2005 LEXUS ES300 Repair Manual

2606R-02
START
Preliminary Check
Tire pressure
Vehicle height
Brake dragging ROAD TEST
Does the vehicle lead/pull?
Cross switch front tire & wheel
assemblies (left & right).
Does the vehicle lead/pull in
same direction as before?
Check front wheel alignment.
Is it within specification?
Adjust front wheel alignment.Reverse the front left side
tire and rebalance it.
Does the vehicle
lead/pull to the left?
COMPLETE
Are the tires uni-directional type?
Choose the position of front tire & wheel
assemblies where there is least amount of pull.
Increase left front camber and decrease
right front camber until lead/pull is eliminated.Increase right front camber and decrease
left front camber until lead/pull is eliminated.
NO
YES
YES
NO
YES
YES
NO
YES
NO COMPLETE
NONOYES NOIs there steering
off center?
Adjust front tie rods.
NO
YES
Is the lead/pull stronger
than before?
YES
NOTICE : Do not exceed 1° of cross camber.
Do not exceed adjustment range.
Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed
of 35mph. Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in
a straight line for 100 meters at a constant speed of 35mph without holding the steering wheel.
(1) The vehicle can keep straight but the steering wheel has some angle.
STEERING OFF CENTER (See page 50-4)
(2) The vehicle cannot keep straight.
STEERING PULL
YES NO
YES ROAD TEST
Does the vehicle still lead/pull?
NO ROAD TEST
Does the vehicle still lead/pull? ROAD TEST
Does the vehicle still lead/pull?
ROAD TEST
Does the vehicle still lead/pull?NO
Contact your local retail tire distributor.YES
*
*
26-2
- FRONT SUSPENSIONFRONT SUSPENSION SYSTEM
2365 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPAIR
HINT:
This is the repair procedure for vehicle pull.

2601C-06
C93850
N´m (kgf´cm, ft´lbf): Specified torque

Non-reusable part

Front Suspension
Support Sub-assy LH
Front Suspension
Support Bearing LH
Front Coil Spring
Seat Upper LH
Front Coil Spring
Insulator Upper
LH
Front Coil Spring LH
Front Spring Bumper LH
Front Coil Spring
Insulator Lower LH
Shock Absorber Assy
Front LH Front Stabilizer
Link Assy LH
Front Flexible Hose
No. 1
74 (755, 55)
Speed Sensor
Front LH
Front Axle Assy LH
49 (500, 36)
18.8 (192, 14)
14 (143, 10)
80 (816, 59)
w/ H-TEMS: w/ H-TEMS:
Front Shock Absorber
Cap LH
80 (816, 59)
80 (816, 59)
Front Suspension
Upper Brace CenterWasher
210 (2,141, 155)
- FRONT SUSPENSIONFRONT SUSPENSION (From July, 2003)
26-3
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT SUSPENSION (From July, 2003)
COMPONENTS

C93097
74 (755, 55)
Front Stabilizer
Link Assy RH
Stabilizer Bar FrontFront Stabilizer Bracket No. 1 RH
Front Stabilizer Bar Bush No. 1
Front Stabilizer Bracket No. 1 LH
Front Stabilizer Link Assy LH
Rack & Pinion Power
Steering Gear Assy
Speed Sensor
Front LH
Front Frame Assy
Front Lower Arm
Bush Stopper
Lower Ball Joint
Assy Front LH
Front Suspension
Arm Sub-assy
Lower No. 1 LHFront Brake
Caliper Assy
Front Axle Assy LH
Cotter Pin
19 (194, 14)

Cotter Pin
N´m (kgf´cm, ft´lbf): Specified torque

Non-reusable part
Front Disc
74 (755, 55)
74 (755, 55)
206 (2,101, 152)
294 (2,998, 217)
49 (500, 36)
87 (887, 64)
123 (1,254 91)
200 (2,039, 148)
200 (2,039, 148)
75 (765, 55)
70 (714, 52)
70 (714, 52)
8.0 (82, 71 in.Vlbf)
106.9 (1,090, 79)
106.9 (1,090, 79)
19 (194, 14)


210 (2,141, 155)
95 (969, 70)
Transverse Engine
Engine Mounting
Insulator
26-4
- FRONT SUSPENSIONFRONT SUSPENSION (From July, 2003)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

2605T-05
C91608
B Front:A
C91609
C Rear:
D
SA3213
A
DB
Front
C
F40165
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
26-5
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT WHEEL ALIGNMENT (From July, 2003)
ADJUSTMENT
1. INSPECT TIRE (See page 26-5)
2. MEASURE VEHICLE HEIGHT
Vehicle height:
FrontA - B: 120 mm (4.72 in.)
RearD - C: 52 mm (2.05 in.)
Measuring points:
A: Ground clearance of front wheel center
B: Ground clearance of lower suspension arm No. 2 set bolt
center
C: Ground clearance of strut rod set bolt center
D: Ground clearance of rear wheel center
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specified value.
HINT:
Bounce the vehicle at the corners up and down to stabilize the
suspension and inspect the vehicle height.
3. INSPECT TOE-IN
Toe-in:
Toe-in
(total)A + B: 0° ± 12' (0° ± 0.2°)
C - D: 0 ± 2 mm (0 ± 0.08 in.)
If the toe-in is not within the specified value, adjust it at the rack
ends.
4. ADJUST TOE-IN
(a) Remove the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to
adjust the toe-in.
HINT:
Try to adjust the toe-in to the center of the specified value.
(d) Make sure that the lengths of the right and left rack ends
are the same.
(e) Torque the tie rod end lock nuts.
Torque: 74 N´m (755 kgf´cm, 55 ft´lbf)
(f) Place the boots on the seats and install the clips.
HINT:
Make sure that the boots are not twisted.
(g) Perform VSC system calibration. (See page 05-471)

