2005 LEXUS ES300 brake light

4010P-03
C99453
Groove
Neutral
Basic Line
- AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (U151E)
40-7
2522 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSY
(a) Apply the parking brake and turn the ignition switch to ON.
(b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P posi-
tion.
(c) Check that the back-up light is lit and the reverse warning buzzer sounds only when the shift lever is
set in R position.
If a failure is found, check the continuity of the park/neutral position switch.
2. ADJUST PARK/NEUTRAL POSITION SWITCH ASSY
(a) Loosen the 2 bolts of park/neutral position switch and set
the shift lever to the N position.
(b) Align the groove with neutral basic line.
(c) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(d) After adjustment, perform the inspection described in
step 1.

400H6-03
D25118
D25119
40-40
- AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT ASSY
2555 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When shifting from P to R position only with ignition switch ON and brake pedal, make sure that the
shifting lever moves smoothly and can be moderately operated.
(b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position
and moves rearward when shifting to R position.
2. ADJUST SHIFT LEVER POSITION
(a) Loosen the nut on the control shaft lever.
(b) Push the control shaft fully downward.
(c) Return the control shaft lever 2 notches to N position.
(d) Set the shift lever to N position.
(e) While holding the shift lever lightly toward the R position
side, tighten the shift lever nut.
Torque: 14.7 N´m (150 kgf´cm, 10 ft´lbf)
(f) Start the engine and make sure that the vehicle moves
forward when shifting the lever from N to D position and
moves rearward when shifting it to R position.

32-6
- BRAKEBRAKE FLUID
2440 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(1) Connect the vinyl tube to the bleeder plug at the
right front wheel or the right rear wheel and loosen
the bleeder plug.
(2) Operate the brake actuator assy using the hand-
held tester to bleed the air.
NOTICE:

The operation stops automatically in 4 seconds.

At this time, be sure to release the brake pedal.
(3) Check that the operation has stopped, by referring
to the hand-held tester display.
(4) Repeat (2) and (3) until all the air in the fluid is com-
pletely bled out.
(5) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) For the rest of the wheels, bleed the air in the same
way as stated in the above procedure.
(f) Bleed the air out of the pressure reduction line in ºStep3:
Decreaseº on the hand-held tester display.
NOTICE:

Perform air bleeding by following the steps displayed
on the hand-held tester.

Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect a vinyl tube to either one of the bleeder
plugs.
(2) Loosen the bleeder plug.
(3) Using the hand-held tester, operate the brake ac-
tuator assy using hand-held tester, completely de-
press the brake pedal and keep it.
NOTICE:

The operation stops automatically in 4 seconds.
When performing this procedure continuously, an in-
terval of at least 20 seconds is required.

When the operation is completed, the brake pedal
slightly goes down. This is a normal phenomenon
caused when the solenoid opens.

During this procedure, the pedal seems heavy, but
completely depress it so that the brake fluid comes
out from the bleeder plug.

Be sure to keep depressing the brake pedal. Never
depress and release the pedal repeatedly.
(4) Tighten the bleeder plug, then release the brake
pedal.
(5) Repeat (2) to (4) until all the air in the fluid is com-
pletely bled out.
(6) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(7) Repeat the above procedure to bleed the air out of
the brake line for each wheel.

320DV-02
F41697
Stop Lamp
Switch
Push Rod
Pedal Height
32-8
- BRAKEBRAKE PEDAL SUPPORT ASSY
2442 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE PEDAL SUPPORT ASSY
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.
(3) Loosen the stop lamp switch lock nut and remove
the stop lamp switch.
(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.
(8) Connect the connector to the stop lamp switch.
(9) Push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.),
turn the stop lamp switch to lock the nut in the posi-
tion 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.

320DW-02
F42132
Brake Pedal Support
Stop Lamp
Switch Assy
Lock Nut


Brake Pedal Bush


Brake Pedal Bush Stop Light Switch Cushion
Brake Pedal
Push Rod Pin Brake Pedal Return Spring
Clip
Brake Pedal Pad

Non-reusable part
NVm (kgfVcm, ftVlbf) : Specified torque
Lithium soap base glycol grease
26 (265, 19)
37 (375, 27)
13 (130, 9)
13 (130, 9)
20 (204, 15)
32-10
- BRAKEBRAKE PEDAL SUPPORT ASSY
2444 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS

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.

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)

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.