2005 LEXUS ES300 Repair Manual

F41554
F41555
Matchmarks
F41556
32-44
- BRAKEREAR BRAKE
2478 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.)
24. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
25. REMOVE REAR DISC
(a) Put matchmarks on the disc and the axle hub.
(b) Remove the disc.
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 run-
out.
27. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
28. 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: 0.15 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
axle hub runout are normal, adjust the disc runout or grind
it on a ºOn-carº 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

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)

320E1-02
- BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32-47
2481 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE ACTUATOR ASSY (W/O VSC)
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 de-
pressed.
(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

320E2-04
F40998
C84798
To RL W/C
To FR W/C
To FL W/C
To RR W/C From M/C 2nd
From M/C 1st
F40998
32-48
- BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
2482 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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
(a) Using SST, disconnect the 6 brake lines from the actuator.
SST 09023-00101
(b) Use tags or make a memo to identify the place to recon-
nect.
(c) Disconnect the brake actuator connector.
(d) Remove the 3 nuts and brake actuator with bracket.
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 NVm (55 kgfVcm, 48 in.Vlbf)
5. INSTALL BRAKE ACTUATOR WITH BRACKET
(a) Install the brake actuator with the 3 nuts.
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
(b) Connect the brake actuator connector.

C84798
To RL W/C
To FR W/C
To FL W/C
To RR W/C From M/C 2nd
From M/C 1st
- BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32-49
2483 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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 NVm (155 kgfVcm, 11 ftVlbf)
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)

3203J-09
32-50
- BRAKEBRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
2484 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
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 de-
pressed.
(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

3211Y-04
F45680
F45681
From M/C 1st
To FL W/CFrom M/C 2nd
To RR W/C
To RL W/CTo FR W/C
F45682
- BRAKEBRAKE ACTUATOR ASSY (W/VSC)(From July, 2003)
32-51
2485 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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
(a) Using SST, disconnect the 6 brake lines from the actuator.
SST 09023-00101
(b) Use tags or make a memo to identify the place to recon-
nect.
(c) Disconnect the actuator connector.