Lexus 2005 IS300 User Manual
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Lexus 2005 IS300 User Manual

2005 lexus is300
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Table of Contents

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HOW TO USE THIS MANUAL

1.
INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the Section Title and major heading are given at the top of every
page.
2.
GENERAL DESCRIPTION
At the beginning of each section, a General Description is given that pertains to all repair operations con-
tained in that section.
Read these precautions before starting any repair task.
3.
TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page
Be sure to read this before performing troubleshooting.
4.
PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
Slotted Spring Pin
15 (155, 11)
Cylinder
N·m (kgf·cm, ft·lbf)
: Specified torque
f Non-reusable part
2005 LEXUS IS300 (RM1140U)
INTRODUCTION
-
Filler Cap
Float
Reservoir Tank
f Grommet
12 (120, 9)
Piston
HOW TO USE THIS MANUAL
f Gasket
Boot
Snap Ring
Washer
Push Rod
Author :
IN-1
IN00U-90
IN-22
.
Clevis Pin
Clip
Clevis
Lock Nut
N17080
Date :
1

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Summary of Contents for Lexus 2005 IS300

  • Page 1: How To Use This Manual

    Boot f Grommet Slotted Spring Pin 12 (120, 9) Clevis 15 (155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque f Non-reusable part N17080 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 2 The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 3: Identification Information

    A: Vehicle Identification Number Plate B: Certification Label B12091 ENGINE SERIAL NUMBER 2JZ-GE The engine serial number is stamped on the engine block, as shown in the illustration. B12487 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 4: Repair Instructions

    When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply Seal Lock Adhesive new seal lock adhesive to the bolt, nut or threads. Z11554 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 5 DO NOT exceed the rating or use Equal Amperage Rating one with a lower rating. BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M-FUSE HIGH CURRENT FUSE H-FUSE FUSIBLE LINK CIRCUIT BREAKER V00076 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 6 When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak air. IN0252 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 7 20°C (68°F). Mea- surement should be made after the engine has cooled IN0002 down. If measured at high temperatures immediately af- ter the vehicle has been running, resistance may be out- side specifications. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 8 Differential carrier CAUTION : When jacking-up the front and rear, make sure the vehicle is not carrying any extra weight. PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand and swing arm type lift I19098 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 9 Check the interference of the attachment with the front floor cover when placing the attachment on the plate. Attachment dimensions 85 mm (3.35 in.) 70 mm (2.76 in.) 100 mm (3.94 in.) 200 mm (7.87 in.) I19099 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 10: For All Of Vehicles

    PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The LEXUS IS300 is equipped with an Supplemental Re- straint System (SRS), such as the driver airbag, front pas- senger airbag assembly, side airbag assembly, curtain shield airbag assembly and seat belt pretensioners.
  • Page 11 Refer to SR-25 of this manual concerning correct steer- ing wheel installation. Marks F01322 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 12 SST before disposal (see page RS-17 ). Deploy airbags in a safe place away from electrical noise. Example: CORRECT WRONG B17163 Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER Z13950 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 13 SST before disposal (see page RS-31 Deploy airbags in a safe place away from electrical noise. Example: CORRECT WRONG H15183 B11669 B17162 Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER Z13951 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 14 SST before disposal (see page RS-44 ). Deploy airbags in safe place away from electrical noise. Example: CORRECT WRONG B17197 Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER B01546 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 15 As a safety measure, always deploy airbags using an SST before disposal (see page RS-59 ). Deploy airbags in a safe place away from electrical noise. Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER B08605 H12059 R06952 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 16 The seat belt pretensioner becomes hot after ac- tivation. Allow it to cool before disposing. Never use water to cool seat belt pretensioner. Example: NEVER USE OHMMETER ON AN AIRBAG OR PRETENSIONER B02121 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 17 All the connectors in the system are a standard yellow color. If the SRS wire har- ness becomes disconnected or the connector becomes broken, etc., repair or replace it as shown on page RS-82 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 18 When using a 2-wheel drum tester such as a speedometer tester or chassis dynamometer, etc., or jacking up the rear wheels and driving the wheels, always push in the TRAC cut switch and turn the TRAC system OFF. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 19 VSC OFF indicator light goes off. HINT: The SLIP indicator light blinks and the VSC buzzer sounds when the VSC system is operational. B07101 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 20 Make adjustments if necessary (see page PR-1 No. 3 Joint No. 2 Joint B - C = 2°18’ ± 30’ A - B = - 1°21’ ± 30’ B07659 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 21 IN04S-45 GENERAL INFORMATION A large number of ECU controlled systems are used in the LEXUS IS300. In general, ECU controlled sys- tems are considered to be a very intricate, requiring a high level of technical knowledge to troubleshoot. How- ever, following the problem checking procedures of the ECU controlled system’s circuits carefully is not com- plex.
  • Page 22 After completing repairs, confirm that the problem has been eliminated. (To be absolutely sure the problem no longer ex- ists, perform the confirmation test under the same conditions and environment as when it occurred the first time.) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 23 Customer’s Name Licence No. Odometer Reading Date Vehicle Brought In miles Date Problem First Occurred Other Fine Cloudy Rainy Snowy Weather Temperature Approx. Starting Idling Vehicle Operation Driving Constant speed Acceleration Deceleration Other 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 24 SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the LEXUS IS300 fulfills various functions. The first function is the Diagnostic Trouble Code (DTC) Check. In a DTC Check,a previous malfunc- tion’s DTC can be checked by a technician during troubleshooting. (A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs.)
  • Page 25 Normal Code Display other than in the diagnostic circuit exist displayed No problem Normal code is The problem occurred in a place other symptoms exist displayed than in the diagnostic circuit in the past 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 26 Therefore, check the wire harness and con- nectors (see page IN-33 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 27 Apply slight vibration with a finger to the part of the sensor considered to be the cause of the problem and check wheth- er or not the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. V07268 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 28 OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the mal- function occurs. B02389 B02390 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 29 F Open or short in throttle position sensor circuit Throttle/ Pedal Position Sensor/Switch F Throttle position sensor ”A” Circuit Malfunction F ECM Throttle/ Pedal Position Sensor/ Switch F Throttle position sensor ”A” Circuit Range / Performance Prob- 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 30 1. A/C signal circuit (Compressor circuit) AC-88 High engine idle speed (Poor idling) 2. ECM power source circuit 1. A/C signal circuit idling) 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 31 O = Orange; W = White; GR = Gray; P = Pink; Y = Yellow; SB = Sky Blue. The first letter indicates the basic wire color and the second letter indicates the color of the stripe. V08423 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 32 In this case, care must be taken not to bend the terminals. (with harness). F Indicates the condition of the connector of ECU during the check. E6 Connector E6 Connector Connector being checked is disconnected. Connector being checked is connected. V08425 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 33 The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 34 Bimetallic Vacuum Switching Valve Calif. California Circuit Breaker Catalytic Converter For Oxidation Compact Disc Cornering Force Center Of Gravity Channel COMB. Combination Coupe Combustion Pressure Sensor Central Processing Unit Child Restraint System Center Check Valve 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 35 Fuel Economy Front-Engine Front-Wheel-Drive Fuel Gauge FIPG Formed In Place Gasket Fusible Link Fuel Pump Fuel Pressure Up Front Front-Engine Rear-Wheel-Drive Flywheel FW/D Flywheel Damper Front-Wheel-Drive Gasoline Ground High Altitude Compensator Hatchback 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 36 Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAX. Maximum Microphone Malfunction Indicator Lamp MIN. Minimum Multipurpose Multiplex Communication System Manual Transmission (Transaxle) Mount Mounting Neutral Natural Aspiration Number Overdrive 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 37 Supplemental Restraint System Special Service Materials Special Service Tools Standard Cold-Start Fuel Injection Switch System Transaxle TACH Tachometer Throttle Body Electronic Fuel Injection Turbocharger TCCS TOYOTA Computer-Controlled System Timing Control Valve Top Dead Center 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 38 Vehicle Identification Number Variable Power Steering Vehicle Skid Control Vacuum Switching Valve Vacuum Transmitting Valve With Wagon Wire Harness Without First Second Two Wheel Drive Vehicle (4x2) Four Wheel Drive Vehicle (4x4) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 39 INTRODUCTION TERMS IN03Q-04 GLOSSARY OF SAE AND LEXUS TERMS This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their LEXUS equivalents. LEXUS TERMS SAE TERMS ABBREVIATIONS ( )--ABBREVIATIONS...
  • Page 40 Smoke Puff Limiter Service Reminder Indicator System Readiness Test Scan Tool Throttle Body Throttle Body Single Point Injection Throttle Body Fuel Injection Central Fuel Injection (Ci) Turbocharger Turbocharger Torque Converter Clutch Torque Converter 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 41 Air Flow Meter Voltage Regulator Voltage Regulator Vehicle Speed Sensor Vehicle Speed Sensor Wide Open Throttle Full Throttle WU-OC Warm Up Oxidation Catalytic Converter WU-TWC Warm Up Three-Way Catalytic Converter Third Gear Fourth Gear 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 42: Air Conditioning System

    BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insuffi- cient cooling, poor fuel economy, engine overheating etc. 2005 LEXUS IS300 (RM1140U) Author : Date : 2467...
  • Page 43 AIR CONDITIONING AIR CONDITIONING SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The LEXUS IS300 is equipped with an SRS (Supplemental Re- straint System) such as the driver, passenger and side airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident.
  • Page 44 Close both the high and low hand valves and stop the vac- uum pump. Leave the system in this condition for 5 minutes or more and check that there is no gauge indicator. High Pressure Service Valve Vacuum Pump Adapter N13791 2005 LEXUS IS300 (RM1140U) Author : Date : 2476...
  • Page 45 Using a gas leak detector, check the system for leakage. If leak is found, repair the faulty component or connection. CAUTION: Use the refrigerant recovery/ recycling machine to recover the refrigerant whenever replacing parts. Gas Leak Detector N13792 2005 LEXUS IS300 (RM1140U) Author : Date : 2477...
  • Page 46 Open the low pressure hand valve. CAUTION: Do not open the high pressure hand valve. Charge refrigerant until bubbles disappear and check the pressure on the gauge through the sight glass. Properly Charged Insufficiently Charged I11031 2005 LEXUS IS300 (RM1140U) Author : Date : 2478...
  • Page 47 Solar Sensor Room Temperature Expansion Valve Evaporator Sensor Air Inlet Servomotor Air Outlet Evaporator Servomotor Temperature Sensor Heater Radiator Air Refiner Filter Blower Motor Control Relay Air Mix Servomotor Blower Motor I18050 2005 LEXUS IS300 (RM1140U) Author : Date : 2479...

  • Page 48: Troubleshooting

    10.Compressor AC-38 11.Condenser AC-47 12.Evaporator AC-30 13.Heater radiator AC-30 14.Expansion valve AC-52 15.A/C control assembly AC-79 16.Wire harness 1. Air mix servomotor AC-30 No temperature control 2. A/C control assembly AC-79 2005 LEXUS IS300 (RM1140U) Author : Date : 2480...
  • Page 49 Set temperature value does not match up with operation of tem- 1. A/C control assembly AC-79 perature control switch 1. Headlight and taillight system BE-31 Brightness does not change when light control switch is turned 2. A/C control assembly AC-79 2005 LEXUS IS300 (RM1140U) Author : Date : 2481...

  • Page 50: Drive Belt

    ”A” of the scale. If it is out side area ”A”, replace the drive belt. Type B HINT: When a new belt is installed, it should be lie within area B. P10652 2005 LEXUS IS300 (RM1140U) Author : Date : 2482...
  • Page 51 REMOVE ENGINE UNDER COVER REMOVE DRIVE BELT Using SST, loosen the drive belt tension by turning the drive belt tensioner arm clockwise from the bottom side, and remove the drive belt. 09216-00041 I22629 2005 LEXUS IS300 (RM1140U) Author : Date : 2483...
  • Page 52 AC-18 AIR CONDITIONING DRIVE BELT AC37U-01 INSTALLATION Installation is in the reverse order of removal (See page AC-17 AFTER INSTALLATION, CHECK DRIVE BELT’S INSTALLATION CONDITION 2005 LEXUS IS300 (RM1140U) Author : Date : 2484...

  • Page 53: Manifold Gauge Set

    CONNECT QUICK DISCONNECT ADAPTERS TO SER- VICE VALVES HINT: Push the quick disconnect adapter onto the service valve, then Sleeve slide the sleeve of the quick disconnect adapter downward to lock it. N04392 2005 LEXUS IS300 (RM1140U) Author : Date : 2485...
  • Page 54 Slide the sleeve of the quick disconnect adapter upward to un- lock the adapter and remove it from the service valve. INSTALL CAPS TO SERVICE VALVES ON REFRIGER- N06553 ANT LINES 2005 LEXUS IS300 (RM1140U) Author : Date : 2486...

  • Page 55: Refrigerant Line

    AIR CONDITIONING REFRIGERANT LINE REFRIGERANT LINE AC15S-01 ON-VEHICLE INSPECTION INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. 2005 LEXUS IS300 (RM1140U) Author : Date : 2487...
  • Page 56 AC-22 AIR CONDITIONING REFRIGERANT LINE AC15T-04 COMPONENTS 10 (100, 7) Condenser Liquid Tube 10 (100, 7) Suction Tube Compressor 10 (100, 7) Discharge Hose N·m (kgf·cm, ft·lbf) : Specified amount I18042 2005 LEXUS IS300 (RM1140U) Author : Date : 2488...
  • Page 57 EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. INSPECT AIR CONDITIONING OPERATION 2005 LEXUS IS300 (RM1140U) Author : Date : 2489...
  • Page 58 Water Hose 10 (100, 7) Liquid Tube F O-Ring Suction Tube A/C Unit Blower Unit Bracket Air Duct LH Air Duct RH F Non-reusable part N·m (kgf·cm, ft·lbf) : Specified torque I18268 2005 LEXUS IS300 (RM1140U) Author : Date : 2490...
  • Page 59 (Unit Side) Air Outlet Insulator Servomotor Drain Hose Drain Hose Air Mix Servomotor Cover Pipe Clamp Blower Motor Control Relay Heater Radiator N·m (kgf·cm, ft·lbf) :Specified torque F Non-reusable part I12414 2005 LEXUS IS300 (RM1140U) Author : Date : 2491...
  • Page 60 DISCONNECT WATER HOSES FROM HEATER RA- DIATOR PIPES Grip the claws of the hose clip and slide the hose clip along the hose. Disconnect the water hose. I18090 2005 LEXUS IS300 (RM1140U) Author : Date : 2492...
  • Page 61 Slide the floor carpet backward. Remove the air ducts LH, RH. I18091 REMOVE A/C UNIT Disconnect the connectors. Disconnect the wire harness clamps. Remove the 2 nuts, 2 bolt and A/C unit. I02363 2005 LEXUS IS300 (RM1140U) Author : Date : 2493...
  • Page 62 Tape the screwdriver tip before use. Release the 2 claws and sensor from bracket plate. REMOVE EVAPORATOR Remove air mix servomotor. Disconnect the connector. Remove the 3 screws and servomotor. I18092 2005 LEXUS IS300 (RM1140U) Author : Date : 2494...
  • Page 63 At the time of installation, please refer to the following item. If evaporator is replaced, add compressor oil to evaporator. Add 40 cc (1.4 fl.oz.) Compressor oil: ND-OIL 8 or equivalent I18093 REMOVE INSULATOR FROM HEATER CASE REMOVE AIR DUCT 2005 LEXUS IS300 (RM1140U) Author : Date : 2495...
  • Page 64 Never use water to clean the evaporator. Check fitting for cracks or scratches. If necessary, repair or replace. INSPECT HEATER RADIATOR Inspect fins for blockage. If the fins are clogged, clean them with compressed air. 2005 LEXUS IS300 (RM1140U) Author : Date : 2496...
  • Page 65 AC-31 AIR CONDITIONING AIR CONDITIONING UNIT AC15Y-02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC-28 2005 LEXUS IS300 (RM1140U) Author : Date : 2497...
  • Page 66 AC-32 AIR CONDITIONING AIR CONDITIONING UNIT AC15Z-02 INSTALLATION Installation is in the reverse order of removal (See page AC-26 2005 LEXUS IS300 (RM1140U) Author : Date : 2498...

