Page 256 of 969
320DX-02
- BRAKEBRAKE PEDAL SUPPORT ASSY
32-1 1
2445 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1)
2. REMOVE INSTRUMENT PANEL REINFORCEMENT (SEE PAGE 71-1 1)
3. REMOVE BRAKE PEDAL RETURN SPRING
4. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
5. REMOVE BRAKE PEDAL SUPPORT ASSY
(a) Disconnect the stop lamp switch connector.
(b) Remove the bolt, 4 nuts and brake pedal support assy.
6. REMOVE STOP LAMP SWITCH ASSY
(a) Loosen the lock nut and remove the stop lamp switch.
7. REMOVE BRAKE PEDAL SUB-ASSY
(a) Remove the nut, bolt and brake pedal sub-assy from brake pedal support assy.
8. REMOVE BRAKE PEDAL PAD
9. REMOVE BRAKE PEDAL BUSH
(a) Remove the 2 brake pedal bushes from brake pedal.
10. REMOVE STOP LAMP SWITCH CUSHION
11. INSTALL STOP LAMP SWITCH CUSHION
12. INSTALL BRAKE PEDAL BUSH
(a) Install the new 2 brake pedal bushes to brake pedal.
HINT:
Apply the lithium soap base glycol grease to the parts indicates by arrows (see page 32-10).
13. INSTALL BRAKE PEDAL PAD
14. INSTALL BRAKE PEDAL SUB-ASSY
(a) Install the brake pedal sub-assy with the bolt and nut.
Torque: 37 NVm (375 kgfVcm, 27 ftVlbf)
15. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch with the lock nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
16. INSTALL BRAKE PEDAL SUPPORT ASSY
(a) Install the brake pedal support assy with the bolt and 4 nuts.
Torque:
Bolt: 20 NVm (204 kgfVcm, 15 ftVlbf)
Nut: 13 NVm (130 kgfVcm, 9 ftVlbf)
17. 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 32-10).
18. INSTALL BRAKE PEDAL RETURN SPRING
19. INSTALL INSTRUMENT PANEL REINFORCEMENT (SEE PAGE 71-1 1)
20. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1)
21. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8)
22. CHECK PEDAL FREE PLAY (SEE PAGE 32-8)
23. CHECK PEDAL RESERVE DISTANCE (SEE PAGE 32-8)
Page 257 of 969
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.
Page 259 of 969
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
Page 261 of 969
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
Page 265 of 969
F16914
F16911
32-20- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2454 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
34. INSTALL BRAKE PEDAL RETURN SPRING
35. INSTALL DRIVER SIDE JUNCTION BLOCK ASSY
(a) Install the junction block assy with the 3 nuts, then con-
nect the each connector.
36. INSTALL STEERING COLUMN ASSY (SEE PAGE 50-8)
37. CONNECT STEERING SLIDING YOKE SUB-ASSY (SEE PAGE 50-8)
38. CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (SEE PAGE 50-8)
39. INSPECT CHECK KEY INTERLOCK OPERATION (SEE PAGE 50-8)
40. INSTALL TURN SIGNAL SWITCH ASSY (SEE PAGE 50-8)
41. INSPECT SPIRAL CABLE SUB-ASSY (SEE PAGE 60-31)
42. INSTALL STEERING COLUMN COVER (SEE PAGE 50-8)
43. INSTALL STEERING COLUMN COVER LWR NO.2 (SEE PAGE 50-8)
44. INSTALL HEATER TO FOOT DUCT NO.3 (SEE PAGE 32-14)
45. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
46. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
47. INSTALL FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
48. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
49. INSTALL STEERING WHEEL ASSY (SEE PAGE 50-8)
50. INSPECT HORN BUTTON ASSY (SEE PAGE 60-22)
51. INSTALL HORN BUTTON ASSY (SEE PAGE 60-22)
52. INSTALL STEERING PAD SWITCH (SEE PAGE 82-1)
53. INSTALL CONNECTOR COVER (SEE PAGE 82-1)
54. INSTALL STEERING WHEEL COVER LOWER NO.2
55. INSPECT SRS WARNING LIGHT (SEE PAGE 05-818)
Page 267 of 969
C69097
R12236
(A)
F41707
F09717
R12236
(A) 32-22
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
2456 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Push in the piston and remove the piston stopper bolt and
gasket.
(e) Remove the No.1 piston sub-assy, pulling straight out not
at an angle.
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
(f) Place a waste cloth and 2 wooden blocks on the work
table and lightly edges until the No.2 piston sub-assy
drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag the top of the blocks
is at least 100 mm (3.94 in.).
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
9. REMOVE BRAKE MASTER CYLINDER KIT (W/ VSC)
(a) Place master cylinder in vise.
(b) Remove the O-ring.
(c) Push in the piston and remove the snap ring with snap
ring pliers.
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
(d) Push in the piston with a screwdriver, and remove the
straight pin by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(e) Remove the No.1 piston sub-assy, pulling straight out not
at an angle.
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
(f) Place a waste cloth and 2 wooden blocks on the work
table and lightly edges until the No.2 piston sub-assy
drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag the top of the blocks
is at least 100 mm (3.94 in.).
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
Page 273 of 969
3211X-04
F40995
F40996
BR3753
32-28
- BRAKEBRAKE BOOSTER ASSY
2462 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. REMOVE AIR CLEANER ASSY
2. DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluid immediately if it comes into contact with a painted surface.
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
4. REMOVE VACUUM HOSE ASSY
(a) Remove the bolt and separate the vacuum hose from the
vacuum hose bracket.
(b) Slide the clip and disconnect the vacuum hose from the
brake booster.
5. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
6. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
7. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
8. REMOVE BRAKE PEDAL RETURN SPRING
9. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
10. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Loosen the lock nut and remove the push rod clevis.
11. REMOVE FRONT BRAKE TUBE NO.5
(a) Using SST and remove the front brake tube No.5.
SST 09023-00101
12. REMOVE BRAKE BOOSTER ASSY
(a) Remove the 4 nuts.
(b) Pull out the brake booster assy.
Page 274 of 969
BR3753
F40996
F40995
- BRAKEBRAKE BOOSTER ASSY
32-29
2463 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. REMOVE BRAKE BOOSTER GASKET
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster.
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster with the 4 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
16. INSTALL FRONT BRAKE TUBE NO.5
(a) Using SST and install the front brake tube No.5.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
17. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the push rod clevis and lock nut.
18. INSTALL PUSH ROD PIN
(a) Install the push rod pin and clip.
HINT:
Apply the lithium soap base glycol grease to the part indicate by arrow (see page 32-27).
19. INSTALL BRAKE PEDAL RETURN SPRING
20. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
21. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
22. INSTALL FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
23. INSTALL VACUUM HOSE ASSY
(a) Install the vacuum hose and vacuum hose bracket to the
body with a bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(b) Connect the vacuum hose to the brake booster with the
clip.
24. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE PAGE 32-21)
SST 09737-00013, 09737-00020
25. INSTALL BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
26. FILL RESERVOIR WITH BRAKE FLUID
