOTICE:
Be careful not to damage the control valve rings.
SST
Valve Ring
Vinyl Tape
R11573
F41508
(e) To prevent power steering control valve upper oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
(f) Coat the power steering control valve upper oil seal lip with power steering fluid.
(g) Install the control valve to the control valve housing.
NOTICE:
Be careful not to damage the control valve ring and power steering control valve upper oil seal lip.
(h) Coat a new oil seal lip with power steering fluid.
(i) Using SST and a press, install the oil seal.
SST 09612-2201 1
NOTICE:
Make sure that the oil seal is installed facing in the correct direction.
F41509
(j) Apply grease to the needle bearing.
(k) Install a new gasket to the control valve housing.
(l) Wind vinyl tape around the serration part of the control valve.
(m) Install the control valve housing to the rack housing with the 2 bolts.
Torque: 21 N
⋅ m (214 kgf
⋅ cm, 15 ft
⋅ lbf)
F41512
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2607
SST
51-33
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
(n) Using SST, stop the control valve rotation and install a new lock nut.
Torque: 24.5 N
⋅ m (250 kgf
⋅ cm, 18 ft
⋅ lbf)
SST 09616-0001 1
(o) Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
F41513
(p) Using a socket wrench (27 mm), install the rack housing cap.
Torque: 58.5 N
⋅ m (597 kgf
⋅ cm, 43 ft
⋅ lbf)
F41502
(q) Using a punch and a hammer, stake the rack housing cap and rack housing.
F41608
47.
INSTALL RACK GUIDE
(a) Apply molybdenum disulfide lithium base grease to the rack guide.
(b) Install the rack guide.
(c) Install the compression spring.
(d) Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(e) Temporarily install the rack guide spring cap.
SST
F41514
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
48.
ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH steering rack ends sub-assy.
(b) Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 N
⋅ m (255 kgf
⋅ cm, 18 ft
⋅ lbf)
Author: Date:
2608
51-34
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
(c) Using SST, loosen the rack guide spring cap.
SST 09631-10021
SST
SST
SST
F41515
(d) Using SST, turn the control valve to the right and left 1 or
2 times.
SST 09616-0001 1
(e) Using SST, loosen the rack guide spring cap until the compression spring is not functioning.
SST 09631-10021
F41516
SST
Rack Guide
Spring Cap
F41517
(f) Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification.
SST 09616-0001 1, 09631-10021
Preload (turning):
1.2 - 1.5 N
⋅ m (12.2 - 15.3 kgf
⋅ cm, 10.6 - 13.3 in.
⋅ lbf)
(g) Apply sealant to 2 or 3 threads of the rack guide spring cap nut.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(h) Temporarily install the rack guide spring cap nut.
Rack Guide Spring
Cap Nut
SST
Fulcrum Length
SST
F41518
(i) Using SST, hold the rack guide spring cap and using another SST, tighten the rack guide spring cap nut.
SST 09616-0001 1, 09922-10010
Torque: 48 N
⋅ m (489 kgf
⋅ cm, 35 ft
⋅ lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustration.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(j) Precheck the total preload.
Preload (turning):
1.2 - 1.5 N
⋅ m (12.2 - 15.3 kgf
⋅ cm, 10.6 - 13.3 in.
⋅ lbf)
(k) Remove the RH and LH steering rack ends sub-assy.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2609
51-35
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
(l) Apply MP grease into the control valve, as shown in the illustration.
MP Grease
Vinyl Tape
F40555
(m) Wind vinyl tape around the serration part of the control valve.
(n) Install the dust cover to the control valve housing.
F40538
Fulcrum
Length
SST
F43004
49.
INSTALL STEERING RACK END SUB-ASSY
SST
F41576
(a) Install a new 2 claw washers, and temporarily install the
2 steering rack ends sub-assy.
HINT:
Align the claws of the claw washer with the power steering rack grooves.
(b) Using 2 SSTs, install the 2 steering rack ends sub-assy.
SST 09922-10010
Torque: 58.5 N
⋅ m (597 kgf
⋅ cm, 43 ft
⋅ lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustration.
HINT:
Using SST, hold the power steering rack and install the steering rack end sub-assy.
Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).
(c) Using a brass bar and a hammer, stake the claw washer.
NOTICE:
Avoid any impact to the power steering rack.
C35928
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2610
51-36
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
50.
INSPECT STEERING RACK END SUB-ASSY
(a) Ensure that the steering rack end sub-assy hole is not clogged with grease.
HINT:
If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned.
ZX9390
F41951
51.
INSTALL STEERING RACK BOOT NO.2
(a) Install the steering rack boot No.2.
52.
INSTALL STEERING RACK BOOT NO.1
HINT:
Remove the steering rack boot No.1 by the same procedures with steering rack boot No.2.
53.
INSTALL STEERING RACK BOOT NO.2 CLAMP
SST
F40556
(a) Using SST, tighten the steering rack boot No.2 clamp, as shown in the illustration.
SST 09521-24010
Clearance: 3.0 mm (0.118 in.) or less
NOTICE:
Be careful not to damage the steering rack boot No.2.
54.
INSTALL STEERING RACK BOOT NO.1 CLAMP
SST 09521-24010
NOTICE:
Be careful not to damage the steering rack boot No.1.
HINT:
Install the steering rack boot No.1 clamp by the same procedures with steering rack boot No.2 clamp.
55.
INSTALL STEERING RACK BOOT CLIP
(a) Using pliers, install the 2 steering rack boot clips.
56.
INSTALL TIE ROD ASSY LH
(a) Screw the lock nut and tie rod assy LH onto the steering rack end sub-assy until the matchmarks are aligned.
HINT:
After adjusting toe-in, torque the lock nut.
57.
INSTALL TIE ROD ASSY RH
HINT:
Install the RH side by the same procedures with LH side.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2611
Fulcrum
Length
Fulcrum
Length
SST
SST
51-37
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
F41519
58.
INSTALL STEERING LEFT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install them to the steering left turn pressure tube.
(b) Using SST, install the steering left turn pressure tube to
HINT: the rack & pinion power steering gear assy.
SST 09023-38201
Torque: 11.5 N
⋅ m (117 kgf
⋅ cm, 8 ft
⋅ lbf)
Use a torque wrench with a fulcrum length of 345 mm
(9.84 in.).
This torque value is effective in the case that SST is parallel to a torque wrench.
F41613
59.
INSTALL STEERING RIGHT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install them to the steering right turn pressure tube.
(b) Using SST, install the steering right turn pressure tube to the rack & pinion power steering gear assy.
HINT:
SST 09023-38201
Torque: 11.5 N
⋅ m (117 kgf
⋅ cm, 8 ft
⋅ lbf)
Use a torque wrench with a fulcrum length of 345 mm
(11.81 in.).
This torque value is effective in the case that SST is parallel to a torque wrench.
60.
INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR
(a) Install the power steering rack housing heat insulator.
HINT:
Install nut when installing the return clamp.
61.
INSTALL RACK & PINION POWER STEERING GEAR
ASSY
(a) Install the rack & pinion power steering gear assy with the
2 bolts and 2 nuts.
Torque: 70 N
⋅ m (714 kgf
⋅ cm, 52 ft
⋅ lbf)
F41496
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2612
51-38
Fulcrum
Length
Fulcrum
Length
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
(b) Connect the tube clamp with the bolt.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 87 in.
⋅ lbf)
F41568
62.
CONNECT PRESSURE FEED TUBE ASSY
SST
F41587
(a) Using SST, connect the pressure feed tube assy to the rack & pinion power steering gear assy.
SST 09023-12701
Torque: 22.5 N
⋅ m (229 kgf
⋅ cm, 17 ft
⋅ lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in the case that SST is parallel to a torque wrench.
SST
F41586
(b) Using SST, connect the return tube assy to the rack & pinion power steering gear assy.
SST 09023-12701
Torque: 22.5 N
⋅ m (229 kgf
⋅ cm, 17 ft
⋅ lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in the case that SST is parallel to a torque wrench.
(c) Install the return tube assy clamp with the nut.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 87 in.
⋅ lbf)
F41602
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2613
51-39
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
63.
INSTALL FRONT STABILIZER BRACKET NO.1 LH
(a) Install the front stabilizer bracket No. 1 LH with the 2 bolts.
Torque: 19 N
⋅ m (194 kgf
⋅ cm, 14 ft
⋅ lbf)
F41523
64.
INSTALL FRONT STABILIZER BRACKET NO.1 RH
HINT:
Remove the RH side by the same procedures with LH side.
65.
CONNECT FRONT STABILIZER LINK ASSY LH
(a) Connect the front stabilizer link assy LH to the shock absorber assy front LH with the nut.
Torque: 74 N
⋅ m (755 kgf
⋅ cm, 55 ft
⋅ lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.
F41570
66.
CONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Connect the RH side by the same procedures with LH side.
Matchmarks
67.
CONNECT STEERING INTERMEDIATE SHAFT
SUB-ASSY
(a) Align the matchmarks on the steering intermediate shaft sub-assy and rack & pinion power steering gear assy.
(b) Install the bolt.
Torque: 35.3 N
⋅ m (360 kgf
⋅ cm, 26 ft
⋅ lbf)
F41595
(c) Tighten the bolt.
Torque: 35.3 N
⋅ m (360 kgf
⋅ cm, 26 ft
⋅ lbf)
(d) Install the steering column hole cover No.2 to the steering hole cover No.1.
(e) Connect the clamp to the steering column hole cover
No.1 and tighten the bolt.
C92274
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2614
51-40
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
68.
CONNECT TIE ROD ASSY LH
(a) Connect the tie rod assy LH with the nut.
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for a new cotter pin are not aligned, tighten the nut further up 60 .
69.
CONNECT TIE ROD ASSY RH
HINT:
Install the RH side by the same procedures with LH side.
70.
INSTALL FRONT WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
71.
BLEED POWER STEERING FLUID (See page 51-3 )
72.
CHECK POWERSTEERING FLUID LEAKAGE
73.
INSTALL SPIRAL CABLE SUB-ASSY
(See page 50-8 )
74.
CENTER SPIRAL CABLE(See page 50-8 )
75.
INSTALL STEERING WHEEL ASSY
(See page 50-8 )
76.
INSTALL HORN BUTTON ASSY
(See page 60-22 )
77.
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26-5 )
78.
INSPECT STEERING WHEEL CENTER POINT
79.
INSPECT SRS WARNING LIGHT(See page 05-826 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2615
27-1
REAR SUSPENSION REAR SUSPENSION SYSTEM
2701I-09
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.
Symptom
Bottoming
Sways/pitches
Rear wheel shimmy
Suspect Area
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
See page
-
27-4
27-4
28-1
27-16
27-4
28-1
28-1
27-4
26-5
27-3
30-2
Abnormal tire wear
5. Hub bearing (Worn)
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
-
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2383
27-2
REAR SUSPENSION REAR SUSPENSION
COMPONENTS
Rear Suspension Member
Sub-Assy
RH Side: w/o TEMS:
Rear Suspension Support
No. 1 Cover LH
5.4 (55, 48 in.
⋅ lbf)
49 (500, 36)
39 (400, 29)
Suspension Support
Spring Bumper
100 (1,020, 74)
55 (561, 41)
100 (1,020, 74)
Coil Spring
Rear Suspension
Arm Assy No. 2 LH
38 (387, 28)
55 (561, 41)
Rear Suspension
Arm Assy No. 1 LH
100 (1,020, 74)
113 (1,150, 83)
113 (1,150, 83)
Strut Rod Assy Rear
Lower Insulator
100 (1,020, 74)
19 (195, 14)
2704V-06
Collar w/TEMS:
Bracket
Bushing
5.4 (55, 48 in.
⋅ lbf)
19 (195, 14)
39 (400, 29)
Parking Brake Cable
Stabilizer Bar Rear
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
Rear Stabilizer
Link Assy LH
255 (2,600, 188)
Shock Absorber
Assy Rear LH
C92643
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2384
27-3
REAR SUSPENSION 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.
2704P-06
A
D
Front
B
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 replace the suspension parts if necessary.
C
SA3213
4.
ADJUST TOE-IN
(a) Measure the lengths of the right and left No. 2 lower suspension 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.), adjust it by following the procedures below.
C91810
C91811
(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’ (1 12’, 10.8 mm, 0.425 in.).
(d) Torque the lock nut.
Torque: 56 N
⋅ m (570 kgf
⋅ cm, 41 ft
⋅ lbf)
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.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2385
27-4
REAR SUSPENSION 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 )
2706G-03
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.
C66631
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.
F41030
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2386
w/o TEMS w/ TEMS
27-5
REAR SUSPENSION SHOCK ABSORBER ASSY REAR LH
(b) Loosen the 2 bolts on the lower side of the shock absorber.
HINT:
Do not remove the 2 bolts.
(c) Support the rear axle carrier with a jack.
SST
C66634
(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.
C92644
(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.
28mm
(1.1 in)
F40121
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
C92184
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.
Author: Date:
2387
27-6
SST
REAR SUSPENSION SHOCK ABSORBER ASSY REAR LH
(b) Using SST, compress the coil spring.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(c) Remove the nut, collar and susupension support.
(d) Remove the coil spring, spring bumper and lower insulator.
F41028
C83163
18.
INSPECT SHOCK ABSORBER ASSY REAR LH
(a) Compress and extend the shock absorber rod, and check that there is no abnormal resistance or unusual operation sound.
If there is any abnormality, replace the shock absorber with a new one.
NOTICE:
When disposing the shock absorber, see DISPOSAL on page 27-9 .
19.
INSTALL SHOCK ABSORBER ASSY REAR LH
(a) Install the spring bumper.
(b) Install the lower insulator, as shown in the illustration.
F40193
SST
F41029
(c) Using SST, compress the coil spring.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(d) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of the lower seat.
Check that the 2 flat faces of the piston rod are position in parallel with the 2 flat faces of the rear suspension support.
C93791
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2388
Front
27-7
5
REAR SUSPENSION SHOCK ABSORBER ASSY REAR LH
Lower Bracket
(e) Align the suspension support with the shock absorber lower bracket, as shown in the illustration.
HINT:
Set the suspension support so that the ribbed part of the suspension support faces out side.
5
Suspension support
Outside
C93768
(f) Install the collar to the piston rod.
(g) Temporarily install a new nut.
(h) Remove the SST.
SST 09727-30021
HINT:
After removing SST, recheck the direction of the suspension support.
F02773
20.
INSTALL REAR SHOCK ABSORBER WITH COIL
SPRING
(a) Install the shock absorber with the coil spring and 3 nuts.
Torque: 39 N
⋅ m (400 kgf
⋅ cm, 29 ft
⋅ lbf)
C92184
(b) Install the shock absorber with the coil spring, 2 bolts and nuts.
Torque: 255 N
⋅ m (2,600 kgf
⋅ cm, 188 ft
⋅ lbf)
HINT:
Keep the bolt fixed while tightening the nut.
C66634
A
B
F41030
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Install the flexible hose and ABS speed sensor wire harness with the 2 bolts.
Torque:
A: Flexible hose: 19 N
⋅ m (194 kgf
⋅ cm, 14 ft
⋅ lbf)
B: ABS speed sensor wire harness:
5.5 N
⋅ m (56 kgf
⋅ cm, 49 in
⋅ lbf)
Author: Date:
2389
27-8 w/o TEMS w/ TEMS
SST
REAR SUSPENSION SHOCK ABSORBER ASSY REAR LH
(d) w/o TEMS:
Tighten the nut in the center of suspension support.
(e) w/ TEMS:
Tighten the nut in the center of suspension support.
SST 09817-33190
Torque: 49 N
⋅ m (500 kgf
⋅ cm, 36 ft
⋅ lbf)
HINT:
If the shock absorber has not been disassembled, it is necessary to tighten the nut.
C92644
21.
INSTALL REAR SUSPENSION SUPOPORT NO.1 COVER LH (W/O H-TEMS SUSPENSION)
22.
INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER (See page 61-15 )
23.
INSTALL REAR STABILIZER LINK ASSY LH
(a) Install the stabilizer bar link to the shock absorber with the nut.
Torque: 39 N
⋅ m (400 kgf
⋅ cm, 29 ft
⋅ lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud.
C66631
24.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
25.
INSPECT REAR WHEEL ALIGNMENT (See page 27-3 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2390
27-9
REAR SUSPENSION SHOCK ABSORBER ASSY REAR LH
2701L-09
DISPOSAL
1.
DISPOSE OF SHOCK ABSORBER ASSY REAR LH
(a) Fully extend the shock absorber rod.
(b) Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside.
CAUTION:
When drilling, chips may fly out. Work carefully.
The gas is colorless, odorless and non-poisonous.
C83384
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2391
27-10
REAR SUSPENSION REAR SUSPENSION ARM ASSY NO.1 LH
REPLACEMENT
HINT:
COMPONENTS: See page 27-2
1.
REMOVE REAR WHEEL
2.
REMOVE EXHAUST PIPE ASSY CENTER (See page 15-2 )
3.
REMOVE STABILIZER BAR REAR (See page 27-16 )
4.
SEPARATE STRUT ROD ASSY REAR (See page 27-18 )
5.
SEPARATE HEIGHT CONTROL SENSOR SUB-ASSY REAR RH (See page 65-33 )
2706H-02
6.
SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH
(a) Remove the bolt, nut and rear suspension arm No. 2 (outer side) from the rear carrier.
HINT:
Keep the nut fixed while loosening and removing the bolt.
B53735
7.
SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH
HINT:
Separate the RH side by the procedures with the LH side.
8.
SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH
(a) Remove the bolt, nut and rear suspension arm No. 1 (outer side) from rear axle carrier.
HINT:
Keep the nut fixed while loosening and removing the bolt.
B53736
9.
SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH
HINT:
Separate the RH side by the procedures with the LH side.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2392
27-1 1
REAR SUSPENSION REAR SUSPENSION ARM ASSY NO.1 LH
10.
REMOVE REAR SUSPENSION MEMBER SUB-ASSY
(a) Support the rear suspension member with a jack.
(b) Remove the 4 nuts, 2 bolts and 4 retainers from the rear suspension member.
B53742
11.
REMOVE REAR SUSPENSION ARM ASSY NO.1 LH
(a) Lower the rear suspension member.
(b) Remove the bolt, nut and lower suspension arm No. 1.
B53744
12.
INSTALL REAR SUSPENSION ARM ASSY NO.1 LH
(a) Install the lower suspension No. 1 with the bolt, nut and temporarily tighten the bolt.
B53744
(b) Set suspension arm in the position shown in the illustration and fully tighten the bolt.
Torque: 100 N
⋅ m (1,020 kgf
⋅ cm, 74 ft
⋅ lbf)
38 mm (1.5 in.)
B53747
Front
HINT:
Install the lower suspension No. 1 so that the bracket leans toward the front of the vehicle, as shown in illustration.
B53748
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2393
27-12
REAR SUSPENSION REAR SUSPENSION ARM ASSY NO.1 LH
13.
INSTALL REAR SUSPENSION MEMBER SUB-ASSY
(a) Support the rear suspension member with a jack.
(b) Install the rear suspension member with the 4 nuts, 2 bolts and 4 retainers.
Torque:
A, B: 55 N
⋅ m (561 kgf
⋅ cm, 41 ft
⋅ lbf)
C: 38 N
⋅ m (387 kgf
⋅ cm, 28 ft
⋅ lbf)
B53742
14.
TEMPORARILY TIGHTEN REAR SUSPENSION ARM
ASSY NO.1 LH
(a) Connect the rear suspension arm No. 1 (outer side) to the rear axle carrier with the bolt and nut, and temporarily tighten the bolt and nut.
HINT:
Insert the bolt from the front side of the vehicle and temporarily install the bolt.
B53736
15.
TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH
HINT:
Temporarily tighten the RH side by the procedures with the LH side.
16.
TEMPORARILY TIGHTEN REAR SUSPENSION ARM
ASSY NO.2 LH
(a) Connect the rear suspension arm No. 2 (outer side) to the rear axle carrier with the bolt and nut, and temporarily tighten the bolt.
HINT:
Insert the bolt from the rear side of the vehicle and temporarily install the bolt.
B53735
17.
TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH
HINT:
Temporarily tighten the RH side by the procedures with the LH side.
18.
CONNECT HEIGHT CONTROL SENSOR SUB-ASSY REAR RH (See page 65-33 )
19.
TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (See page 27-18 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2394
27-13
REAR SUSPENSION REAR SUSPENSION ARM ASSY NO.1 LH
20.
STABILIZE SUSPENSION
(a) Jack up the rear axle carrier, placing a wooden block between them. Apply load to the suspension so that the installed bolt of the suspension arm assy No. 1 (vehicle side) is horizontally aligned with the center of the rear axle hub.
C91813
21.
FULLY TIGHTEN REAR SUSPENSION ARM ASSY
NO.1 LH
(a) Fully tighten the bolt.
Torque: 100 N
⋅ m (1,020 kgf
⋅ cm, 74 ft
⋅ lbf)
HINT:
While fixing the nut, turn the bolt.
C82996
22.
FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH
HINT:
Fully tighten the RH side by the procedures with the LH side.
23.
FULLY TIGHTEN REAR SUSPENSION ARM ASSY
NO.2 LH
(a) Fully tighten the bolt.
Torque: 100 N
⋅ m (1,020 kgf
⋅ cm, 74 ft
⋅ lbf)
HINT:
While fixing the nut, turn the bolt.
C82997
24.
FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH
HINT:
Fully tighten the RH side by the procedures with the LH side.
25.
FULLY TIGHTEN STRUT ROD ASSY REAR (See page 27-18 )
26.
INSTALL STABILIZER BAR REAR (See page 27-16 )
27.
INSTALL EXHAUST PIPE ASSY CENTER (See page 15-2 )
28.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
29.
INSPECT REAR WHEEL ALIGNMENT (See page 27-3 )
30.
HEADLIGHT AIM ONLY (See page 65-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2395
27-14
REAR SUSPENSION REAR SUSPENSION ARM ASSY NO.2 LH
REPLACEMENT
HINT:
COMPONENTS: See page 27-2
1.
REMOVE REAR WHEEL
2.
REMOVE EXHAUST PIPE ASSY CENTER (See page 15-2 )
3.
REMOVE STABILIZER BAR REAR (See page 27-16 )
4.
SEPARATE STRUT ROD ASSY REAR (See page 27-18 )
5.
SEPARATE HEIGHT CONTROL SENSOR SUB-ASSY REAR RH (See page 65-33 )
6.
SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH (See page 27-10 )
7.
SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH
HINT:
Separate the RH side by the procedures with the LH side.
8.
SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH (See page 27-10 )
9.
SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH
HINT:
Separate the RH side by the procedures with the LH side.
10.
REMOVE REAR SUSPENSION MEMBER SUB-ASSY (See page 27-10 )
2706I-02
11.
REMOVE REAR SUSPENSION ARM ASSY NO.2 LH
(a) Remove the bolt and rear suspension arm No. 2 (inner side).
C82992
(b) Remove the bolt, nut and disconnect the rear suspension arm No. 2 (outer side) from rear axle carrier.
HINT:
Keep the nut fixed while loosening and removing the bolt.
C82993
12.
INSTALL REAR SUSPENSION ARM ASSY NO.2 LH
(a) Install the rear suspension arm No. 2 (inner side) with the bolt and temporarily tighten the bolt.
C82992
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2396
27-15
REAR SUSPENSION REAR SUSPENSION ARM ASSY NO.2 LH
(b) Set the suspension arm in the position in the illustration and fully tighten the bolt.
Torque: 100 N
⋅ m (1,020 kgf
⋅ cm, 74 ft
⋅ lbf)
38 mm (1.5 in.)
B53747
13.
INSTALL REAR SUSPENSION MEMBER SUB-ASSY (See page 27-10 )
14.
TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (See page 27-10 )
15.
TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH
HINT:
Temporarily tighten the RH side by the procedures with the LH side.
16.
TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (See page 27-10 )
17.
TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH
HINT:
Temporarily tighten the RH side by the procedures with the LH side.
18.
TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (See page 27-18 )
19.
CONNECT HEIGHT CONTROL SENSOR SUB-ASSY REAR RH (See page 65-33 )
20.
STABILIZE SUSPENSION (See page 27-10 )
21.
FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (See page 27-10 )
22.
FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH
HINT:
Fully tighten the RH side by the procedures with the LH side.
23.
FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (See page 27-10 )
24.
FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH
HINT:
Fully tighten the RH side by the procedures with the LH side.
25.
FULLY TIGHTEN STRUT ROD ASSY REAR (See page 27-18 )
26.
INSTALL STABILIZER BAR REAR (See page 27-16 )
27.
INSTALL EXHAUST PIPE ASSY CENTER (See page 15-2 )
28.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
29.
INSPECT REAR WHEEL ALIGNMENT (See page 27-3 )
30.
HEADLIGHT AIM ONLY (See page 65-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2397
27-16
REAR SUSPENSION STABILIZER BAR REAR
REPLACEMENT
HINT:
COMPONENTS: See page 27-2
1.
REMOVE REAR WHEEL
2701O-06
2.
REMOVE REAR STABILIZER LINK ASSY LH
(a) Remove the 2 nuts and stabilizer bar link.
HINT:
If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud.
C91816
3.
REMOVE REAR STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures with the LH side.
4.
INSPECT REAR 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 - 1.0 N·m (0.5 - 10 kgf·cm, 0.4 - 8.7 in.·lbf)
C66721
5.
REMOVE STABILIZER BAR REAR
(a) Remove the 8 bolts, 2 No. 1 brackets and 2 bushings.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2398
B
A
27-17
REAR SUSPENSION STABILIZER BAR REAR
6.
INSTALL STABILIZER BAR REAR
(a) Install the bushing and bracket with the 2 bolts (LH side).
Torque: 19 N
⋅ m (195 kgf
⋅ cm, 14 ft
⋅ lbf)
HINT:
2 types of bolts (A, B) are used, so make sure the correct bolts are installed.
C93541
Install the bushing to the inner side of the bushing stopper on the stabilizer bar.
B53738
7.
INSTALL REAR STABILIZER LINK ASSY LH
(a) Remove the 2 nuts and stabilizer bar link.
Torque: 39 N
⋅ m (400 kgf
⋅ cm, 29 ft
⋅ lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud.
C91816
8.
INSTALL REAR STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures with the LH side.
9.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
10.
INSPECT REAR WHEEL ALIGNMENT (See page 27-3 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2399
27-18
REAR SUSPENSION STRUT ROD ASSY REAR
REPLACEMENT
HINT:
COMPONENTS: See page 27-2
1.
REMOVE REAR WHEEL
2706J-02
2.
REMOVE STRUT ROD ASSY REAR
(a) Remove the bolt, nut and disconnect the parking brake cable.
B53739
(b) Remove the bolt, nut and disconnect the strut rod (front side).
HINT:
Keep the nut fixed while loosening and removing the bolt.
B53740
(c) Remove the bolt, nut and strut rod from rear axle carrier.
HINT:
Keep the nut fixed while loosening and removing the bolt.
B53741
3.
TEMPORARILY TIGHTEN STRUT ROD ASSY REAR
(a) Install the strut rod (rear side), bolt nut and temporarily tighten the bolt.
HINT:
Insert the bolt from the inner side of the vehicle and temporarily install the bolt.
While fixing the nut, turn the bolt.
B53741
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2400
REAR SUSPENSION STRUT ROD ASSY REAR
(b) Connect the strut rod (inner side) with the bolt.
Torque: 113 N
⋅ m (1,150 kgf
⋅ cm, 83 ft
⋅ lbf)
HINT:
While fixing the nut, turn the bolt.
27-19
B53740
4.
STABILIZE SUSPENSION (See page 27-10 )
5.
FULLY TIGHTEN STRUT ROD ASSY REAR
(a) Fully tighten the bolt.
Torque: 113 N
⋅ m (1,152 kgf
⋅ cm, 83 ft
⋅ lbf)
HINT:
While fixing the nut, turn the bolt.
B53741
(b) Install the parking brake cable with the bolt and nut.
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
B53739
6.
INSTALL REAR WHEEL
Torque: 103 N
⋅ m (1,050 kgf
⋅ cm, 76 ft
⋅ lbf)
7.
INSPECT REAR WHEEL ALIGNMENT (See page 27-3 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2401
19-1
STARTING & CHARGING STARTING SYSTEM (3MZ-FE)
INSPECTION
190SE-01
1.
INSPECT STARTER ASSY
NOTICE:
These tests must be performed within 3 to 5 seconds to prevent burnout of the coil.
(a) Perform the pull-in test.
(1) Remove the nut, then disconnect the lead wire from terminal C.
A79718
Terminal C
(2) Connect the battery to the repair service starter kit as shown in the illustration. Check that the clutch pinion gear is extended.
If the clutch pinion gear does not move, replace the starter magnetic switch.
Body
Terminal 50
Body
Battery
A86236
Terminal C
Disconnect
Battery
A86239
(b) Perform the hold-in test.
(1) Disconnect the negative (-) lead from terminal C with the lead wire disconnected from terminal C.
Check that the clutch pinion gear remains extended.
If the clutch pinion gear returns inward, replace the starter magnetic switch.
(c) Check the operation.
(1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return inward, replace the starter magnetic switch.
Disconnect
Battery
A86238
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2333
19-2
STARTING & CHARGING STARTING SYSTEM (3MZ-FE)
(d) Perform the no-load performance test.
(1) Connect the lead wire to terminal C. Make sure that the lead is not grounded.
Torque: 10 N
⋅ m (102 kgf
⋅ cm, 7 ft
⋅ lbf)
A79718
Body
Terminal 50
Terminal 30
Ammeter
Battery
A86237
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current.
Specified current: 90 A or less at 11.5 V
If the current is not as specified, replace the starter.
Battery
Ohmmeter
A86241
2.
INSPECT STARTER RELAY ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Standard:
Tester Connection
3 - 5
3 - 5
Specified Condition
10 k
Ω
or higher
Below 1
Ω
(Apply battery voltage to terminals 1 and 2
If the result is not as specified, replace the starter relay.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2334
STARTING & CHARGING STARTER ASSY (3MZ-FE)
COMPONENTS
Clip x7
Clip
19-3
190SF-01
9.0 (92, 79 in.
⋅ lbf)
3.5 (36, 31 in.
⋅ lbf)
Radiator Lower Air Deflector
Air Cleaner Hose
No. 1
Vacuum Hose
Mass
Air Flow Meter
Connector
VSV Connector
Battery Clamp Sub-assy
Vacuum Hose
Battery
5.0 (51, 44 in.
⋅ lbf)
5.0 (51, 44 in.
