2005 LEXUS ES300 ECU

F41544
F41565
- BRAKEFRONT BRAKE
32-37
2471 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
(b) Using a dial indicator, measure the disc runout 10 mm
(0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
(c) If the disc runout is greater than the maximum value,
check the bearing play in the axial direction and check the
axle hub runout (see page 30-2). If the bearing play and
axle hub runout are normal, adjust the disc runout or grind
it on a ºOn-carº brake lathe.
26. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder.
27. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
28. INSTALL PISTON SEAL
(a) Install the piston seal (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new piston seal.
(2) Install the piston seal to the disc brake cylinder.
(b) Install the 2 piston seals (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 new piston seals.
(2) Install the 2 piston seals to the disc brake cylinder.
29. INSTALL FRONT DISC BRAKE PISTON
(a) Install the front disc brake piston (Single piston Type).
(1) Apply the lithium soap base glycol grease to the piston.
(2) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
(b) Install the 2 front disc brake pistons (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 pistons.
(2) Install the 2 pistons to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
30. INSTALL CYLINDER BOOT
(a) Install the cylinder boot (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new
cylinder boot.
(2) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.

F41566
C68792
F41703
Anti squeal
Shim No.1
Anti squeal
Shim No.2
Anti squeal
Shim No.1
Wear Indicator
32-38
- BRAKEFRONT BRAKE
2472 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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 pis-
ton.
(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.
32. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 106.9 NVm (1,090 kgfVcm, 79 ftVlbf)
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.
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.

F41866
Anti Squeal
Shim
Wear Indicator
- BRAKEFRONT BRAKE
32-39
2473 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(2) Install the wear indicator to the 2 brake pads.
NOTICE:

When replacing worn pads, the anti squeal shims
must be replaced together with the pads.

Install the shims and pad wear indicator correctly of
which positions and directions.
(b) Install the anti squeal shim kit front (Twin piston Type).
(1) Apply the anti squeal shim with pad grease, and
install the anti squeal shim to each pad.
(2) Install the wear indicator to the 2 brake pads.
NOTICE:

When replacing worn pads, the anti squeal shims
must be replaced together with the pads.

Install the shims and pad wear indicator correctly of
which positions and directions.
38. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing upward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.
39. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder with the 2 bolts.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
40. CONNECT FRONT FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 NVm (300 kgfVcm, 22 ftVlbf)
HINT:
Install the flexible hose lock securely in the lock hold of the disc brake cylinder.
41. FILL RESERVOIR WITH BRAKE FLUID
42. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
43. BLEED BRAKE LINE (SEE PAGE 32-4)
44. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
45. CHECK BRAKE FLUID LEAKAGE
46. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)

F41559
F41865
Anti Squeal
Shim No.2 Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Anti Squeal
Shim No.1
Wear Indicator
- BRAKEREAR BRAKE
32-45
2479 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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 cylin-
der boot.
(b) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(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 NVm (630 kgfVcm, 46 ftVlbf)
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.
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
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.

F41551
F41562
Cylinder Slide Pin
Cylinder Mounting
Lithium soap base glycol grease
F41558Lithium soap base glycol grease
32-46
- BRAKEREAR BRAKE
2480 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
40. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), install the cylinder slide
pin.
Torque: 39.2 NVm (400 kgfVcm, 29 ftVlbf)
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.
42. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylin-
der slide bush.
(b) Install the cylinder slide bush to the disc brake cylinder.
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 NVm (350 kgfVcm, 25 ftVlbf)
45. CONNECT REAR LH FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 NVm (300 kgfVcm, 22 ftVlbf)
HINT:
Install the flexible hose lock securely in the lock 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 NVm (1050 kgfVcm, 76 ftVlbf)

3006I-04
C83014
C83008
C83035
30-26
- DRIVE SHAFT / PROPELLER SHAFTREAR AXLE HUB & BEARING ASSY LH
2429 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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
2. DISCONNECT REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the bolt and disconnect the rear flexible hose.
(b) Remove the 2 bolts and rear disc brake caliper assy LH.
(c) Support the rear disc brake caliper assy LH securely.
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.
6. REMOVE SKID CONTROL SENSOR (SEE PAGE 32-56)
7. INSTALL SKID CONTROL SENSOR (SEE PAGE 32-56)

A78535
A78706Align
A78707
Main GearSub Gear
Service Bolt
A78708
101
2
3
4
5
6
7
89
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
14-43
2135 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 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.
(c) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. 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.

A78709
10
1
2
3
4
5
67
8
9
A78710Align
A78711Main GearSub Gear
Service Bolt 14-44
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2136 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
28. REMOVE NO.2 CAMSHAFT
(a) Using several steps, loosen and remove the 10 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. 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.
(b) Secure the exhaust camshaft sub gear to the main gear
with a service bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
Recommended service bolt
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 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.