  • Page 67: Blower Unit

    BLOWER UNIT BLOWER UNIT AC160-05 COMPONENTS Instrument Panel Bracket Air Duct (Duct Side) Blower Unit Air Inlet Servomotor Blower Unit Case Air Refiner Filter Air Refiner Flame Cover Blower Motor I24429 2005 LEXUS IS300 (RM1140U) Author : Date : 2499...
  • Page 68 Remove the wire harness clamp and disconnect the con- nector. I10051 REMOVE BLOWER UNIT Remove the 2 bolts and bracket. Remove the bolt, screw and nut. Release the claw and remove the blower unit. I02369 2005 LEXUS IS300 (RM1140U) Author : Date : 2500...
  • Page 69 Release the 4 claws and remove the cover. Pull out the air refiner filter. REMOVE AIR INLET SERVOMOTOR Remove the 3 screws and servomotor. REMOVE BLOWER MOTOR Remove the 3 screws and blower motor. 2005 LEXUS IS300 (RM1140U) Author : Date : 2501...
  • Page 70 AC-36 AIR CONDITIONING BLOWER UNIT AC163-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC-35 2005 LEXUS IS300 (RM1140U) Author : Date : 2502...
  • Page 71 AC-37 AIR CONDITIONING BLOWER UNIT AC164-01 INSTALLATION Installation is in the reverse order of removal (See page AC-34 2005 LEXUS IS300 (RM1140U) Author : Date : 2503...
  • Page 72 Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to the body ground. Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch. I14838 2005 LEXUS IS300 (RM1140U) Author : Date : 2504...
  • Page 73 52 (530, 38) 52 (530, 38) Compressor Compressor Drive Belt Stator Rotor Pressure Plate Shim Snap Ring Snap Ring 13.2 (135, 9) N·m (kgf·cm, ft·lbf) :Specified torque F Non-reusable part I18294 2005 LEXUS IS300 (RM1140U) Author : Date : 2505...
  • Page 74 Disconnect the PS pump connector and PS pump tube clamp. Disconnect the engine wire. I14842 Remove the 2 PS pump set bolts and slide the PS pump backward. I14841 REMOVE COMPRESSOR Remove the bolt and PS pump bracket. I14843 2005 LEXUS IS300 (RM1140U) Author : Date : 2506...
  • Page 75 COMPRESSOR AND MAGNETIC CLUTCH Remove the 3 bolts and compressor bracket. Disconnect the connector. I14844 Remove the nut and 2 bolts. Using a torx socket (E10), remove the stud bolt and com- pressor. I14845 2005 LEXUS IS300 (RM1140U) Author : Date : 2507...
  • Page 76 Using SST and a socket wrench, remove the pres- sure plate. 07112-66040, 07112-76060 AC0945 Remove the shims from the pressure plate. Shim Pressure Plate AC0946 Remove the rotor. Remove the snap ring. AC0947 2005 LEXUS IS300 (RM1140U) Author : Date : 2508...
  • Page 77 Be careful not to damage the pulley when tapping on the ro- tor. AC1743 Remove the stator. Disconnect the stator lead wire from the compres- sor. AC1744 Remove the snap ring. AC0950 Remove the stator. Stator AC0951 2005 LEXUS IS300 (RM1140U) Author : Date : 2509...
  • Page 78 The snap ring should be installed so that its beveled side Snap Ring faces up. R-Shape Rotor Compressor N20013 Install the pressure plate. Install the shims to the pressure plate. Install the pressure plate on the rotor. Shim Pressure Plate AC0946 2005 LEXUS IS300 (RM1140U) Author : Date : 2510...
  • Page 79 If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance. Shim thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020in.) 2005 LEXUS IS300 (RM1140U) Author : Date : 2511...
  • Page 80 Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. INSPECT A/C OPERATION 2005 LEXUS IS300 (RM1140U) Author : Date : 2512...
  • Page 81 If the fins are bent, straighten them with a screwdriver or pliers. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. 2005 LEXUS IS300 (RM1140U) Author : Date : 2513...
  • Page 82 Radiator Upper Support 10 (100, 7) F O-Ring Bracket Condenser Dryer Filter 12.3 (125, 9) N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part Compressor oil ND-OIL 8 or equivalent I18097 2005 LEXUS IS300 (RM1140U) Author : Date : 2514...
  • Page 83 At the time of installation, please refer to the following item. If condenser is replaced, add compressor oil to the condenser. Add 40 cc (1.4 fl. oz) Compressor oil: ND - OIL 8 or equivalent I11048 2005 LEXUS IS300 (RM1140U) Author : Date : 2515...
  • Page 84 Apply compressor oil to the O-rings and screw part of the cap. Compressor oil: ND-OIL 8 or equivalent Using a hexagon wrench (10 mm, 0.39 in.), install the caps. Torque: 12.3 N·m (125 kgf·cm, 9 ft·lbf) I10094 2005 LEXUS IS300 (RM1140U) Author : Date : 2516...
  • Page 85 AC-51 AIR CONDITIONING CONDENSER AC16D-01 INSTALLATION Installation is in the reverse order of removal (See page AC-49 2005 LEXUS IS300 (RM1140U) Author : Date : 2517...

  • Page 86: Expansion Valve

    Then check that the high pressure reading is 1.37 - 1.57 MPa (14 - 16 kgf/cm , 199 -228 psi). CHECK EXPANSION VALVE If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/cm , 0 psi). 2005 LEXUS IS300 (RM1140U) Author : Date : 2518...
  • Page 87 HINT: At the time of installation, please refer to the following item. Lubricate 6 new O-rings with compressor oil and install them to the tube and valve. 2005 LEXUS IS300 (RM1140U) Author : Date : 2519...
  • Page 88 AC-54 AIR CONDITIONING EXPANSION VALVE AC16M-01 INSTALLATION Installation is in the reverse order of removal (See page AC-53 2005 LEXUS IS300 (RM1140U) Author : Date : 2520...

  • Page 89: Blower Motor

    If operation is not as specified, replace the blower motor. I07284 INSTALL BLOWER MOTOR Install the blower motor with the 3 screws. Connect the connector and wire harness clamp. I10051 2005 LEXUS IS300 (RM1140U) Author : Date : 2521...
  • Page 90 If resistance is not as specified, replace the blower motor con- trol relay. INSTALL BLOWER MOTOR CONTROL RELAY Install the blower motor control relay with the screw. Connect the connectors. INSTALL GLOVE COMPARTMENT DOOR (See page BO-149 I18098 2005 LEXUS IS300 (RM1140U) Author : Date : 2522...
  • Page 91 Connect the positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 7, then check that the arm turns to ”RECIRC” side smoothly. If operations are not as specified, replace the servomotor. RECIRC I18004 2005 LEXUS IS300 (RM1140U) Author : Date : 2523...
  • Page 92 Install the servomotor with the 3 screws. Connect the connector. I03730 INSTALL BRACKET Install the bracket with 2 bolts. Connect the wire harness clamp. INSTALL GLOVE COMPARTMENT DOOR (See page BO-149 I03729 2005 LEXUS IS300 (RM1140U) Author : Date : 2524...
  • Page 93 Connect the positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 7, then check that the arm turns to ”DEF” side smoothly. If operations are not as specified, replace the servomotor. I11855 2005 LEXUS IS300 (RM1140U) Author : Date : 2525...
  • Page 94 Install the servomotor with the 2 screws. Connect the connector. I18100 INSTALL AIR DUCT Install the air duct with the 3 screws. Connect the connector clamp. INSTALL INSTRUMENT PANEL (See page BO-149 I18099 2005 LEXUS IS300 (RM1140U) Author : Date : 2526...
  • Page 95 Remove the cloth from the sensor and subject the sensor to electric light, check that continuity exists between ter- minals. If no continuity exists, replace the sensor. N12651 INSTALL SOLAR SENSOR Connect the connector and install the solar sensor. I11050 2005 LEXUS IS300 (RM1140U) Author : Date : 2527...
  • Page 96 Install the sensor and fit the 2 claws. Connect the aspirator hose and connector. INSTALL LOWER FINISH PANEL Install the lower finish panel and fit the 3 claws. Install the 3 screws. I18101 2005 LEXUS IS300 (RM1140U) Author : Date : 2528...
  • Page 97 50 °C (122 °F) 0.5 - 0.7 kΩ If resistance is not as specified, replace the sensor. I11055 INSTALL AMBIENT TEMPERATURE SENSOR Push the sensor in bumper reinforcement. Connect the connector. I11054 2005 LEXUS IS300 (RM1140U) Author : Date : 2529...
  • Page 98 AC0175 (Ω) Compare the 2 readings on the chart. 5,000 If resistance value is not as specified, replace the sensor. 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1,000 (°C) (°F) Z04352 2005 LEXUS IS300 (RM1140U) Author : Date : 2530...
  • Page 99 INSTALL EVAPORATOR TEMPERATURE SENSOR Install the sensor in bracket plate and 2 claws. I03738 Push in the sensor with the bracket plate. Connect the connector. INSTALL LOWER FINISH PANEL (See page BO-149 I18102 2005 LEXUS IS300 (RM1140U) Author : Date : 2531...