⋅ lbf) x2
Air Cleaner Cap
Sub-assy x3
Air Cleaner Inlet
Assy
Battery Tray
5.0 (51, 44 in.
⋅ lbf)
Air Cleaner Filter
Element Sub-assy
5.0 (51, 44 in.
⋅ lbf)
Air Cleaner Inlet
No. 1
Air Cleaner Case
Sub-assy x2 7.5 (76, 66 in.
⋅ lbf)
Air Cleaner Bracket
A86242
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2335
19-4
STARTING & CHARGING STARTER ASSY (3MZ-FE)
Starter Assy
Starter Connector
9.8 (100, 7) x2
Starter Armature Assy
Starter Commutator End Frame Assy
37 (380, 26)
Washer
Snap Ring
Drive Housing
Starter Bearing Cover x2
Starter Magnetic Switch Assy
6.0 (61, 53 in.
⋅ lbf)
10 (102, 7)
7.5 (76, 66 in.
⋅ lbf) x2
Starter Drive Housing Assy
(w/ Clutch & Drive Lever
& Center Bearing)
Planetary Gear
Starter Armature Plate
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Starter Field Frame
Assy
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86243
2336
REPLACEMENT
STARTING & CHARGING STARTER ASSY (3MZ-FE)
19-5
190SG-01
1.
REMOVE RADIATOR SIDE DEFLECTOR RH
(a) Remove the 8 clips, then remove the radiator lower air deflector.
(c)
(a)
(b)
(c)
(b)
A86308
2.
REMOVE AIR CLEANER INLET ASSY
(a) Remove the wire harness clamp.
(b) Remove the 2 vacuum hoses from the hose clamp.
(c) Remove the 2 bolts, then remove the air cleaner inlet.
A86245
3.
REMOVE BATTERY
4.
REMOVE BATTERY TRAY
(b)
(b)
(b)
(b)
(d)
(c)
(a)
(c)
A81652
5.
REMOVE AIR CLEANER ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the 4 vacuum hoses.
(c) Loosen the 2 air cleaner cap bolts.
(d) Loosen the air cleaner hose clamp bolt, then remove the air cleaner cap.
(e) Remove the air cleaner filter element.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2337
19-6
STARTING & CHARGING STARTER ASSY (3MZ-FE)
(i) (i)
(f) Disconnect the VSV connector.
(g) Disconnect the vacuum hose.
(h) Remove the 3 bolts.
(i) Remove the wire harness from the 2 wire harness clamps, then remove the air cleaner case.
(f)
(g)
(h)
(h)
(h)
A86307
6.
REMOVE AIR CLEANER BRACKET
(a) Remove the 2 bolts, then remove the air cleaner bracket.
A78525
7.
REMOVE AIR CLEANER INLET NO.1
(a) Remove the bolt, then remove the air cleaner inlet No. 1.
Terminal Cap
(c)
A78526
8.
REMOVE STARTER ASSY
(a) Disconnect the starter connector.
(b) Open the terminal cap.
(c) Remove the nut, then disconnect the starter wire.
(a)
A78527
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2338
(d)
STARTING & CHARGING STARTER ASSY (3MZ-FE)
(d) Remove the 2 bolts, then remove the starter.
19-7
(d)
A78528
9.
INSTALL STARTER ASSY
Torque:
37 N
⋅ m (380 kgf
⋅ cm, 26 ft
⋅ lbf) for bolt
9.8 N
⋅ m (100 kgf
⋅ cm, 7 ft
⋅ lbf) for nut
10.
INSTALL AIR CLEANER INLET NO.1
Torque: 5.0 N
⋅ m (51 kgf
⋅ cm, 44 in.
⋅ lbf)
(e)
(d)
1
1
11.
INSTALL AIR CLEANER BRACKET
(a) Install the air cleaner bracket with the 2 bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 7.5 N
⋅ m (76 kgf
⋅ cm, 66 in.
⋅ lbf)
2
A78525
2
3
(b)
(b)
Air Cleaner
Case
12.
INSTALL AIR CLEANER ASSY
(a) Install the air cleaner case to the air cleaner inlet No. 1 as shown in the illustration.
(b) Install the wire harness to the 2 wire harness clamps.
(c) Using several steps, tighten the 3 bolts uniformly in the sequence shown in the illustration.
Torque: 5.0 N
⋅ m (51 kgf
⋅ cm, 44 in.
⋅ lbf)
(d) Connect the vacuum hose.
(e) Connect the VSV connector.
(f) Install the air cleaner filter element.
(g) Install the air cleaner cap, then tighten the air cleaner hose clamp bolt.
(h) Tighten the 2 air cleaner cap bolts.
Torque: 5.0 N
⋅ m (51 kgf
⋅ cm, 44 in.
⋅ lbf)
(i) Connect the 4 vacuum hoses.
(j) Connect the mass air flow meter connector.
Air Cleaner
Inlet No. 1
A86248
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2339
19-8
STARTING & CHARGING STARTER ASSY (3MZ-FE)
13.
INSTALL BATTERY TRAY
14.
INSTALL BATTERY
Torque:
9.0 N
⋅ m (92 kgf
⋅ cm, 79 in.
⋅ lbf) for bolt
3.5 N
⋅ m (36 kgf
⋅ cm, 31 in.
⋅ lbf) for nut
5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf) for terminal
15.
INSTALL AIR CLEANER INLET ASSY
Torque: 5.0 N
⋅ m (55 kgf
⋅ cm, 44 in.
⋅ lbf)
16.
CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
17.
INSTALL RADIATOR SIDE DEFLECTOR RH
18.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2340
OVERHAUL
STARTING & CHARGING STARTER ASSY (3MZ-FE)
19-9
190SH-01
1.
REMOVE STARTER MAGNETIC SWITCH ASSY
(a) Remove the nut, then disconnect the lead wire from terminal C.
A79718
(b) Remove the 2 screws which secure the starter magnetic switch to the starter drive housing.
(c) Remove the starter magnetic switch.
(d) Remove the return spring and plunger from the starter drive housing.
A79719
2.
REMOVE STARTER FIELD FRAME ASSY
(a) Remove the 2 through bolts, then pull out the field frame together with the starter commutator end frame.
A79720
(b) Remove the starter field frame from the starter commutator end frame.
A79721
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2341
19-10
Snap Ring
Pliers
STARTING & CHARGING STARTER ASSY (3MZ-FE)
3.
REMOVE STARTER ARMATURE PLATE
(a) Remove the starter armature plate from the starter field frame.
A79722
4.
REMOVE STARTER COMMUTATOR END FRAME
COVER
(a) Using a screwdriver, remove the starter commutator end frame cover.
A79723
5.
REMOVE STARTER ARMATURE ASSY
(a) Using snap ring pliers, remove the snap ring and plate washer.
(b) Remove the starter armature from the commutator end frame.
A82440
6.
REMOVE PLANETARY GEAR
(a) Remove the 3 planetary gears from the starter drive housing.
A81167
7.
INSPECT STARTER MAGNETIC SWITCH ASSY
(a) Check the operation.
(1) Push in the plunger, then check that it returns quickly to its original position.
If necessary, replace the starter magnetic switch.
A58586
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2342
19-1 1
STARTING & CHARGING STARTER ASSY (3MZ-FE)
Terminal C
Ohmmeter
(b) Check the continuity.
(1) Using an ohmmeter, check that there is continuity between terminals 50 and C.
If there is no continuity, replace the starter magnetic switch.
Terminal 50
Body
A88413
Ohmmeter
(2) Using an ohmmeter, check that there is continuity between terminal 50 and the body.
If there is no continuity, replace the starter magnetic switch.
Terminal 50
Ohmmeter
A88414
8.
INSPECT STARTER ARMATURE ASSY
(a) Check the continuity.
(1) Using an ohmmeter, check that there is continuity between the segments of the commutator.
If there is no continuity between any segments, replace the starter armature.
Ohmmeter
Commutator
Segment
A88416
(2) Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.
If there is continuity, replace the starter armature.
(b) Check the appearance.
(1) Check the commutator surface for dirt or burn.
If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or a lathe.
Coil Core
A88417
Depth
(c) Inspect the depth.
(1) Using vernier calipers, measure the commutator depth.
Standard depth: 3.1 mm (0.122 in.)
Maximum depth: 3.8 mm (0.150 in.)
If the depth is greater than maximum, replace the starter armature.
A58584
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2343
19-12
STARTING & CHARGING STARTER ASSY (3MZ-FE)
Length
9.
INSPECT STARTER COMMUTATOR END FRAME
ASSY
(a) Inspect the length.
(1) Using vernier calipers, measure the brush length.
Standard length: 9.0 mm (0.354 in.)
Minimum length: 4.0 mm (0.158 in.)
If the length is less than minimum, replace the starter commutator end frame.
A76677
Ohmmeter
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between the positive (+) and negative (- ) brushes.
If there is continuity, repair or replace the starter commutator end frame.
A88418
Lock
Free
10.
INSPECT STARTER DRIVE HOUSING ASSY (W/
CLUTCH & DRIVE LEVER & CENTER BEARING)
(a) Check the operation.
(1) Rotate the clutch pinion gear counterclockwise, then check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.
If necessary, replace the starter drive housing.
A81655
Apply Grease
11.
INSTALL PLANETARY GEAR
(a) Apply grease to the planetary gears and pin parts of the planetary shaft.
(b) Install the 3 planetary gears to the starter drive housing.
Snap Ring
Pliers
A81656
12.
INSTALL STARTER ARMATURE ASSY
(a) Apply grease to the plate washer and armature shaft.
(b) Install the starter armature to the starter commutator end frame.
(c) Using snap ring pliers, install the plate washer and a new snap ring.
A82440
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2344
Length
19-13
STARTING & CHARGING STARTER ASSY (3MZ-FE)
(d) Inspect the length.
(1) Using vernier calipers, measure the snap ring length.
Maximum length: 5.0 mm (0.197 in.)
If the length is greater than maximum, replace it with a new snap ring.
A58810
13.
INSTALL STARTER COMMUTATOR END FRAME
COVER
(a) Install the starter commutator end frame cover to the starter commutator end frame.
keyway
Key
A81178
14.
INSTALL STARTER ARMATURE PLATE
(a) Insert the starter armature plate to the starter field frame.
(b) Align the keyway of the starter plate with the key inside the starter yoke, then install the starter plate.
Rubber
Cutout
A73991
15.
INSTALL STARTER COMMUTATOR END FRAME
ASSY
(a) Align the rubber with the cutout of the starter field frame.
(b) Install the starter commutator end frame to the starter field frame.
A79727
16.
INSTALL STARTER FIELD FRAME ASSY
(a) Align the key of the starter field frame with the keyway of the starter drive housing.
Keyway Key
A79728
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2345
19-14
STARTING & CHARGING STARTER ASSY (3MZ-FE)
(b) Install the starter field frame with the 2 through bolts.
Torque: 6.0 N
⋅ m (61 kgf
⋅ cm, 53 in.
⋅ lbf)
A79720
17.
INSTALL STARTER MAGNETIC SWITCH ASSY
(a) Apply grease to the plunger and hook.
(b) Hook the plunger hook of the starter magnetic switch on the drive lever.
(c) Install the plunger and return spring.
A79729
(d) Install the starter magnetic switch with the 2 screws.
Torque: 7.5 N
⋅ m (76 kgf
⋅ cm, 66 in.
⋅ lbf)
A79719
(e) Connect the lead wire to terminal C with the nut.
Torque: 10 N
⋅ m (102 kgf
⋅ cm, 7 ft
⋅ lbf)
A79718
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2346
19-15
STARTING & CHARGING CHARGING SYSTEM (3MZ-FE)
190SI-01
PRECAUTION
1.
SYSTEM INITIALIZATION
NOTICE:
When disconnecting the negative (-) battery terminal, initialize the following systems after the terminal is reconnected.
System Name See Page
Power Window Control System 05-1470
Sliding Roof System 74-8
2.
Check that the battery cables are connected to the correct terminals.
3.
Disconnect the battery cables if a quick charge is given to the battery.
4.
Do not perform tests with a high voltage insulation resistance tester.
5.
Never disconnect the battery while the engine is running.
6.
Check that the charging cable is tightened on terminal B of the generator and the fuse box.
7.
Do not check whether the alternator generates current or not with terminal F connected to the other terminals.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2347
19-16
STARTING & CHARGING CHARGING SYSTEM (3MZ-FE)
190SJ-01
ON-VEHICLE INSPECTION
1.
INSPECT BATTERY (MAINTENANCE- FREE BAT-
TERY)
(a) Check the battery electrolyte level.
(1) Check the electrolyte quantity of each cell.
If the electrolyte quantity is below the recommended amount, replace the battery.
Blue White Red
A01260
(b) Check the battery voltage.
(1) If it has been less than 20 minutes since you stopped driving the vehicle or since the engine was stopped, turn the ignition switch and electrical systems (headlight, blower motor, rear defogger etc.) to the ON position for 60 seconds. This will remove the surface charge on the battery.
(2) Turn the ignition switch and electrical systems OFF.
(3) Using a voltmeter, measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20 C (68 F)
If the voltage is less than the specification, charge the battery.
(c) Check the indicator as shown in the illustration.
HINT:
Blue: OK
White: Charging Necessary
Red: Insufficient Water
A82941
2.
INSPECT BATTERY (EXCEPT MAINTENANCE-FREE
BATTERY)
(a) Check the battery electrolyte level.
(1) Check the electrolyte quantity of each cell.
If the electrolyte quantity is below the recommended amount, add distilled water.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2348
19-17
STARTING & CHARGING CHARGING SYSTEM (3MZ-FE)
(b) Check the battery specific gravity.
(1) Check the specific gravity of each cell.
Standard specific gravity: 1.25 to 1.29 at 20 C (68 F)
If the specific gravity is less than specification, charge the battery.
Blue White Red
A01259
A01260
(c) Check the battery voltage.
(1) If it has been less than 20 minutes since you stopped driving the vehicle or since the engine was stopped, turn the ignition switch and electrical systems (headlight, blower motor, rear defogger etc.) to the ON position for 60 seconds. This will remove the surface charge on the battery.
(2) Turn the ignition switch and electrical systems OFF.
(3) Using a voltmeter, measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20 C (68 F)
If the voltage is less than the specification, charge the battery.
(d) Check the indicator as shown in the illustration.
HINT:
Blue: OK
White: Charging Necessary
Red: Insufficient Water
A82941
3.
INSPECT BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Visually check the battery terminals.
(1) Check that the battery terminals are not loosened or corroded.
(b) Visually check the fusible link and fuses.
(1) Check that there is continuity of the fusible links, high current fuses and regular fuses.
4.
INSPECT V-RIBBED BELT
(a) Visually check the belt for excessive wear, frayed cords, etc.
If any defects are found, replace the v-ribbed belt.
Cracks on the rib side of the belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be replaced.
B00543
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2349
19-18
STARTING & CHARGING CHARGING SYSTEM (3MZ-FE)
(b) Check that the belt fits properly in the ribbed grooves.
Confirm that the belt has not slipped out of the groove on the bottom of the pulley by hand.
B00540
5.
INSPECT GENERATOR WIRING
(a) Visually check the generator wiring.
(1) Check that the wiring is in good condition.
6.
INSPECT ABNORMAL NOISES
(a) Listen to abnormal noises from generator.
(1) Check that no abnormal noise is heard from the generator while the engine is running.
7.
INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on.
(b) Start the engine, then check that the light goes off.
If the light does not operate as specified, troubleshoot the charge warning light circuit.
Battery
Ammeter
Voltmeter
Disconnect Wire from Terminal B
Generator
8.
INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) If a tester is not available, connect a voltmeter to the charging circuit as follows.
(1) Disconnect the wire from terminal B of the generator, then connect it to the negative (-) lead of the ammeter.
(2) Connect the positive (+) lead of the ammeter to ter-
A88419 minal B of the generator.
(3) Connect the positive (+) lead of the voltmeter to terminal B of the generator.
(4) Ground the negative (-) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm, then check the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 13.2 to 14.8 V
9.
INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn the high beam headlights ON and turn the heater blower switch to the ”HI” position.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, repair the generator.
If the battery is fully charged, the indication will sometimes be less than the standard amperage.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2350
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
COMPONENTS
19-19
190SK-01
9.8 (100, 7)
58 (591, 43)
Plate Washer
Generator
Connector
18 (184, 13)
V-ribbed Belt No. 1
Generator Assy
8.4 (86, 74 in.
⋅ lbf)
Wiring Harness Clamp Bracket
N·m (kgf·cm, ft·lbf) : Specified torque
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A87596
2351
19-20
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
Generator Washer
Generator Pulley
Generator Rotor Assy
111 (1,125, 81)
Drive End Frame Assy
Generator
Terminal Insulator
Generator
Brush Holder Assy
5.8 (59, 51 in.
⋅ lbf) x4 x2
1.8 (18, 16 in.
⋅ lbf)
Generator
Rear End Cover
4.6 (47, 41 in.
⋅ lbf) x3
Generator Coil Assy
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
A86392
2352
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
REPLACEMENT
1.
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
19-21
190SL-01
(a)
Terminal Cap
(c)
2.
REMOVE GENERATOR ASSY
(a) Remove the 2 wire harness clamps.
(b) Disconnect the generator connector.
(c) Open the terminal cap.
(d) Remove the nut, then disconnect the generator wire.
(b)
(a)
A86379
(e) Loosen bolts A and B.
(f) Loosen bolt C to lessen the tension of the V-ribbed belt
No.1.
B
A
C
A87594
(g) Remove bolts A and B, then remove the generator.
B
A
A87593
(h) Remove the bolt, then remove the wiring harness clamp bracket.
(h)
A87595
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2353
19-22
B
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
3.
INSTALL GENERATOR ASSY
(a) Install the wiring harness clamp bracket with the bolt.
Torque: 8.4 N
⋅ m (86 kgf
⋅ cm, 74 in.
⋅ lbf)
(b) Temporarily install the generator with bolts A and B.
A
A87593
B
A
C
A87594
(c) Adjust the V-ribbed belt No. 1 tension by tightening bolt
C (see page 14-1 ).
(d) Tighten bolts A and B.
Torque:
18 N
⋅ m (180 kgf
⋅ cm, 13 ft
⋅ lbf) for bolt A
58 N
⋅ m (591 kgf
⋅ cm, 43 ft
⋅ lbf) for bolt B
(e) Install the generator wire with the nut.
Torque: 9.8 N
⋅ m (100 kgf
⋅ cm, 7 ft
⋅ lbf)
(f) Connect the generator connector.
(g) Install the wire harness clamp.
4.
INSPECT DRIVE BELT (See page 14-1 )
5.
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N
⋅ m (55 kgf
⋅ cm, 48 in.
⋅ lbf)
6.
SYSTEM INITIALIZATION (See page 19-15 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2354
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
19-23
190SM-01
OVERHAUL
Turn
SST 1-A
SST 1-B
Hold
A81658
1.
REMOVE GENERATOR PULLEY
SST 09820-6301 1 (09820-06010, 09820-06020)
HINT:
SST 1-A and B
SST 2
09820 - 06010
09820 - 06020
(a) Hold SST 1-A with a torque wrench, then tighten SST
1-B clockwise with the specified torque.
Torque: 39 N
⋅ m (400 kgf
⋅ cm, 29 ft
⋅ lbf)
NOTICE:
Check that SST is secured to the rotor shaft.
(b) Clamp SST 2 in a vise.
(c) Insert SST 1-A and B into SST 2, then attach the pulley nut to SST 2.
Insert
SST 2
SST 1-A
SST 1-B
SST 1
A81659
Turn
SST1-A
A81660
(d) To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration.
NOTICE:
To prevent damage to the rotor shaft, do not loosen the pulley nut more than a half turn.
(e) Remove the generator from SST 2.
(f) Turn SST 1-B, then remove SST 1-A and B.
(g) Remove the pulley nut, then remove the generator pulley.
Turn
Hold
A81661
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2355
19-24
Pulley
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
2.
REMOVE GENERATOR BRUSH HOLDER ASSY
(a) Place the generator on the generator pulley.
(b) Remove the 3 nuts, then remove the generator rear end cover.
A81662
(c) Remove the terminal insulator from the generator coil.
A81146
(d) Remove the 2 screws, then remove the generator brush holder.
A81147
3.
REMOVE GENERATOR COIL ASSY
(a) Remove the 4 bolts.
SST
A81148
Turn
(b) Using SST, remove the generator coil.
SST 09950- 40011 (09951- 04020, 09952- 04010,
09953- 04020, 09954- 04010, 09955- 04071,
09957-04010, 09958-04011)
Hold
A81663
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2356
Generator Washer
19-25
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
4.
REMOVE GENERATOR ROTOR ASSY
(a) Remove the generator washer and generator rotor.
Length
A81664
A79305
5.
INSPECT GENERATOR BRUSH HOLDER ASSY
(a) Inspect the length.
(1) Using vernier calipers, measure the exposed brush length.
Standard exposed brush length: 10.5 mm (0.413 in.)
Minimum exposed brush length: 4.5 mm (0.177 in.)
If the exposed brush length is less than minimum, replace the generator brush holder.
6.
INSPECT GENERATOR ROTOR ASSY
(a) Check that the bearing is not rough or worn.
If necessary, replace the generator rotor.
Slip Ring
A79306
Ohmmeter
(b) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the slip rings.
Resistance: 2.3 to 2.7
Ω
at 20 C (68 F)
If the resistance is not as specified, replace the generator rotor.
Slip Ring
A88420
Rotor Core
Ohmmeter
(c) Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between the slip ring and rotor core.
If there is continuity, replace the generator rotor.
(d) Check the appearance.
(1) Check that the slip rings are not rough or scored.
If rough or scored, replace the generator rotor.
A88421
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2357
19-26
Diameter
Generator Washer
Generator
Pulley
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
(e) Inspect the diameter.
(1) Using vernier calipers, measure the slip ring diameter.
Standard diameter:
14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)
If the diameter is less than minimum, replace the generator rotor.
A75676
7.
INSTALL GENERATOR ROTOR ASSY
(a) Place the generator drive end frame on the generator pulley.
(b) Install the generator rotor and generator washer.
A81670
Deep Socket
Wrench 21
8.
INSTALL GENERATOR COIL ASSY
(a) Using a deep socket wrench 21 and press, press in the generator coil carefully.
A81671
(b) Tighten the 4 bolts.
Torque: 5.8 N
⋅ m (59 kgf
⋅ cm, 51 in.
⋅ lbf)
A81148
Pin (
φ
1.0 mm (0.039 in.))
9.
INSTALL GENERATOR BRUSH HOLDER ASSY
(a) While pushing the 2 brushes to inside the brush holder, insert a pin (
φ
1.0 mm (0.039 in.)) into the brush holder hole.
A79315
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2358
19-27
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
Pin (
φ
1.0 mm (0.039 in.)
(b) Install the generator brush holder with the 2 screws.
Torque: 1.8 N
⋅ m (18 kgf
⋅ cm, 16 in.
⋅ lbf)
(c) Pull out the pin (
φ
1.0 mm (0.039 in.)) from the generator brush holder.
A81672
(d) Install the terminal insulator.
NOTICE:
Pay attention to the mounting orientation of the terminal insulator.
A81146
(e) Install the generator rear end cover with the 3 nuts.
Torque: 4.6 N
⋅ m (47 kgf
⋅ cm, 41 in.
⋅ lbf)
Turn
SST 1-A
SST 1-B
A81164
Hold
A81658
10.
INSTALL GENERATOR PULLEY
SST 09820-6301 1 (09820-06010, 09820-06020)
HINT:
SST 1-A and B 09820 - 06010
SST 2 09820 - 06020
(a) Install the generator pulley to the rotor shaft by tightening the generator pulley nut by hand.
(b) Hold SST 1-A with a torque wrench, then tighten SST
1-B clockwise with the specified torque.
Torque: 39 N
⋅ m (400 kgf
⋅ cm, 29 ft
⋅ lbf)
NOTICE:
Check that SST is secured to the rotor shaft.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2359
19-28
Insert
SST 2
STARTING & CHARGING GENERATOR ASSY (3MZ-FE)
(c) Clamp SST 2 in a vise.
(d) Insert SST 1-A and B into SST 2, then attach the generator pulley nut to SST 2.
Hold
SST 1
A81659
(e) Tighten the generator pulley nut by turning SST 1-A in the direction shown in the illustration.
Torque: 111 N
⋅ m (1,125 kgf
⋅ cm, 81 ft
⋅ lbf)
(f) Remove the generator from SST 2.
SST 1-A
SST 1-B
Turn
SST1-A
A81673
(g) Turn SST 1-B, then remove SST 1-A and B.
(h) Turn the generator pulley, then check that the generator pulley moves smoothly.
Turn
A81661
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2360
50-1
STEERING COLUMN STEERING
5002J-08
PRECAUTION
1.
HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Care must be taken when replacing parts. Incorrect replacement they could affect the performance of the steering system and result in a driving hazard.
2.
HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The LEXUS ES330 is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in correct sequence could cause the
SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing
(including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint system (See page 60-1 ).
Author: Date:
2562
50-2
STEERING COLUMN STEERING
5002K-07
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 the order shown. If necessary, repair or replace these parts.
Symptom
Hard steering
Poor return
Excessive play
Abnormal noise
Suspect Area
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. Power steering vane pump
9. Power steering gear
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gear
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Power steering gear
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering vane pump
4. Power steering gear
See page
28-1
51-3
51-3
51-3
26-5
-
26-16
-
51-9
51-21
28-1
26-5
-
51-21
-
26-16
-
30-19
51-21
51-3
-
51-9
51-21
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2563
STEERING COLUMN STEERING
ON-VEHICLE INSPECTION
50-3
5002L-03
Maximum
Freeplay
1.
CHECK STEERING WHEEL FREEPLAY
(a) Stop the vehicle and face the tires straight ahead.
(b) Rock the steering wheel gently up and down with your hand, check the steering wheel freeplay.
Maximum freeplay: 30 mm (1.18 in.)
30 mm (1.18 in.)
H41575
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2564
50-4
REPAIR
Steering Wheel
Masking Tape
Steering Column
Upper Cover
STEERING COLUMN STEERING
5002V-03
1.
STEERING OFF CENTER REPAIR PROCEDURE
(a) Inspect steering wheel off center.
(1) Apply masking tape on the top center of the steering wheel and steering column upper cover.
(2) Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph (56 km/h), and hold the steering wheel to maintain the course.
Steering Column
Upper Cover
Marked Line
Steering Wheel
F16015
(3) Draw a line on the masking tape as shown in the illustration.
Masking
Tape
F16016
Steering Column
Upper Cover
Marked Line
Steering Wheel
F16017
(4) Turn the steering wheel to its straight position.
HINT:
Refer to the upper surface of the steering wheel, steering spoke and SRS airbag line for the straight position.
(5) Draw a new line on the masking tape or the steering wheel as shown in the illustration.
(6) Measure the distance between the 2 lines on the masking tape of the steering wheel.
(7) Convert the measured distance to steering angle.
Measured distance 1 mm (0.04 in.) = Steering angle approximately 1 deg.
HINT:
Make a note of the steering angle.
(b) Adjust steering angle.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2565
Marked Line
50-5
STEERING COLUMN STEERING
(1) Draw a line on the RH and LH tie rod and rack ends where it can easily be seen.
(2) Using a paper gauge, measure the distance from
RH and LH tie rod ends to the rack end screws.
HINT:
Measure the RH side and LH side.
Make a note of the measured values.
R00429
F16018
(3) Remove the RH and LH boot clips from the rack boots.
(4) Loosen the RH and LH lock nuts.
(5) Turn the RH and LH rack end by the same amount
(but in different directions) according to the steering angle.
1 turn 360 deg. of rack end (1.5 mm (0.059 in.) horizontal movement) - 12 deg. of steering angle.
(6) Tighten the RH and LH lock nuts.
Torque: 74 N
⋅ m (755 kgf
⋅ cm, 55 ft
⋅ lbf)
NOTICE:
Make sure that the difference in length between RH and LH tie rod ends and rack end screws are within 1.5 mm (0.059
in.).
(7) Install the RH and LH boot clips.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2566
50-6
STEERING COLUMN STEERING COLUMN ASSY
COMPONENTS
5002H-02
Steering Column
Cover
Steering Column Cover
Lower No.2
Steering Column Assy
21 (214, 15)
Steering Column Hole
Cover Sub-assy No. 2
21 (214, 15)
35 (360, 26)
Hose Clamp
35 (360, 26)
Heater to Foot
Duct No. 3
Steering Intermediate
Shaft Sub-assy
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Horn Button Assy
Steering Wheel Assy
Steering Wheel
Cover Lower No. 2
Instrument Panel
Finish Plate
50 (510, 37)
8.8 (90, 78 in.
⋅ lbf)
Connector
Cover
Steering Pad Switch
Turn Signal Switch Assy
Instrument Panel Sub-assy Upper
Instrument Panel Insert
Sub-assy Lower LH
Front Door Scuff Plate LH
C90698
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2567
50-7
Un-lock Waring
Switch Assy
STEERING COLUMN STEERING COLUMN ASSY
Transponder Key Amplifier
Ignition Switch Lock
Cylinder Assy
Steering Column Upper w/ Switch Bracket Assy
Steering Column Assy
Ignition or Starter
Switch Assy
Steering Sliding
Yoke Sub-assy
Steering Column
Clamp Upper
Tapered-Head Bolt
35 (360, 26)
N
⋅ m (kgf
⋅ cm, ft
⋅ lbf) : Specified torque
Non-reusable part
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
C92308
2568
50-8
STEERING COLUMN STEERING COLUMN ASSY
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
6.
REMOVE STEERING PAD SWITCH
(a) Remove the 2 screws.
(b) Disconnect the connector and remove the steering pad switch.
7.
REMOVE HORN BUTTON ASSY(See page 60-22 )
8.
REMOVE STEERING WHEEL ASSY
(a) Remove the steering wheel assy set nut.
5002I-04
Matchmarks
(b) Place matchmarks on the steering wheel assy and steering main shaft assy.
(c) Using SST, remove the steering wheel assy.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05021)
SST
C90684
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 71-1 1 )
13.
REMOVE STEERING COLUMN COVER LWR NO.2
(a) Remove the steering column cover lwr No.2.
C90685
14.
REMOVE STEERING COLUMN COVER
(a) Remove the 3 screws and steering column cover.
C90686
Author: Date: 2569
50-9
STEERING COLUMN STEERING COLUMN ASSY
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.
C90687
18.
DISCONNECT STEERING SLIDING YOKE SUB-ASSY
(a) Place the matchmarks on the steering sliding yoke subassy and intermediate shaft sub-assy.
(b) Remove the bolt and disconnect the steering sliding yoke sub-assy .
