2005 LEXUS ES300 Repair Manual

A81659
SST 2
Insert
SST 1
A81673
TurnSST1-A
A81661
SST 1-A
SST 1-B
Turn
Hold 19-28
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Clamp SST 2 in a vise.
(d) Insert SST 1-A and B into SST 2, then attach the genera-
tor pulley nut to SST 2.
(e) Tighten the generator pulley nut by turning SST 1-A in the
direction shown in the illustration.
Torque: 111 NVm (1,125 kgfVcm, 81 ftVlbf)
(f) Remove the generator from SST 2.
(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.

5002J-08
- STEERING COLUMNSTEERING
50-1
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STEERING
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 precaution-
ary notice for the supplemental restraint system (See page 60-1).

5002K-07
50-2
- STEERING COLUMNSTEERING
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.
SymptomSuspect AreaSee page
Hard steering
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 gear28-1
51-3
51-3
51-3
26-5
-
26-16
-
51-9
51-21
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gear28-1
26-5
-
51-21
Excessive play
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-
26-16
-
30-19
51-21
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering vane pump
4. Power steering gear51-3
-
51-9
51-21

5002L-03
H41575
Maximum
Freeplay
30 mm (1.18 in.)
- STEERING COLUMNSTEERING
50-3
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ON-VEHICLE INSPECTION
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.)

5002V-03
F16015
Steering Wheel
Masking Tape
Steering Column
Upper Cover
F16016
Steering Wheel
Masking
Tape Steering Column
Upper Cover
Marked Line
F16017
Steering Wheel Steering Column
Upper Cover
Marked Line
50-4
- STEERING COLUMNSTEERING
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPAIR
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.
(3) Draw a line on the masking tape as shown in the il-
lustration.
(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.

R00429
Marked Line
F16018
- STEERING COLUMNSTEERING
50-5
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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.
(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.) horizon-
tal movement) - 12 deg. of steering angle.
(6) Tighten the RH and LH lock nuts.
Torque: 74 NVm (755 kgfVcm, 55 ftVlbf)
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.

5002H-02
C90698
Steering Column
CoverHorn Button Assy
Steering Wheel Assy
Steering Pad SwitchConnector
Cover
Turn Signal Switch Assy
50 (510, 37)
Steering Column Cover
Lower No.2Instrument Panel
Finish Plate
NVm (kgfVcm, ftVlbf) : Specified torque
21 (214, 15)
8.8 (90, 78 in.Vlbf)
Steering Wheel
Cover Lower No. 2
Instrument Panel Sub-assy Upper
Steering Column Assy
Steering Column Hole
Cover Sub-assy No. 2
Hose Clamp
Heater to Foot
Duct No. 3
Steering Intermediate
Shaft Sub-assyInstrument Panel Insert
Sub-assy Lower LH
Front Door Scuff Plate LH
35 (360, 26)
35 (360, 26)
21 (214, 15)
50-6
- STEERING COLUMNSTEERING COLUMN ASSY
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
STEERING COLUMN ASSY
COMPONENTS

C92308
NVm (kgfVcm, ftVlbf) : Specified torque
35 (360, 26)
Non-reusable partUn-lock Waring
Switch AssyTransponder 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-assySteering Column
Clamp Upper
 Tapered-Head Bolt
- STEERING COLUMNSTEERING COLUMN ASSY
50-7
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)