SA0028
AB
FrontA B
A: Inside
B: Outside
Z03382
Alignment
TesterGauge
C93871
26-6
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
2369 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully left and right, and measure
the turning angle.
Wheel turning angle:
Inside wheel36°39' ± 2° (36.65° ± 2°)
Outside wheel: Reference32°11' (32.18°)
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.
6. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
(a) Put the front wheel on the center of the alignment tester.
(b) Set the camber - caster - kingpin gauge at the center of
the axle hub or drive shaft.
Camber, caster and steering axis inclination:
Camber
Left-right error-0°43' ± 45' (-0.72° ± 0.75°)
45' (0.75°) or less
Caster
Left-right error2°46' ± 45' (2.77° ± 0.75°)
45' (0.75°) or less
Steering axis inclination11°27' (11.45°)
If the caster and steering axis inclination are not within the spec-
ification, after the camber has been correctly adjusted, recheck
the suspension parts for damage and/or worn out parts.
7. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheel.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
HINT:
When removing nuts, stop the bolt from rotating and loosen the
nut.
(c) Clean the installation surfaces of the shock absorber and
the steering knuckle.
(d) Temporarily install the 2 nuts.

C93869
1
2
Bolt
Adjusting
ValueSet BoltAdjusting Bolt90105-17008 90105-17009 90105-17010 90105-17011
121212121 Dot
2 Dots3 Dots
15'
30'
45'
100'
115'
130'
- FRONT SUSPENSIONFRONT WHEEL ALIGNMENT (From July, 2003)
26-7
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
(f) Tighten the nuts.
Torque: 210 NVm (2,141 kgfVcm, 155 ftVlbf)
NOTICE:
When installing the nuts, keep the bolts from rotating and
then torque the nut.
(g) Install the front wheel.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
HINT:

Try to adjust the camber to the center of the specified val-
ue.

Adjusting value for the set bolts is 6' to 30' (0.1° to 0.5°).
If the camber is not within the specified valve, estimate how
much additional camber adjustment will be required, and select
the camber adjusting bolt.
NOTICE:
Tighten the adjusting bolt with a new nut.
(i) Do the steps mentioned above again. At step (b), replace
1 or 2 selected bolts.
HINT:
When replacing the 2 bolts, replace 1 bolt for each time.

2606S-02
F40136
C91030
C93102
SST
26-8
- FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
2371 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT SHOCK ABSORBER WITH COIL SPRING
OVERHAUL
HINT:
COMPONENTS: See page 26-3.
1. REMOVE FRONT WHEEL
2. DISCONNECT FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the front stabilizer link
assy LH from the shock absorber assy front LH.
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
3. REMOVE FRONT SHOCK ABSORBER CAP LH
(H-TEMS SUSPENSION)
(a) Disconnect the connector.
(b) Remove the 3 nuts, harness clamp and the front shock
absorber cap LH.
4. REMOVE FRONT SHOCK ABSORBER WITH COIL
SPRING
(a) w/ H-TEMS:
Using SST, loosen the lock nut.
SST 09817-33190
(b) w/o H-TEMS:
Loosen the lock nut.
NOTICE:

Do not loosen except for the case with disassembling
the shock absorber assy front LH with coil spring.

Do not remove the lock nut.

C65925
C93871
F40140
F03956
SST
SST
- FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
26-9
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Remove the bolt, disconnect the front flexible hose No. 1
and speed sensor front LH.
(d) Remove the 2 nuts and 2 bolts on the lower side of front
shock absorber with coil spring.
NOTICE:
When removing bolt, stop the bolt from rotating and loosen
the nut.
(e) Remove the 3 nuts on the upper side of the front shock
absorber with coil spring.
(f) Remove the front shock absorber with the coil spring.
NOTICE:
Be careful not to drop the 2 washers in the case that there
is front suspension upper brace center.
5. FIX FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower side of
the front shock absorber with coil spring and secure it in
a vise.
6. REMOVE SHOCK ABSORBER ASSY FRONT LH
(a) Using SST, compress the front coil spring LH.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
HINT:
Use 2 of the same type of SST.
(b) Remove the front suspension support sub-assy LH, front suspension support bearing LH, front coil
spring seat upper LH, front coil spring insulator upper LH, front coil spring LH, front spring bumper LH
and front coil spring insulator upper LH.