Matchmarks
C90688
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.
Author: Date:
2570
50-10
STEERING COLUMN STEERING COLUMN ASSY
(c) Remove the 2 nuts, bolt and steering column assy from the instrument panel reinforcement assy.
C90844
C90690
Matchmarks
Matchmarks
C90689
21.
REMOVE STEERING INTERMEDIATE SHAFT
SUB-ASSY
(a) Place the matchmarks on the steering intermediate shaft sub-assy and steering gear assy.
(b) Remove the bolt and steering intermediate shaft subassy.
22.
REMOVE STEERING SLIDING YOKE SUB-ASSY
(a) Place the matchmarks on the steering sliding yoke subassy and steering main shaft assy.
(b) Remove the bolt and steering yoke sub-assy.
H41505
C90692
23.
REMOVE TRANSPONDER KEY AMPLIFIER
(a) Widen the claw hung on the upper bracket by approx. 1.0
mm (0.039 in.) using a screwdriver.
(b) Pull the transponder key amplifier toward the rear of the vehicle with the claw open.
NOTICE:
Take care not to use excessive force to prevent the case from being damage.
Author: Date: 2571
Screw Extractor
50-1 1
STEERING COLUMN STEERING COLUMN ASSY
24.
REMOVE STEERING COLUMN UPPER W/SWITCH
BRACKET ASSY
(a) Using a centering punch, mark the center of the 2 tapered-head bolts.
(b) Using a 3 - 4 mm (0.12 - 0.16 in.) drill, drill in to the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts and steering column upper w/switch bracket assy.
C90693
25.
REMOVE IGNITION SWITCH LOCK CYLINDER ASSY
(a) Place the ignition switch lock cylinder assy at the ACC position.
(b) Push down the stop pin with a screwdriver, and pull out the ignition switch lock cylinder assy.
C90695
26.
REMOVE UN-LOCK WARNING SWITCH ASSY
(a) Disconnect the un-lock warning switch assy connector from the ignition or starter switch assy.
(b) Remove the un-lock warning switch assy by pushing up the center part and releasing the 2 screws.
C90696
27.
REMOVE IGNITION OR STARTER SWITCH ASSY
(a) Remove the 2 screws and ignition or starter switch assy from the steering column upper w/switch bracket assy.
28.
INSTALL IGNITION OR STARTER SWITCH ASSY
(a) Install the ignition switch assy to the steering column upper w/switch bracket assy with the 2 screws.
29.
INSTALL UN-LOCK WARNING SWITCH ASSY
(a) Install the un-lock warning switch assy.
(b) Connect the un-lock warning switch assy connector to the ignition or starter switch assy.
30.
INSTALL IGNITION SWITCH LOCK CYLINDER ASSY
(a) Make sure the ignition switch lock cylinder assy at the ACC position.
(b) Install the ignition switch lock cylinder assy.
31.
INSPECT STEERING LOCK OPERATION
(a) Check that the steering lock mechanism is activated when removing the key.
(b) Check that the steering lock mechanism is deactivated when inserting the key and turning it to ACC position.
Author: Date:
2572
50-12
Matchmarks
STEERING COLUMN STEERING COLUMN ASSY
32.
INSTALL STEERING COLUMN UPPER W/SWITCH
BRACKET ASSY
(a) Temporarily install the steering column upper w/switch bracket assy and steering column upper clamp with 2 new tapered-head bolts.
(b) Tighten the 2 tapered-head bolts until the bolt heads break off.
C90694
C90697
33.
INSTALL TRANSPONDER KEY AMPLIFIER
(a) Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined.
(b) Push the transponder key amplifier up and connect it to the upper bracket.
NOTICE:
Take care not to push the amplifier up with excessive force to prevent it from being damaged.
34.
INSTALL STEERING SLIDING YOKE SUB-ASSY
(a) Align the matchmarks on the steering sliding yoke subassy and steering main shaft assy.
(b) Install the steering sliding yoke sub-assy with the bolt.
Torque: 35 N
⋅ m (360 kgf
⋅ cm, 26 ft
⋅ lbf)
C90844 H41505
35.
INSTALL STEERING COLUMN HOLE COVER SUB-ASSY NO.2
(a) Install the steering column hole cover sub-assy No.2.
(b) Install the hose clamp.
Matchmarks
C90689
36.
INSTALL STEERING INTERMEDIATE SHAFT
SUB-ASSY
(a) Align and steering gear assy.
(b) Install the steering intermediate shaft sub-assy with the bolt.
Torque: 35 N
⋅ m (360 kgf
⋅ cm, 26 ft
⋅ lbf)
Author: Date: 2573
50-13
STEERING COLUMN STEERING COLUMN ASSY
37.
INSTALL STEERING COLUMN ASSY
(a) Install the steering column assy with the 2 nuts and bolt.
Torque: 21 N
⋅ m (214 kgf
⋅ cm, 15 ft
⋅ lbf)
(b) Connect the driver side junction block.
(c) Connect the connectors and wire harness clamps.
C90690
38.
CONNECT STEERING SLIDING YOKE SUB-ASSY
(a) Align the matchmarks on the steering sliding yoke subassy and steering intermediate shaft sub-assy.
(b) Connect the steering sliding yoke sub-assy with the bolt.
Torque: 35 N
⋅ m (360 kgf
⋅ cm, 26 ft
⋅ lbf)
Matchmarks
C90688
39.
CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY
(a) Place the ignition switch lock cylinder assy at the key ACC position.
(b) Install the floor shift parking lock cable assy.
40.
INSPECT CHECK KEY INTERLOCK OPERATION(See page 40-31 )
41.
INSTALL INSTRUMENT PANEL FINISH PLATE(See page 71-1 1 )
42.
INSTALL TURN SIGNAL SWITCH ASSY
(a) Install the turn signal switch assy with the 3 screws.
(b) Connect the airbag connector.
(c) Connect the 3 connectors.
43.
INSPECT SPIRAL CABLE SUB-ASSY(See page 60-31 )
44.
INSTALL STEERING COLUMN COVER
(a) Install the steering column cover with the 3 screws.
45.
INSTALL STEERING COLUMN COVER LWR NO.2
46.
INSTALL HEATER TO FOOT DUCT NO.3(See page 71-1 1 )
47.
INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
48.
INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
49.
INSTALL FRONT DOOR SCUFF PLATE LH
50.
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
Author: Date:
2574
50-14
STEERING COLUMN STEERING COLUMN ASSY
51.
INSTALL STEERING WHEEL ASSY
(a) Align the matchmarks on the steering wheel assy and steering main shaft assy.
(b) Install the steering wheel assy set nut.
Torque: 50 N
⋅ m (510 kgf
⋅ cm, 37 ft
⋅ lbf)
52.
INSPECT HORN BUTTON ASSY(See page 60-22 )
53.
INSTALL HORN BUTTON ASSY(See page 60-22 )
54.
INSTALL STEERING PAD SWITCH
(a) Connect the connector.
(b) Install the steering pad switch with the 2 screws.
55.
INSTALL CONNECTOR COVER
56.
INSTALL STEERING WHEEL COVER LOWER NO.2
57.
INSPECT SRS WARNING LIGHT(See page 05-818 )
Author: Date: 2575
25-1
SUSPENSION CONTROL SYSTEM FRONT ACCELERATION SENSOR
REPLACEMENT
1.
REMOVE FRONT DOOR SCUFF PLATE RH (See page 71-1 1 )
2.
REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (See page 71-1 1 )
3.
REMOVE INSTRUMENT PANEL SUB-ASSY LOWER (See page 71-1 1 )
2500O-02
F41643
4.
REMOVE ACCELERATION SENSOR ASSY
(a) Disconnect the acceleration sensor connector.
(b) Remove the nut and acceleration sensor from the instrument panel reinforcement.
5.
INSTALL ACCELERATION SENSOR ASSY
(a) Install the acceleration sensor with the nut.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
(b) Connect the acceleration sensor connector.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2361
25-2
SUSPENSION CONTROL SYSTEM REAR ACCELERATION SENSOR
REPLACEMENT
1.
REMOVE REAR SEAT CUSHION ASSY (See page 72-39 )
2.
REMOVE REAR SEATBACK ASSY (See page 72-39 )
3.
REMOVE ROOF SIDE GARNISH INNER RH (See page 74-10 )
2500P-02
C91471
4.
REMOVE ACCELERATION SENSOR
(a) Disconnect the acceleration sensor connector.
(b) Remove the bolt and acceleration sensor from the side pillar RH.
5.
INSTALL ACCELERATION SENSOR
(a) Install the acceleration sensor with the bolt.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
(b) Connect the acceleration sensor connector.
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2362
25-3
SUSPENSION CONTROL SYSTEM ABSORBER CONTROL ECU
REPLACEMENT
1.
REMOVE FRONT DOOR SCUFF PLATE LH (See page 71-1 1 )
2.
REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (See page 71-1 1 )
3.
REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (See page 71-1 1 )
4.
REMOVE ABSORBER CONTROL ECU
(a) Disconnect the 2 absorber control ECU connectors.
(b) Remove the 2 nuts and absorber control ECU.
5.
INSTALL ABSORBER CONTROL ECU
(a) Install the absorber control ECU with the 2 nuts.
Torque: 7.8 N
⋅ m (80 kgf
⋅ cm, 69 in.
⋅ lbf)
(b) Connect the 2 absorber control ECU connectors.
2500Q-02
F41644
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2363
Technical Service
Information Bulletin
December 16, 2004
Title:
Models:
’90 – Current All Models
Introduction This service bulletin contains inspection procedures to more precisely confirm proper operation of the following temperature sensors of the air conditioning system. Follow the procedures in this service bulletin when inspecting these sensors. These contents will be reflected in future repair manuals.
S
Room Temperature Sensor
S
Ambient Temperature Sensor
S
Air Duct Sensor
S
Evaporator Temperature Sensor
S
Solar Sensor
S
Room Humidity Sensor
Applicable
Vehicles
S
All 1990 – Current model year Lexus vehicles.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04
Inspection
Procedure
1. Inspect Room Temperature Sensor.
A. Measure the sensor resistance.
Resistance Value at 77
°
F
(25
°
C)
1700 +/– 85
Ω
NOTE:
S
Even slightly touching the sensor may change the resistance value.
Be sure to hold the connector of the sensor.
S
When measuring, the sensor temperature must be the same as the ambient temperature.
HINT:
As the temperature increases, the resistance decreases.
TEMPERATURE
°
F (
°
C)
50 (10)
59 (15)
68 (20)
77 (25)
86 (30)
95 (35)
104 (40)
113 (45)
122 (50)
131 (55)
140 (60)
SPECIFICATION k
Ω
3.00 to 3.73
2.45 to 2.88
1.95 to 2.30
1.60 to 1.80
1.28 to 1.47
1.00 to 1.22
0.80 to 1.00
0.65 to 0.85
0.50 to 0.70
0.44 to 0.60
0.36 to 0.50
December 16, 2004
Resistance k
Ω
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
32
(0)
Max
68
(20)
104
(40)
Temperature
°
F (
°
C)
Min
140
(60)
Page 2 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04
Inspection
Procedure
(Continued)
2. Inspect Ambient
Temperature Sensor.
A. Measure the sensor resistance according to the selected graph
(specification).
Resistance Value at 77
°
F
(25
°
C)
1700 +/– 85
Ω
NOTE:
S
Even slightly touching the sensor may change the resistance value.
Be sure to hold the connector of the sensor.
S
When measuring, the sensor temperature must be the same as the ambient temperature.
HINT:
As the temperature increases, the resistance decreases.
TEMPERATURE
°
F (
°
C)
50 (10)
59 (15)
68 (20)
77 (25)
86 (30)
95 (35)
104 (40)
113 (45)
122 (50)
131 (55)
140 (60)
SPECIFICATION k
Ω
3.00 to 3.73
2.45 to 2.88
1.95 to 2.30
1.60 to 1.80
1.28 to 1.47
1.00 to 1.22
0.80 to 1.00
0.65 to 0.85
0.50 to 0.70
0.44 to 0.60
0.36 to 0.50
December 16, 2004
Resistance k
Ω
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
32
(0)
Max
68
(20)
104
(40)
Temperature
°
F (
°
C)
Min
140
(60)
Page 3 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04
Inspection
Procedure
(Continued)
3. Inspect Air Duct Sensor.
A. Measure the sensor resistance according to the table and graph (specification).
NOTE:
S
Even slightly touching the sensor may change the resistance value.
Be sure to hold the connector of the sensor.
S
When measuring, the sensor temperature must be the same as the ambient temperature.
HINT:
As the temperature increases, the resistance decreases.
TEMPERATURE
°
F (
°
C)
50 (10)
59 (15)
68 (20)
77 (25)
86 (30)
95 (35)
104 (40)
113 (45)
122 (50)
131 (55)
140 (60)
SPECIFICATION k
Ω
9.48 to 10.49
7.50 to 8.28
5.95 to 6.57
4.77 to 5.25
3.85 to 4.21
3.12 to 3.40
2.53 to 2.79
2.06 to 2.30
1.69 to 1.91
1.39 to 1.59
1.15 to 1.33
Resistance k
Ω
15.0
10.0
December 16, 2004
5.0
Max
0.0
32
(0)
Min
68
(20)
104
(40)
140
(60)
Temperature
°
F (
°
C)
176
(80)
Page 4 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04
Inspection
Procedure
(Continued)
4. Inspect Evaporator Temperature Sensor.
December 16, 2004
Select the appropriate graph (specification) using the following table.
NOTE:
Please inspect the sensors for model years not indicated by this bulletin, according to the instructions in the applicable repair manual.
MODEL
ES 300
GS 300
GS 300/400/430
IS 300
LS 400
LS 430
LX 450
LX 470
RX 300
RX 330
SC 300/400
MODEL YEAR
1992 – 2001
2002 – 2003
2003
1993 – 1997
1998 – 2002
2003 2005
2000 – 2001
1990 – 1992
1993 – 1994
1995 – 2000
2001 – 2005
1996 – 1997
1998 – 2000
1998 – 2002
2003 – 2005
1998 – 2003
2004
2004 2005
1991 – 2000
COMMENTS
Thermistor No. 1
Thermistor No. 2
Thermistor No. 2
Thermistor No. 1
CBU
CBU
NAP
PART NUMBER
88625–33070
88625–17130
88625–33170
88625–3A020
88625–3A120
88625–35050
88625–16210
88625–48010
88625–32040
88625–50100
88625–50140
88625–50160
88625–60060
88625–60140
88625–60130
88625–47011
88625–48010
88625–48050
88625–32040
2
2
2
2
2
2
2
2
2
3
2
2
2
1
GRAPH
2
2
3
2
2
Page 5 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04
Inspection
Procedure
(Continued)
December 16, 2004
A. Measure the sensor resistance according to the selected graph (specification).
NOTE:
S
Even slightly touching the sensor may change the resistance value.
Be sure to hold the connector of the sensor.
S
When measuring, the sensor temperature must be the same as the ambient temperature.
HINT:
As the temperature increases, the resistance decreases.
Graph 1:
TEMPERATURE
°
F (
°
C)
14 (–10)
23 (–5)
32 (0)
41 (5)
50 (10)
59 (15)
68 (20)
77 (25)
86 (30)
SPECIFICATION k
Ω
7.30 to 9.10
5.65 to 6.95
4.40 to 5.35
3.40 to 4.15
2.70 to 3.25
2.14 to 2.58
1.71 to 2.05
1.38 to 1.64
1.11 to 1.32
Graph 2:
TEMPERATURE
°
F (
°
C)
14 (–10)
23 (–5)
32 (0)
41 (5)
50 (10)
59 (15)
68 (20)
77 (25)
86 (30)
SPECIFICATION k
Ω
7.40 to 9.20
5.65 to 7.00
4.35 to 5.40
3.40 to 4.20
2.68 to 3.30
2.10 to 2.60
1.66 to 2.10
1.32 to 1.66
1.05 to 1.35
Resistance k
Ω
12.0
11.0
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
–4
(–20)
Min
Max
32
(0)
68
(20)
Temperature
°
F (
°
C)
104
(40)
Resistance k
Ω
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
–4
(–20)
Min
Max
32
(0)
68
(20)
Temperature
°
F (
°
C)
104
(40)
Page 6 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04
Inspection
Procedure
(Continued)
Graph 3:
TEMPERATURE
°
F (
°
C)
14 (–10)
23 (–5)
32 (0)
41 (5)
50 (10)
59 (15)
68 (20)
77 (25)
86 (30)
SPECIFICATION k
Ω
8.00 to 10.00
6.15 to 7.65
4.75 to 5.85
3.70 to 4.55
2.91 to 3.55
2.32 to 2.80
1.85 to 2.22
1.48 to 1.77
1.20 to 1.43
December 16, 2004
Resistance k
Ω
12.0
11.0
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
–4
(–20)
Min
Max
32
(0)
68
(20)
Temperature
°
F (
°
C)
104
(40)
Page 7 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04 December 16, 2004
Inspection
Procedure
(Continued)
5. Inspect Solar Sensor.
Four types of solar sensors are used on Lexus vehicles depending on the vehicle specifications. The inspection procedure for each type of sensor differs from the others. Select the appropriate inspection procedure from the table below according to vehicle specifications and perform the inspection.
EQUIPPED WITH AUTOMATIC
LIGHT CONTROL SYSTEM
No
No
Yes
Yes
A/C SYSTEM WITH RIGHT/LEFT
INDEPENDENT TEMPERATURE CONTROL
No
Yes
Yes
No
INSPECTION
PROCEDURE
A
B
C
D
Procedure A: a. Disconnect the solar sensor connector.
b. Measure the resistance between terminals 1 and 2 of the solar sensor under the following conditions:
S
Cover the sensor with a cloth to avoid direct light.
S
Expose the sensor to light from a distance of 300 mm
(11.81 in.) or less with an inspection light.
NOTE:
S
Terminal 1 of the sensor is always on the right, when the lock is facing up.
S When using an analog tester, connect the positive (+) lead to terminal 2 and negative (–) lead to terminal 1 of the solar sensor.
Lock
HINT:
If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.
Standard:
CONDITION
When the sensor is covered with a cloth
(to avoid direct light)
When the sensor is exposed to light
SPECIFICATION
Infinite ohms
Less than infinite resistance
Page 8 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04
Inspection
Procedure
(Continued)
Procedure B: a. Disconnect the solar sensor connector.
b. Measure the resistance between terminals 2 and 3 of the solar sensor under the following conditions:
S
Cover the sensor with a cloth to avoid direct light.
S
Expose the sensor to light from a distance of 300 mm
(11.81 in.) or less with an inspection light.
NOTE:
When using an analog tester, connect the positive (+) lead to terminal 3 and negative (–) lead to terminal 2 of the solar sensor.
December 16, 2004
Lock
HINT:
If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.
Standard:
CONDITION
When the sensor is covered with a cloth
(to avoid direct light)
When the sensor is exposed to light
SPECIFICATION
Infinite ohms
Less than infinite resistance
Page 9 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04 December 16, 2004
Inspection
Procedure
(Continued)
Procedure C: a. Turn the ignition switch ON.
b. Measure the voltage between terminals TSR (+) and CLTE (–) of the connector under the following conditions:
S
Cover the sensor with a cloth to avoid direct light.
S Expose the sensor to light from a distance of 300 mm
(11.81 in.) or less with an inspection light.
TSR
CLTE
HINT:
S If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.
S Do not disconnect the solar sensor connector.
Standard:
CONDITION
When the sensor is covered with a cloth
(to avoid direct light)
When the sensor is exposed to light
SPECIFICATION
Below 0.8 V
4.3 +/– 0.3 V c. Measure the voltage between terminals TSL (+) and CLTE (–) of the connector under the following conditions:
S
Cover the sensor with a cloth to avoid direct light.
S Expose the sensor to light from a distance of 300 mm
(11.81 in.) or less with an inspection light.
TSL
CLTE
HINT:
S If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.
S Do not disconnect the solar sensor connector.
Standard:
CONDITION
When the sensor is covered with a cloth
(to avoid direct light)
When the sensor is exposed to light
SPECIFICATION
Below 0.8 V
4.3 +/– 0.3 V
Page 10 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04
Inspection
Procedure
(Continued)
Procedure D: a. Turn the ignition switch ON.
b. Using the tester, measure the voltage between terminals
TSD (+) and CLTE (–) of the connector under the following conditions:
S
Cover the sensor with a cloth to avoid direct light.
S
Expose the sensor to light from a distance of 300 mm
(11.81 in.) or less with an inspection light.
CLTE
December 16, 2004
TSD
HINT:
S If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.
S
Do not disconnect the solar sensor connector.
Standard:
CONDITION
When the sensor is covered with a cloth
(to avoid direct light)
When the sensor is exposed to light
SPECIFICATION
Below 0.8 V
4.3 +/– 0.3 V
Page 11 of 12
SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM – AC005-04
Inspection
Procedure
(Continued)
6. Inspect Room Humidity Sensor.
Measure the humidity and output voltage of the humidity sensor when the sensor is installed on the vehicle and the temperature at the humidity sensor position (room temperature sensor position) is 77
°
F (25
°
C).
If the output voltage is within the specifications according to the graph and table below, the sensor is normal.
HINT:
For the inspection procedure of the room temperature sensor, refer to
“Room Temperature Sensor Inspection
Procedure” in this bulletin.
50
60
70
80
90
10
20
30
40
A. Turn the ignition switch to the
ON position.
B. Measure the voltage between terminal VO (3) and GND (2) of the room humidity sensor.
C. Measure the humidity and voltage when the room temperature
(humidity sensor position) is 77
°
F
(25
°
C). According to the result, determine whether the sensor is normal or not.
HUMIDITY (% RH)
OUTPUT VOLTAGE
AT 77
°
F (25
°
C)
0.70 to 1.08 V
0.72 to 1.57 V
1.13 to 1.95 V
1.61 to 2.24 V
1.99 to 2.46 V
2.26 to 2.66 V
2.48 to 2.85 V
2.68 to 3.04 V
2.87 to 3.05 V
VO GND
December 16, 2004
Resistance k
Ω
3.50
3.00
2.50
2.00
1.50
1.00
0.50
0.00
32
(0)
Max
Min
68
(20)
104
(40)
140
(60)
176
(80)
Temperature
°
F (
°
C)
212
(100)
Page 12 of 12
Technical Service
Information Bulletin
July 13, 2005
Title:
Models:
’98 – ’06 All Models
Introduction The following procedures are recommended to maintain windshield wiper blade performance.
Applicable
Vehicles
S
1998 – 2006 model year Lexus vehicles.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Maintenance,
Cleaning
& Use
Recommendations for Windshield Wiper Maintenance, Cleaning, and Use:
1. Scheduled Maintenance
S
Check wiper rubber blades every 4 – 6 months or 7,500 miles for wear, cracking, and contamination.
S
Clean glass and rubber wiper blades if blades are not clearing glass adequately.
If this does not correct the problem, then replace the rubber elements.
2. Cleaning Procedure
S
Wiper Rubber: Bugs, dirt, sap, and road grime on blades will cause streaking.
Clean wiper rubber of road and environmental debris using cloth or paper towel soaked with windshield washer fluid or mild detergent.
S
DO NOT USE fuel, kerosene, or petroleum based products to clean rubber wiper blades.
S
Windshield: Bugs, sap, road grime, and car wash wax treatments decrease wiper performance.
S
Rinse windshield with water and apply non–abrasive cleaner, such as Bon–Ami
(www.faultless.com), with a sponge.
NOTE:
Make sure to use plenty of water with all powder based cleaners so the glass is not scratched.
Lexus Supports ASE Certification
Page 1 of 2
WINDSHIELD WIPER BLADE MAINTENANCE AND CLEANING – BO004-05 July 13, 2005
Maintenance,
Cleaning
& Use
(Continued)
3. Contributors to Poor Performance/Decreased Rubber Blade Life (require rubber replacement)
S
Dusty areas cause the rubber edge to wear quickly.
S
Sand and salt used for road conditioning during winter causes the edge to wear quickly, so areas with significant snowfall require more frequent wiper replacement.
S
Heat and time cause the rubber to become excessively “permanent set,” so the rubber does not turn over, resulting in streaking and/or unwiped areas on the glass.
S
Rubber is easily cut or torn while using ice scrapers on the glass.
S
Rubber can be torn when pulling blades off a frozen windshield.
S
Using wipers instead of an ice scraper to remove frost and ice from the windshield during a car warm up can dull, nick, or tear the rubber.
S
Banging wiper on the glass to remove ice & snow can cause the blade to bend and rubber to come out of the blade providing the potential to scratch the glass.
S
Ice forms in wiper blade pin joints, which causes streaking and unwiped areas.
To remove ice from pin joints, compress the blade and rubber with your hand to loosen the frozen joints. To prevent this condition, use winter blades with a rubber cover.
Page 2 of 2
Technical Service
Information Bulletin
September 29, 2004
Title:
Models:
’03 – ’05 Model Year
Introduction
TSIB REVISION NOTICE:
S December 9, 2005: The “Rear Seat Belt Extender Applications” section has been updated. In the Part Number Information table, the part numbers for series Q–6 have been updated.
S June 28, 2005: In the “Rear Seat Belt Extender Applications” section, the series number for the ’05 ES 330 has been updated to R–7.
Previous versions of this TSIB should be discarded.
Lexus customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Lexus dealer.
S
The extender is available in 6 inch,
9 inch, 12 inch, 15 inch, and
18 inch lengths.
S
The extender is available only in black.
S Owners are informed of the Seat Belt
Extender availability through the Lexus
Owner’s Manual included in each vehicle.
Seat Belt
Extender
The customer (individual requiring the extender) must visit a Lexus dealership to have the required measurements made and to complete the Seat Belt Extender Worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place an order through Dealer Daily.
The dealership service department should complete the affixed Seat Belt Extender
Customer Information Label on the part and review the “Owner Instruction Sheet” with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer’s file.
To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue.
It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for proper fitting to individual customers.
This bulletin contains the following information:
Procedure and Sample Label . . . . . . . . . .
Application Charts . . . . . . . . . . . . . . . . . . . .
Part Number Information . . . . . . . . . . . . . .
Owner Instructions . . . . . . . . . . . . . . . . . . .
Seat Belt Extender Worksheet . . . . . . . . .
Page 2
Page 3
Page 4
Page 5
Page 6
S
2003 – 2005 model year Lexus vehicles.
Applicable
Vehicles
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 6
SEAT BELT EXTENDER: ’03–’05 MODEL YEAR – BO009-04 Revised September 29, 2004
Procedure 1. Customer requests a Seat Belt Extender from dealer.
2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this
TSIB and copies the Worksheet.
3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct part number and places an order for the part through Dealer Daily.
4. Dealer receives Seat Belt Extender and calls the customer to check the fit of the part.
5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer
Information Label on the part, explains usage of the part, and gives the customer a copy of the completed Worksheet.
6. Dealer places copy of the completed Worksheet in the customer’s records.
DEALER DEALER OWNER
MEASURE
CUSTOMER
&
COMPLETE
WORKSHEET
PLACE
ORDER
THROUGH
DEALER
DAILY
PARTS
SUPPLY
SHIP SEAT
BELT
EXTENDER
TO DEALER
TEST FIT
CUSTOMER
WITH PART
COMPLETE
LABEL AND
ADVISE
CUSTOMER
RECEIVE
COPY OF
WORKSHEET
& USE
EXTENDER
FILE
WORKSHEET
IN
CUSTOMER
RECORDS
Sample Seat
Belt Extender
Customer
Information
Label
THIS SEAT BELT EXTENDER IS TO BE USED ONLY BY :
ON VEHICLE:
VIN:
SEATING POSITION:
USE BY OTHERS, OR IN ANOTHER SEATING POSITION, OR IN ANOTHER VEHICLE
COULD REDUCE SEAT BELT RESTRAINT IN AN ACCIDENT AND RESULT IN
PERSONAL INJURY.
Page 2 of 6
SEAT BELT EXTENDER: ’03–’05 MODEL YEAR – BO009-04 Revised
Front Seat
Belt Extender
Applications
MODEL
ES 300
ES 330
GS 300
GS 430
GX 470
IS 300
LS 430
LX 470
RX 300
RX 330
SC 430
September 29, 2004
FRONT SEAT – EXTENDER APPLICATION
TYPE ’05
All Models
–
R–6
R–3
R–3
K–6
K–6
R–3
K–6
–
R–7
R–3
’04
–
R–6
R–3
R–3
K–6
K–6
R–3
K–6
–
R–7
R–3
’03
R–5
–
R–3
R–3
K–6
K–6
R–3
K–6
R–5
–
R–3
Rear Seat
Belt Extender
Applications
MODEL
ES 300
ES 330
GS 300
GS 430
GX 470
IS 300
LS 430
LX 470
RX 300
RX 330
SC 430
REAR SEAT – EXTENDER APPLICATION
TYPE ’05
RH, LH
RH, LH
All Models
–
R–7
K–5
K–5
K–5
R–5
R–3
K–5
–
R–6 or
Q–5
R–5
NOTE:
The extender must NOT be used for the center rear seat belt.
’04
–
R–5
K–5
K–5
K–5
R–5
R–3
K–5
–
R–6 or
Q–5
R–5
’03
R–5
–
K–5
K–5
K–5
R–5
R–3
K–5
R–5
–
R–5
Page 3 of 6
SEAT BELT EXTENDER: ’03–’05 MODEL YEAR – BO009-04 Revised
Part Number
Information
R–3
R–5
R–6
R–7
N–6
K–5
K–6
Q–5
Q–6
6 INCH
–50010
–16060
–35110
–48010
–20160
–35010
–35060
–AE010
–AE061
PART NUMBER PREFIX: 73399–
9 INCH
–50020
–16070
–35120
–48020
–20170
–35020
–35070
–AE020
–AE071
LENGTH
12 INCH
–50030
–16080
–35130
–48030
–20180
–35030
–35080
–AE030
–AE081
15 INCH
–50040
–16090
–35140
–48040
–20190
–35040
–35090
–AE040
–AE091
September 29, 2004
18 INCH
–50050
–16100
–35150
–48050
–20200
–35050
–35100
–AE050
–AE101
Page 4 of 6
SEAT BELT EXTENDER: ’03–’05 MODEL YEAR – BO009-04 Revised
Owner
Instructions
September 29, 2004
Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury.
If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Lexus dealer free of charge.
Please visit your local Lexus dealer so that the dealer can order the proper required length extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Lexus dealer.
When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure that the retractor is locked when in use.
To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat belt are both facing outward as shown.
Seat Belt Release
You will hear a click when the tab locks into the buckle.
When not in use, remove the extender and store in the vehicle for future use.