  • Page 100: Pressure Switch

    If operation is not as specified, replace the pressure switch. 1,520 kPa (No Continuity) (15.5/kgf/cm , 220 psi) STOP ENGINE AND SET OFF MANIFOLD GAUGE SET 1,230 kPa (12.5 kgf/cm , 178 psi) CONNECT CONNECTOR TO PRESSURE SWITCH I05079 2005 LEXUS IS300 (RM1140U) Author : Date : 2532...
  • Page 101 At the time of installation, please refer to the following item. I11781 Lubricate a new O-ring with compressor oil and install the switch. 2005 LEXUS IS300 (RM1140U) Author : Date : 2533...
  • Page 102 AC-68 AIR CONDITIONING PRESSURE SWITCH AC171-01 INSTALLATION Installation is in the reverse order of removal (See page AC-67 2005 LEXUS IS300 (RM1140U) Author : Date : 2534...
  • Page 103 Z19533 block. Install the passenger side junction block set nuts. Connect the connectors. INSTALL COWL SIDE TRIM BOARD LH (See page BO-149 INSTALL FRONT DOOR SCUFF PLATE LH (See page BO-149 2005 LEXUS IS300 (RM1140U) Author : Date : 2535...
  • Page 104 Condition Tester connection Specified condition Constant 1 - 2 Continuity Apply B+ between 3 - 5 Continuity terminals 1 and 2. If continuity is not as specified, replace the relay. I05027 2005 LEXUS IS300 (RM1140U) Author : Date : 2536...
  • Page 105 If continuity is not as specified, replace the relay. INSPECT NO.3 COOLING FAN RELAY N23635 (Marking: FAN NO.3) CONTINUITY Check the relay in the same way as for ”MAGNETIC CLUTCH RELAY”. 2005 LEXUS IS300 (RM1140U) Author : Date : 2537...
  • Page 106 Specified amperage: 8.5 - 11.5 A ar 20 °C (68 °F) If operation is not as specified, replace the fan motor. If operation is as specified, check the pressure switch, cooling fan relays and engine coolant temp. switch. B02073 2005 LEXUS IS300 (RM1140U) Author : Date : 2538...
  • Page 107 Air Cleaner and MAF Meter Assembly Cooling Fan Connector MAF Meter Connector Cooling Fan Assembly Radiator Reservoir Hose 5 (50, 44 in.·lbf) ECM Outlet Duct N·m (kgf·cm, ft·lbf) : Specified torque B11925 2005 LEXUS IS300 (RM1140U) Author : Date : 2539...
  • Page 108 AC-74 AIR CONDITIONING CONDENSER FAN No.2 Fan Motor No.1 Fan Motor No.2 Fan Connector Holder Fan Shroud Assembly No.1 Fan B00918 2005 LEXUS IS300 (RM1140U) Author : Date : 2540...
  • Page 109 Disconnect the wire for cooling fan from the clamp on the cooling fan. Disconnect the 2 cooling fan connector. Disconnect the radiator reservoir hose from the radiator. Remove the 6 bolts and cooling fan. B02071 2005 LEXUS IS300 (RM1140U) Author : Date : 2541...
  • Page 110 Remove the 2 fans. B00919 REMOVE FAN MOTORS Disconnect the wires and connector holders from the fan shroud. Remove the 3 screws and fan motor. Remove the 2 fan motors. B00921 2005 LEXUS IS300 (RM1140U) Author : Date : 2542...
  • Page 111 B00921 Install the wires and connector holders to the fan shroud as shown in the illustration. B00920 INSTALL FANS Install the fan with the nut. Install the 2 fans. B00919 2005 LEXUS IS300 (RM1140U) Author : Date : 2543...
  • Page 112 Connect the radiator reservoir hose to the radiator. INSTALL AIR CLEANER AND MAF METER AS- SEMBLY INSTALL AIR CLEANER INLET FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS 2005 LEXUS IS300 (RM1140U) Author : Date : 2544...
  • Page 113 B5 - Ground Constant Battery positive voltage If the circuit is not as specified, inspect the circuit connected to other parts. If the circuit is as specified, proceed to ”INSPECTION” on page AC-88 2005 LEXUS IS300 (RM1140U) Author : Date : 2545...
  • Page 114 B2 G B2 - Ground Parking drake lever: Operate Below 1.0 V Pattern select switch: Except PWR Battery positive voltage B3 G B3 - Ground Pattern select switch: PWR Below 1.0 V 2005 LEXUS IS300 (RM1140U) Author : Date : 2546...
  • Page 115 B10 G B10 - Ground Passenger seat belt: fasted Battery positive voltage If the circuit is not as specified, proceed to ”INSPECTION” on page AC-88 INSTALL A/C CONTROL ASSEMBLY (See page AC-91 2005 LEXUS IS300 (RM1140U) Author : Date : 2547...
  • Page 116 AC-82 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY AC262-02 COMPONENTS w/ LEXUS Navigation System: Center Register Cover Center Cluster Finish Panel Center Cluster Finish Panel Brackets A/C Control Assembly Brackets Radio Assembly Lower Center Cluster Finish Panel I11755 2005 LEXUS IS300 (RM1140U)
  • Page 117 AC-83 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY A/C Amplifier Bulbs Bulbs P/C Board Knob Sets Lens Dial Knobs Panel I18269 2005 LEXUS IS300 (RM1140U) Author : Date : 2549...
  • Page 118 Remove the 4 bolts and pull out the A/C control assembly with radio assembly, then disconnect the connectors. I18104 Remove the 12 screws and 2 brackets. Separate the A/C control assembly and radio assembly. I11765 2005 LEXUS IS300 (RM1140U) Author : Date : 2550...
  • Page 119 Connector Lock I11759 REMOVE BULBS Using a screwdriver, turn the bulbs to the left and pull out the bulbs. I18290 REMOVE P/C BOARD Remove the 4 screws and P/C board. I18291 2005 LEXUS IS300 (RM1140U) Author : Date : 2551...
  • Page 120 Do not let any oil, dirt or foreign object attach on the Contact connecting part of the connector. Do not deform the contact. Be careful not to drop the contact. I11757 REMOVE KNOB SETS Pull out the knob sets. I11766 2005 LEXUS IS300 (RM1140U) Author : Date : 2552...
  • Page 121 AC-87 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY NOTICE: Rubber Contact Do not let any oil, dirt or foreign object attach on the rubber contact part. I11758 REMOVE LENS I11767 2005 LEXUS IS300 (RM1140U) Author : Date : 2553...
  • Page 122 INSPECT BULB OPERATION Apply the tester as shown in the illustration to the test for conti- nuity. If continuity exists, replace the P/C board. If on continuity exists, replace the bulb. I07872 2005 LEXUS IS300 (RM1140U) Author : Date : 2554...
  • Page 123 16 - 21 Continuity 17 - 21 Continuity If operations is not as specified, replace the P/C board. If operations is as specified, check the wire harness or replace the A/C amplifier. I18271 2005 LEXUS IS300 (RM1140U) Author : Date : 2555...
  • Page 124 AC-90 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY AC266-02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC-85 2005 LEXUS IS300 (RM1140U) Author : Date : 2556...
  • Page 125 AC-91 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY AC267-02 INSTALLATION Installation is in the reverse order of removal (See page AC-84 2005 LEXUS IS300 (RM1140U) Author : Date : 2557...
  • Page 126 SWITCH Install the new O-ring to the switch. Install the engine coolant temperature switch. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) FILL WITH ENGINE COOLANT TO RADIATOR INSTALL ENGINE UNDER COVER 2005 LEXUS IS300 (RM1140U) Author : Date : 2558...
  • Page 127 AC-94 AIR CONDITIONING AIR REFINER FILTER AC0Y1-01 INSTALLATION Installation is in the reverse order of removal (See page AC-93 2005 LEXUS IS300 (RM1140U) Author : Date : 2560...
  • Page 128 AT-1 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION SYSTEM AUTOMATIC TRANSMISSION SYSTEM AT0HC-01 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. 2005 LEXUS IS300 (RM1140U) Author : Date : 1623...
  • Page 129 Reverse Neutral ON OFF OFF ON OFF M (5)* OFF ON OFF OFF : Operating * : When the shift lever position is ”M” and the gear position indicator shows ”5”. 2005 LEXUS IS300 (RM1140U) Author : Date : 1624...
  • Page 130 EM-100 FILL ATF AND CHECK FLUID LEVEL (See page DI-338 REMOVE NO. 1 REAR FLOOR BOARD REMOVE LH FRONT FLOOR CENTER COVER INSTALL NO. 1 AND NO. 2 ENGINE UNDER COVERS 2005 LEXUS IS300 (RM1140U) Author : Date : 1625...
  • Page 131 REMOVE ENGINE REAR SUPPORT MEMBER Remove the 4 nuts. Remove the 4 bolts and rear support member. D04839 REMOVE TRANSMISSION MOUNTING BRACKET Remove the 4 bolts and the transmission mounting bracket from the transmission. D04840 2005 LEXUS IS300 (RM1140U) Author : Date : 1626...

  • Page 132: Kgf/Cm

    Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) Install the 4 nuts. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) REMOVE JACK INSTALL VEHICLE SPEED SENSOR (See page AT-7 INSTALL PROPELLER SHAFT (See page PR-10 D04839 2005 LEXUS IS300 (RM1140U) Author : Date : 1627...
  • Page 133 EM-100 FILL ATF AND CHECK FLUID LEVEL (See page DI-338 INSTALL NO. 1 REAR FLOOR BOARD INSTALL LH FRONT FLOOR CENTER COVER INSTALL NO. 1 AND NO. 2 ENGINE UNDER COVERS 2005 LEXUS IS300 (RM1140U) Author : Date : 1628...

