2005 LEXUS ES300 Repair Manual

320OF-03
F42717
Stop Lamp
Switch Assy
Push Rod
Pedal Height
32-12- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2446 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
ADJUSTMENT
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 sub-
assy 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 NVm (265 kgfVcm, 19 ftVlbf)
(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 low-
er.

F42718
Pedal Free Play
R00934
Pedal Reserve
Distance
- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)32-13
2447 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.)
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.

320OJ-03
F16915
Instrument Panel Insert
Sub-assy Lower LH
Instrument Panel
Sub-assy Upper
Front Door Scuff Plate LH Driver Side
Junction Block AssyHeater to Foot Duct No.3Steering Column Cover LowerSteering Column Cover Upper Instrument Cluster Finish Panel
Steering Column Assy
Steering Intermediate
Shaft Sub-assyHorn Button Assy Steering Wheel Cover
No.2 Steerig Wheel Assy
20.6 (210, 15)
20.6 (210, 15)50 (510, 37)
8.8 (90, 78 in.Vlbf)
NVm (kgfVcm, ftVlbf) : Specified torqueSteering Wheel
Cover No.3
Connector Cover
Steering Column
Cover Lower No.2
32-14- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2448 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS

F16916
Push Rod Pin
Brake Pedal Support Assy Stop Lamp Switch Connector
Stop Lamp Switch Assy
Accelerator Pedal Assy
Accel Position
Sensor Connector
Accelerator Pedal Pad Brake Pedal Pad Brake Pedal
Return Spring Stop Lamp
Switch CushionClip
NVm (kgfVcm, ftVlbf) : Specified torque
Lithium soap base glycol grease
19.1 (194, 14)
13 (130, 9)
12 (122, 8.8)
26 (265, 19)
- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)32-15
2449 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

320OG-05
F16911
F16914
32-16- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2450 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. PRECAUTION (SEE PAGE 60-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE STEERING WHEEL COVER LOWER NO.2
5. REMOVE CONNECTOR COVER (SEE PAGE 82-1)
6. REMOVE STEERING PAD SWITCH (SEE PAGE 82-1)
7. REMOVE HORN BUTTON ASSY (SEE PAGE 60-22)
8. REMOVE STEERING WHEEL ASSY (SEE PAGE 50-8)
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
9. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
10. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
11. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
12. REMOVE HEATER TO FOOT DUCT NO.3 (SEE PAGE 32-14)
13. REMOVE STEERING COLUMN COVER LWR NO.2 (SEE PAGE 50-8)
14. REMOVE STEERING COLUMN COVER (SEE PAGE 50-8)
15. REMOVE TURN SIGNAL SWITCH ASSY (SEE PAGE 50-8)
16. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (SEE PAGE 50-8)
17. DISCONNECT STEERING SLIDING YOKE SUB-ASSY (SEE PAGE 50-8)
18. REMOVE STEERING COLUMN HOLE COVER SUB-ASSY NO.2 (SEE PAGE 50-8)
19. REMOVE STEERING COLUMN ASSY (SEE PAGE 50-8)
20. REMOVE DRIVER SIDE JUNCTION BLOCK ASSY
(a) Remove the 3 nuts and junction bloke assy, then discon-
nect the connector.
21. REMOVE BRAKE PEDAL RETURN SPRING

F16908
F16906
F16910
F16907
F16909
- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)32-17
2451 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
22. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
23. REMOVE ACCELERATOR & BRAKE PEDAL ASSY
(a) Disconnect the stop lamp switch connector.
(b) Disconnect the accel position sensor connector.
(c) Remove the 4 bolts, nuts and accelerator & brake pedal
assy.
24. REMOVE STOP LAMP SWITCH ASSY
(a) Loosen the nut and remove the stop lamp switch assy.

F16905
F16904
F16904
F16905
32-18- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2452 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. REMOVE BRAKE PEDAL PAD
26. REMOVE STOP LAMP SWITCH CUSHION
27. REMOVE ACCELERATOR PEDAL ASSY
(a) Remove the bolt, nut and accelerator pedal assy.
28. INSTALL ACCELERATOR PEDAL ASSY
(a) Install the accelerator pedal assy with nut and bolt.
Torque: 12 NVm (122 kgfVcm, 8.8 ftVlbf)
29. INSTALL STOP LAMP SWITCH CUSHION
30. INSTALL BRAKE PEDAL PAD

F16909
F16907
F16910
F16906
F16908
- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)32-19
2453 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
31. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch assy with a nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
32. INSTALL ACCELERATOR & BRAKE PEDAL ASSY
(a) Install the accelerator & brake pedal assy with the 4 nuts
and bolts.
Torque:
Nut: 13 NVm (130 kgfVcm, 9 ftVlbf)
Bolt: 19.1 NVm (194 kgfVcm, 14 ftVlbf)
(b) Connect the accel position sensor connector.
(c) Connect the stop lamp switch connector.
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).