Seat Belt Extender
CAUTION:
On vehicles equipped with SRS – Occupant Classification System (OCS)*, it is critical that the extender tab be buckled into the buckle AFTER the occupant sits down in the seat.
Leaving extender installed in the buckle before sitting down will cause the OCS to be in the “airbag off” or disarmed state.
* OCS will enable or disable the passenger front and side airbags based on passenger weight and seat belt latch position classifying the passenger as a child or adult.
CAUTION:
When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury.
S Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it.
S
The Seat Belt Extender must never be used with any child safety seats.
S Remember that the extender provided for you may not be safe when used on a different vehicle, for another person or for a different seating position than the one originally intended.
Page 5 of 6
SEAT BELT EXTENDER WORKSHEET
PLEASE COPY THIS ORIGINAL WORKSHEET FOR EACH EXTENDER NEEDED
CAUTIONS:
S
To minimize the chance and/or severity of injury in an accident, the Seat Belt Extender must only be used:
1 By the person for whom it was provided.
2 In the seat position for which it was provided.
S The Seat Belt Extender must never be used with any child safety seats.
S When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when extender belt is in use.
APPLICANT
DEALER CODE
DEALER
DEALER NAME
ADDRESS
SEAT BELT EXTENDER APPLICATION
APPLICANT NAME
ADDRESS
CITY & STATE
EMPLOYEE NAME MODEL YEAR
ZIP
BODY TYPE
CITY & STATE
SEATING POSITION
ZIP
VEHICLE IDENTIFICATION NUMBER
PHONE
DIRECTIONS FOR DETERMINING PROPER EXTENDER LENGTH
1.
Place the seat in the position the applicant normally uses.
2.
With the applicant in the seat, wearing the thickest coat expected to be worn, pull belt all the way out and try to buckle belt.
S If belt latches into buckle and feels comfortable against upper chest area, an extender is not needed.
S If belt does not buckle, continue with Step 3.
S If buckle latches but belt has no slack remaining, continue with Step 3.
3.
Measure distance between applicant’s navel and seat belt buckle (Dimension A) and enter on Worksheet.
4.
With belt all the way out, measure distance between latch tip and buckle tip (Dimension B) and enter on Worksheet.
NOTE: If belt latches but there is no slack enter zero as Dimension B.
5.
Subtract Dimension B from Dimension A and record number in Check Number box on Worksheet.
6.
Seat Belt Extender length is Dimension B rounded up to next extender length (without exceeding
Check Number).
NOTE: If extender length exceeds Check Number, an extender cannot be provided to the customer.
CAUTION:
On vehicles equipped with SRS — Occupant Classification System (OCS), it is critical that the extender tab be buckled into the buckle AFTER the occupant sits down in the seat.
Leaving extender installed in the buckle before sitting down will cause the OCS to be in the “airbag off” or disarmed state.
Dimension A:
NAVEL TO BUCKLE
Navel
Dimension B:
LATCH TO BUCKLE Latch
A
Buckle B
Buckle
DIMENSION A:
SEAT BELT EXTENDER CALCULATION
DIMENSION B: CHECK NUMBER:
SEAT BELT EXTENDER AUTHORIZATION
S The same Seat Belt Extender can be used for right and left seating applications. Each Seat Belt
Extender will have a label identifying the owner, VIN and seating position.
S
Applicant’s Signature: Date:
(Actual user of Seat Belt Extender)
Page 6 of 6
Technical Service
Information Bulletin
November 9, 2005
Title:
Models:
’05 ES 330
Introduction
TSIB REVISION NOTICE:
S
November 10, 2005: The second Op Code has been updated in Warranty Information
(Combo A for “Opposite Side”).
Previous versions of this TSIB should be discarded.
The rear seat belt buckle tether strap has been modified to improve the ease of use for the customer.
Applicable
Vehicles
S
2005 model year ES 330 vehicles produced BEFORE the Production Change
Effective VINs shown below.
Production
Change
Information
MODEL PART NAME
RR Seat Inner w/ CTR, RH
RR Seat Inner w/ CTR, LH
PART NUMBER
73470–33040–A0
73470–33040–B0
73470–33040–C0
73480–33130–A0
73480–33130–B0
73480–33130–C0
PRODUCTION CHANGE EFFECTIVE VIN
JTHBA30G955128105
JTHBA30G455128366
JTHBA30G855128774
JTHBA30G955128220
JTHBA30G755128247
JTHBA30G755128409
Parts
Information
PREVIOUS PART NUMBER CURRENT PART NUMBER
73470–33040–A0
73470–33040–B0
73470–33040–C0
73480–33130–A0
73480–33130–B0
73480–33130–C0
PART NAME bl RR S t I bl RR S t I /
/
QTY
1
1
Warranty
Information
OP CODE
711511
Combo A
DESCRIPTION
R & R Rear Seat Belt Buckle
Opposite Side
TIME
0.4
0.2
OFP
73480–33130–#0
T1 T2
Applicable Warranty*:
This repair is covered under the Lexus Powertrain Warranty. This warranty is in effect for 72 months or 70,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 9
REAR BUCKLE EASE OF USE IMPROVEMENT – BO011-05 Revised
Parts
Identification
Previous Part New Part
November 9, 2005
Repair
Procedure
HINT:
Use the same procedure for the LH side and RH side.
NOTE:
For removal of rear seat, refer to the Technical Information System (TIS), 2005 model year ES 330 Repair Manual: Seat: Rear Seat Assy: Overhaul.
1. Remove the rear seat cushion assembly.
2. Remove the rear seatback assembly.
3. Remove the rear door opening trim weatherstrip LH.
4. Remove the rear door opening trim weatherstrip RH.
5. Remove the roof side garnish inner LH.
6. Remove the roof side garnish inner RH.
7. Remove the center stop lamp assembly (without sun shade).
8. Remove the child restraint seat tether anchor cover.
Page 2 of 9
REAR BUCKLE EASE OF USE IMPROVEMENT – BO011-05 Revised November 9, 2005
Repair
Procedure
(Continued)
9. Remove the rear seat shoulder belt cover.
Using a screwdriver, disengage the 12 claws and remove the 3 rear seat shoulder belt covers.
HINT:
Tape the screwdriver tip before use.
: Claw
10. Remove the package tray trim panel assembly.
A. Remove the 2 bolts and release the floor anchors of the seat belts.
Page 3 of 9
REAR BUCKLE EASE OF USE IMPROVEMENT – BO011-05 Revised
Repair
Procedure
(Continued)
B. Without Sun Shade:
November 9, 2005
Disengage the 6 claws and 2 clips and remove the package tray trim panel assembly.
: Claw
: Clip
C. With Sun Shade:
Disengage the 2 clips and remove the package tray trim panel assembly.
: Clip
11. Remove the rear seat center belt assembly RH.
Remove the bolt holding the retractor and disengage the claws of the stopper to remove the rear seat center belt assembly RH.
Page 4 of 9
REAR BUCKLE EASE OF USE IMPROVEMENT – BO011-05 Revised November 9, 2005
Repair
Procedure
(Continued)
12. Install the rear seat center belt assembly RH.
A. Check the degree of tilt when the ELR begins to lock.
Check that the belt does NOT lock at less then 15 r
of tilt in any direction but locks at over 45 r
of tilt when gently moving the installed retractor.
Unlock
45
°
Lock
B. Install the retractor of the rear seat center belt assembly RH and torque the bolt.
Torque: 42 N
S m (420 kgf
S cm, 31 ft
S lbf)
C. Check the ELR lock.
Check that the belt locks when pulled out quickly.
D. Check the fastening function for the child restraint system.
NOTE:
Check should be done with the assembly installed.
a. Check that the belt cannot be pulled out any more but can be rewound after being pulled out.
b. Check that the belt can be pulled out and rewound after being fully rewound.
Page 5 of 9
REAR BUCKLE EASE OF USE IMPROVEMENT – BO011-05 Revised
Repair
Procedure
(Continued)
November 9, 2005
E. Install the floor anchor of the rear seat center belt assembly RH with the bolt facing the arrow mark on the plate toward the front of the vehicle.
Torque: 42 N S m (420 kgf S cm, 31 ft S lbf)
NOTE:
Ensure that the anchor does NOT run into any protrusions on the floor panel.
Front
Protrusion
Protrusion
F. Check the ELR lock.
Check that the belt locks when pulled out quickly.
13. Remove the rear seat center belt assembly LH.
Remove the bolt and remove the rear seat center belt assembly LH.
Page 6 of 9
REAR BUCKLE EASE OF USE IMPROVEMENT – BO011-05 Revised November 9, 2005
Repair
Procedure
(Continued)
14. Install the rear seat center belt assembly LH.
A. Check the degree of tilt when the ELR begins to lock.
Check that the belt does NOT lock at less then 15 r
of tilt in any direction but locks at over 45 r
of tilt when gently moving the installed retractor.
Unlock
45
°
Lock
B. Install the retractor of the rear seat center belt assembly LH and torque the bolt.
Torque: 42 N S m (420 kgf S cm, 31 ft S lbf)
C. Check the ELR lock.
Check that the belt locks when pulled out quickly.
D. Check the fastening function for the child restraint system.
NOTE:
Check should be done with the assembly installed.
a. Check that the belt cannot be pulled out any more but can be rewound after being pulled out.
b. Check that the belt can be pulled out and rewound after being fully rewound.
Page 7 of 9
REAR BUCKLE EASE OF USE IMPROVEMENT – BO011-05 Revised
Repair
Procedure
(Continued)
November 9, 2005
E. Install the floor anchor of the rear seat center belt assembly LH with the bolt facing the arrow mark on the plate toward the front of the vehicle.
Torque: 42 N S m (420 kgf S cm, 31 ft S lbf)
NOTE:
Ensure that the anchor does NOT run into any protrusions on the floor panel.
Front
Protrusion
Protrusion
F. Check the ELR lock.
Check that the belt locks when pulled out quickly.
15. Install the package tray trim panel assembly.
A. Without Sun Shade:
Engage the 6 claws and 2 clips to install the package tray trim panel assembly.
: Claw
: Clip
Page 8 of 9
REAR BUCKLE EASE OF USE IMPROVEMENT – BO011-05 Revised
Repair
Procedure
(Continued)
B. With Sun Shade:
November 9, 2005
Engage the 2 clips to install the package tray trim panel assembly.
: Clip
16. Reinstall the seat cushions in the reverse order of removal.
17. Dispose of the old seat belt appropriately. For proper disposal procedures, refer to
TIS, 2005 model year ES 330 Repair Manual: Seat Belt: Rear Seat Belt: Disposal.
Page 9 of 9
Technical Service
Information Bulletin
December 22, 2004
Title:
Models:
’02 – ’05 ES 300 & ES 330
Introduction For improved durability, the center console door lock opener for ES 300 and ES 330 vehicles are now made from metal, instead of the previous plastic material. This improved lock is available as a service part and will not require replacement of the entire console lid.
Applicable
Vehicles
S
2002 – 2005 model year ES 300 and ES 330 vehicles produced BEFORE the
Production Change Effective VINs shown below.
Production
Change
Information
PLANT
Tsutsumi
Kanto
Parts
Information
PREVIOUS PART NUMBER CURRENT PART NUMBER
58908–32050 58908–32020
PRODUCTION CHANGE EFFECTIVE VIN
JTHBA30G#50024455
JTHBA30G#55077938
PART NAME
Lock Assembly, Console
Compartment Door
QTY
1
Warranty
Information
OP CODE
BD4024
DESCRIPTION
Replace Center Console Lock
TIME
0.2
OFP
58908–32050
T1 T2
62 12
Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 1
Technical Service
Information Bulletin
November 10, 2005
Title:
Models:
’97 – ’06 All Lexus Models
TSIB UPDATE NOTICE:
The information contained in this TSIB supercedes TSIB No. BO004-98.
TSIB No. BO004-98 is now obsolete and should be discarded.
Introduction Beginning in 1997, Lexus introduced side airbags for the LS 400. Starting with 1998, all Lexus vehicles are equipped with side airbags as standard equipment.
Lexus does NOT recommend replacement of original seat covers* with non-Lexus leather or other seat cover materials due to the following:
S
Seat covers NOT recommended by Lexus may affect side airbag performance, in general or in part, during an accident.
S
Modifications that negatively affect side airbag performance can result in severe occupant injuries.
S
Seat covers are an integral part of this safety system. Replacing original seat covers* with non-Lexus leather or other seat cover materials may compromise the effectiveness of this safety system.
S
The design of the seat is complex, integrating safety and strength with comfort and luxury.
*NOTE:
Lexus original seat covers that were NOT designed for side airbag equipped seats cannot be used due to the effect on proper airbag performance.
Lexus strongly discourages modifying original equipment seats that have side airbags.
Additionally, Lexus strongly advises against the installation or use of aftermarket seat covers, which could impair the performance of the side airbags in the event of an accident.
Applicable
Vehicles
S All 1997 – 2006 model year Lexus vehicles.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
Lexus Supports ASE Certification
TIME
–
OFP
–
T1 T2
– –
Page 1 of 1
Technical Service
Information Bulletin
February 16, 2005
Title:
Models:
’04 – ’05 ES 330
Introduction Under certain driving conditions, some 2004 and 2005 model year ES 330 vehicles may exhibit a M.I.L. “ON” with at least one of the following DTCs:
S
P0031 (Oxygen Sensor Heater Control Circuit Low [Bank 1, Sensor 1])
S
P0051 (Oxygen Sensor Heater Control Circuit Low [Bank 2, Sensor 1])
S
P2238 (Oxygen Sensor Pumping Current Circuit Low (for A/F Sensor)
[Bank 1, Sensor 1])
S
P2241 (Oxygen Sensor Pumping Current Circuit Low (for A/F Sensor)
[Bank 2, Sensor 1])
The A/F sensor manufacturing process and the Engine Control Module (ECM)
(SAE term: Powertrain Control Module/PCM) logic have been modified to improve these conditions.
NOTE:
S
Version 12.01a or later Diagnostic Tester software is required to perform this procedure.
S Before proceeding, verify the ECM (PCM) calibration has NOT been updated by checking for the Authorized Modifications Label (shown in step 2 of the
Repair Procedure).
Applicable
Vehicles
S
2004 model year ES 330 vehicles.
S
2005 model year ES 330 vehicles produced BEFORE the Production Change
Effective VIN shown below.
Production
Change
Information
MODEL
2005 ES 330
PRODUCTION CHANGE EFFECTIVE VIN
JTHBA30G*55086805
Warranty
Information
OP CODE
EG4029
DESCRIPTION
Recalibrate ECM (PCM) Engine,
R & R Both A/F Sensors
TIME
1.6
OFP
89661–33A40
89661–33A41
89661–33B30
T1 T2
8A 99
Applicable Warranty*:
This repair is covered under the Lexus Federal Emissions Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 4
M.I.L. “ON” DTC P0031, P0051, P2238, AND/OR P2241 – EG003-05
Parts
Information
PREVIOUS PART NUMBER CURRENT PART NUMBER
89467–33110 Same
89467–33100
N/A
Same
00451–00001–LBL
February 16, 2005
PART NAME
Sensor, Air Fuel Ratio, Rear
(Bank 1)
Sensor, Air Fuel Ratio, Front
(Bank 2)
Authorized Modifications Label
QTY
1
1
1
NOTE:
Authorized Modification Labels may be ordered in packages of 25 from the Materials
Distribution Center (MDC) through Dealer Daily Dealer Support Materials System or by calling the MDC at 1–800–622–2033.
Required
SSTs
SPECIAL SERVICE TOOLS (SSTs)
Lexus Diagnostic Tester Kit*
PART NUMBER QUANTITY
01001270 1
12 Megabyte Diagnostic Tester Program Card with version 12.01a Software (or later)*
* Essential SSTs.
01002593-005
NOTE:
Additional Diagnostic Tester Kits, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
1
Calibration
Identification
Chart
ENGINE
3MZ–FE
ECM (CPU)
Main
PREVIOUS CALIBRATION ID
33350000
33350100
33360000
53334000
NEW CALIBRATION ID
33360100
Sub 53340000
NOTE:
S Although the calibration description in the Calibration Update Wizard and on the
Diagnostic Tester reads “04 ES 330,” these calibrations apply to 2004 and 2005 model year ES 330 vehicles produced before the Production Change Effective VIN shown on page 1 of this TSIB.
S 2004 model year ES 330 vehicles, which have been flash reprogrammed using the procedures in this TSIB, will contain upgraded 2005 model year OBD II logic. Refer to the 2005 model year ES 330 Repair Manual information on the Technical
Information System (TIS) when checking Powertrain Diagnostic Trouble Codes
(DTCs) on 2004 model year vehicles that have been reprogrammed.
Page 2 of 4
M.I.L. “ON” DTC P0031, P0051, P2238, AND/OR P2241 – EG003-05 February 16, 2005
Repair
Procedure
1. Replace both Bank 1, Sensor 1 and Bank 2, Sensor 1 air fuel ratio sensors.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if ECM (PCM) calibration has been updated. If not the latest ECM (PCM) calibration — go to step 3.
Replacement
ECM (PCM)
Part
Number
Calibration
ID(s)
THE FOLLOWING MODIFICATIONS HAVE BEEN MADE:
89661–33A40
33360100, 53340000
THESE MODIFICATIONS HAVE BEEN APPROVED
AS APPROPRIATE BY EPA AND CARB
DEALER CODE:
CHANGE AUTHORITY:
DATE:
TSIB EG003–05
Dealer Code TSIB Number
Figure 1. Location of Authorized Modifications Label on 2004 ES 330
Date
Completed
Page 3 of 4
M.I.L. “ON” DTC P0031, P0051, P2238, AND/OR P2241 – EG003-05 February 16, 2005
Repair
Procedure
(Continued)
3. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle’s current ECU calibration (see Figure 2).
– The sample screen prints seen below are the 12.01a software version and may differ from subsequent software versions.
A
ECU REPROGRAM
MAIN MENU
B
CURRENT ECU CAL
CALIBRATION ID
1: GET CAL FROM PC
2: CURRENT ECU CAL
3: UPDATE ECU CAL
4: CAL ON TESTER
5: CLEAR CAL DATA
33350000
53334000
Figure 2. Determining Current ECU Calibration
NOTE:
S
If Calibration ID matches “Previous Calibration ID” as shown in Calibration
Identification Chart on page 2, proceed with flash reprogramming.
S If Calibration ID matches “New Calibration ID” as shown in Calibration
Identification Chart, this vehicle has already been programmed.
Refer to TIS for diagnostic procedures applicable to any stored DTCs.
4. If ECU calibration ID is not the same as the “New Calibration ID” listed previously, proceed to Flash Reprogram ECM (PCM).
5. Flash Reprogram ECM (PCM)
A. Follow the procedures outlined in TSIB No. SS001–01, “ECU Flash
Reprogramming Process,” and flash the ECM (PCM) with the new calibration file update.
B. Enter the required information on the Authorized Modifications Label and affix it to the vehicle at the location shown in Figure 1 (page 3). The Authorized
Modifications Label is available through the MDC, P/N 00451–00001–LBL.
6. Follow the procedures outlined in TSIB No. EG012–04, “Entering VIN During ECM
(PCM) Replacement and/or DTC P0630,” and write the VIN to the ECM (PCM).
7. The repair is complete. Test drive vehicle to confirm normal operation.
Page 4 of 4
Technical Service
Information Bulletin
March 15, 2005
Title:
Models:
’04 – ’05 ES 330
Introduction Under certain driving conditions, some 2004 and 2005 model year ES 330 vehicles may exhibit a M.I.L. “ON” with the following DTC:
S
P0346 (Camshaft Position Sensor “A” Circuit Range/Performance [Bank 2])
The Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM) logic have been modified to change this condition.
NOTE:
S Version 12.01a or later Diagnostic Tester software is required to perform this procedure.
S
Before proceeding, verify the ECM (PCM) calibration has NOT been updated by checking for the Authorized Modifications Label (shown in step 1 of the
Repair Procedure).
Applicable
Vehicles
S
2004 model year ES 330 vehicles.
S
2005 model year ES 330 vehicles produced BEFORE the Production Change
Effective VIN shown below.
Production
Change
Information
MODEL
2005 ES 330
PRODUCTION CHANGE EFFECTIVE VIN
JTHBA30G*55086805
Warranty
Information
OP CODE
EG5013
DESCRIPTION
Recalibrate ECM (PCM) Engine
TIME
0.8
OFP
89661–33A40
89661–33A41
89661–33B30
T1 T2
8A 99
Applicable Warranty*:
This repair is covered under the Lexus Federal Emissions Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 4
M.I.L. “ON” DTC P0346 – EG006-05
Parts
Information
PREVIOUS PART NUMBER CURRENT PART NUMBER
N/A 00451–00001–LBL
March 15, 2005
PART NAME
Authorized Modifications Label
QTY
1
NOTE:
Authorized Modification Labels may be ordered in packages of 25 from the Materials
Distribution Center (MDC) through Dealer Daily Dealer Support Materials System or by calling the MDC at 1–800–622–2033.
Required
SSTs
SPECIAL SERVICE TOOLS (SSTs)
Lexus Diagnostic Tester Kit*
PART NUMBER QUANTITY
01001270 1
12 Megabyte Diagnostic Tester Program Card with version 12.01a Software (or later)*
* Essential SSTs.
01002593-005
NOTE:
Additional Diagnostic Tester Kits, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
1
Calibration
Identification
Chart
ENGINE
3MZ–FE
ECM (CPU)
Main
PREVIOUS CALIBRATION ID
33350000
33350100
33360000
53334000
NEW CALIBRATION ID
33360100
Sub 53340000
NOTE:
S Although the calibration description in the Calibration Update Wizard and on the
Diagnostic Tester reads “04 ES 330,” these calibrations apply to 2004 and 2005 model year ES 330 vehicles produced before the Production Change Effective VIN shown on page 1 of this TSIB.
S 2004 model year ES 330 vehicles, which have been flash reprogrammed using the procedures in this TSIB, will contain upgraded 2005 model year OBD II logic. Refer to the 2005 model year ES 330 Repair Manual information on the Technical
Information System (TIS) when checking Powertrain Diagnostic Trouble Codes
(DTCs) on 2004 model year vehicles that have been reprogrammed.
Page 2 of 4
M.I.L. “ON” DTC P0346 – EG006-05 March 15, 2005
Repair
Procedure
1. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if ECM (PCM) calibration has been updated. If not the latest ECM (PCM) calibration — go to step 2.
Replacement
ECM (PCM)
Part
Number
Calibration
ID(s)
THE FOLLOWING MODIFICATIONS HAVE BEEN MADE:
89661–33A40
33360100, 53340000
THESE MODIFICATIONS HAVE BEEN APPROVED
AS APPROPRIATE BY EPA AND CARB
DEALER CODE:
CHANGE AUTHORITY:
DATE:
TSIB EG006–05
Dealer Code TSIB Number
Figure 1. Location of Authorized Modifications Label on 2004 ES 330
Date
Completed
Page 3 of 4
M.I.L. “ON” DTC P0346 – EG006-05 March 15, 2005
Repair
Procedure
(Continued)
2. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle’s current ECU calibration (see Figure 2).
– The sample screen prints seen below are the 12.01a software version and may differ from subsequent software versions.
A
ECU REPROGRAM
MAIN MENU
B
CURRENT ECU CAL
CALIBRATION ID
1: GET CAL FROM PC
2: CURRENT ECU CAL
3: UPDATE ECU CAL
4: CAL ON TESTER
5: CLEAR CAL DATA
33350000
53334000
Figure 2. Determining Current ECU Calibration
NOTE:
S
If Calibration ID matches “Previous Calibration ID” as shown in Calibration
Identification Chart on page 2, proceed with flash reprogramming.
S If Calibration ID matches “New Calibration ID” as shown in Calibration
Identification Chart, this vehicle has already been programmed.
Refer to TIS for diagnostic procedures applicable to any stored DTCs.
3. If ECU calibration ID is not the same as the “New Calibration ID” listed previously, proceed to Flash Reprogram ECM (PCM).
4. Flash Reprogram ECM (PCM)
A. Follow the procedures outlined in TSIB No. SS001–01, “ECU Flash
Reprogramming Process,” and flash the ECM (PCM) with the new calibration file update.
B. Enter the required information on the Authorized Modifications Label and affix it to the vehicle at the location shown in Figure 1 (page 3). The Authorized
Modifications Label is available through the MDC, P/N 00451–00001–LBL.
5. Follow the procedures outlined in TSIB No. EG012–04, “Entering VIN During ECM
(PCM) Replacement and/or DTC P0630,” and write the VIN to the ECM (PCM).
6. The repair is complete. Test drive vehicle to confirm normal operation.
Page 4 of 4
Technical Service
Information Bulletin
March 28, 2005
Title:
Models:
All Models
Introduction The procedure for inspecting the radiator cap has been revised. Please refer to the following procedures when inspecting the radiator cap on all Lexus models.
Applicable
Vehicles
S
All Lexus models.
Required
Equipment
MANUFACTURER
Snap–On/Sun
SVTS262A
(or equivalent)
Cooling System Tester
(Radiator Cap Tester)
EQUIPMENT
NOTE:
Additional Lexus Approved Dealer Equipment may be ordered by calling Lexus
Approved Dealer Equipment at 1–800–368–6787.
QTY
1
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 7
RADIATOR CAP INSPECTION – EG007-05
Required
SSTs
ITEM
NO.
SPECIAL SERVICE TOOLS (SSTs)
1 Radiator Cap Test Set*
March 28, 2005
PART NUMBER QTY DRW**
09230–00030–02 1 7
2 Radiator Cap Test Set (Small)* 09230–00020–02 1
* Essential SSTs.
** Refers to drawer number in SST Storage System.
NOTE:
Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
7
Radiator Cap
Identification
Procedure
1. Use the illustration below to identify the vehicle’s radiator cap type and kPa rating.
2. Proceed to the required inspection procedure for the radiator cap and kPa rating.
Radiator Cap Identification
N–Cap kPa Rating
Compact Cap Plastic Cap
Page 2 of 7
RADIATOR CAP INSPECTION – EG007-05
Radiator Cap
Inspection
Procedure
Type: N–cap, 88 kPa
1. Remove coolant and any foreign material on rubber points “A,” “B,” and “C.”
2. Check that points “A,” “B,” and “C” are not deformed, cracked, or swollen.
3. Check that points “C” and “D” are not stuck together.
4. Apply engine coolant to points “B” and “C” before using the radiator cap tester.
S
Radiator Cap Tester:
Snap–On/Sun P/N SVTS262A
(or equivalent)
5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:
S
SST P/N 09230–00030–02
(09231–10080–01) or
09230–00020–02 (09231–10060–01)
6. When using the radiator cap tester, tilt it more than 30 degrees.
7. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
N–Cap: 88 kPa
A
B
C
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens.
The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Radiator
Cap
March 28, 2005
D
Radiator Cap
Tester
30
°
or more
Specification:
VALVE OPENING PRESSURE
Standard value
(for brand–new cap)
Minimum standard value
(for in–service cap)
SPECIFIED CONDITION
74.0 to 103.0 kPa
(0.75 to 1.05 kgf/cm 2 , 10.7 to 14.9 psi)
59 kPa (0.60 kgf/cm 2 , 8.53 psi)
If the maximum pressure is less than the minimum standard value, replace the radiator cap sub–assembly.
Page 3 of 7
RADIATOR CAP INSPECTION – EG007-05
Radiator Cap
Inspection
Procedure
(Continued)
Type: N–cap, 108 kPa
1. Remove coolant and any foreign material on rubber points “A,” “B,” and “C.”
2. Check that points “A,” “B,” and “C” are not deformed, cracked, or swollen.
3. Check that points “C” and “D” are not stuck together.
4. Apply engine coolant to points “B” and “C” before using the radiator cap tester.
S
Radiator Cap Tester:
Snap–On/Sun P/N SVTS262A
(or equivalent)
5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:
S
SST P/N 09230–00030–02
(09231–10080–01) or
09230–00020–02 (09231–10060–01)
6. When using the radiator cap tester, tilt it more than 30 degrees.
7. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
N–Cap: 108 kPa
A
B
C
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens.
The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Radiator
Cap
Radiator Cap
Tester
30
°
or more
March 28, 2005
D
Specification:
VALVE OPENING PRESSURE
Standard value
(for brand–new cap)
Minimum standard value
(for in–service cap)
SPECIFIED CONDITION
93.3 to 122.7 kPa
(0.95 to 1.25 kgf/cm 2 , 13.5 to 17.8 psi)
78.5 kPa (0.80 kgf/cm 2 , 11.38 psi)
If the maximum pressure is less than the minimum standard value, replace the radiator cap sub–assembly.
Page 4 of 7
RADIATOR CAP INSPECTION – EG007-05
Radiator Cap
Inspection
Procedure
(Continued)
Type: Compact Cap, 88 kPa
1. Remove coolant and any foreign material on rubber points “A,” “B,” and “C.”
2. Check that points “A” and “B” are not deformed, cracked, or swollen.
3. Check that points “B” and “C” are not stuck together.
4. Apply engine coolant to point “B” before using the radiator cap tester.
S
Radiator Cap Tester:
Snap–On/Sun P/N SVTS262A
(or equivalent)
5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:
S
SST P/N 09230–00030–02
(09231–10080–01) or
09230–00020–02 (09231–10060–01)
6. When using the radiator cap tester, tilt it more than 30 degrees.
7. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
Compact Cap: 88 kPa
A
B
C
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens.
The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Radiator
Cap
March 28, 2005
Radiator Cap
Tester
30
°
or more
Specification:
VALVE OPENING PRESSURE
Standard value
(for brand–new cap)
Minimum standard value
(for in–service cap)
SPECIFIED CONDITION
74.0 to 103.0 kPa
(0.75 to 1.05 kgf/cm 2 , 10.7 to 14.9 psi)
59 kPa (0.60 kgf/cm 2 , 8.53 psi)
If the maximum pressure is less than the minimum standard value, replace the radiator cap sub–assembly.
Page 5 of 7
RADIATOR CAP INSPECTION – EG007-05
Radiator Cap
Inspection
Procedure
(Continued)
Type: Compact Cap, 108 kPa
1. Remove coolant and any foreign material on rubber points “A,” “B,” and “C.”
2. Check that points “A” and “B” are not deformed, cracked, or swollen.
3. Check that points “B” and “C” are not stuck together.
4. Apply engine coolant to point “B” before using the radiator cap tester.
S
Radiator Cap Tester:
Snap–On/Sun P/N SVTS262A
(or equivalent)
5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:
S
SST P/N 09230–00030–02
(09231–10080–01) or
09230–00020–02 (09231–10060–01)
6. When using the radiator cap tester, tilt it more than 30 degrees.
7. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
Compact Cap: 108 kPa
A
B
C
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens.