  • Page 134: Vehicle Speed Sensor

    Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) INSTALL NO. 1 REAR FLOOR BOARD INSTALL LH FRONT FLOOR CENTER COVER INSTALL NO. 1 AND NO. 2 ENGINE UNDER COVERS 2005 LEXUS IS300 (RM1140U) Author : Date : 1629...
  • Page 135 Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) INSTALL NO. 1 REAR FLOOR BOARD INSTALL LH FRONT FLOOR CENTER COVER INSTALL NO. 1 AND NO. 2 ENGINE UNDER COVERS 2005 LEXUS IS300 (RM1140U) Author : Date : 1630...
  • Page 136 Install the blade of SST between the transmission case and oil pan, cut off applied sealer, and remove the oil pan. 09032-00100 NOTICE: When removing the oil pan, be careful not to damage the oil pan flange. Q07487 2005 LEXUS IS300 (RM1140U) Author : Date : 1631...
  • Page 137 Remove the bolt, solenoid connector and O-ring. INSTALL SOLENOID WIRING WITH ATF TEMPERA- TURE SENSOR Install the solenoid connector and a new O-ring with the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) D00916 2005 LEXUS IS300 (RM1140U) Author : Date : 1632...
  • Page 138 Seal Breadth 2 - 3 mm (0.08 - 0.12 in.) oil on the contacting surfaces of the transmission case and oil pan. Apply FIPG to the oil pan. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent D01917 2005 LEXUS IS300 (RM1140U) Author : Date : 1633...
  • Page 139 Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) FILL FLUID AND CHECK FLUID (See page DI-338 INSTALL NO. 1 REAR FLOOR BOARD INSTALL LH FRONT FLOOR CENTER COVER D00910 INSTALL NO. 1 AND NO. 2 ENGINE UNDER COVERS 2005 LEXUS IS300 (RM1140U) Author : Date : 1634...
  • Page 140 REMOVE VALVE BODY Remove the 20 bolts and valve body. D00754 REMOVE CHECK BALL BODY AND SPRING NOTICE: Do not drop the check ball body and spring. Spring Check Ball Body D09391 2005 LEXUS IS300 (RM1140U) Author : Date : 1635...
  • Page 141 10 N·m (100 kgf·cm, 7 ft·lbf) INSTALL CHECK BALL BODY AND SPRING Spring Check Ball Body D09391 INSTALL VALVE BODY Align the groove of the manual valve to pin of the lever. D00913 2005 LEXUS IS300 (RM1140U) Author : Date : 1636...
  • Page 142 Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) FILL FLUID AND CHECK FLUID (See page DI-338 INSTALL NO. 1 REAR FLOOR BOARD INSTALL LH FRONT FLOOR CENTER COVER INSTALL NO. 1 AND NO. 2 ENGINE UNDER COVERS 2005 LEXUS IS300 (RM1140U) Author : Date : 1637...
  • Page 143 Check that the parking lock pawl operates smoothly. INSTALL VALVE BODY (See page AT-13 INSTALL NO. 1 REAR FLOOR BOARD INSTALL LH FRONT FLOOR CENTER COVER INSTALL NO. 1 AND NO. 2 ENGINE UNDER COVERS 2005 LEXUS IS300 (RM1140U) Author : Date : 1638...

  • Page 144: Shift Lock System

    AUTOMATIC TRANSMISSION SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM AT0HM-02 LOCATION Stop Light Switch Key Interlock Solenoid Shift Lock Release Button Shift Lock Control ECU Shift Lock Control Switch Shift Lock Solenoid D09393 2005 LEXUS IS300 (RM1140U) Author : Date : 1639...
  • Page 145 Check the solenoid operating sound when connecting the battery positive terminal to 4 (KLS ) and battery negative terminal to 3 (KLS If the solenoid does not operate, replace the solenoid. D05064 2005 LEXUS IS300 (RM1140U) Author : Date : 1640...
  • Page 146 P position (Release button P - P1 Continuity is not pushed) P position (Release button P - P1 Continuity is pushed) P - P2 D05065 Except P position P - P2 Continuity 2005 LEXUS IS300 (RM1140U) Author : Date : 1641...
  • Page 147 Consol Box Assembly 8.3 (85, 73 in.·lbf) Parking Brake Hole Cover Assembly Floor Shift Lever Assembly No. 1 Floor Shift Gear Shifting Rod 13 (130, 9) N·m (kgf·cm, ft·lbf) : Specified torque D11503 2005 LEXUS IS300 (RM1140U) Author : Date : 1642...
  • Page 148 Plate Washer F O-Ring Shaft Lower Control Bush 13 (130, 9) F O-Ring F Spacer Shift Lever Plate N·m (kgf·cm, ft·lbf) : Specified torque Shift Lever Seal Non-reusable part MP grease D11504 2005 LEXUS IS300 (RM1140U) Author : Date : 1643...
  • Page 149 Remove the parking brake hole cover assembly. Remove the console box assembly. REMOVE FLOOR SHIFT LEVER ASSEMBLY Remove the 4 bolts. Disconnect the 2 connectors. Remove the floor shift lever assembly. D11506 2005 LEXUS IS300 (RM1140U) Author : Date : 1644...
  • Page 150 Remove the shift lock control ECU bracket and shift lever anti-rattle cushion from the shift lock control ECU. Disconnect the E-shift main switch connector from the shift lever guide housing. Remove the shift lock release button and spring. D09408 2005 LEXUS IS300 (RM1140U) Author : Date : 1645...
  • Page 151 Release the locking lag of the terminals 1 and 6, and pull the terminals out from the rear. Remove the E-shift main switch. D05066 REMOVE SHIFT LEVER SUB-ASSEMBLY Using a magnetic finger, remove the detent shift lever pin and spring. D09410 2005 LEXUS IS300 (RM1140U) Author : Date : 1646...
  • Page 152 Using pliers, remove the E-ring. Remove the swivel, 2 plate washer, shaft lower control bush and spacer. Remove the shift lever seal. Remove the 4 collars. Remove the 2 spring nuts. D09413 2005 LEXUS IS300 (RM1140U) Author : Date : 1647...
  • Page 153 Install the shift lock solenoid link with shift lock solenoid plunger and spring to the shift lock solenoid. CONNECT SHIFT LOCK CONTROL ECU, SHIFT LOCK SOLENOID, SHIFT LOCK CONTROL SWITCH AND E- SHIFT MAIN SWITCH D04855 2005 LEXUS IS300 (RM1140U) Author : Date : 1648...
  • Page 154 Install the pattern select switch to the position indicator housing. Install the position indicator housing. Connect the pattern select switch connector. Install the shift lock release cover to the position indicator housing. INSTALL SHIFT LEVER KNOB 2005 LEXUS IS300 (RM1140U) Author : Date : 1649...
  • Page 155 Connect the No. 1 floor shift gear shifting rod and con- necting rod swivel with the nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) CHECK SHIFTING LEVER POSITION (See page DI-338 D11505 2005 LEXUS IS300 (RM1140U) Author : Date : 1650...
  • Page 156 43 (438, 32) No. 1 Engine Under Cover LH Front Floor Center Cover No. 2 Engine Under Cover No. 1 Rear Floor Board N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part D09394 2005 LEXUS IS300 (RM1140U) Author : Date : 1651...
  • Page 157 Pressure Test Hole Plug 12 (120, 9) 37 (380, 27) 25 (260, 19) Starter Filler Pipe Level Gauge 13 (130, 9) O-Ring N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part D09436 2005 LEXUS IS300 (RM1140U) Author : Date : 1652...
  • Page 158 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) REMOVE PROPELLER SHAFT (See page PR-4 D09365 DISCONNECT OIL COOLER PIPE Remove the 3 bolts and 3 clamps. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) D09366 2005 LEXUS IS300 (RM1140U) Author : Date : 1653...

  • Page 159: Author : Date

    Take care so that the cooling fan does not come in contact with the fan shroud. Disconnect the following connectors: O/D direct clutch speed sensor connector Vehicle speed sensor connector Park/neutral position switch connector D09397 Solenoid connector 2005 LEXUS IS300 (RM1140U) Author : Date : 1654...
  • Page 160 17 mm head: 72 N·m (730 kgf·cm, 53 ft·lbf) 14 mm head: 37 N·m (380 kgf·cm, 27 ft·lbf) D01926 HINT: At the time of installation, please refer to the following item. Lift the front side of the engine. Q06924 2005 LEXUS IS300 (RM1140U) Author : Date : 1655...
  • Page 161 Adjust the shift lever position (See page DI-338 Fill ATF and check fluid level (See page DI-338 Do the road test (See page DI-338 Fill with engine coolant (See page CO-2 2005 LEXUS IS300 (RM1140U) Author : Date : 1656...
  • Page 162 If excessive runout cannot be corrected, replace the torque converter clutch. AT4184 HINT: Mark the position of the torque converter clutch to ensure cor- rect installation. Remove the torque converter clutch. 2005 LEXUS IS300 (RM1140U) Author : Date : 1657...

