2005 LEXUS ES300 light

3203F-08
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
C16481
Ventilation
No Ventilation 32-26
- BRAKEBRAKE BOOSTER ASSY
2460 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE BOOSTER ASSY (From July, 2003)
ON-VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Air tightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press 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 run-
ning, 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.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion 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.
(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.

3203S-1 1
32-60
- BRAKESTEERING SENSOR
2494 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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)

3305G-02
F41011
Adjusting Nut
Lock Nut 33-2
- PARKING BRAKEPARKING BRAKE SYSTEM
2498 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. REMOVE REAR WHEEL
2. ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16)
3. INSTALL REAR WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
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)
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 NVm (55 kgfVcm, 48 in.Vlbf)
(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.

3305G-02
F41011
Adjusting Nut
Lock Nut 33-2
- PARKING BRAKEPARKING BRAKE SYSTEM
2498 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. REMOVE REAR WHEEL
2. ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16)
3. INSTALL REAR WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
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)
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 NVm (55 kgfVcm, 48 in.Vlbf)
(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.

W01994
Vinyl Tape
R10425
SST
R10426
F40646
225.4
2.0 mm
(8.87
0.079 in.) 30-14
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
2417 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
28. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Install a new front drive shaft LH hole snap ring.
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.
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.

A85669
TC
CG
A82935
Tester TerminalEngine Wire 14-2
- ENGINE MECHANICALENGINE (3MZ-FE)
2094 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) When not using the hand-held tester or OBD II scan tool:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)
of the DLC3.
SST 09843-18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connecting wrong terminals can damage the
engine.

Turn OFF all electrical systems before connecting the
terminals.

Perform this inspection after the cooling fan motor is
turned OFF.
(2) Remove the V-bank cover.
(3) Pull out the engine wire colored by black and red as
shown in the illustration.
(4) Connect the tester terminal of the timing light to the
engine.
NOTICE:
Use a timing light which detects the first signal.
(5) Inspect the ignition timing at idle.
Ignition timing: 8 to 12 BTDC
NOTICE:
When checking the ignition timing, the transmission is in
the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, then check
that the engine speed returns to the idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Inspect the ignition timing at idle.
Ignition timing: 7 to 24 BTDC
(8) Confirm that the ignition timing advances when the
engine speed is increased.
(9) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the hand-held tester or OBD II scan tool:
(1) Connect the hand-held tester or OBD II scan tool to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester or OBD II scan tool.
Idle speed: 630 to 730 rpm
NOTICE:

When checking the idle speed, the transmission is in the neutral position.

Check the idle speed with the cooling fan OFF.

Switch OFF all accessories and air conditioning before connecting the hand-held tester or OBD
II scan tool.
HINT:
Refer to the hand-held tester or OBD II scan tool operator's manual for further details.

A78668
LH Bank:EX
IN
5
6
1
4 Front
5
1 RH Bank:
4
6
IN
EX
A78669
Upward
Notch
A78670
Front of No. 1 and No. 2 Cylinders:
Others:
SST (A)
SST (B)
SST (B)
SST (A)
7
9
- ENGINE MECHANICALVALVE CLEARANCE (3MZ-FE)
14-9
2101 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Turn the crankshaft by 2/3 of a revolution (240), then in-
spect the valves indicated in the illustration on the left.
(1) Using a feeler gauge, measure the clearance be-
tween 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.
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.
(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
º9º or º7º 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)09248-05410
SST (B)09248-05420

A05739
A05740
P12596
14-46
- ENGINE MECHANICALPARTIAL ENGINE ASSY (3MZ-FE)
2138 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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.
(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.