The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Radiator
Cap
March 28, 2005
Radiator Cap
Tester
30
°
or more
Specification:
VALVE OPENING PRESSURE
Standard value
(for brand–new cap)
Minimum standard value
(for in–service cap)
SPECIFIED CONDITION
93.3 to 122.7 kPa
(0.95 to 1.25 kgf/cm 2 , 13.5 to 17.8 psi)
78.5 kPa (0.80 kgf/cm 2 , 11.38 psi)
If the maximum pressure is less than the minimum standard value, replace the radiator cap sub–assembly.
Page 6 of 7
RADIATOR CAP INSPECTION – EG007-05 March 28, 2005
Radiator Cap
Inspection
Procedure
(Continued)
Type: Plastic Cap, 108 kPa
1. Remove coolant and any foreign material on O–ring “A.”
2. Check that O–ring “A” is not deformed, cracked, or swollen.
3. Apply engine coolant to O–ring “A” and rubber point “B” before using the radiator cap tester.
S
Radiator Cap Tester:
Snap–On/Sun P/N SVTS262A
(or equivalent)
4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester:
S
SST P/N 09230–00030–02
(09231–10080–01) or
09230–00020–02 (09231–10060–01)
5. When using the radiator cap tester, tilt it more than 30 degrees.
6. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
Plastic Cap: 108 kPa
A
30
°
or more
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens.
The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Radiator
Cap
B
Radiator Cap
Tester
Specification:
VALVE OPENING PRESSURE
Standard value
(for brand–new cap)
Minimum standard value
(for in–service cap)
SPECIFIED CONDITION
93.3 to 122.7 kPa
(0.95 to 1.25 kgf/cm 2 , 13.5 to 17.8 psi)
78.5 kPa (0.80 kgf/cm 2 , 11.38 psi)
If the maximum pressure is less than the minimum standard value, replace the radiator cap sub–assembly.
Page 7 of 7
Technical Service
Information Bulletin
October 14, 2004
Title:
Models:
’04 – ’05 ES 330 & RX 330
Introduction The main bearing journal diameter stamp location has been changed on some 2004 and
2005 model year vehicles with 3MZ–FE engines. The stamping on the front of the block has been discontinued. Review this TSB for the stamping location.
Applicable
Vehicles
S 2004 – 2005 model year ES 330 and RX 330 vehicles meeting the following specifications:
S 3MZ–FE equipped vehicles with engine serial numbers starting after 0138096.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 2
MAIN BEARING JOURNAL DIAMETER STAMPING LOCATION REVISION – EG011-04
Main Bearing
Location
Cylinder Block Main Journal Bearing Diameter Location
Underside of Cylinder Block
(Contact Surface with Oil Pan No. 1)
October 14, 2004
Front of Cylinder Block
Previous Location
(Discontinued)
Current
Location
Front
HINT:
If replacing a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table on the bottom of this page for the appropriate bearing number. The No. 1 and No. 4 journal bearings have 5 standard bearing sizes, marked 3, 4, 5, 6, and 7 accordingly.
The No. 2 and No. 3 journal bearings have 5 standard bearing sizes, marked 1, 2, 3, 4, and 5 accordingly.
Page 2 of 2
No. 3
No. 2
No. 1
No. 4
No. 1
No. 2
No. 3
No. 4
Number
Mark
Number
Mark
Number
Mark
Cylinder Block + Crankshaft =
Replacement Bearing
0 to 5
3
EXAMPLE:
Cylinder block imprinted number mark is “06.”
Crankshaft imprinted number mark is “08.”
6 + 8 = 14
Select the bearing marked “5.”
6 to 11
4
12 to 17 18 to 23 24 to 28
5 6 7
Technical Service
Information Bulletin
October 14, 2004
Title:
Models:
All ’04 – ’06 Models
TSIB REVISION NOTICE:
S
June 3, 2005: Content has been updated to include 2004 and 2006 model year vehicles. Step 4 of the VIN Write Procedure (page 2) and step 3 of the VIN Read
Procedure (page 3) have been clarified to include RX 400h vehicles.
Previous versions of this TSB should be discarded.
Introduction All 2005 and subsequent model year Lexus vehicles have the VIN (Vehicle Identification
Number) stored in the Electronic Control Module (ECM) (SAE term: Powertrain Control
Module/PCM) non–volatile memory. The VIN is accessible on the data stream using the
Lexus Diagnostic Tester and can also be written to a new ECM (PCM) using a “VIN
Read/Write” utility.
Service ECMs (supply parts) are shipped without the VIN; therefore, as part of the ECM
(PCM) replacement procedure, the VIN must be written to the replacement ECM (PCM) using the Diagnostic Tester utility function. Failure to write the VIN to the ECM (PCM) will result in a M.I.L. “ON” condition and set DTC P0630: VIN Not Programmed or Mismatch –
ECM (PCM).
It is very important to remember to enter the VIN on these vehicles. Vehicles with missing
VINs are subject to failing some state and local vehicle emissions Inspection and
Maintenance programs.
NOTE:
2004 model year vehicles which have been flash reprogrammed may contain updated
2005 model year OBD II logic. These vehicles will require VIN entry into the ECM (PCM) after reprogramming.
Applicable
Vehicles
S
2004 model year vehicles that have been flash reprogrammed.
S
All 2005 – 2006 model year vehicles.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 3
ENTERING VIN DURING ECM REPLACEMENT AND/OR DTC P0630 – EG012-04 Revised October 14, 2004
Required
SSTs
ITEM
NO.
SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTY DRW**
1
Lexus Diagnostic Tester Kit*
NOTE:
S All components from this kit/set are required
S 12 Megabyte Diagnostic Tester Program Card
(P/N 01002593–005) with version 12.2a Software
(or later) is required
LEX220036 1 8
CAN Interface Module Kit*
2
NOTE:
S All components from this kit/set are required
* Essential SSTs.
** Refers to drawer number in SST Storage System.
01002744 1
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other
SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
8
VIN Write
Procedure
To write a VIN to a replacement ECM
(PCM), use the following process:
1. Confirm the VIN. It is located on the front left of the instrument panel.
2. Connect the Diagnostic Tester to DLC3.
3. Turn the ignition switch and
Diagnostic Tester switch ON.
4. All vehicles except RX 400h:
Select from the Diagnostic Tester menus: DIAGNOSIS, ENHANCED
OBDII, VIN, and VIN WRITE.
RX 400h vehicles:
Select from the Diagnostic Tester menus: DIAGNOSIS, OBD/MOBD,
HV ECU, VIN, and VIN WRITE.
5. Write the VIN in accordance with the
Diagnostic Tester display.
6. Compare the VIN displayed on the
Diagnostic Tester with the VIN on the instrument panel. If these are not the same, write the VIN again after turning the ignition switch OFF.
Input a new VIN
If you want to clear the VIN,
press [NO] key.
PRESS [ENTER]
WRITING COMPLETE
The following VIN has been written.
The DTCs have been erased correctly.
PRESS [ENTER]
Page 2 of 3
ENTERING VIN DURING ECM REPLACEMENT AND/OR DTC P0630 – EG012-04 Revised
VIN Read
Procedure
1. Connect the Diagnostic Tester to DLC3.
2. Turn the ignition switch and
Diagnostic Tester switch ON.
3. All vehicles except RX 400h:
Select from the Diagnostic Tester menus: DIAGNOSIS, ENHANCED
OBDII, VIN, and VIN READ.
RX 400h vehicles:
Select from the Diagnostic Tester menus: DIAGNOSIS, OBD/MOBD,
HV ECU, VIN, and VIN READ.
4. Check the VIN displayed on the
Diagnostic Tester.
HINT:
For further explanations, refer to the
Technical Information System (TIS), appropriate model repair manual:
Diagnostics: SFI System: Registration.
VIN Is Displayed
October 14, 2004
*********************************
[ VIN ]
*********************************
PRESS [EXIT]
Page 3 of 3
Technical Service
Information Bulletin
November 17, 2005
Title:
Models:
’05 – ’06 ES 330
Introduction Under certain driving conditions, some 2005 and 2006 model year ES 330 vehicles may exhibit a M.I.L. “ON” condition with at least one of the following DTCs:
S
P0171 (System Too Lean [Bank 1])
S
P0174 (System Too Lean [Bank 2])
S
P2195 (Oxygen [A/F] Sensor Signal Stuck Lean [Bank 1, Sensor 1])
S P2197 (Oxygen [A/F] Sensor Signal Stuck Lean [Bank 2, Sensor 1])
The Air Fuel (A/F) sensor manufacturing process has been improved to correct this condition. The following repair procedures should be used to properly diagnose and repair the affected vehicles.
Applicable
Vehicles
S
2005 – 2006 model year ES 330 vehicles produced BEFORE the Production Change
Effective VIN shown below.
Production
Change
Information
MODEL
ES 330
ENGINE
3MZ–FE
PRODUCTION CHANGE EFFECTIVE VIN
JTHBA3#G#65148433
Parts
Information
MODEL ENGINE
PREVIOUS
PART NUMBER
89467–33100
CURRENT
PART NUMBER
Same
89467–33110 Same
PART NAME
Sensor, Air Fuel Ratio
(Bank 1)
Sensor, Air Fuel Ratio
(Bank 2)
QTY
1
1
Warranty
Information
OP CODE
895131
DESCRIPTION
R & R A/F Sensor
TIME
0.6
OFP
89467–33100
89467–33110
T1 T2
8A 71
Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 2
M.I.L. “ON” DTC P0171, P0174, P2195, OR P2197 – EG019-05 November 17, 2005
Required
SSTs
ITEM
NO.
SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTY DRW**
1
Lexus Diagnostic Tester Kit*
NOTE:
S All components from this kit/set are required
S 12 Megabyte Diagnostic Tester Program Card
(P/N 01002593–005) with version 13.0a Software
(or later) is required
LEX220036 1 8
CAN Interface Module Kit*
2
NOTE:
S All components from this kit/set are required
* Essential SSTs.
** Refers to drawer number in SST Storage System.
01002744 1
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other
SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
8
Repair
Procedure
DTC P0171 or P0174
Refer to the Technical Information System (TIS), 2005 or 2006 model year ES 330 Repair
Manual: Diagnostics: SFI System (3MZ–FE): P0171, P0174.
NOTE:
Only replace the A/F sensor indicated by the M.I.L. “ON” DTC(s).
DTC P2195 or P2197
Refer to TIS, 2005 or 2006 model year ES 330 Repair Manual: Diagnostics: SFI System
(3MZ–FE): P2195, P2197.
NOTE:
Only replace the A/F sensor indicated by the M.I.L. “ON” DTC(s).
Page 2 of 2
Technical Service
Information Bulletin
February 22, 2005
Title:
Models:
’04 – ’05 ES 330 & RX 330
Introduction The passenger airbag indicator lamp may switch from ON to OFF for front seat passengers weighing approximately less than 100 pounds, depending on their seating position. It is important for the front seat passengers to know that proper operation of the advanced frontal airbag system is highly dependent on the pressure placed on the seat bottom. Situations that add or subtract sensed weight can result in occupant misclassification. To minimize this situation:
S
Check seating posture.
– Passengers should be seated upright with their back against the seatback and feet on the floor.
S Check loading conditions.
– Extra weight from items such as bags or groceries or toys hanging on the seatback can add to the sensed weight of the front seat passenger.
– A rear seat passenger lifting the front seat with their legs, objects placed under the front seat, or the front seatback in contact with the rear seat can subtract from the sensed weight of the front seat passenger.
If the passenger airbag indicator lamp continues to switch ON to OFF after checking the above conditions, perform the following repair procedure.
NOTE:
The safest place for children is in the rear seat. Please note that Lexus recommends that you NEVER install a rear–facing child restraint in the front passenger seat, even if the passenger “Airbag OFF” lamp is illuminated. Please refer to the Owner’s Manual for additional details.
Applicable
Vehicles
S
2004 – 2005 model year ES 330 and RX 330 vehicles produced BEFORE the
Production Change Effective VINs shown on the following page.
Warranty
Information
OP CODE
EL4014
DESCRIPTION
R & R Occupant Detection ECU
TIME
0.7
OFP
89952–33010
89952–48010
T1 T2
8A 74
Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 2
PASSENGER AIRBAG INDICATOR LAMP – EL002-05
Production
Change
Information
MODEL PLANT
Tsutsumi
Kanto
DRIVETRAIN
2WD
4WD
2WD
4WD
Parts
Information
PREVIOUS PART NUMBER CURRENT PART NUMBER
89952–33010
89952–48010
89952–33011
89952–48011
Required
SSTs
SPECIAL SERVICE TOOLS (SSTs)
Lexus Diagnostic Tester Kit*
February 22, 2005
PRODUCTION CHANGE EFFECTIVE VIN
JTHBA30G#50024130
JTHBA30G#55068000
JTJGA3#U#50046500
JTJHA3#U#50076003
2T2GA3#U#5C021700
2T2HA3#U#5C046800
PART NAME QTY
1
1
PART NUMBER QUANTITY
01001270 1
12 Megabyte Diagnostic Tester Program Card with version 12.01a Software (or later)*
Occupant Seat Weight Set*
01002593-005 1
00002–09077–01 1
* Essential SSTs.
NOTE:
Additional Diagnostic Tester Kits, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
Repair
Procedure
1. Unfasten passenger seat and rock the assembly back providing access to the underside of the seat. For information to unfasten the passenger seat, refer to the
Technical Information System (TIS): 2004 – 2005 model year ES 330 or RX 330
Repair Manual: Seat: Front Seat Assembly LH: Overhaul.
2. Disconnect the negative terminal of the vehicle battery.
3. Disconnect electrical connectors from Occupant Detection ECU.
4. Remove and replace the Occupant Detection ECU.
5. Reinstall the seat assembly. For more information, refer to TIS: 2004 – 2005 model year ES 330 or RX 330 Repair Manual: Seat: Front Seat Assembly LH: Overhaul.
Torque: 36.8 N S m (375 kgf S cm, 27 ft S lbf)
6. Reconnect the negative terminal of the vehicle battery.
7. Perform Zero Point Calibration and Sensitivity Check following prompts in the
Diagnostic tool found under the Occupant Detect menu item (refer to
TSIB No. EL007–03, “ Occupancy Classification System Calibration
(DTC B1150 & B1650).”
8. Reinitialize systems affected by the disconnection of the vehicle battery.
Page 2 of 2
Technical Service
Information Bulletin
January 31, 2003
Title:
Models:
’02 – ’06 All Models
Introduction
TSIB REVISION NOTICE:
S May 11, 2005: Applicable Vehicles has been updated to include 2004 – 2006 model years.
The previous TSB should be discarded.
On some vehicles, when Rapgard t
is removed, the paint may have a stained appearance under the clear coat. These stains should not be considered a defect in the paint (clear coat or color coat). Wrinkles in the Rapgard t
sometimes trap water and cause the paint to stain from the trapped moisture, especially on horizontal surfaces, such as the hood, roof, and trunk. Stains can be removed by heating the stained surface to remove the trapped moisture.
Stains
Applicable
Vehicles
S
2002 – 2006 model year vehicles, all models.
Warranty
Information
OP CODE
BD1055
DESCRIPTION
Remove Paint Stain Under Rapgard t
TIME
0.6
OFP
53301–#####
T1 T2
67 99
Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 2
PAINT STAINS UNDER RAPGARD t
– PA001-03 Revised
Required
Tools &
Material
TOOLS & MATERIALS
Infrared Lamp or Heat Gun
Aluminum Foil or Damp Cloth
Thermometer
January 31, 2003
QUANTITY
1
1
1
Repair
Procedure
1. Use the aluminum foil or damp cloth to cover plastic/rubber parts that are near the stain.
2. Apply heat to the stain using an infrared lamp or heat gun.
NOTE:
Apply heat for 5 – 10 minutes at 158 r
F – 176 r
F (70 r
C – 80 r
C). Do NOT allow the surface to become hotter than 176 r
F (80 r
C). Measure the temperature with a thermometer.
3. After applying heat for 5 minutes, examine the area to determine if the stain has been removed. If the stain still exists, continue to apply heat and re–examine the stain 5 minutes later.
Page 2 of 2
Technical Service
Information Bulletin
January 12, 2005
Title:
Models:
’94 – Current
Introduction The purpose of this bulletin is to provide information regarding the proper procedures to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust.
Applicable
Vehicles
Required
Tools &
Materials
S
1994 – Current model year Lexus vehicles.
TOOLS & MATERIALS
Auto Magic r Special Cleaner Concentrate t #713*
Rubber Gloves, Aprons, Boots
Eye Protection
Sponges or Wash Mitts
Pail or Bucket
QUANTITY
1
* Contact the main office of Auto Wax Company Inc. (1–800–826–0828 or www.automagic.biz) to find a local source for Auto Magic r
Special Cleaner Concentrate.
t
Condition During rail transportation or extended storage near industrial areas, vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc.
Inspection This type of contamination can be identified by the presence of small red or brown particles on the paint surface. These particles are often difficult to see on dark color paints, but can be easily felt when brushing a hand across horizontal body surfaces such as hood, roof, or deck lid.
CAUTION:
Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be attempted to repair the paint surface of an affected vehicle.
This will result in further paint damage and detract from vehicle appearance.
Repair Washing the affected paint surfaces with Auto Magic r
Special Cleaner Concentrate t
is the recommended method to dislodge embedded iron particles and remove the surrounding rust stains. The correct usage of Auto Magic r
Special Cleaner
Concentrate t
is described in this bulletin.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 2
IRON PARTICLE RUST CONTAMINATION REPAIR – PA001-05
General
Precautions
January 12, 2005
WARNING:
Auto Magic r
Special Cleaner Concentrate t is a corrosive material. Appropriate personal protection equipment must be worn to protect persons performing the contamination removal procedure. Please refer to the precautions on the product prior to use.
CAUTION:
Consult local or state regulations regarding the handling, use, and disposal of Auto
Magic r
Special Cleaner Concentrate t
prior to use.
Under no circumstances should contamination removal be performed in direct sunlight or contamination removal solution be allowed to dry on vehicle surfaces, as staining of plastic, rubber, or painted parts may result.
Repair
Procedure
1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid car wash detergent. Rinse again thoroughly with fresh water.
2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution ratio when applying to any other surface. Apply the diluted cleaner concentrate so that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate the surface.
3. Thoroughly rinse vehicle with fresh water.
4. Inspect vehicle carefully both visually and by feel to determine if all iron particles have been removed. Repeat the wash several times if necessary to achieve complete removal.
5. Dry vehicle with a soft terry cloth towel and apply a non–abrasive, non–silicone glaze to obtain a high–gloss finish.
Page 2 of 2
Technical Service
Information Bulletin
July 16, 2004
Title:
Models:
All Models with Wheel Film
Introduction To prevent brake rotor rust from forming during transportation and storage, wheel film will be adopted instead of using a cardboard type anti–rust cover.
The purpose of the wheel film is to protect the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel as long as possible.
NOTE:
S Retain the wheel film on the disc wheel during vehicle display and storage.
S Do not remove the wheel film right away at Pre–Delivery Service (PDS) if the vehicle will be stored after PDS.
S
Remove the wheel film just prior to delivery to customers.
Wheel Film
Features of Wheel Film:
Material: Polyethylene
Color: Transparent
Applicable
Vehicles
S All Models with wheel film.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 2
WHEEL FILM FOR BRAKE ROTOR RUST PREVENTION – PD001-04
Removal
Procedure
Firmly hold the outer end of the wheel film to pull it off.
July 16, 2004
NOTE:
S If film adhesive residue is found on the disc wheel, remove it with a soft cloth dipped in ethyl alcohol (ethanol). Do not use thinner to remove the adhesive residue.
S
When the wheel film is removed below an ambient temperature of 0 r
C (32 r
F), it is possible that the film may tear. For ease of film removal in cold conditions, please warm the film above 0 r
C (32 r
F) using one of the following methods:
– Splash (hot) water on the wheel film.
– Warm wheel film with cotton cloth soaked in hot water.
– Warm wheel film with heat gun. Be sure not to overheat the film and wheel.
– Warm wheel film by infrared heater (lamp) for paint. Be sure not to overheat the film and wheel.
– Warm wheel film by steam car wash.
– Park vehicle indoors (e.g. garage, etc.) for an extended period of time.
Disposal
Procedure
Please follow local laws for disposal. Polyethylene film will not generate harmful gasses when it is burned.
Introduction
Schedule
MODEL
REAR)
GS 430/300
GX 470
LX 470
JAPAN
TMMC
1 2 3 4 5
2003
6 7 8 9 10 11 12 1
2004
2 3 4 5 6 7 8 9 10 11 12
Beginning January 2005
Beginning January 2005
Beginning January 2005
SC 430
This is a tentative schedule. There is a possibility that the introduction timing may be delayed on some models.
Page 2 of 2
Technical Service
Information Bulletin
August 26, 2003
Title:
Models:
’04 ES 330
Introduction The following items need to be performed during Pre–Delivery Service (PDS) on
2004 model year ES 330 vehicles.
Applicable
Vehicles
S
2004 model year ES 330 vehicles.
Contents
4
5
6
ITEM NO.
1
SUBJECT
D.C.C. Fuse Installation During PDS
2
3
Removal of Front Emergency Towing Eyelet and Installation of Towing Eyelet Hole Cover (Performed at Port)
Front License Plate Mounting Bracket Installation
Initialization of Moon Roof
Initial Calibration of Compass
Installation of Rubber Body Plugs
PAGE
2
3
4
5
6
9
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 9
PRE–DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 – PD002-03 August 26, 2003
ITEM NO. 1: D.C.C. FUSE INSTALLATION DURING PDS
Introduction The D.C.C. fuse has been removed at the assembly plant to reduce parasitic current draw in transit and storage.
Installation
Procedure
The removed D.C.C. fuse (30 A) is stored in the blank space of the Junction Block in the engine compartment. The D.C.C. fuse must be reinstalled during Pre–Delivery
Service (PDS) in the dealership as shown below.
Junction Block
Remove This Fuse
Install D.C.C. Fuse (30 A)
Here (Original Location)
NOTE:
S
Removing the D.C.C. fuse cuts off power sources relating to the Dome, ECU–B and
RAD No. 1 fuses.
S If the vehicle is stored in the dealership for a long period of time after PDS, disconnect the negative battery terminal to prevent battery discharge. Refer to TSIB
PG009–02 for battery maintenance information.
Page 2 of 9
PRE–DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 – PD002-03 August 26, 2003
ITEM NO. 2: REMOVAL OF FRONT EMERGENCY TOWING EYELET AND INSTALLATION OF
TOWING EYELET HOLE COVER (PERFORMED AT PORT)
Installation
Procedure
1. Remove the emergency towing eyelet from the front bumper by turning counterclockwise.
NOTE:
If it is hard to loosen the emergency towing eyelet, use a steel bar.
Emergency Towing Eyelet
2. Place the removed emergency towing eyelet in the tool tray in the luggage compartment.
3. Install the front towing eyelet hole cover which is stored in the glove box onto the front bumper as shown in the diagram.
Page 3 of 9
PRE–DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 – PD002-03 August 26, 2003
ITEM NO. 3: FRONT LICENSE PLATE MOUNTING BRACKET INSTALLATION
Introduction The front license plate bracket and two self tapping screws are included in the luggage compartment.
Installation
Procedure
1. Aligning the holes “A” of the mounting bracket with the dimples on the front bumper cover, mark the location of the holes “B” on the front bumper cover.
NOTE:
S Holes “A” are used for installation of the mounting bracket to the bumper cover.
S Holes “B” are used for installation of the front license plate to the mounting bracket.
2. Drill two relief holes with a diameter of
12 mm (0.47 in.) at the marks on the front bumper cover to prevent the license plate retaining bolt end from contacting the cover.
NOTE:
Do not drill the dimples on the front bumper cover.
3. Install the mounting bracket to the front bumper cover using the two self tapping screws.
Install the front license plate to the mounting bracket using bolts of the following dimensions:
Length: less than 25 mm (0.98 in.)
Diameter: 6.0 mm (0.24 in.)
Pitch: 1.0 mm (0.04 in.)
Mark And Drill Holes
Mounting Bracket
Dimples
A B B A
Tapping Screws
Page 4 of 9
PRE–DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 – PD002-03 August 26, 2003
ITEM NO. 4: INITIALIZATION OF MOON ROOF
Introduction The moon roof is controlled by the sliding roof ECU which detects and memorizes the moon roof position by counting pulses of its motor from the fully tilt–up position as the start position. Once the battery terminal has been disconnected and reconnected, the sliding roof ECU does not detect and memorize the moon roof position, resulting in no functions of the “one–touch tilt up and down,” “one–touch slide open and close” and “jam protection.” Please initialize the moon roof position after reconnecting the battery terminal as outlined below.
Initialization
Procedure
1. Turn the ignition switch to the
“ON” position.
2. Push and hold the moon roof switch to the “TILT– UP” side until the moon roof tilts all the way up and then tilts down slightly (approximately 10 mm at rear end).
3. Check for proper operation of the
“One–touch slide open and close” and
“One–touch tilt up and down” functions by pushing the switch briefly to the
“SLIDE OPEN” and “TILT UP” positions.
NOTE:
Jam protection function becomes effective through the above initialization procedure.
Approx. 10 mm
Page 5 of 9
PRE–DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 – PD002-03 August 26, 2003
ITEM NO. 5: INITIAL CALIBRATION OF COMPASS
Introduction The compass indicates the direction that the vehicle is heading by detecting the direction and strength of the earth’s magnetic field and processing this data using the compass sensor and microcomputer.
Detection of the direction and strength of the earth’s magnetic field varies according to the area in which the vehicle is used and is affected by the residual magnetism of the vehicle. For this reason, the geographic direction displayed may also deviate from the direction determined by the earth’s magnetic field according to the area in which the vehicle is used.
Therefore, please perform the initial calibration of the compass in your dealership prior to delivery to customers.
“COMP” Switch
Compass
Page 6 of 9
PRE–DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 – PD002-03
ITEM NO. 5: INITIAL CALIBRATION OF COMPASS (Continued)
Compass
Calibration
Procedure
1. Turn the ignition switch to the “ON” position and check that the direction
(N, NE, E, SE, S, SW, W, NW) appears on the compass display.
NOTE:
Pushing the “COMP” switch turns on or off the compass display.
2. Push the “COMP” switch for approximately 3 seconds until the zone number (1 – 15) appears on the display. Then push the switch to select the number of the zone where the vehicle is located.
See the map below for zone reference.
August 26, 2003
North America
Hawaii: 5
Puerto Rico: 10
A. Samoa: 5
Guam:
Saipan:
Taiwan:
Korea: 10
8
8
9
Page 7 of 9
PRE–DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 – PD002-03
ITEM NO. 5: INITIAL CALIBRATION OF COMPASS (Continued)
Compass
Calibration
Procedure
(Continued)
3. Check that the direction appears several seconds after adjustment.
4. Start the engine and push the switch for about 6 seconds until “C” appears on the display.
August 26, 2003
5. Drive the vehicle slowly at 5 mph, or less, in a circle until the direction is displayed. If there is not enough space to drive in a circle, drive around the block until the direction is displayed.
After driving in circles 1 to 3 times, calibration is complete with the direction shown on the display.
Page 8 of 9
NOTE:
S
Do not perform calibration of the compass in a place where the earth’s magnetic field is subject to interference by artificial magnetic fields (underground parking, under a steel tower, between buildings, roof parking, near a railroad crossing, near a large vehicle, etc.)
S
During calibration, do not operate electric systems (moon roof, power windows, etc.) as they may interfere with the calibration.
PRE–DELIVERY SERVICE (PDS) INFORMATION FOR ES 330 – PD002-03 August 26, 2003
ITEM NO. 6: INSTALLATION OF RUBBER BODY PLUGS
Introduction The ES 330 is provided with front and rear torque box holes to tie down the vehicle by wire or carrier truck transportation.
Installation
Procedure
Four (4) rubber body plugs are included in the glove compartment at the assembly plant.
Install them into the two (2) front and two (2) rear torque box holes during Pre–Delivery
Service (PDS).
NOTE:
If the rubber body plugs are not securely installed, road (tire) noise will transfer to the vehicle interior through the torque box holes and rust could occur inside the torque boxes by water entry.
Front Torque Box Hole Rear Torque Box Hole
Front
Front
Page 9 of 9
Technical Service
Information Bulletin
February 11, 2005
Title:
Models:
’05 All Lexus Models
Introduction The following is a list of the vehicle systems (Power Window, Sliding Roof, Tire
Pressure Warning System, etc.) that need initialization during Pre–Delivery Service
(PDS) and the TSIB numbers containing details on initializing each specific system.
NOTE:
Items in RED also need to be initialized any time the battery has been disconnected.
Applicable
Vehicles
S
All 2005 model year Lexus vehicles.
’05 MY Power
System
Initialization
Table
MODEL
NAME
ES 330 PD002-03
GS 430/300 PG007-00
GX 470
IS 300
LS 430
LX 470
RX 330
SC 430
PG017-02
PG022-01
PG009-01
PG007-00
PG010-01
POWER
WINDOW
-
-
-
-
-
-
POWER
INTIALIZATION SYSTEM ITEMS
BACK DOOR
SLIDING
ROOF
TIRE PRESSURE
WARNING SYSTEM
DIRECT INDIRECT
-
-
-
-
-
-
-
PD002-03
-
PG016-02
-
-
-
PD005-04 PD003-04 PD002-04 PD004-04
-
-
-
PD005-03
-
-
-
-
PG006-01
-
-
-
-
PD003-03
-
PD006-04
-
-
-
-
-
-
PG011-02
-
-
-
-
-
-
PG010-00
-
-
PG005-03
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 1
Technical Service
Information Bulletin
August 22, 2005
Title:
Models:
’05 – ’06 ES 330
Introduction The DCC fuse has been removed at the assembly plant to reduce parasitic current draw in transit and storage.
Applicable
Vehicles
Installation
Procedure
S
2005 – 2006 model year ES 330 vehicles.
The removed DCC fuse (30A) is stored in the blank space of the Junction Block in the engine compartment. The DCC fuse must be reinstalled during Pre-Delivery Service
(PDS) in the dealership as shown below.
Junction Block
Remove This Fuse
Install DCC Fuse (30A)
Here (Original Location)
NOTE:
S Removing the DCC fuse cuts off power sources relating to the DOME, ECU–B, and
RAD No. 1 fuses.
S If the vehicle is stored in the dealership for a long period of time after PDS, disconnect the negative (–) battery terminal to prevent battery discharge. Refer to
TSIB No. PG009–02, “ Battery Maintenance for In-Stock Vehicles & Pre-Delivery,” for battery maintenance information.