  • Page 163: Body Electrical System

    Even if the light operates normally, there is a possibility that the fail-safe function works. SRS (SUPPLEMENTAL RESTRAINT SYSTEM) The LEXUS IS300 is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag, side airbag, curtain shield airbag. Failure to carry out service operation in the correct se- quence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious acci- dent.
  • Page 164 BE-2 BODY ELECTRICAL TROUBLESHOOTING TROUBLESHOOTING BE16S-06 PROBLEM SYMPTOMS TABLE IGNITION SWITCH AND This system uses the multiplex communication system, so check diagnosis system of the multiplex commu- nication system before you proceed with troubleshooting. Symptom Suspect Area See page 11.Ignition switch BE-21 Ignition switch is not set to each position.
  • Page 165 BE-3 BODY ELECTRICAL TROUBLESHOOTING 1. Bulb 2. H-LP L-UPR Fuse BE-15 ”HI-Beam” does not light (One side). 3. H-LP R-UPR Fuse BE-15 4. Wire Harness 1. H-LP L-UPR Fuse BE-15 2. H-LP R-UPR Fuse BE-15 ”Flash” does not light. 3. Headlight Dimmer Switch BE-31 4.
  • Page 166 BE-4 BODY ELECTRICAL TROUBLESHOOTING w/ Daytime running light system: HEADLIGHT AND TAILLIGHT SYSTEM This system uses the multiplex communication system, so check diagnosis system of the multiplex commu- nication system before you proceed with troubleshooting. HINT: To inspect the bulb and light control ECU, replace them with the ones working normally and judge whether they work normally or not.
  • Page 167 BE-5 BODY ELECTRICAL TROUBLESHOOTING 1. Headlight Control Relay BE-31 2. Daytime Running Light Main Relay BE-31 3. Daytime Running Light No.2 Relay BE-31 4. Headlight Dimmer Switch BE-31 Headlight does not come on. 5. Light Control Switch BE-31 6. Wire Harness 7.
  • Page 168 BE-6 BODY ELECTRICAL TROUBLESHOOTING FOG LIGHT SYSTEM This system uses the multiplex communication system, so check diagnosis system of the multiplex commu- nication system before you proceed with troubleshooting. Symptom Suspect Area See page 1. Bulbs 2. FR FOG Fuse BE-15 Front fog light does not light up with light control SW TAIL or 3.
  • Page 169 BE-7 BODY ELECTRICAL TROUBLESHOOTING 1. Rear-Left Door Courtesy Switch BE-58 The room light does not come on when the rear-left door is 2. Wire Harness opened. 3. Body ECU DI-893 4. Room Light BE-58 Only one of the bulbs comes ON. Bulb 1.

  • Page 170: Stop Light System

    BE-8 BODY ELECTRICAL TROUBLESHOOTING STOP LIGHT SYSTEM Symptom Suspect Area See page 1. STOP Fuse BE-15 2. Stop Light Switch BE-68 Stop light does not light up. 3. Light Failure Relay BE-31 4. Wire Harness 1. Stop Light Switch BE-68 Stop light always lights up.

  • Page 171: Combination Meter

    BE-9 BODY ELECTRICAL TROUBLESHOOTING 1. Rear Wiper Switch BE-75 Rear wiper does not operate in INT or ON position. 2. Wire Harness 1. Rear Wiper Motor BE-75 Rear wiper does not return to OFF position. 2. Wire Harness 1. Rear Washer Motor BE-75 Rear Washer Motor does not operate.
  • Page 172 BE-10 BODY ELECTRICAL TROUBLESHOOTING 1. Bulb 2. Meter Circuit Plate BE-90 Check engine warning light does not light up. 3. Wire Harness 4. ECM DI-1 1. Bulb 2. Fuel Level Warning Switch BE-90 Fuel level warning light does not light up. 3.

  • Page 173: Theft Deterrent System

    BE-1 1 BODY ELECTRICAL TROUBLESHOOTING 1. Key Unlock Warning Switch BE-21 2. Door Courtesy Switch BE-58 Key confinement prevention function does not operate. 3. Wire Harness 4. Body ECU DI-893 1. Luggage Compartment Door Opener Switch BE-121 2. Luggage Compartment Door Opener Motor BE-121 Luggage compartment door opener function does not operate.
  • Page 174 BE-12 BODY ELECTRICAL TROUBLESHOOTING 1. Ignition Switch BE-21 2. Key Unlock Warning Switch BE-21 While the warning is given, the system cannot be canceled by 3. RAD NO. 2 Fuse BE-15 turning the ignition switch to ACC or ON with key. 4.

  • Page 175: Audio System

    BE-13 BODY ELECTRICAL TROUBLESHOOTING POWER SEAT CONTROL SYSTEM Symptom Suspect Area See page 1. P/SEAT Fuse BE-15 Driver’s seat does not operate. 2. Power Seat Switch BE-151 3. Wire Harness 1. Power Seat Switch BE-151 ”Slide operation” does not operate. 2.
  • Page 176 BE-14 BODY ELECTRICAL TROUBLESHOOTING HORN SYSTEM Symptom Suspect Area See page 1. HORN Fuse BE-15 2. Horn Relay BE-233 Horn system does not operate. 3. Horn Switch BE-233 4. Horn BE-233 5. Wire Harness 1. Horn Relay BE-233 Horns blow all the time. 2.