Warranty
Information
OP CODE
N/A
Lexus Supports ASE Certification
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Page 1 of 1
Technical Service
Information Bulletin
August 22, 2005
Title:
Models:
’05 – ’06 ES 330
Introduction The moon roof is controlled by the sliding roof ECU, which detects and memorizes the moon roof position by counting pulses of its motor from the fully “TILT-UP” position as the start position. Once the battery terminal has been disconnected and reconnected, the sliding roof ECU does not detect and memorize the moon roof position, resulting in no functions of the “one-touch tilt up and down,” “one-touch slide open and close,” and
“jam protection.” Initialize the moon roof position after reconnecting the battery terminal as outlined below.
NOTE:
Any time the battery terminal has been disconnected, initialize the moon roof after reconnecting the battery terminal.
Applicable
Vehicles
S
2005 – 2006 model year ES 330 vehicles.
Initialization
Procedure
1. Turn the ignition switch to the
“ON” position.
2. Push and hold the moon roof switch to the “TILT-UP” side until the moon roof tilts all the way up and then tilts down slightly (approximately 10 mm
[0.39 in.] at rear end).
3. Check for proper operation of the
“one-touch slide open and close” and
“one-touch tilt up and down” functions by pushing the switch briefly to the
“SLIDE OPEN” and “TILT-UP” positions.
NOTE:
Jam protection function becomes effective through the above initialization procedure.
Approx. 10 mm
Warranty
Information
OP CODE
N/A
Lexus Supports ASE Certification
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Page 1 of 1
Technical Service
Information Bulletin
August 22, 2005
Title:
Models:
’05 – ’06 ES 330
Introduction The compass indicates the direction that the vehicle is heading by detecting the direction and strength of the Earth’s magnetic field and processing this data using the compass sensor and microcomputer.
Detection of the direction and strength of the Earth’s magnetic field varies according to the area in which the vehicle is used and is affected by the residual magnetism of the vehicle. For this reason, the geographic direction displayed may also deviate from the direction determined by the Earth’s magnetic field according to the area in which the vehicle is used.
Perform the initial calibration of the compass in your dealership prior to delivery to customers.
Compass
“COMP” Switch
Applicable
Vehicles
S 2005 – 2006 model year ES 330 vehicles.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 3
INITIAL CALIBRATION OF COMPASS DURING PDS – PD034-05
Compass
Calibration
Procedure
1. Turn the ignition switch to the “ON” position and check that the direction
(N, NE, E, SE, S, SW, W, NW) appears on the compass display.
NOTE:
Pushing the “COMP” switch turns the compass display ON or OFF.
2. Push the “COMP” switch for approximately 3 seconds until the zone number (1 – 15) appears on the display. Then push the switch to select the number of the zone where the vehicle is located.
See the map below for zone reference.
North America
August 22, 2005
Hawaii: 5
Puerto Rico: 10
A. Samoa: 5
Guam:
Saipan:
Taiwan:
Korea: 10
8
8
9
Page 2 of 3
INITIAL CALIBRATION OF COMPASS DURING PDS – PD034-05
Compass
Calibration
Procedure
(Continued)
3. Check that the direction appears several seconds after adjustment.
4. Start the engine and push the switch for about 6 seconds until “C” appears on the display.
August 22, 2005
5. Drive the vehicle slowly at 5 mph
(8 km/h), or less, in a circle until the direction is displayed. If there is not enough space to drive in a circle, drive around the block until the direction is displayed.
After driving in 1 to 3 circles, calibration is complete with the direction shown on the display.
NOTE:
S Do NOT perform calibration of the compass in a place where the Earth’s magnetic field is subject to interference by artificial magnetic fields (underground parking, under a steel tower, between buildings, roof parking, near a railroad crossing, near a large vehicle, etc.)
S During calibration, do NOT operate electric systems (moon roof, power windows, etc.) as they may interfere with the calibration.
Page 3 of 3
Technical Service
Information Bulletin
August 25, 2005
Title:
Models:
’05 – ’06 ES 330
Introduction The ES 330 is equipped with front and rear torque box holes to tie down the vehicle during transportation. Rubber body plugs need to be installed during Pre-Delivery
Service (PDS).
Applicable
Vehicles
S
2005 – 2006 model year ES 330 vehicles.
Installation
Procedure
Four (4) rubber body plugs are included in the glove compartment at the assembly plant.
Install them into the two (2) front and two (2) rear torque box holes located under the vehicle on both sides.
NOTE:
If the rubber body plugs are NOT securely installed, road (tire) noise will transfer to the vehicle interior through the torque box holes and rust could occur inside the torque boxes by water entry.
Front Torque Box Hole Rear Torque Box Hole
Front
Front
Warranty
Information
OP CODE
N/A
Lexus Supports ASE Certification
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Page 1 of 1
Technical Service
Information Bulletin
August 25, 2005
Title:
Models:
’05 – ’06 ES 330
Introduction The ES 330 front license plate mounting bracket and two self-tapping screws are placed in the luggage compartment of the vehicle at the assembly plant. For states that require a front license plate, install the bracket and bolts on the bumper cover during Pre-Delivery Service (PDS) according to the following procedure.
Applicable
Vehicles
S
2005 – 2006 model year ES 330 vehicles.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Installation
Procedure
1. Aligning the holes “A” of the mounting bracket with the dimples on the front bumper cover, mark the location of the holes “B” on the front bumper cover.
NOTE:
S Holes “A” are used for installation of the mounting bracket to the bumper cover.
S Holes “B” are used for installation of the front license plate to the mounting bracket.
2. Drill two relief holes with a diameter of
12 mm (0.47 in.) at the marks on the front bumper cover to prevent the license plate retaining bolt end from contacting the cover.
NOTE:
Do not drill the dimples on the front bumper cover.
Mark and Drill Holes
Mounting Bracket
Dimples
A B B A
Lexus Supports ASE Certification
Page 1 of 2
FRONT LICENSE PLATE MOUNTING BRACKET INSTALLATION – PD036-05
Installation
Procedure
(Continued)
3. Install the mounting bracket to the front bumper cover using the two self-tapping screws.
4. Install the front license plate to the mounting bracket using bolts of the following dimensions:
Length: Less than 25 mm (0.98 in.)
Diameter: 6.0 mm (0.24 in.)
Pitch: 1.0 mm (0.04 in.)
Tapping Screws
August 25, 2005
Page 2 of 2
Technical Service
Information Bulletin
August 26, 2005
Title:
Models:
’05 – ’06 ES 330
Introduction The 2005 – 2006 model year ES 330 is shipped with a front emergency towing eyelet.
Follow the procedure below to remove the eyelet and save for customer use.
Applicable
Vehicles
S
2005 – 2006 model year ES 330 vehicles.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Installation
Procedure
1. Remove the emergency towing eyelet from the front bumper by turning counterclockwise.
NOTE:
If it is hard to loosen the emergency towing eyelet, use a steel bar.
Lexus Supports ASE Certification
Emergency Towing Eyelet
Page 1 of 2
FRONT EMERGENCY TOWING EYELET & EYELET HOLE COVER – PD037-05
Installation
Procedure
(Continued)
2. Place the emergency towing eyelet in the tool tray in the luggage compartment.
August 26, 2005
3. Install the front towing eyelet hole cover, which is stored in the glove box, onto the front bumper as shown in the illustration.
Page 2 of 2
Technical Service
Information Bulletin
January 1, 1999
Title:
Models:
All Models
Introduction Lexus Technical Service Information Bulletins (TSIBs) continue to be one of the most current sources of technical information available. To ensure complete access to this reference source, use the following steps:
S
Volume Four will begin with 1999 Technical Service Information Bulletins.
S
Place this bulletin along with all 1999 TSIBs into the new binders received with this bulletin.
S
Label this new binder “Volume Four“ using the labels provided with the binder.
S
Additional copies of 1994 through 1999 TSIBs are available to all Lexus Dealerships through the Non–Parts System (MDC NPM System) by using the following Part
Number designation:
Related TSIB
Part Numbers
MATERIAL DESCRIPTION
1999 TSIB Binder complete with all bulletins issued to date
New TSIB Binder and tabs only
PART NUMBER
VOL4
00216–00001
Lexus Supports ASE Certification
Page 1 of 1
Technical Service
Information Bulletin
January 18, 2002
Title:
Models:
All Models
Introduction
TSB UPDATE NOTICE:
The information contained in this TSIB updates PG015–01 dated May 4, 2001.
Revised text is red and underlined . The changes will take place February 1, 2002.
Replacement Certification Labels (vinyl label affixed to driver’s door or door post)
may be available from Lexus providing the request meets one of the criteria listed below.
Certification Label Location
MFD.BY:TOYOTA MOTOR CORPORATION DATE 10/01
GVWR: 2247KG (3040LB)
GAWR: FRT 1379KG (3040LB) WITH P225/70R16 TIRES
16X6 1/2JJ RIMS AT 210 KPA (30PSI) COLD
RR 1153KG (2540LB) WITH P225/70R16 TIRES.
16X6 1/2JJ RIMS AT 210 KPA (30PSI) COLD
THIS VEHICLE CONFORMS TO ALL APPLICABLE
FEDERAL MOTOR VEHICLE SAFETY, BUMPER, AND
THEFT PREVENTION STANDARDS IN EFFECT ON
THE DATE OF MANUFACTURE SHOWN ABOVE.
JT0XX00X0X0000000 MPV MCU10L–AWPGKA
C/TR 8P4/LB00
A/TM –01A/
U140E
MADE IN JAPAN
NO. 736
Applicable
Vehicles
Certification
Label Criteria
S
All Lexus vehicles.
1. The vehicle is in an accident and the label is damaged or is attached to a part that will be replaced during the repair.
NOTE:
S Processing a new label will be delayed significantly if the original certification label is not available.
S A replacement label MAY NOT be available if the vehicle is more than 5 years old and the old label does not accompany this request.
2. The label is stolen.
Procurement
Procedure
To request a replacement label, complete a copy of the form on the back of this bulletin.
Your dealer parts account will be billed $25.00
for each replacement of a damaged or stolen label.
NOTE:
All replacement labels for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any specific questions, contact
(310) 468–3390.
Warranty
Information
OP CODE
N/A
Lexus Supports ASE Certification
DESCRIPTION
Not Applicable to Warranty
TIME
–
OPN
–
T1 T2
– –
Page 1 of 2
APPLICATION FOR REPLACEMENT CERTIFICATION LABEL
REASON FOR REPLACEMENT
ACCIDENT DAMAGE
STOLEN
OTHER
PLEASE PROVIDE CORRECT VIN
REASON/EXPLANATION
A MOTOR CORPORATION DATE 10/01
GVWR: 2247KG (3040LB)
GAWR: FRT 1379KG (3040LB) WITH P225/70R16 TIRES
16X6 1/2JJ RIMS AT 210 KPA (30PSI) COLD
RR 1153KG (2540LB) WITH P225/70R16 TIRES.
16X6 1/2JJ RIMS AT 210 KPA (30PSI) COLD
THIS VEHICLE CONFORMS TO ALL APPLICABLE
FEDERAL MOTOR VEHICLE SAFETY, BUMPER, AND
THEFT PREVENTION STANDARDS IN EFFECT ON
THE DATE OF MANUFACTURE SHOWN ABOVE.
JT0XX00X0X0000000 MPV MCU10L–AWPGKA
C/TR 8P4/LB00
A/TM –01A/
U140E
MADE IN JAPAN
NO. 736
NOTE:
Original label MUST accompany this application or order will be significantly delayed.
DEALER INFORMATION
DEALER CODE:
DEALER NAME:
ADDRESS:
STREET ADDRESS
TELEPHONE:
CITY, STATE, ZIP CODE
( )
AREA CODE, TELEPHONE NUMBER
CONTACT:
FIRST NAME, LAST NAME
MAIL ( DO
NOT
FAX) THE COMPLETED REQUEST FORM WITH THE OLD LABEL TO:
TOYOTA MOTOR SALES, U.S.A. INC.
TECHNICAL COMPLIANCE DEPARTMENT, S207
19001 S. WESTERN AVENUE
TORRANCE, CA 90509–2991
Technical Service
Information Bulletin
March 2, 2005
Title:
Models:
’05 – ’06 All Lexus
Introduction During the manufacturing process, tire characteristics are measured. Tires are then mounted on the vehicle as matched sets to help reduce conditions such as pulling or drifting. If the wheels are replaced or refinished before vehicle delivery, it is important that the tires remain on the vehicle in the same location and in the same direction of rotation.
Please refer to the following procedure to ensure that the original tires stay in the same location on the vehicle.
Applicable
Vehicles
S
All 2005 – 2006 model year Lexus vehicles.
Installation
Procedure
1. Mark the tire installation position on the inward facing tire sidewall.
Example: Front Right = FR, Front Left = FL, Rear Right = RR, Rear Left = RL
2. Install the original tires on the new or refinished wheels with the marked side facing inwards.
3. Place the tire/wheel assemblies on the vehicle in the marked positions.
NOTE:
Torque the wheel nuts to the proper torque value in sequence.
Warranty
Information
OP CODE
N/A
Lexus Supports ASE Certification
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Page 1 of 1
Technical Service
Information Bulletin
January 18, 2002
Title:
Models:
All Models
Introduction
TSB UPDATE NOTICE:
The information contained in this TSIB updates PG016–01 dated May 4, 2001.
Revised text is red and underlined . The changes will take place February 1, 2002.
Replacement VIN plates (metal plates riveted to dashboard) may be available from
Lexus providing the request meets the criteria listed below.
Applicable
Vehicles
Replacement
VIN Plate
Criteria
VIN Plate Location
S All Lexus vehicles.
S
The vehicle is in an accident and the plate is damaged.
NOTE:
NOTE:
If a plate is stolen, be sure to contact the State Police or your State’s Department of
Motor Vehicles (DMV). In most cases the State DMV will issue a unique number so that the original number can be included on stolen vehicle listings. If this is the case, a replacement plate is NOT available from Lexus. However, the original VIN, NOT the state issued VIN, must be used on all warranty claims.
Procurement
Procedure
To request a replacement plate, complete a copy of the form on the back of this page.
Note that the damaged VIN plate MUST accompany the request form. Your dealer parts account will be billed $25.00
for each replacement of a damaged plate.
NOTE:
All replacement plates for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any specific questions, contact
(310) 468–3390.
Warranty
Information
OP CODE
N/A
Lexus Supports ASE Certification
DESCRIPTION
Not Applicable to Warranty
TIME
–
OPN
–
T1 T2
– –
Page 1 of 2
APPLICATION FOR REPLACEMENT VIN PLATE
REASON FOR REPLACEMENT
ACCIDENT DAMAGE
OTHER
PLEASE PROVIDE CORRECT VIN
REASON/EXPLANATION
DEALER INFORMATION
DEALER CODE:
DEALER NAME:
ADDRESS:
TELEPHONE:
CONTACT:
STREET ADDRESS
CITY, STATE, ZIP CODE
( )
AREA CODE, TELEPHONE NUMBER
FIRST NAME, LAST NAME
MAIL ( DO NOT FAX) THE COMPLETED REQUEST FORM WITH THE OLD PLATE TO:
TOYOTA MOTOR SALES, U.S.A. INC.
TECHNICAL COMPLIANCE DEPARTMENT, S207
19001 S. WESTERN AVENUE
TORRANCE, CA. 90509–2991
Technical Service
Information Bulletin
September 12, 2002
Title:
Models:
All Models & Model Years Through Current
Introduction A battery in a stored vehicle is subject to conditions that can reduce its performance and life. These conditions include storage period, temperature, parasitic drain, and battery load. Because of these factors, battery inspection and maintenance are required in order to ensure proper operation and optimal battery life.
As a matter of policy, Lexus does not provide battery warranty coverage for discharged and/or failed batteries due to lack of maintenance; it is the dealer’s responsibility to maintain the specified state of charge of the vehicle’s battery while in stock and assure proper state of charge at delivery.
To eliminate customer service concerns due to an undercharged battery during the first few weeks of ownership, all dealers should check battery state of charge and
recharge, if necessary, just prior to delivery (i.e., within 48 hours of delivery).
This new procedure will improve the new vehicle ownership experience by greatly reducing the risk of having a low performance battery concern due to extended storage periods and/or short engine run times prior to the vehicle sale.
Applicable
Vehicles
S
All models and model years through current.
Required
Tools &
Material
SPECIAL SERVICE TOOLS (SSTs)
MICROPRO 815 Digital
Battery Analyzer
(Essential SST)*
MANUFACTURER
Midtronics
PART NUMBER
00002–MP815–T
* This SST can be ordered through SPX/OTC by calling 1–800–933–8335.
NOTE:
MICROPRO 815 Digital Battery Analyzer should be periodically updated through the
Technical Information System (TIS) for new vehicle models. For detailed information, please see TSIB SS002–02, “Midtronics Battery Tester Software Update.”
Warranty
Information
OP CODE
N/A
Lexus Supports ASE Certification
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Page 1 of 4
BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG009-02 September 12, 2002
Recommended
Equipment
TOOLS & EQUIPMENT
Fast Battery Charger**
Fast Battery Charger**
MANUFACTURER
Associated
Christie
PART NUMBER
ASE6003
CAPPDQ
** These tools can be ordered through the Lexus Approved Dealer Equipment program by calling
1–800–368–6787.
NOTE:
The “Fast Battery Chargers” listed above have been tested and approved by Lexus.
These state–of–the–art “smart” chargers were designed to charge batteries at an accelerated rate, without the possibility of damage. Using non–microprocessor controlled battery chargers for fast charging purposes can damage the battery.
Inspection
Procedure
All vehicles are to be inspected according to the procedures listed below using the
MICROPRO 815 battery tester no more than 48 hours prior to customer vehicle delivery.
PRIOR TO TESTING:
If necessary, remove battery surface charge by turning on high beam headlights for 60 seconds, then let battery voltage recover for one minute.
1. Connect test clamps to battery.
(Display will show four zeros indicating a good connection).
2. For cold battery (<32 r
F) or after charge test, press TEST MODE key until appropriate test is selected.
3. Input battery stock number.
NOTE:
Stock number must be used for warranty cases because you cannot read the warranty code if CCA/CA rating is input.
4. Press STK#/Code key to start test.
NOTE:
Stock numbers are listed on the reference card located in the tester’s cover. Stock numbers can also be referenced on TIS. The TIS listings will always have up–to–date information.
Stock number location in TIS:
1. Go to TIS Home Page.
2. Click on “Diagnostics.”
3. Click on “Midtronics Battery Tester
Software.”
4. Click on “Stock Number Chart.”
Page 2 of 4
BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG009-02
Inspection
Procedure
(Continued)
5. Read STATE OF CHARGE and
BATTERY CONDITION.
a. If battery is at 75% STATE OF
CHARGE or greater, release vehicle to new owner.
b. If battery is less than 75%
STATE OF CHARGE proceed to Battery Service Procedure.
September 12, 2002
Battery
Service
Procedure
Follow the procedures below according to the BATTERY CONDITION results.
BATTERY CONDITION: “Good return to service” (less than 75% State of Charge)
Charge battery using one of the recommended chargers indicated above (or equivalent) following the Quick Charge instructions accompanying that machine.
BATTERY CONDITION: “Charge and return to service”
Charge battery using one of the recommended chargers indicated above (or equivalent) following the Quick Charge instructions accompanying that machine.
BATTERY CONDITION: “Charge and retest”
The battery must be Quick Charged and retested using the After charge test mode.
Carry out the service according to the result of the retest.
BATTERY CONDITION: “Replace”
The battery must be replaced. Press the STK#/CODE key to show the warranty code for the repair order and for the Warranty Battery Label.
Battery
Replacement
If a vehicle battery needs to be replaced for a warrantable condition, make sure to complete a Warranty Battery Label and affix it to the failed battery for proper warranty parts and claim processing.
Please include the Vehicle
Identification Number and warranty code on the Warranty Battery Label.
WARRANTY BATTERY LABEL
ETIQUETA PARA BATERIA DE GARANTIA
(Please Print / Llénese con Letra de Molde Por Favor)
Dealer Code
Código de Agencia
Vehicle Identification Number (VIN)
Número de Identificación de Vehículo (NIV)
Repair Order No.
No. de Orden de Reparación
Repair Date
Fecha de Reparación
Failure Code
Código de Falla
Veh. Date of First Use
Fecha de Primer
Uso del Veh.
Original Install Date
Fecha de Instalación Original
(Svc. part replacement only/ solamente para el reemplazo de partes de servicio)
Battery Mos. In Svc.
Número de meses que
Batería está en servicio
08/02 00404–BTTRY–LABEL
Page 3 of 4
BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG009-02 September 12, 2002
Recommended
Battery
Maintenance
In addition to this new pre–delivery battery test, a monthly battery inspection is still required for stored vehicles. If your dealership is located in an area subject to extreme temperatures (hot or cold), periodic maintenance may need to be performed more frequently.
To reduce parasitic battery drain for vehicles in storage for one week or more, the negative battery cable should always be disconnected to reduce battery discharge.
When the negative battery cable is reconnected, please check and reset electrical components such as the clock, radio, etc.
NOTE:
For your reference, the electrical system is made inoperative by removing the appropriate fuse indicated in the Electrical Wiring Diagram.
Page 4 of 4
Technical Service
Information Bulletin
March 11, 2005
Title:
Models:
’04 – ’05 Applicable Models
TSIB REVISION NOTICE:
S
June 23, 2005: The “Required SSTs” section has been updated.
The previous TSIB should be discarded.
Introduction If the Diagnostic Tester fails to initialize CAN–based communication with on–board vehicle controllers, a damaged cable or inoperative CAN Interface Module may be at fault. This bulletin provides test procedures to check the integrity of the Diagnostic Tester cables and the CAN Interface Module.
Applicable
Vehicles
S 2004 – 2005 model year CAN–equipped vehicles including 2004 model year LS 430 and 2005 model year GX 470 and LS 430.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 6
FAILURE TO INITIALIZE CAN INTERFACE MODULE – SS001-05 Revised
Required
SSTs
ITEM
NO.
SPECIAL SERVICE TOOLS (SSTs)
1 Diagnostic Tool Set*
Four (4) components from this kit/set are required:
S Tester
(P/N 02002019)
S 12 Megabyte Program Card Kit
(P/N 01002593–005) with version 12.2a Software
(or later)
S 14/26 Pin DLC Cable
(P/N 02001637)
S 14 Pin DLC Self Test Adapter
(P/N 02001607)
2 CAN Module Kit*
March 11, 2005
PART NUMBER QTY DRW**
LEX220036 1 8
01002744 1 8
NOTE:
S All components from this kit/set are required
S Module box cannot be ordered separately
S J1962 OBD2–II (CAN DLC)
(P/N 02003180)
* Essential SSTs.
** Refers to drawer number in SST Storage System.
NOTE:
Additional Diagnostic Tool Sets, CAN Module Kits, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
Page 2 of 6
FAILURE TO INITIALIZE CAN INTERFACE MODULE – SS001-05 Revised March 11, 2005
Diagnostic
Procedure
Failure to initialize CAN–based communications between the Diagnostic Tester and on–board vehicle controllers can be caused by the following issues:
S
The 14/26 Pin DLC cable is damaged, causing an open communication circuit.
S
The DLC cable is damaged, causing an open communication circuit.
S
The CAN Interface Module is damaged.
S The vehicle’s CAN Communication System has a fault, requiring further vehicle diagnostics.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD/MOBD and
CARB OBDII with a damaged cable or CAN module.
Figure 1
14/26 Pin
DLC Cable
(P/N 02001637)
CAN Interface
Module Only
J1962 OBD2–II
Cable (CAN DLC)
Only (P/N 02003180)
NOTE:
To lengthen the Diagnostic Tester cable life, do not wrap the cable around the tester, or hold the tester only by the cable.
J1962 OBD2–II Cable &
CAN Interface Module
(P/N 01002744)
Page 3 of 6
FAILURE TO INITIALIZE CAN INTERFACE MODULE – SS001-05 Revised March 11, 2005
Diagnostic
Procedure
(Continued)
To determine the cause of communication error, perform the following steps:
1. Using the Diagnostic Tester, perform the CAN MODULE VERSION self test.
Select DIAGNOSIS/SETUP/SELF TEST and perform the following screen flow.
NOTE:
Before performing test, confirm that the Diagnostic Tester, 14/26 Pin DLC cable, and
CAN Interface Module are all securely connected.
Figure 2
SELF TEST MENU
1: DISPLAY/LEDs
2: KEYBOARD
3: SOUND
4: MEMORY
5: DATA LINK
6: AUTOPROBE
7: RS232
8: INST PORT
9: SYSTEM INFO
0: CAN MODULE VER
INITIALIZING CAN
INTERFACE
PLEASE WAIT.
OK
Toyota CAN VIM 1.0
NG
CAN VIM did not respond
PRESS [EXIT]
SELF TEST Result:
Press [ENTER]
CAN VIM did not respond. Go to step 2.
SELF TEST PASSED: Go to step 3.
This response verifies the CAN module and the 14/26 Pin DLC cable are OK.
Page 4 of 6
FAILURE TO INITIALIZE CAN INTERFACE MODULE – SS001-05 Revised
Diagnostic
Procedure
(Continued)
2. Perform the Data Link Self Test (Figure 3).
Figure 3
SELF TEST MENU
1: DISPLAY/LEDs
2: KEYBOARD
3: SOUND
4: MEMORY
6: AUTOPROBE
7: RS232
8: INST PORT
9: SYSTEM INFO
DATA LINK SELF–TEST
Install Data Link
Self–Test Adapter to the end of the
Data Link Cable
Press [ENTER]
March 11, 2005
The Data Link Self Test
Adapter (P/N 02001607) is included in the Lexus
Diagnostic Tool Set
(P/N LEX220036)
DATA LINK SELF–TEST
Now testing the data link.
To test cable integrity, please flex cable repeatedly.
(15–20 seconds)
Press [EXIT] to QUIT
OK
DATA LINK SELF–TEST
PASSED
NG
DATA LINK SELF–TEST
**FAILED**
FAILED
SDL 1
Check Self–Test
Adapter Installation
PRESS [EXIT] Press [EXIT]
DATA LINK SELF TEST Result:
Replace 14/26 Pin DLC cable
(P/N 02001637).
DATA LINK TEST PASSED: Replace CAN Interface Module (P/N 01002744).
Page 5 of 6
FAILURE TO INITIALIZE CAN INTERFACE MODULE – SS001-05 Revised March 11, 2005
Diagnostic
Procedure
(Continued)
3. Inspect the J1962 OBD2–II cable (CAN DLC).
A. Disconnect the CAN Interface Module from the J1962 OBD2–II cable (CAN DLC).
A small Phillips screwdriver is required to separate the CAN Interface Module from the J1962 OBD2–II cable.
B. Test the J1962 OBD2–II cable (CAN DLC) for continuity.
Figure 4
CABLE TEST
J1962 OBD2–II Cable
(P/N 02003180)
Pin 5 to
Pin 15
Pin 15 to
Pin 22
J1962 OBD2–II Cable (CAN DLC) Test Result:
(More than 6
Ω)
Replace the J1962 OBD2–II cable
(CAN DLC, P/N 02003180).
Suspect vehicle side problem.
Refer to the Technical Information System (TIS): applicable model year Repair
Manual: Diagnostics: CAN Communication System: Problem Symptoms Table:
Check CAN Bus Line.
NOTE:
If the Diagnostic Tester successfully communicates with another CAN–equipped vehicle, suspect vehicle side problem.
Page 6 of 6
Technical Service
Information Bulletin
August 26, 2002
Title:
Models:
Applicable ES 300, GS 430, GS 300,
IS 300, & LX 470
TSIB REVISION NOTICE:
S
August 26, 2005: The model years for each model have been specifically defined in the “Applicable Vehicles” section. The “Required SSTs” section has been updated.
S
February 11, 2003: Model years for LX 470 revised to apply to 2001 and 2002 only.
S August 26, 2002: ES 300, GS 300, and IS 300 models added. Model years for GS 430 and LX 470 vehicles expanded to include 2002 and later. Diagnostic Tester software in Required Tools & Material updated to version 9.01a (or later).
Previous versions of this TSIB should be discarded.
Introduction Immobilizer Reset is a new feature that allows the registration of a new Master Key even if all original Master Keys are lost. Once the Immobilizer system is reset, all previously registered keys will be erased.
Applicable
Vehicles
MODEL YEAR
2001 – 2005*
2001 – 2002*
2002 – 2003*
2002 – 2005*
2002 & Later*
MODEL
GS 430
LX 470
ES 300
GS 300
IS 300
* Immobilizer Key Code Reset procedure is not available for prior model years.
NOTE:
Refer to TIS (Technical Information System) for the most current applicable vehicle information.
ENGINE MODEL
3UZ–FE
2UZ–FE
1MZ–FE
2JZ–GE
2JZ–GE
Parts
Information
PREVIOUS PART NUMBER CURRENT PART NUMBER
N/A Model Specific
PART NAME
Replacement Key (Master or Sub)
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 6
IMMOBILIZER KEY CODE RESET – SS002-01 Revised August 26, 2002
Required
SSTs
ITEM
NO.
SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTY DRW**
1
Lexus Diagnostic Tester Kit*
NOTE:
S All components from this kit/set are required
S 12 Megabyte Diagnostic Tester Program Card
(P/N 01002593–005) with version 13.0a Software
(or later) is required
LEX220036 1 8
CAN Interface Module Kit*
2
NOTE:
S All components from this kit/set are required
* Essential SSTs.
** Refers to drawer number in SST Storage System.
01002744 1
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other
SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
8
Function
Description
The Immobilizer Reset function is a 5-step process:
1. Using the Diagnostic Tester, retrieve a “Seed Number” through the OBD/MOBD
Immobilizer function.
S A “Seed Number” is a unique number provided by the Diagnostic Tester and validated by TIS (Technical Information System) in order to return a Passcode.
2. Using TIS, select Immobilizer Reset, and complete the request form to retrieve a
“Passcode Number.”
S A “Passcode Number” is a unique number required by the Diagnostic Tester to reset the ECU allowing it to accept a new Master Key.
3. Enter the “Passcode Number” received from TIS into the Diagnostic Tester.
4. Confirm successful Immobilizer reset and new Master Key registration.
5. Register any additional customer keys.
Page 2 of 6
IMMOBILIZER KEY CODE RESET – SS002-01 Revised August 26, 2002
Key Code
Reset
Procedure
NOTE:
Ensure that the Diagnostic Tester is equipped with the latest version of software (13.0a
or later).