  • Page 177: Power Source

    BE-15 BODY ELECTRICAL POWER SOURCE POWER SOURCE BE1WP-04 LOCATION Power Source Engine Room Junction Block Engine Room Relay Block Passenger Side Junction Block Driver Side Junction Block I27323 2005 LEXUS IS300 (RM1140U) Author : Date : 2016...
  • Page 178 23. CDS FAN 30A 24. RDI FAN 30A 25. ALT 120A 26. ABS1 60A 27. SPARE 28. SPARE 29. H-LP L UPR 10A 30. H-LP R UPR 10A 31. - I11570 2005 LEXUS IS300 (RM1140U) Author : Date : 2017...
  • Page 179 POWER SOURCE F Engine Room Relay Block Relays A. DIMMER Relay B. A/C COMP Relay C. FAN NO.3 Relay D. FAN NO.2 Relay E. FAN NO.1 Relay F. FUEL PMP Relay I23236 2005 LEXUS IS300 (RM1140U) Author : Date : 2018...
  • Page 180 18. WIPER 25A 19. RADIO NO.2 10A 20. - Condenser 21. DEF CDS 22. DEF CDS Relays A. Deicer Relay B. TAIL Relay C. RR DEF Relay D. FLSH Relay I11547 2005 LEXUS IS300 (RM1140U) Author : Date : 2019...
  • Page 181 15. SRS-B 7.5A 16. TV 7.5A 17. - 18. OBD 7.5A 19. IGN 7.5A 20.- Relays A. FR FOG Relay B. HTR Relay C. MIR HTR Relay D. P/W Relay I11548 2005 LEXUS IS300 (RM1140U) Author : Date : 2020...
  • Page 182 BE-20 BODY ELECTRICAL IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE01L-18 LOCATION Ignition Switch and Key Unlock Warning Switch I27324 2005 LEXUS IS300 (RM1140U) Author : Date : 2021...
  • Page 183 Battery Positive Voltage 7 - Ground Always Battery Positive Voltage 8 - Ground Ignition switch START Battery Positive Voltage If circuit is not as specified, inspect the circuits connected to oth- er parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2022...
  • Page 184 I04032 Tester connection Condition Specified condition 1 - Ground Always Continuity If circuit is not as specified, inspect the circuits connected to oth- er parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2023...
  • Page 185 F Body ECU Passenger Side F TAIL Fuse Junction Block F ECU-IG Fuse F MPX-B Fuse F Taillight Control Relay Combination Switch F Light Control Switch F Headlight Dimmer Switch I27325 2005 LEXUS IS300 (RM1140U) Author : Date : 2024...
  • Page 186 BE-24 BODY ELECTRICAL HEADLIGHT AND TAILLIGHT SYSTEM Sedan: Headlights w/o Rear fog light: Taillights Taillights Wagon: Headlights w/o Rear fog light: Taillights Taillights I23132 2005 LEXUS IS300 (RM1140U) Author : Date : 2025...
  • Page 187 BE-25 BODY ELECTRICAL HEADLIGHT AND TAILLIGHT SYSTEM BE29N-02 COMPONENTS Steering Column Upper Cover Light Control Switch and Headlight Dimmer Switch Steering Column Lower Cover I15596 2005 LEXUS IS300 (RM1140U) Author : Date : 2026...
  • Page 188 Luggage Compartment Trim Side Cover RH Side Cover LH Luggage Compartment Trim Side Cover No. 2 Rear Combination Light Assembly RH Rear Combination Light Luggage Compartment Trim Assembly LH Rear Cover I11324 2005 LEXUS IS300 (RM1140U) Author : Date : 2027...
  • Page 189 Deck Side Trim Board RH Service Hole Cover Floor Board Deck Side Board RH Deck Side Board LH Rear Combination Light Assembly RH Back Door Scuff Plate Rear Combination Light Assembly LH I23133 2005 LEXUS IS300 (RM1140U) Author : Date : 2028...
  • Page 190 Pull the pin toward the rear of the vehicle, and disconnect the engagement of 2 pins. From the inside of the luggage room, separate the con- nector and disconnect the LH rear combination light as- sembly. I11326 2005 LEXUS IS300 (RM1140U) Author : Date : 2029...
  • Page 191 Follow the same procedure for RH as for LH. Remove a part of luggage compartment door trim. Remove the nut. Compress the claw to disconnect the engagement as I11568 shown in the illustration. 2005 LEXUS IS300 (RM1140U) Author : Date : 2030...
  • Page 192 Installation is in the reverse order of removal. Only if there is a specified procedure for installation it is shown. Remove the back door trim service hole cover. Remove the bulb socket and bulb. I23138 2005 LEXUS IS300 (RM1140U) Author : Date : 2031...
  • Page 193 Tester connection Specified condition Low beam 16 - 17 Continuity High beam 7 - 16 Continuity Flash 7 - 8 - 16 Continuity If continuity is not as specified, replace the switch. 2005 LEXUS IS300 (RM1140U) Author : Date : 2032...
  • Page 194 I11538 Tester connection Condition Specified condition 16 - Ground Always Continuity 13 - Ground Light control switch HEAD Battery Positive Voltage If circuit is not as specified, inspect the wire harness. 2005 LEXUS IS300 (RM1140U) Author : Date : 2033...
  • Page 195 Light control switch HEAD and 17 - Ground dimmer switch HIGH or FLASH and fog light Battery Positive Voltage switch ON If circuit is not as specified, inspect the wire harness. 2005 LEXUS IS300 (RM1140U) Author : Date : 2034...
  • Page 196 1 - 2 Continuity Apply B+ between 3 - 5 Continuity terminals 1 and 2. If continuity is not as specified, replace the relay. INSPECT TAILLIGHT CONTROL RELAY CIRCUIT (See page DI-913 I01200 2005 LEXUS IS300 (RM1140U) Author : Date : 2035...
  • Page 197 INSPECT AUTOMATIC LIGHT CONTROL SYSTEM Turn the ignition switch ON. Turn the light control switch to AUTO. Gradually cover the top of the sensor. Check the accessory lights and the headlights should turn I11559 2005 LEXUS IS300 (RM1140U) Author : Date : 2036...
  • Page 198 4 - Ground Ignition switch LOCK or ACC No voltage 4 - Ground Ignition switch ON 5.2 - 9.0 V If circuit is as specified, perform the inspection on the following page. 2005 LEXUS IS300 (RM1140U) Author : Date : 2037...
  • Page 199 (Sensor is not covered) If circuit is as specified, try replacing the sensor with a new one. If the circuit is not as specified, inspect the circuit connected to other parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2038...
  • Page 200 When connecting the connec- tor again take care not to wake the aiming out of adjustment. When covering the headlight, finish it within 3 minutes. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 201 As shown in the illustration, adjust aiming of the LH and RH lights respectively. Adjust the headlight in vertical direction. Using adjusting bolt A, adjust the headlight aim to within the specifications. 2005 LEXUS IS300 (RM1140U) Author : Date : 2040...
  • Page 202 HEADLIGHT BEAM LEVEL CONTROL SYSTEM BE29P-02 LOCATION Engine Room Headlight Assembly Junction Block F Headlight Beam Level F PWR-IG Fuse Control Actuator Headlight Beam Control ECU Headlight Beam Level Ignition Switch Control ECU I27327 2005 LEXUS IS300 (RM1140U) Author : Date : 2041...
  • Page 203 BE-41 BODY ELECTRICAL HEADLIGHT BEAM LEVEL CONTROL SYSTEM Sedan: Height Control Sensor Wagon: Height Control Sensor I27326 2005 LEXUS IS300 (RM1140U) Author : Date : 2042...
  • Page 204 Ignition switch OFF Continuity 5 - 11 Ignition switch OFF Continuity 20 - Ground Ignition switch OFF Continuity If circuit is not as specified, perform the inspection on the follow- ing page. 2005 LEXUS IS300 (RM1140U) Author : Date : 2043...
  • Page 205 7 - 11 Ignition switch ON 10 - 20 Ignition switch OFF Continuity 20 - Body ground Ignition switch OFF Continuity If the circuit is not as specified, replace the ECU. 2005 LEXUS IS300 (RM1140U) Author : Date : 2044...
  • Page 206 The correct waveform is as shown in the illustration. *1 Pulse generation *2 Pulse generation Motor operating Motor operating / Division / Division 10 m sec./ Division 10 m sec./ Division I03276 2005 LEXUS IS300 (RM1140U) Author : Date : 2045...
  • Page 207 Front Fog Lights Rear Fog Light Switch Front Fog Lights Passenger Side Junction Block F Front Fog Light Relay F FR Fog Fuse Combination Switch F Front Fog Light Switch I27803 2005 LEXUS IS300 (RM1140U) Author : Date : 2046...
  • Page 208 BE-46 BODY ELECTRICAL FOG LIGHT SYSTEM Sedan: Rear Fog Light Wagon: Rear Fog Light I27804 2005 LEXUS IS300 (RM1140U) Author : Date : 2047...
  • Page 209 REMOVE FRONT FOG LIGHT BULB HINT: Follow the same procedure for RH as for LH. Remove a part of LH front fender liner. Separate the connector and remove the bulb. I11321 2005 LEXUS IS300 (RM1140U) Author : Date : 2048...
  • Page 210 LO and fog light switch ON Light control switch HEAD and headlight dimmer 11 - Ground Battery Positive Voltage switch LO and fog light switch OFF If circuit is not as specified, inspect the wire harness. 2005 LEXUS IS300 (RM1140U) Author : Date : 2049...
  • Page 211 Condition Tester connection Specified condition Always 1 - 2 Continuity Apply B+ between 3 - 5 Continuity terminals 1 and 2. If continuity is not as specified, replace the relay. I01200 2005 LEXUS IS300 (RM1140U) Author : Date : 2050...
  • Page 212 FOG LIGHT SYSTEM BE164-05 ADJUSTMENT ADJUST FRONT FOG LIGHT AIM A-bolt: Vertical Direction HINT: Insert a driver into the hole for aiming in the fender liner to per- form aiming. I11317 2005 LEXUS IS300 (RM1140U) Author : Date : 2051...
  • Page 213 LOCATION Engine Room Junction Block F TURN & HAZ Fuse Turn Signal Lights Hazard Warning Switch Driver Side Junction Block F Turn Signal Flasher Combination Switch F Turn Signal Switch I27807 2005 LEXUS IS300 (RM1140U) Author : Date : 2052...
  • Page 214 BE-52 BODY ELECTRICAL TURN SIGNAL AND HAZARD WARNING SYSTEM Sedan: Turn Signal Lights Side Marker Lights Turn Signal Lights Wagon: Turn Signal Lights Side Marker Lights Turn Signal Lights I27808 2005 LEXUS IS300 (RM1140U) Author : Date : 2053...
  • Page 215 Battery Positive Voltage 3 - Ground Ignition switch ON and turn signal switch Right Battery Positive Voltage If circuit is not as specified, inspect the circuits connected to oth- er parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2054...