Connect the Diagnostic Tester to DLC3 and turn ignition ON.
1. Using the Diagnostic Tester, follow the screen flows below to retrieve the “Seed
Number.” (DO NOT DISCONNECT the Diagnostic Tester from the vehicle during this process.)
FIGURE 2. DIAGNOSTIC TESTER SCREEN FLOW
A
*APPLICATION SELECT*
1: DIAGNOSIS
2: CUSTOMIZE
3: ECU REPROGRAM
B
FUNCTION SELECT
FOR NORTH AMERICA
1: OBD/MOBD
2: ENHANCED OBD II
3: CARB OBD II
4: BREAK-OUT BOX
5: NVH
6: AUTOPROBE
7: O2 RPM CHECK
8: SNAPSHOT REVIEW
9: SETUP
0: GAS ANALYSIS
C
OBD/MOBD MENU
1: CODES (ALL)
2: ENGINE AND ECT
3: ABS / VSC
4: CCS
5: IMMOBILIZER
6: SRS AIRBAG
D
DIAGNOSTIC MENU
IMMOBILIZER
1: CURRENT DATA
2: TROUBLE DATA
4: KEY CODE UTILITY
E
KEY CODE UTILITY
1: KEY REGISTRATION
2: KEY CODE ERASURE
3: AUTO REG CLOSURE
9: KEY CODE RESET
*
F
KEY CODE RESET
CONFIRM
– Master Key is in ignition.
– ignition is ON.
NOTE: If ignition is OFF, then EXIT to OBD/MOBD
Menu.
PRESS [ENTER]
G
KEY CODE RESET
This Function will
RESET
the registered
Key Code.
DO YOU WISH TO
CONTINUE RESETTING?
H
KEY CODE RESET
SEED NUMBER
999999
Please input
SEED NUMBER into TIS
PRESS [ENTER]
NOTICE:
S
Do NOT turn the ignition OFF.
S
Do NOT disconnect the
Diagnostic Tester.
* Option “9: KEY CODE RESET” will not appear if your present vehicle does not support the key code reset functions.
Page 3 of 6
IMMOBILIZER KEY CODE RESET – SS002-01 Revised August 26, 2002
Key Code
Reset
Procedure
(Continued)
2. Using TIS, select Immobilizer Reset, and complete the request form to retrieve a
“Passcode Number.”
A. Click on Diagnostics.
B. Click on Immobilizer Reset.
FIGURE 3. SELECTING IMMOBILIZER RESET ON TIS
A
B
C. Read the instructions on the screen and click on Continue.
(See Figure 4 below.)
FIGURE 4. IMMOBILIZER RESET INSTRUCTIONS ON TIS
C
Page 4 of 6
IMMOBILIZER KEY CODE RESET – SS002-01 Revised
Key Code
Reset
Procedure
(Continued)
August 26, 2002
D. Complete the request form and enter the “Seed Number” from the Diagnostic
Tester. Click on Submit (Figure 5).
NOTE:
All fields must be completed.
FIGURE 5. REQUEST FORM ON TIS
D
E. TIS will now return the Passcode that needs to be entered into the Diagnostic Tester.
NOTE:
The Passcode given by TIS is only valid for one Immobilizer Reset Event.
FIGURE 8. RECEIVING PASSCODE FOR DIAGNOSTIC TESTER
E
Page 5 of 6
IMMOBILIZER KEY CODE RESET – SS002-01 Revised August 26, 2002
Key Code
Reset
Procedure
(Continued)
3. Using the numbered keys (0–9) on the Diagnostic Tester, enter the “Passcode
Number” received from TIS. (See Figure 7 below.) Press ENTER to clear all registered key codes.
NOTE:
Key Code Reset takes approximately 16 minutes.
FIGURE 7. PASSCODE ENTRY SCREEN FLOW
A
KEY CODE RESET
B
KEY CODE RESET
Please insert PASSCODE
NUMBER from TIS
**NOW RESETTING**
If the key was in the IG cylinder, do not remove it.
PASSCODE NUMBER
000414
PRESS [ENTER]
Remaining Time
<16> Min.
C
KEY CODE RESET
RESET COMPLETE
If the engine starts, this key code is registered correctly.
PRESS [ENTER]
4. Confirm successful Immobilizer reset and new Master Key registration by starting the vehicle.
NOTE:
If the vehicle starts, the new Master Key code is registered correctly.
If the vehicle does not start, perform the Immobilizer Reset function again.
5. All previously registered key codes have been erased except the Master Key used during “Key Code Reset.”
Register any additional customer keys by using “Key Registration.”
Each key will start the engine if registered correctly.
S
Please refer to TSIB No. SS006–99, “Scantool Immobilizer Key Code Utility,” for additional detail on this procedure.
FIGURE 8. KEY REGISTRATION
A
KEY CODE UTILITY
1: KEY REGISTRATION
2: KEY CODE ERASURE
3: AUTO REG CLOSURE
(See TSIB No. SS006–99)
9: KEY CODE RESET
Page 6 of 6
Technical Service
Information Bulletin
November 28, 2005
Title:
Models:
’01 – ’06 All Models
Introduction Lexus has developed a master CD to be used for customer complaints of the CD player skipping or CD player cannot read disc. This disc has been specially manufactured to test the performance of the Lexus CD players. Using this master CD will confirm that the radio exceeds Lexus’ specification for CD player performance.
Applicable
Vehicles
S
2001 – 2006 model year Lexus vehicles.
Test Disc
Specifications
9
10
11
12
5
6
7
8
TRACKS
1
2
3
4
13
14
15
DEFECT
None
0.8 mm Black Dot
0.6 mm Black Dot
None
None
None
0.4 mm Scratch
0.6 mm Scratch
0.8 mm Scratch
1.0 mm Scratch
None
None
Fingerprint 65 um
None
Fingerprint 75 um
MUSIC
Minuetto
2ème Gymnopédie
Overture Minature
Marche
Claire de Lune
Nocturne
Danse de la Fée Dragée
Danse Arabe
Fantanisie-Improptu
Hungarian Dance No. 5
Prelude <Raindrop>
Maiden’s Prayer
Valse des Fleurs
1ère Gymnopedie
Danse Des Mirlitons
TRACK TIME
3:15
2:32
3:02
2:36
3:09
3:12
2:28
2:29
2:51
2:02
3:38
3:15
3:08
2:54
2:06
Warranty
Information
OP CODE
N/A
Lexus Supports ASE Certification
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Page 1 of 2
CD SKIP VERIFICATION USING LEXUS MASTER CD – SS003-05 November 28, 2005
Required
SSTs
ITEM
NO.
SPECIAL SERVICE TOOLS (SSTs)
1
Lexus Master CD*
NOTE:
S All components from this kit/set are required
* Essential SSTs.
** Refers to drawer number in SST Storage System.
PART NUMBER
00002–07130–SCD
NOTE:
Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
QTY DRW**
1 22
Repair
Procedure
1. Make sure the vehicle is stationary during the test.
2. Insert a compact disc (NOT the Lexus Master CD) to make sure the radio can accept and eject the disc without damaging it.
3. Check the Lexus Master CD for any unintended scratches or dirt. Wipe away dirt using a glass cleaning cloth. If the disc is damaged, order a replacement master CD.
4. Insert the Lexus Master CD and change to track number 9.
5. Play the track for one minute.
A. If skips are heard, replace the CD player.
B. If NO skips are heard, the CD player is working normally. Check the customer’s
CDs for scratches or other damage to the discs. Confirm that the customer is using a pre-recorded CD, NOT CD-Rs or CD-RWs as they may NOT have been burned properly.
NOTE:
S Tracks 1 – 8 and 11 – 14 are reference tracks. They can be used, but the conditions are less severe than track 9. Do NOT use tracks 10 and 15.
S
Track 9 (0.8 mm scratch) is much more severe than the Lexus engineering specification in order to ensure customer satisfaction. If the customer’s radio passes this test, a replacement radio will NOT improve the performance.
S
This disc has been specially manufactured with a physical defect for the purposes of testing the CD player’s performance. It is NOT possible to make copies of this disc that can be used to test the CD player’s performance.
Page 2 of 2
Technical Service
Information Bulletin
July 6, 2001
Title:
Models:
Applicable ES 330, GS 300, GS 430, GX 470,
LS 430, LX 470, RX 330, & SC 430
TSIB REVISION NOTICE:
S
August 26, 2005: The model years for each model have been specifically defined in the “Applicable Vehicles” section. The following vehicles have been added to the “Applicable Vehicles” section: ES 330, GS 300, GS 430, and RX 330.
The “Required SSTs” section has been updated.
S
January 9, 2003: GX 470 and LX 470 have been added to Applicable Vehicles.
The “Required SSTs” section has been updated to the current version software.
Screen flows revised (screen C and D) in Figures 1 (screen C and D), 2 (screen C),
3 (screen C), 4 (screen C and G), and 9 (screen A).
S
The information contained in this TSIB supercedes the original SS005–01.
Previous versions of this TSIB should be discarded.
Introduction The Diagnostic Tester incorporates support for Immobilizer system service. This bulletin covers the following Immobilizer functions available using the Diagnostic Tester:
S
Transponder Key Type
S
Transponder Code Registration
S Transponder Code Erasure
S Transponder ECU Reset
S
Transponder ECU Replacement
S
Engine ECU Replacement
NOTE:
The available functions and procedures for the models listed in this TSIB differ slightly from previous models and other Immobilizer systems currently in use on
Lexus vehicles.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised
Applicable
Vehicles
MODEL YEAR
2001 & Later
2002 & Later
MODEL
LS 430
SC 430
GX 470
LX 470
ES 330
RX 330
GS 300 (w/o Smart Key)
GS 430 (w/o Smart Key)
July 6, 2001
ENGINE MODEL
3UZ–FE
3UZ–FE
3GR–FSE
3UZ–FE
NOTE:
Refer to TIS (Technical Information System) for the most current applicable vehicle information.
Parts
Information
PREVIOUS PART NUMBER CURRENT PART NUMBER
N/A Model Specific
PART NAME
Replacement Transponder Key (Master or Sub)
Required
SSTs
ITEM
NO.
SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTY DRW**
1
Lexus Diagnostic Tester Kit*
NOTE:
S
All components from this kit/set are required
S 12 Megabyte Diagnostic Tester Program Card
(P/N 01002593–005) with version 13.0a Software
(or later) is required
LEX220036 1 8
CAN Interface Module Kit*
2
NOTE:
S All components from this kit/set are required
* Essential SSTs.
** Refers to drawer number in SST Storage System.
01002744 1
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other
SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
8
Page 2 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised July 6, 2001
Function
Description
1. Transponder Key Type
Before any Immobilizer functions are performed, verify the type of transponder key that you are attempting to use for the service operation. Some functions may only be performed with a registered Master Key.
2. Transponder Code Registration
This function allows the registration of additional transponder keys (Master or Sub) using a registered Master Key.
3. Transponder Code Erasure
This function allows the user to erase all the transponder keys except the registered
Master Key used during this function.
4. Transponder ECU Reset
This function allows the registration of a new Master Key even if all original Master
Keys are lost. Once the Immobilizer system is reset, all previous registered keys will be erased.
5. Transponder ECU Replacement
When the Transponder ECU is replaced, the transponder keys must be registered to the new ECU, auto registration closed, and ECU communication completed.
6. Engine ECU Replacement
When the Engine ECU is replaced, ECU communication must be completed to synchronize an encrypted security code between the engine and Transponder ECUs.
Page 3 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised July 6, 2001
Operation
Procedure
TRANSPONDER
KEY TYPE
1. Transponder Key Type
Before any Immobilizer functions are performed, verify the type of transponder key that you are attempting to use for the service operation. Some functions may only be performed with a registered Master Key.
A. Insert the current key into the ignition cylinder and turn to the ON position.
HINT:
The Immobilizer key blanks are preconfigured as Master or Sub Keys. Master Key blanks cannot be registered as Sub Keys nor can Sub Key blanks be registered as
Master Keys. Also, the flat key is now enabled as a full function Master Key that must be registered.
B. Follow the screen flow in Figure 1 to determine the key type.
C. Key type and registration status will be indicated on the Immobilizer data list
(Figure 1, screen E).
S
“MATCH” = The key in the ignition cylinder matches this key type.
S
“NOMATCH” = The key in the ignition cylinder does NOT match this key type.
FIGURE 1. TRANSPONDER KEY IDENTIFICATION
A
FUNCTION SELECT
1: OBD/MOBD
2: ENHANCED OBD II
3: CARB OBD II
4: BREAK OUT BOX
5: NVH
6: AUTOPROBE
7: O2 RPM CHECK
8: SNAPSHOT REVIEW
9: SETUP
0: GAS ANALYSIS
B
OBD/MOBD MENU
1: CODES (ALL)
2: ENGINE AND ECT
3: TIRE PRES WARN
4: ABS / VSC
5: CCS
6: AIR CONDITIONER
7: IMMOBILIZER
8: SRS AIRBAG
9: GATEWAY
C
DIAGNOSTIC MENU
IMMOBILIZER
1: DATA LIST
2: DTC INFO
3: ACTIVE TEST
4: SNAPSHOT
5: ID UTILITY
D
SELECT DATA
ALL
USER DATA
E
KEY SW
IG SW
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
ON
ON
IMMOBILIZER . . . . . . . .
PERMIT (START)
UNSET
. . . . . . . . . . OK
RESPONSE . . . . . . . . . . . . . . OK
FRAME . . . . . . . . . . . . . . . . . .
SERIAL NUMBER . . . . . . . . .
OK
OK
ENCRYPT CODE
STATUS
. . . . . . . . . .
. . . . . . . . . . . . . . . . . .
OK
OK
BCC . . . . . . . . . . . . . . . . . . . . .
SUB KEY . . . . . . . . .
OK
NOMATCH
MASTER KEY . . . . . . . . MATCH
REGIST SUB CODE
REGIST MAS CODE
. . . . . . . .
. . . . . . . .
1
2
REG CODE SPACE . . NOT FUL
Page 4 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised July 6, 2001
Operation
Procedure
(Continued)
TRANSPONDER
CODE
REGISTRATION
2. Transponder Code Registration
This function allows the normal registration of additional transponder keys (Master or
Sub) using a registered Master Key.
NOTE:
This function requires the use of one registered Master Key. The use of a Sub Key will
NOT complete Transponder Code Registration. Attempting registration of additional keys with only a Sub Key will result in errors and incomplete registration.
HINT:
The Immobilizer key blanks are preconfigured as Master or Sub Keys. Master Key blanks cannot be registered as Sub Keys nor can Sub Key blanks be registered as
Master Keys. Also, the flat key is now enabled as a full function Master Key that must be registered.
A. Insert a registered Master Key into the ignition cylinder and turn to the ON position.
B. Follow the screen flow in Figure 2 to register new Master or Sub keys. It is possible to register up to 5 Master Keys and 3 Sub Keys.
C. Be sure to follow the instructions on key insertion, ignition ON/OFF and key removal exactly as described on the Diagnostic Tester.
HINT:
The security indicator light reveals the following information:
S Always ON and NO key in IG * = Transponder ECU in Auto Registration mode
S
Blinking and NO key in IG = Normal operation
S Blinking Code 21
S
Blinking Code 22
=
=
Transponder Code Registration failed
Attempt was made to register an already registered Transponder Code
Blinks
1.8 sec 0.25 sec
Code 2–1
1 sec 0.25 sec
Code 2–2
1 sec
0.2
sec
0.25
sec
0.5
sec
0.25
sec
0.5
sec
* Immediately after the transponder ECU is installed, the security indicator will blink.
Page 5 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised
Operation
Procedure
(Continued)
TRANSPONDER
CODE
REGISTRATION
FIGURE 2. REGISTRATION OF ADDITIONAL TRANSPONDER KEY
A
FUNCTION SELECT
1: OBD/MOBD
2: ENHANCED OBD II
3: CARB OBD II
4: BREAK OUT BOX
5: NVH
6: AUTOPROBE
7: O2 RPM CHECK
8: SNAPSHOT REVIEW
9: SETUP
0: GAS ANALYSIS
D
ID UTILITY
IMMOBILIZER
1: TRANSP CODE REG
2: TRANSP CODE ERS
B
OBD/MOBD MENU
1: CODES (ALL)
2: ENGINE AND ECT
3: TIRE PRES WARN
4: ABS / VSC
5: CCS
6: AIR CONDITIONER
7: IMMOBILIZER
8: SRS AIRBAG
9: GATEWAY
E
THIS FUNCTION WILL
REGISTER THE
TRANSPONDER CODE.
Do you wish to
continue the registration?
9: TRANSP CODE RESET
G
Please remove the Master
Key from the IG cylinder within 20 seconds.
Then press [ENTER]
PRESS [YES] OR [NO]
H
Please insert the New Key into the IG cylinder within
10 seconds.
DO NOT TURN IG ON
Remaining Time:
[20] Seconds
J
THE TRANSPONDER
CODE WAS REGISTERED
CORRECTLY.
PRESS [ENTER]
Remaining Time:
[10] Seconds
K
Please insert a
Master Key and turn the IG to
ON.
If the ignition is already ON, please turn it
OFF and back to
ON.
PRESS [ENTER]
July 6, 2001
C
DIAGNOSTIC MENU
IMMOBILIZER
1: DATA LIST
2: DTC INFO
3: ACTIVE TEST
4: SNAPSHOT
5: ID UTILITY
F
Please remove the
Master Key from the IG cylinder, insert it again, and turn the IG ON within 120 seconds.
Then press [ENTER]
Remaining Time:
[120] Seconds
I
**NOW REGISTERING**
Please wait.
[60] Seconds
Page 6 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised July 6, 2001
Operation
Procedure
(Continued)
TRANSPONDER
CODE ERASURE
3. Transponder Code Erasure
This function allows the user to erase all the transponder keys except the registered
Master Key used during this function.
NOTE:
This function requires the use of one registered Master Key. The use of a Sub Key will
NOT complete Transponder Code Erasure.
A. Insert a registered Master Key into the ignition cylinder and turn to the ON position.
B. Follow the screen flow in Figure 3 below to erase all Master or Sub keys, except the registered Master Key used for this procedure.
FIGURE 3. ERASING TRANSPONDER CODES
A
FUNCTION SELECT
1: OBD/MOBD
2: ENHANCED OBD II
3: CARB OBD II
4: BREAK OUT BOX
5: NVH
6: AUTOPROBE
7: O2 RPM CHECK
8: SNAPSHOT REVIEW
9: SETUP
0: GAS ANALYSIS
B
OBD/MOBD MENU
1: CODES (ALL)
2: ENGINE AND ECT
3: TIRE PRES WARN
4: ABS / VSC
5: CCS
6: AIR CONDITIONER
7: IMMOBILIZER
8: SRS AIRBAG
9: GATEWAY
C
DIAGNOSTIC MENU
IMMOBILIZER
1: DATA LIST
2: DTC INFO
3: ACTIVE TEST
4: SNAPSHOT
5: ID UTILITY
D
ID UTILITY
IMMOBILIZER
1: TRANSP CODE REG
2: TRANSP CODE ERS
9: TRANSP CODE RESET
E
This function will
ERASE ALL
TRANSPONDER CODES except the
Master key in the
IG cylinder.
DO YOU WISH TO
CONTINUE ERASING?
F
Please remove the
Master Key from the IG cylinder, insert it again, and turn the IG ON within 120 seconds.
Then press [ENTER]
Remaining Time:
[120] Seconds
G
***NOW ERASING***
WARNING: Master Key must be removed from
IG cylinder within 10 seconds or erasure will not complete.
Remaining Time:
[10] Seconds
H
ALL TRANSPONDER
CODES EXCEPT THE
INSERTED MASTER
KEY’S TRANSPONDER
CODE WERE ERASED.
PRESS [ENTER]
Page 7 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised July 6, 2001
Operation
Procedure
(Continued)
TRANSPONDER
ECU RESET
4. Transponder ECU Reset
This function allows the registration of a new Master Key even if all original Master
Keys are lost. Once the Immobilizer system is reset, all previous registered keys will be erased. Use a new transponder Master Key to complete Transponder ECU Reset.
Immobilizer Reset
The Immobilizer Reset function is a 4-step process:
A. Using the Diagnostic Tester, retrieve a “Seed Number” through the OBD/MOBD
Immobilizer function.
S
A “Seed Number” is a unique number provided by the Diagnostic Tester and validated at TMS in order to return a Passcode.
B. Using the TIS (Technical Information System) workstation, select Immobilizer
Reset, and complete the request form to retrieve a “Passcode Number.”
S
A “Passcode Number” is a unique number required by the Diagnostic Tester to reset the ECU allowing it to accept a new Master Key.
C. Enter the “Passcode Number” received from TIS into the Diagnostic Tester, register any additional customer keys, and close auto registration mode.
D. Confirm successful Immobilizer reset and new Master Key registration.
Page 8 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised
Operation
Procedure
(Continued)
TRANSPONDER
ECU RESET
July 6, 2001
A. Connect the Diagnostic Tester to DLC3 and turn ignition ON.
a. Using the Diagnostic Tester, retrieve a “Seed Number” through the
OBD/MOBD Immobilizer function.
b. Follow each step outlined in Figure 4.
FIGURE 4. RETRIEVING A SEED NUMBER
A
FUNCTION SELECT
1: OBD/MOBD
2: ENHANCED OBD II
3: CARB OBD II
4: BREAK OUT BOX
5: NVH
6: AUTOPROBE
7: O2 RPM CHECK
8: SNAPSHOT REVIEW
9: SETUP
0: GAS ANALYSIS
B
OBD/MOBD MENU
1: CODES (ALL)
2: ENGINE AND ECT
3: TIRE PRES WARN
4: ABS / VSC
5: CCS
6: AIR CONDITIONER
7: IMMOBILIZER
8: SRS AIRBAG
9: GATEWAY
C
DIAGNOSTIC MENU
IMMOBILIZER
1: DATA LIST
2: DTC INFO
3: ACTIVE TEST
4: SNAPSHOT
5: ID UTILITY
D
ID UTILITY
IMMOBILIZER
1: TRANSP CODE REG
2: TRANSP CODE ERS
E
Please open the
Driver’s Door.
F
This function will RESET the
TRANSPONDER CODE.
DO YOU WISH TO
CONTINUE RESETTING?
9: TRANSP CODE RESET
PRESS [ENTER]
G
SEED NUMBER
999999
NOTICE:
S Do NOT turn the ignition OFF
S Do NOT disconnect the
Diagnostic Tester from the vehicle.
Please insert SEED
NUMBER into TIS
PRESS [ENTER]
Page 9 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised
Operation
Procedure
(Continued)
TRANSPONDER
ECU RESET
July 6, 2001
B. Using the TIS workstation, select Immobilizer Reset, and complete the request form to retrieve a “Passcode Number.” a. Click on Diagnostics.
b. Click on Immobilizer Reset.
FIGURE 5. SELECTING IMMOBILIZER RESET ON TIS a b c. Read the instructions on the screen and click on Continue.
(See Figure 6 below.)
FIGURE 6. IMMOBILIZER RESET INSTRUCTIONS ON TIS c
Page 10 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised
Operation
Procedure
(Continued)
TRANSPONDER
ECU RESET
July 6, 2001 d. Complete the request form and enter the “Seed Number” from the Diagnostic
Tester. Click on Submit (Figure 7).
NOTE:
All fields must be completed.
FIGURE 7. REQUEST FORM ON TIS d e. TIS will now return the Passcode that needs to be entered into the Diagnostic Tester.
NOTE:
The Passcode given by TIS is only valid for one Immobilizer Reset Event.
FIGURE 8. RECEIVING PASSCODE FOR DIAGNOSTIC TESTER e
Page 11 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised
Operation
Procedure
(Continued)
TRANSPONDER
ECU RESET
July 6, 2001
C. Using the numbered keys (0–9) on the Diagnostic Tester, enter the “Passcode
Number” received from TIS into the Diagnostic Tester (see Figure 9 below).
Press ENTER to clear all registered transponder codes except the Master key in the ignition cylinder.
NOTE:
S
During the reset process do not remove the key from the ignition.
S
This step takes approximately 16 minutes.
FIGURE 9. PASSCODE ENTRY
A
Please insert PASSCODE
NUMBER from TIS
PASSCODE NUMBER
000414
PRESS [ENTER]
D
Master Keys and Sub key may be registered by inserting keys into IG.
*INSERT KEYS NOW*
PRESS [ENTER]
B
**NOW RESETTING**
If the key was in the IG cylinder, do not remove it.
Remaining Time
<16> Min.
E
To turn off auto– matic registration, insert a Master key and cycle IG 5 times within 10 seconds.
[HINT] On automatic registration mode, the security indicator remains on unless a key is in the IG cylinder.
PRESS [ENTER]
C
RESETTING SUCCEEDED
All TRANSPONDER
CODES were successfully reset.
If a key remains in the IG cylinder, please remove it.
PRESS [ENTER]
S
Following a reset, the Transponder ECU is in auto registration mode.
S
Auto registration mode allows 3 Master Keys and one Sub Key to register automatically.
S
To register additional keys, remove the Master Key currently in the ignition.
Insert keys (Master or Sub) into the ignition cylinder without turning the ignition on or off – simply insert and remove. (See Figure 9, screen D.)
NOTE:
S If 4 keys are registered at this time, auto registration mode is automatically closed.
S
If less than 4 keys are registered at this time, auto registration mode must be closed manually by cycling the ignition ON/OFF more than 5 times in 10 seconds. (See
Figure 9, screen E.)
S
If more than 4 keys need to be registered, use Transponder Code Registration.
Page 12 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised
Operation
Procedure
(Continued)
TRANSPONDER
ECU RESET
July 6, 2001
D. Verify that keys are registered correctly by starting the engine with each newly registered key.
NOTE:
S
If the vehicle starts, the new key code was registered correctly.
S If the vehicle does not start with any key, perform the Immobilizer Reset function again.
S
If only one of the registered keys will not start the vehicle, attempt to register the key again following the Transponder Code Registration procedure (page 5 of this bulletin).
TRANSPONDER
ECU
REPLACEMENT
5. Transponder ECU Replacement
When the Transponder ECU is replaced, the transponder keys must be registered, auto registration closed, and ECU communication completed.
A. Replacement transponder ECUs are in auto registration mode. This allows transponder keys to automatically register as they are inserted into the ignition cylinder. It is possible to automatically register 3 Master Keys, and 1 Sub Key.
NOTE:
S If 4 keys are registered at this time, auto registration mode is closed.
S If less than 4 keys are registered at this time, auto registration mode must be closed manually by cycling the ignition ON/OFF more than 5 times in 10 seconds.
S If more than 4 keys need to be registered, use Transponder Code Registration procedure (page 5 of this bulletin).
B. Once auto registration mode is closed, ECU Communication must be performed between the transponder ECU and the Engine ECU. Complete ECU communication using the following steps: a. Insert registered Master Key into the ignition cylinder.
b. Turn ignition ON (engine OFF).
c. Short Tc and CG terminals of DLC3 using Diagnosis Check Wire
(SST 09843–18040 or equivalent) and leave for 30 minutes. (See Figure 10.)
FIGURE 10. DLC3
SST 09843–18040
Tc = Pin 13
CG = Pin 4
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
View of Connector Is From Passenger Compartment d. After 30 minutes, turn ignition OFF and remove check wire from DLC3 e. Start the vehicle to confirm successful ECU communication.
NOTE:
If ECU communication is not completed correctly, the engine will not start and DTC
B2799 will be set. DTC B2799 will be cleared after engine starts correctly.
Page 13 of 14
DIAGNOSTIC TESTER IMMOBILIZER FUNCTIONS – SS005-01 Revised
Operation
Procedure
(Continued)
TRANSPONDER
ECU
REPLACEMENT
HINT:
The security indicator light reveals the following information:
July 6, 2001
S
Always ON and NO key in IG * = Transponder ECU in Auto Registration mode
S Blinking and NO key in IG = Normal operation
S Blinking Code 21
S Blinking Code 22
=
=
Transponder Code Registration failed
Attempt was made to register an already registered Transponder Code
Blinks
1.8 sec 0.25 sec
Code 2–1
1 sec 0.25 sec
Code 2–2
1 sec
0.2
sec
0.25
sec
0.5
sec
0.25
sec
0.5
sec
* Immediately after the transponder ECU is installed, the security indicator will blink.
ENGINE ECU
REPLACEMENT
6. Engine ECU Replacement
When the Engine ECU is replaced, ECU communication must be completed.
ECU Communication must be performed between the transponder ECU and the
Engine ECU. Complete ECU communication using the following steps:
A. Insert registered Master Key into the ignition cylinder.
B. Turn ignition ON (engine OFF).
C. Short Tc and CG terminals of DLC3 using Diagnosis Check Wire
(SST 09843–18040 or equivalent) and leave for 30 minutes. (See Figure 11.)
FIGURE 11. DLC3
SST 09843–18040
Tc = Pin 13
CG = Pin 4
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
View of Connector Is From Passenger Compartment
D. After 30 minutes, turn ignition OFF and remove check wire from DLC3
E. Start the vehicle to confirm successful ECU communication.
NOTE:
If ECU communication is not completed correctly, the engine will not start and DTC
B2799 will be set. DTC B2799 will be cleared after engine starts correctly.
Page 14 of 14
Technical Service
Information Bulletin
April 29, 2005
Title:
Models:
’03 ES 300, ’04 – ’05 ES 330
Introduction Some customers may hear and feel a clunk, pop, or knock type noise when turning the steering wheel left or right. A new intermediate shaft has been developed to address this concern.
Steering Column
Intermediate Shaft
Applicable
Vehicles
S
2003 model year ES 300 vehicles.
S 2004 model year ES 330 vehicles.
S
2005 model year ES 330 vehicles produced BEFORE the Production Change
Effective VINs shown below.
Production
Change
Information
MODEL
ES 330
PRODUCTION CHANGE EFFECTIVE VIN
JTHBA30G#55098506
Warranty
Information
OP CODE
ST4008
DESCRIPTION
R & R Steering Intermediate Shaft
TIME
0.9
OFP
45220–33200
T1 T2
91 19
Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 2
STEERING INTERMEDIATE SHAFT NOISE – ST001-05
Parts
Information
PREVIOUS PART NUMBER CURRENT PART NUMBER
45220–33200 45220–33240
April 29, 2005
PART NAME
Intermediate Shaft Assembly
QTY
1
Repair
Procedure
Prior to removing the steering intermediate shaft, make sure the steering wheel and front wheels remain stationary. Once the intermediate shaft is removed, do NOT allow the steering wheel to spin freely.
For information on replacing the steering intermediate shaft assembly, refer to the
Technical Information System (TIS): 2003 – 2004 model year ES 330 Repair Manual:
Steering Column: Steering Column Assy: Overhaul.
Page 2 of 2
Technical Service
Information Bulletin
December 21, 2001
Title:
Models:
All ’02 – ’06 Model
TSIB REVISION NOTICE:
S
October 5, 2005: 2003 – 2006 model years have been added to Applicable Vehicles.
A note has been added to the illustration in step 3.
S
March 1, 2002: OP Codes updated in Warranty Information.
All previous versions of this TSIB should be discarded.
Introduction This bulletin contains general vehicle pulling diagnosis and repair procedures along with specific information to help correct pulling complaints.
This information supplements Repair Manual procedures when the symptoms are:
S
The driver holds the steering wheel without exerting steering effort while driving straight ahead, and the vehicle drifts to the right or the left.
S
While driving straight ahead, the driver has to steer either to the right or the left to maintain straight driving.
Applicable
Vehicles
S
2002 – 2006 model year Lexus vehicles.
Warranty
Information
OP CODE
ST1004
Combo A
Combo B
Combo C
Combo D
Combo E
420091
Combo A
DESCRIPTION
Preliminary Check & Road Test
Switch Front Tire/Wheel & Road Test
Reverse the Front One Side Tire
Check Front Wheel Alignment
Adjust Front Wheel Alignment
Adjust Camber Setting
Dismount and Mount Tire and Balance Wheel and Tire Assembly
Each additional Wheel
NOTE:
Above combination codes A, B, D and E include road test time.
TIME
0.6
0.5
0.7
1.2
0.7
0.7
0.5
0.3
OPN T1 T2
31 99
Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 12 months or 20,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised December 21, 2001
Contents This bulletin is divided into the following sections:
Wheel Alignment and Tire Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 2–3
Repair Procedure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
Repair Procedures
1. Important Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 5–6
3. Vehicle Pulling Caused by Wheel Alignment . . . . . . . . . . . . . . . . . . . Pages 6–7
4. Vehicle Pulling Caused by Tire Conicity . . . . . . . . . . . . . . . . . . . . . . . Pages 7–9
5. Camber Adjustment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 9–10
Page 2 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised December 21, 2001
Wheel
Alignment &
Tire
Characteristics
1. Relationship Between Wheel Alignment and Vehicle Pulling to One Side
When the cross camber or caster of the front wheel alignment is large, it can cause vehicle pulling.
WHEEL ALIGNMENT
Camber
Caster
CAMBER
DIRECTION OF VEHICLE PULLING
Vehicle pulls in direction of wheel with large camber value
Vehicle pulls in direction of wheel with small caster value
Straight–Ahead
Driving
Direction of Pull
CASTER
Front
P’ T’
T
P a’ a
Caster Trail
(Small)
Caster Trail
(Large)
O O’
F F’
P, P’: Driving Force a, a’: Steering Axes
O, O’: Center of Tire–Road
Contact Area
F, F’: Reactive Force
If the cross camber or caster is within the specified range (30’ or less), noticeable vehicle pulling will not occur due to side-to-side differences in camber or caster.
NOTE:
On a flat road, if the cross camber or caster is 30’ or less and the steering wheel is held without exerting steering effort for 100 m (109 yards) when driving at 100 km/h
(62 mph), the alignment–induced drift distance is approximately 0.5 m (1.64 ft).
Page 3 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised December 21, 2001
Wheel
Alignment &
Tire
Characteristics
(Continued)
2. Relationship Between Tire Characteristics and Vehicle Pulling to One Side
When radial tires are rotating, they have the characteristic of generating force in the lateral direction between the tire and the road surface. This lateral force is comprised of two factors:
S
Ply–steer, which changes direction according to the rotation direction of the tires.
S
Conicity, which is generated in a fixed direction regardless of the tire rotation direction.
If these lateral forces are too strong, vehicle pulling will occur.
A. Ply–Steer
Lateral force due to ply-steer is produced by the construction of the belts inside the tire tread. With radial tires, the wire of the belt is slanted as shown in the illustration below. Thus, it is in the lateral direction that tire tread easily changes shape (stretches), and lateral force is generated between the tire and the road surface in the lateral direction.
Rotation Direction
Easily–Stretched
Direction
Wire
Belt
Ply–Steer
(Direction of Force Generation Varies
According to Tire Rotation)
NOTE:
Lateral force from ply-steer prevents vehicle drift caused by road slant, so in many cases lateral force to the right is provided for left-handed steering vehicles.
B. Conicity
Conicity is lateral force resulting from uneven formation of the left and right sides of the tire. The direction the lateral force is exerted depends on the hardness of the side walls and the difference in height between the left/right sides of the tire.
Hard
Part
Conicity
(Direction Is Fixed Regardless of
Direction of Tire Rotation)
NOTE:
S In the case of vehicle pulling caused by tires, the lateral force which is exerted as a result of conicity has the greatest effect. On a flat road, if the steering wheel is held without exerting steering effort for 100 m (109 yards) when travelling at 100 km/h (62 mph), the vehicle may drift as much as 1.5 m (5 ft).
S When vehicle pulling is due to conicity, the amount of drift can be reduced and the direction of drift can be changed by changing the location of the tire or reversing the tire when installing it on the wheel.
Page 4 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised
Repair
Procedure
Flow Chart
START
December 21, 2001
Preliminary Check
S
S
S
Tire Pressure
Vehicle height
Brake Dragging
*ROAD TEST
Does the vehicle lead/pull?
YES
NO
Is there steering off center?
YES
Adjust front tie rods.
See TSIB ST002–01
NO
COMPLETE
YES
Are the tires uni–directional type?
NO
Cross switch front tire and wheel assemblies (left & right)
ROAD TEST
YES
NO
Does the vehicle still lead/pull?
Choose the position of front tire & wheel assemblies where there is least amount of pull.
Check front wheel alignment.
Is it within specification?
NO
Adjust front wheel alignment.
YES
YES
Does the vehicle lead/pull in the same direction as before?
NO
NO Is the lead/pull stronger than before?
YES
Reverse the front left side tire and rebalance it.
ROAD TEST
Does the vehicle still lead/pull?
NO YES
ROAD TEST
Does the vehicle still lead/pull?
YES
NO
COMPLETE Does the vehicle lead/pull to the left?
YES
Increase right front camber and decrease left front camber until lead/pull is eliminated.
NO
NOTE: Do not exceed 1 r
of cross camber.
Do not exceed adjustment range.
Increase left front camber and decrease right front camber until lead/pull is eliminated.
NO ROAD TEST
Does the vehicle still lead/pull?
YES
Contact your regional office.
* Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed of
35 mph. Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph without exerting steering effort on the steering wheel.
(1) The vehicle goes straight but the steering wheel has some angle.
STEERING OFF CENTER
(2) The vehicle doesn’t go straight.
STEERING PULL
Page 5 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised December 21, 2001
Repair
Procedures
1. IMPORTANT NOTICE
Before repairing vehicle pulling to one side, it is necessary to clearly identify the cause of the pulling condition. Frequently, the cause of the vehicle pulling to one side is diagnosed as wheel alignment. However, the actual cause may be lateral force generated by the tires. Performing wheel alignment when tire force is the cause could result in the wheel alignment being set at a value outside of specifications. This would then cause other problems such as uneven tire wear, etc.
2. Troubleshooting
First determine whether vehicle pulling to one side is caused by a wheel alignment problem or tire characteristics, then decide which repairs to make.
A. Perform the following checks and correct as necessary.
a. Check tires for size, wear and for proper inflation pressure.
b. Check whether the vehicle is noticeably tilted backward/forward or left/right.
NOTE:
Tilting of the vehicle produces a left–right difference in the camber and caster and can cause vehicle pulling to one side.
c. Check brakes for dragging.
B. Confirm problem symptoms.
With the customer accompanying you, drive the vehicle to confirm if the customer’s complaint involves vehicle pulling to one side or steering wheel off center. If the problem is steering wheel off center, adjust the front tie rods on the vehicle. Refer to Lexus TSIB ST002–01. Also check the direction of vehicle pulling and the extent of the pulling.
C. Decide if vehicle pulling is due to wheel alignment or tires.
a. Switch the left and right front tires (If the tires are non–unidirectional).
b. Conduct a drive test to check whether the direction that the vehicle pulls has changed.
SYMPTOM
No change in vehicle pulling condition
Vehicle pulling eliminated
Vehicle pulling direction is reversed
PROBABLE CAUSE
Front wheel alignment
Tire conicity
Tire conicity
CORRECTIVE ACTION
Proceed to Repair Procedure 3. Vehicle pulling caused by Wheel Alignment (Page 6)
Repair complete. Vehicle Pulling Caused by Tire
Conicity (Page 3 and 6)
Proceed to Repair Procedure 4. Vehicle Pulling
Caused by Tire Conicity (Page 7)
Page 6 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised December 21, 2001
Repair
Procedures
(Continued)
Helpful hints to determine cause of vehicle pulling:
S
The direction of lateral force from tire conicity becomes reversed when the left and right tires are switched. Therefore, if the pulling direction changes when the tires are switched, it can be concluded that vehicle pulling is caused by tire conicity.
ORIGINAL TIRE POSITIONS
Vehicle Pulling
Direction (Right)
Lateral Force by
Conicity
TIRES SWITCHED
Vehicle Pulling
Direction (Left)
Lateral Force by
Conicity
The Vehicle is Pulled to the Right by the Lateral Force Exerted to the Right.
The Direction of the Tires Which Exerted Lateral
Force to the Right has Been Changed, so the Tires
Now Exert Lateral Force to the Left and the Vehicle
Now Pulls to the Left.
S If the pulling direction does not change after the front tires are switched, the cause of vehicle pulling is not tire conicity. In this case, the likely cause is a front wheel alignment condition.
3. Vehicle Pulling Caused by Wheel Alignment
When it is determined by troubleshooting that the vehicle pulling to one side is caused by wheel alignment, perform repairs according to the following procedure.
Vehicle Pulling to One Side
Check Front Wheel Alignment
Not Within Specification
Adjust Front Wheel Alignment
Road Test
Vehicle Still Pulls
OK
Within Specification
Within Specification But
Vehicle Pulls
Adjust Cross Camber to Eliminate Vehicle Pulling
NOTE: Do not exceed 1 r of cross camber.
Page 7 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised
Repair
Procedures
(Continued)
WHEN VEHICLE PULLS TO LEFT
Increase right front camber and decrease left front camber until vehicle pulling is eliminated
December 21, 2001
WHEN VEHICLE PULLS TO RIGHT
Increase left front camber and decrease right front camber until vehicle pulling is eliminated
NOTE:
S Keep the cross camber within 1 r or less.
S
Keep the camber of each wheel within specifications (+/–45’ of center value).
S
If adjustment exceeds the specifications, uneven tire wear will result.
4. Vehicle Pulling Caused by Tire Conicity
When it is determined by troubleshooting that the vehicle pulling to one side is caused by tire conicity, perform repairs according to the following procedures.
Indication of Tire Conicity as a Cause:
When the front tires are switched, the pulling direction changes. Proceed to STEP 1.
STEP 1:
Remove the front left tire from the wheel and reverse the tire. Then perform a road test and check for change in the pulling direction.
HINT:
By performing this operation, it can be checked whether the left or right tire exerts a stronger lateral force. Either tire can be reversed. Shown here is an example of the left tire reversed.
If Vehicle Pulls in the Same Direction: Go to STEP 2.
The lateral force generated by the right front tire is greater than the left tire, so the vehicle is pulling due to the lateral force of the right tire.
ORIGINAL TIRE POSITIONS LEFT TIRE REVERSE INSTALLATION
Vehicle Pulling
Direction
Vehicle Pulling Direction
(Same Direction)
Reversed
Lateral Force by
Conicity (Smaller)
Lateral Force by
Conicity (Larger)
Lateral Force by
Conicity (Smaller)
Lateral Force by
Conicity (Larger)
Page 8 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised
Repair
Procedures
(Continued)
If Vehicle Pulls in the Opposite Direction: Go to STEP 2.
December 21, 2001
The lateral force generated by the left front tire is greater than the right tire, so the vehicle is pulling due to the lateral force of the left tire.
ORIGINAL TIRE POSITIONS
Vehicle Pulling
Direction
LEFT TIRE REVERSE INSTALLATION
Reversed
Vehicle Pulling
Direction
(Opposite Direction)
Lateral Force by
Conicity (Larger)
Lateral Force by
Conicity (Smaller)
Lateral Force by
Conicity (Larger)
Lateral Force by
Conicity (Smaller)
If Vehicle Pull Is Eliminated: Repair Is Now Complete.
The lateral force generated by the left and right front tires is virtually the same, so the lateral force is neutralized and the vehicle travels straight ahead. The repair operation is now completed.
STEP 2:
Rotate the larger lateral force front tire with the rear tire and check the change in the vehicle pulling.
NOTE:
By shifting the front tire with the larger lateral force to the rear, the vehicle pulling level is usually reduced.
If Vehicle Is Still Pulling: Go to STEP 3.
If Vehicle Pull Is Eliminated: Repair Is Now Complete.
Page 9 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised
Repair
Procedures
(Continued)
STEP 3:
Adjust cross camber to eliminate vehicle pulling.
December 21, 2001
HINT:
If the tires are placed in the positions they were in during tire rotation when the least amount of vehicle pulling occurred, wheel alignment can be performed with a minimal amount of adjustment.
WHEN VEHICLE PULLS TO LEFT
Increase right front camber and decrease left front camber until vehicle pulling is eliminated
WHEN VEHICLE PULLS TO RIGHT
Increase left front camber and decrease right front camber until vehicle pulling is eliminated
NOTE:
S Keep the cross camber within 1 r or less.
S Keep the camber of each wheel within specifications (+/–45’ of center value).
S
If adjustment exceeds the specifications, uneven tire wear will result.
5. Camber Adjustment Method
NOTE:
After the camber has been adjusted, inspect the toe–in.
NOTE:
The method of camber adjustment differs for different models, so please refer to the repair manual of the vehicle involved. (This is a sample from the RX 300 Repair Manual).
A. Remove the front wheels and
ABS speed sensor clamp.
B. Remove the two nuts on the lower side of the shock absorber.
C. Coat the threads of the nuts with engine oil.
D. Temporarily install the two nuts.
E. Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required.
F. Tighten the nuts.
Torque: 210 N
S m
(2,150 kgf
S cm, 155 ft
S lbf)
1
2
Page 10 of 11
REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST004-01 Revised
Repair
Procedures
(Continued)
G. Install the front wheels.
Torque: 103 N
S m (1,050 kgf
H. Check the camber.
S cm, 76 ft
S lbf)
NOTE:
Adjusting value for the set bolts is
6’ – 30’ (0.1
r – 0.5
r ).
When making an adjustment of more than 45’, replace the upper and lower steering knuckle set bolts with the adjusting bolts. If the camber is not within the specification, use the table shown to estimate how much additional camber adjustment will be required, and select the appropriate camber adjusting bolt.
I.
Follow steps 5–a through 5–h again. Between steps 5–b and
5–c, exchange one or two selected bolts.
HINT:
When exchanging the two bolts, exchange one bolt each time.
December 21, 2001
If Vehicle Pull Is Eliminated: Repair Is Now Complete.
If Vehicle Is Still Pulling: Contact Your Regional Office For Further Assistance.
Page 11 of 11
Technical Service
Information Bulletin
May 5, 2003
Title:
Models:
’98 – ’05 Applicable Models
TSIB REVISION NOTICE:
December 20, 2004: Applicable Vehicles section has been updated and modified,
2004 and 2005 model years added; and Reset Procedure 2 has been revised.
Previous versions of this TSIB should be discarded.
Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to erase Engine Control Module (ECM, SAE term:
Powertrain Control Module, PCM) “Learned Values” and minimize subsequent performance concerns.
CAUTION:
Failure to follow the following procedure may lengthen the time to readjust the
“Learned Values,” potentially resulting in performance concerns.
Applicable
Vehicles
Refer to Reset Procedure 1 for the following vehicles with Electronically Controlled
Automatic Transmissions:
S
1999 – 2003 model year ES 300 and RX 300 vehicles.
S
2003 – 2005 model year GX 470 vehicles.
S 2004 – 2005 model year RX 330 vehicles.
Refer to Reset Procedure 2 for the following vehicles with Electronically Controlled
Automatic Transmissions:
S
1998 – 2005 model year GS 430/400/300, LS 430/400, LX 470, and
SC 430/400/300 vehicles.
S
2001 – 2005 model year IS 300 vehicles.
Warranty
Information
OP CODE
N/A
DESCRIPTION
Not Applicable to Warranty
TIME
–
OFP
–
T1 T2
– –
Lexus Supports ASE Certification
Page 1 of 3
RESET MEMORY FUNCTION – TC002-03 Revised
Required
SSTs
SPECIAL SERVICE TOOLS (SSTs)
Lexus Diagnostic Tester Kit*
May 5, 2003
PART NUMBER QUANTITY
01001270 1
CAN Interface Module Kit* 01002744 1
12 Megabyte Diagnostic Tester Program Card with version 12.01a Software (or later)*
* Essential SSTs.
01002593-005
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other
SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
1
Reset
Procedure 1
1. Connect the Lexus Diagnostic Tester to the vehicle.
2. Reset the ECM (PCM). Refer to the procedures below.
A
*APPLICATION SELECT*
1: DIAGNOSIS
2: CUSTOMIZE
3: ECU REPROGRAM
D
RESET MEMORY
NOTICE
DO NOT USE THIS
FUNCTION UNLESS
INSTRUCTED BY
REPAIR MANUAL.
ONLY USE AFTER
REPLACING THE ENGINE,
AUTO TRANS, OR ECM
ON CERTAIN VEHICLES.
B
FUNCTION SELECT FOR
NORTH AMERICA
1: OBD/MOBD
2: ENHANCED OBD II
3: CARB OBD II
4: BREAK–OUT BOX
5: NVH
6: AUTOPROBE
7: 02 RPM CHECK
8: SNAPSHOT REVIEW
9: SETUP
0: GAS ANALYSIS
E
RESET MEMORY
EXECUTING THIS
FUNCTION WILL RESET
THE LEARNED VALUES
IN THE ECM.
DO YOU WISH TO
RESET THE ECM?
[YES] to CONTINUE
[NO] to EXIT
C
DIAGNOSTIC MENU
ENGINE
1: DATA LIST
2: DTC INFO
3: ACTIVE TEST
4: SNAPSHOT
5: SYSTEM CHECK
6: RESET MEMORY
7: MONITOR STATUS
8: CHECK MODE
F
RESET MEMORY
RESETTING COMPLETE
PRESS [ENTER]
3. Start the engine and warm it up to normal operating temperatures before test–driving.
4. Perform a thorough test drive with several accelerations from a stop with “light throttle” application until proper transmission shifting is verified.
Page 2 of 3
RESET MEMORY FUNCTION – TC002-03 Revised May 5, 2003
Reset
Procedure 2
1. Disconnect the negative battery cable for 5 minutes.
2. Reconnect battery cable.
3. Start the engine and warm it up to normal operating temperatures before test–driving.
4. Perform a thorough test drive with several accelerations from a stop with “light throttle” application until proper transmission shifting is verified.
Page 3 of 3
Technical Service
Information Bulletin
August 4, 2003
Title:
Models:
’02 – ’03 ES 300 & ’04 – ’05 ES 330
Introduction
REVISION NOTICE:
S
April 1, 2005: 2004 – 2005 model year ES 330 vehicles have been added to
Applicable Vehicles. Introduction and Note have been updated on page 1.
Calibration Identification Chart has been updated to include ES 330 calibration IDs.
S
August 6, 2003: There has been a change in Warranty Time.
Previous versions of this TSIB should be discarded.
To improve the transmission shift feeling during specific operating modes, the Engine
Control Module (SAE term: Powertrain Control Module/PCM) calibration has been revised. These improvements include:
S
Reduced downshift lag when accelerating at speeds from 10 to 20 mph.
S
Less gear hunting when driving on/off accelerator pedal at 20 to 30 mph
(for example: during heavy rush–hour traffic).
S
Improved response rate during heavy acceleration from a stop.
NOTE:
S
Version 12.01a or later Diagnostic Tester software is required to perform this procedure.
S
Before proceeding, verify the ECM (PCM) calibration has NOT been updated by checking for the Authorized Modifications Label (shown in step 1 of the
Repair Procedure).
S Harsh ATM shifting may result if any Repair Procedure steps are omitted
(specifically steps 2 and 4 of “Flash Reprogram ECM” on page 6).
Applicable
Vehicles
S
2002 – 2003 model year ES 300 vehicles.
S 2004 – 2005 model year ES 330 vehicles.
Warranty
Information
OP CODE
EG5017
DESCRIPTION
Recalibrate ECM Engine & Transmission
TIME
0.9
OFP
89666–3325#
89666–3344#
89661–33B3#
89661–33A4#
T1 T2
26 99
Applicable Warranty*:
This repair is covered under the Lexus Federal Emissions Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle’s in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Lexus Supports ASE Certification
Page 1 of 6
ECM CALIBRATION: SHIFTING ENHANCEMENT – TC004-03 Revised
Parts
Information
PREVIOUS PART NUMBER CURRENT PART NUMBER
N/A 00451–00001–LBL
August 4, 2003
PART NAME
Authorized Modifications Label
QTY
1
NOTE:
Authorized Modification Labels may be ordered in packages of 25 from the Materials
Distribution Center (MDC) through Dealer Daily Dealer Support Materials System or by calling the MDC at 1–800–622–2033.
Required
SSTs
SPECIAL SERVICE TOOLS (SSTs)
CAN Interface Module Kit*
PART NUMBER
01002744
QTY DRW**
1 8
Lexus Diagnostic Tester Kit*
01001270 1 8
12 Megabyte Diagnostic Tester Program Card with version 12.01a Software (or later)*
01002593-005
(Component of 01001270)
1
* Essential SSTs.
** Refers to drawer number in SST Storage System.
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other
SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
Page 2 of 6
ECM CALIBRATION: SHIFTING ENHANCEMENT – TC004-03 Revised
Calibration
Identification
Chart
MODEL
ES 300
2004 – 2005
ECM (CPU)
Main
Sub
Main
Sub
PREVIOUS CALIBRATION ID
33323000
33323100
33323200
33341000
33341100
33341200
33341300
33341400
53314000
53314100
53314200
53328000
53328100
53328200
53328300
53328400
33350000
33350100
33360000
33360100
53334000
53340000
August 4, 2003
NEW CALIBRATION ID
33387000
53343000
33360200
53340100
NOTE:
S 2004 model year ES 330 vehicles, which have been flash reprogrammed using the procedures in this TSIB, will contain upgraded 2005 model year OBD II logic and will require VIN input. Refer to the 2005 model year ES 330 Repair Manual information on the Technical Information System (TIS) when checking Powertrain Diagnostic Trouble
Codes (DTCs) on 2004 model year ES 330 vehicles that have been reprogrammed.
S 2002 model year ES 300 vehicles, which have been flash reprogrammed using the procedures in this TSIB, will contain upgraded 2003 model year OBD II logic. Refer to the 2003 model year ES 300 Repair Manual information on the Technical Information
System (TIS) when checking Powertrain Diagnostic Trouble Codes (DTCs) on 2002 model year ES 300 vehicles that have been reprogrammed.
Page 3 of 6
ECM CALIBRATION: SHIFTING ENHANCEMENT – TC004-03 Revised August 4, 2003
Repair
Procedure
1. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if ECM (PCM) calibration has been updated. If not the latest ECM (PCM) calibration — go to step 2.
Replacement
ECM (PCM)
Part
Number
Calibration
ID(s)
THE FOLLOWING MODIFICATIONS HAVE BEEN MADE:
89666–33441
33387000, 53343000
THESE MODIFICATIONS HAVE BEEN APPROVED
AS APPROPRIATE BY EPA AND CARB
DEALER CODE:
CHANGE AUTHORITY:
DATE:
TSIB TC004–03
Dealer Code TSIB Number
Figure 1. Location of Authorized Modifications Label on 2002 and 2003 ES 300
Date
Completed
Page 4 of 6
ECM CALIBRATION: SHIFTING ENHANCEMENT – TC004-03 Revised August 4, 2003
Repair
Procedure
(Continued)
2. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle’s current ECU calibration (see Figure 2).
– The sample screen prints seen below are the 12.01a software version and may differ from subsequent software versions.
A
ECU REPROGRAM
MAIN MENU
1: GET CAL FROM PC
2: CURRENT ECU CAL
3: UPDATE ECU CAL
4: CAL ON TESTER
5: CLEAR CAL DATA
B
CURRENT ECU CAL
CALIBRATION ID
33341300
53328300
Figure 2. Determining Current ECU Calibration
NOTE:
S If Calibration ID matches “Previous Calibration ID” as shown in Calibration
Identification Chart on page 3, proceed with flash reprogramming.
S If Calibration ID matches “New Calibration ID” as shown in Calibration Identification
Chart, this vehicle has already been programmed. Refer to TIS for diagnostic procedures applicable to any stored DTCs.
3. If ECU calibration ID is not the same as the “New Calibration ID” listed previously, proceed to Flash Reprogram ECM (PCM).
4. Flash Reprogram ECM (PCM)
Follow the procedures outlined in Lexus TSIB No. SS001–01, “ECU Flash
Reprogramming Process,” and flash the ECM (PCM) with the new calibration file update.
NOTE:
If the “Check Engine” light is ON when the ignition is turned back on to begin the reprogramming process, a scan tool cable problem exists. Refer to TSIB No.
SS001–01, “ECU Flash Reprogramming Process.”
Page 5 of 6
ECM CALIBRATION: SHIFTING ENHANCEMENT – TC004-03 Revised August 4, 2003
Repair
Procedure
(Continued)
5. Reset the ECM (PCM) learned values using the diagnostic tester. Refer to the procedures below.
– The sample screen prints seen below are the 12.01a software version and may differ from subsequent software versions.
NOTE:
Failure to reset the ECM (PCM) memory will result in continued ATM shifting complaints.
A
*APPLICATION SELECT*
1: DIAGNOSIS
2: CUSTOMIZE
3: ECU REPROGRAM
D
RESET MEMORY
NOTICE
DO NOT USE THIS
FUNCTION UNLESS
INSTRUCTED BY
REPAIR MANUAL.
ONLY USE AFTER
REPLACING THE ENGINE,
AUTO TRANS, OR ECM
ON CERTAIN VEHICLES.
Figure 3. ECM (PCM) Learned Values Reset
B
FUNCTION SELECT FOR
NORTH AMERICA
1: OBD/MOBD
2: ENHANCED OBD II
3: CARB OBD II
4: BREAK–OUT BOX
5: NVH
6: AUTOPROBE
7: 02 RPM CHECK
8: SNAPSHOT REVIEW
9: SETUP
0: GAS ANALYSIS
E
RESET MEMORY
EXECUTING THIS
FUNCTION WILL RESET
THE LEARNED VALUES
IN THE ECM.
DO YOU WISH TO
RESET THE ECM?
[YES] to CONTINUE
[NO] to EXIT
C
DIAGNOSTIC MENU
ENGINE
1: DATA LIST
2: DTC INFO
3: ACTIVE TEST
4: SNAPSHOT
5: SYSTEM CHECK
6: RESET MEMORY
7: MONITOR STATUS
8: CHECK MODE
F
RESET MEMORY
RESETTING COMPLETE
PRESS [ENTER]
6. Follow the procedures outlined in TSIB No. EG012–04, “Entering VIN During ECM
(PCM) Replacement and/or DTC P0630,” and write the VIN to the ECM (PCM).
7. Start the engine and warm it up to normal operating temperature before test–driving.
8. Test drive vehicle to confirm proper vehicle operation.
9. Enter the required information on the Authorized Modifications Label and affix it to the vehicle at the location shown in Figure 1 (page 4). The Authorized Modifications
Label is available through the MDC, P/N 00451–00001–LBL.
10. Calibration update is complete.
NOTE:
S Select premium unleaded gasoline with an Octane Rating of 91 (Research Octane
Number 96) or higher for optimum engine performance.
S The effect of the new calibration may become more apparent after several days of driving as the ECM (PCM) ”learned values” are re–established from the customer’s driving.
Page 6 of 6
28-1
TIRE & WHEEL WHEEL AND TIRE SYSTEM
INSPECTION
28009-17
1.
INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure:
Tire size
P215/60R16 94V
P215/55R17 93V
Front, Rear kPa (kgf/cm 2 , psi)
200 (2.0, 29)
210 (2.1, 30)
(b) Using a dial indicator, check the tire runout.
Tire runout: 1.0 mm (0.039 in.) or less
(A)
Front
(B)
R03031
2.
ROTATE TIRES
HINT:
Rotate tires as shown in illustration (A) if a spare tire is not included in the rotation.
Rotate tires as shown in illuatration (B) if a spare tire is included in the rotation.
F13676
3.
INSPECT WHEEL BALANCE
(a) Check and adjust the Off-the-car balance.
(b) If necessary, check and adjust the On-the-car balance.
Imbalance after adjustment: 8.0 g (0.018 lb) or less
C80976
4.
INSPECT BEARING LOOSENESS (SEE PAGE 30-2 )
5.
INSPECT AXLE HUB RUNOUT (SEE PAGE 30-2 )
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date:
2402
28-2
TIRE & WHEEL WHEEL AND TIRE SYSTEM
HOW TO PROCEED WITH TROUBLESHOOTING
1.
VEHICLE PULLING DIAGNOSIS (SEE PAGE 26-2 )
2.
DIAGNOSIS OF TIRE VIBRATION
Check that the wheel nuts are fully tightened
NG
Repair
NG
OK
Inspect bearing looseness
OK
Inspect axle hub runout
2805R-01
Replace tire(s)
Check tire pressure
OK
NG
Adjustment
OK
Return the vehicle to customer
Check wheel balance
NG
Adjustment
OK
Inspect bearing looseness
Inspect axle hub runout
NG
Repair
NG
OK
Check wheel balance
3.
DIAGNOSIS OF IRREGULAR TIRE WEAR
Check tire pressure
NG
OK
Adjustment
Check wheel alignment
OK
NG
Adjustment
NG
Check wheel alignment
OK
Tire rotation or replace tire(s)
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2403
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What is the function of the valve body in an automatic transmission/transaxle system?
The valve body is a part of the automatic transmission/transaxle system. It is related to bolt tightening specifications and the removal/installation of components like the valve body oil strainer and solenoids.
What is the function of the valve body in an automatic transmission or transaxle system?
The valve body is a component in the automatic transmission/transaxle system. It is related to bolt tightening specifications and the removal/installation of components like the valve body oil strainer and solenoids.
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