  • Page 216: Interior Light System

    Front Personal Light Vanity Light Sedan: Room Light Vanity Light License Plate Light Door Courtesy Light Door Courtesy Switches Luggage Compartment Door Lock Assembly Luggage Compartment Light F Courtesy Switch I27805 2005 LEXUS IS300 (RM1140U) Author : Date : 2055...
  • Page 217 INTERIOR LIGHT SYSTEM Wagon: Front Personal Light Vanity Light Room Light Vanity Light License Plate Light Door Courtesy Light Door Courtesy Switches Back Door Lock Assembly F Courtesy Switch Rear Room Light I27806 2005 LEXUS IS300 (RM1140U) Author : Date : 2056...
  • Page 218 Installation is in the reverse order of removal. Only if there is a specified procedure for installation it is shown. Remove a part of luggage compartment door trim. Disconnect the bulb sockets and remove the bulbs. I11332 2005 LEXUS IS300 (RM1140U) Author : Date : 2057...
  • Page 219 Installation is in the reverse order of removal. Only if there is a specified procedure for installation it is shown. Remove the back door trim. Disconnect the bulb sockets and remove the bulbs. I23200 2005 LEXUS IS300 (RM1140U) Author : Date : 2058...
  • Page 220 2 and body ground. I01263 Turn the room light switch DOOR, check that continuity exists between terminals 1 and 2. If continuity is not as specified, replace the light assembly or bulb. I01264 2005 LEXUS IS300 (RM1140U) Author : Date : 2059...
  • Page 221 Check that no continuity exists between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. I01267 2005 LEXUS IS300 (RM1140U) Author : Date : 2060...
  • Page 222 I04051 Tester connection Condition Specified condition 2 - Ground Always Continuity 1 - Ground Always Battery Positive Voltage If circuit is not as specified, inspect power source or wire har- ness. 2005 LEXUS IS300 (RM1140U) Author : Date : 2061...
  • Page 223 INSPECT LUGGAGE COMPARTMENT DOOR COUR- Wire Harness Side TESY SWITCH CIRCUIT (See page DI-923 Disconnect the connector from the switch and inspect the con- nector on the wire harness side, as shown. I04185 2005 LEXUS IS300 (RM1140U) Author : Date : 2062...
  • Page 224 Specified condition 1 - Ground Always Continuity 2 - Ground Light control switch TAIL or HEAD Battery Positive Voltage If circuit is not as specified, inspect power source or wire har- ness. 2005 LEXUS IS300 (RM1140U) Author : Date : 2063...
  • Page 225 BE-63 BODY ELECTRICAL BACK-UP LIGHT SYSTEM BACK-UP LIGHT SYSTEM BE29X-03 LOCATION Back-up Light (M/T) Park/Neutral Position Switch (A/T) Ignition Switch I27809 2005 LEXUS IS300 (RM1140U) Author : Date : 2064...
  • Page 226 BE-64 BODY ELECTRICAL BACK-UP LIGHT SYSTEM Sedan: Back-up Lights Wagon: Back-up Lights I27810 2005 LEXUS IS300 (RM1140U) Author : Date : 2065...
  • Page 227 Switch position Specified condition Push Continuity Free No continuity Push If continuity is not as specified, replace the switch. INSPECT PARK/NEUTRAL POSITION SWITCH CON- Free I01269 TINUITY (A/T) (See page DI-371 2005 LEXUS IS300 (RM1140U) Author : Date : 2066...
  • Page 228 Driver Side Junction Block F STOP Fuse w/ Spoiler: Hi-Mounted Stop Light w/o Spoiler: Hi-Mounted Stop Light Sedan: Hi-Mounted Stop Light Wagon: w/o Rear fog light: Stop Lights Stop Lights Stop Lights I27811 2005 LEXUS IS300 (RM1140U) Author : Date : 2067...
  • Page 229 Installation is in the reverse order of removal. Only if there is a specified procedure for installation it is shown. Remove center stop light assembly. Remove the bulb sockets and bulbs. I11335 2005 LEXUS IS300 (RM1140U) Author : Date : 2068...
  • Page 230 I04063 Tester connection Condition Specified condition 2 - Ground Always Battery Positive Voltage If circuit is not as specified, inspect the power source or wire harness. 2005 LEXUS IS300 (RM1140U) Author : Date : 2069...
  • Page 231 HEADLIGHT CLEANER SYSTEM BE023-13 LOCATION Headlight Cleaner Relay Headlight Cleaner Nozzle Headlight Cleaner Nozzle Washer Tank F Headlight Cleaner Motor Headlight Cleaner Switch Ignition Switch Driver Side Junction Block F H-CLN Fuse I27812 2005 LEXUS IS300 (RM1140U) Author : Date : 2070...
  • Page 232 Connect the negative (-) lead from the battery to terminal 4, and check that continuity exists between terminals 2 and 5 for 0.9 - 1.1 seconds, then no continuity exists. If operation is not as specified, replace the motor. I01687 2005 LEXUS IS300 (RM1140U) Author : Date : 2071...
  • Page 233 If operation is not as specified, replace the motor. I04068 INSPECT HEADLIGHT CLEANER MOTOR CIRCUIT Wire Harness Side Disconnect the connector from the cleaner motor and inspect the connector on wire harness side, as shown. I04069 2005 LEXUS IS300 (RM1140U) Author : Date : 2072...
  • Page 234 BE-72 BODY ELECTRICAL HEADLIGHT CLEANER SYSTEM Tester connection Condition Specified condition 2 - Ground Always Continuity If circuit is not as specified, inspect the circuits connected to oth- er parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2073...
  • Page 235 WIPER AND WASHER SYSTEM BE29Z-04 LOCATION Front Wiper Motor Washer Tank F Washer Motor Combination Switch F Wiper and Washer Switch Ignition Switch Driver Side Junction Block F WIPER Fuse F WASHER Fuse I27813 2005 LEXUS IS300 (RM1140U) Author : Date : 2074...
  • Page 236 BE-74 BODY ELECTRICAL WIPER AND WASHER SYSTEM Wagon: Rear Wiper Motor I27814 2005 LEXUS IS300 (RM1140U) Author : Date : 2075...
  • Page 237 17 - Ground Ignition switch LOCK or ACC No voltage 17 - Ground Ignition switch ON Battery Positive Voltage If circuit is not as specified, inspect the circuits connected to oth- er parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2076...
  • Page 238 If operation is not as specified, replace the motor. Connector disconnected: Wire Harness Side INSPECT FRONT WIPER MOTOR CIRCUIT Disconnect the connector from the motor and inspect the con- nector on the wire harness side, as shown. I04076 2005 LEXUS IS300 (RM1140U) Author : Date : 2077...
  • Page 239 I23237 Disconnect the negative (-) lead from terminal 1, check that the motor stops running at the stop position. If operation is not as specified, replace the motor. I23238 2005 LEXUS IS300 (RM1140U) Author : Date : 2078...
  • Page 240 (-) lead to terminal 1, check that the motor oper- ates. NOTICE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. I01272 2005 LEXUS IS300 (RM1140U) Author : Date : 2079...
  • Page 241 If operation is not as specified, replace the motor. I12044 Wagon, Connector disconnected: Wire Harness Side INSPECT WASHER MOTOR CIRCUIT Disconnect the connector from the motor and inspect the con- nector on the wire harness side, as shown. I23252 2005 LEXUS IS300 (RM1140U) Author : Date : 2080...
  • Page 242 WIPER AND WASHER SYSTEM Tester connection Condition Specified condition 2 - Ground Ignition switch ON Battery positive voltage If circuit is not as specified, inspect the power source, wire har- ness and wiper switch. 2005 LEXUS IS300 (RM1140U) Author : Date : 2081...

  • Page 243: Combination Meter

    F SRS-B Fuse Combination Meter Light Control Rheostat Parking Brake Switch Occupant Driver Side Junction Block F Body ECU Detection Sensor F GAUGE Fuse Seat Belt F TAIL Fuse Buckle Switch I27815 2005 LEXUS IS300 (RM1140U) Author : Date : 2082...
  • Page 244 BE-82 BODY ELECTRICAL COMBINATION METER Sedan: Sub Fuel Sender Gauge Main Fuel Sender Gauge Wagon: Sub Fuel Sender Gauge Main Fuel Sender Gauge I27816 2005 LEXUS IS300 (RM1140U) Author : Date : 2083...
  • Page 245 BE-83 BODY ELECTRICAL COMBINATION METER Water Temperature Sender Gauge Oil Pressure Switch M/T Vehicle Speed Sensor Back-up Light Switch A/T Vehicle Neutral Start Switch I11340 2005 LEXUS IS300 (RM1140U) Author : Date : 2084...
  • Page 246 BE-84 BODY ELECTRICAL COMBINATION METER BE16C-04 CIRCUIT Connector ”B” Connector ”A” I18580 2005 LEXUS IS300 (RM1140U) Author : Date : 2085...
  • Page 247 SRS +B A8 SRS Check Engine A7 CHECK ENGINE A9 ABS TRC OFF B3 TRC OFF SLIP B4 SLIP Rear Lights B6 Rear Lights H-LP LEVEL A11 H-LP LEVEL B5 VSC I27848 2005 LEXUS IS300 (RM1140U) Author : Date : 2086...
  • Page 248 TAIL Fuse Speed signal ground (M/T vehicle only) ABS and TRC ECU ABS and TRC ECU ABS and TRC ECU (w/ VSC) Light failure sensor Theft deterrent ECU Daytime running light ECU 2005 LEXUS IS300 (RM1140U) Author : Date : 2087...
  • Page 249 COMBINATION METER BE0HJ-13 COMPONENTS Bulbs Wire Harness Combination Meter Case Combination Meter ECU Trip Knob Sub Circuit Plate Speedometer Assembly Tachometer Fuel Receiver Gauge Combination Meter Glass Combination Meter Plate No.1 I18579 2005 LEXUS IS300 (RM1140U) Author : Date : 2088...
  • Page 250 Remove it in the same procedure as for the speed meter as- sembly. REMOVE FUEL RECEIVER GAUGE. HINT: Remove it in the same procedure as for the speed meter as- sembly. REMOVE TRIP KNOB REMOVE COMBINATION METER COMPUTER AS- SEMBLY 2005 LEXUS IS300 (RM1140U) Author : Date : 2089...
  • Page 251 I11369 INSTALL WIRE HARNESS Route the wire harness as shown in the illustration and install it to the combination meter case. I11370 2005 LEXUS IS300 (RM1140U) Author : Date : 2090...
  • Page 252 BE-90 BODY ELECTRICAL COMBINATION METER BE1WU-04 INSPECTION INSPECT COMBINATION METER CIRCUIT Connector connected: Connect connector ”A” and ”B” from the combination meter and inspect the connectors on the wire harness side as shown in the table. Connector connected Connector B” Connector A”...
  • Page 253 BE-91 BODY ELECTRICAL COMBINATION METER A16 - Ground Always Battery voltage (DOME +B) A17 - Ground Ignition switch ON Battery voltage (IGN) A18 - Ground Always Continuity (Power ground) A19 - Ground Always Continuity (Signal ground) A20 - Ground Ignition switch ON Pulse generation (MPX+) A21 - Ground...
  • Page 254 BE-92 BODY ELECTRICAL COMBINATION METER INSPECT SPEEDOMETER/ON-VEHICLE Using a speedometer tester, inspect the speedometer for allow- able indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indica- tion error. USA (mph) CANADA (km/h) Standard indication...
  • Page 255 BE-93 BODY ELECTRICAL COMBINATION METER HINT: The voltage change should be 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. INSPECT TACHOMETER/ON-VEHICLE Connect a tune-up test tachometer, and start the engine. NOTICE: Reversing the connection of the tachometer will dam- age the transistors and diodes inside.
  • Page 256 BE-94 BODY ELECTRICAL COMBINATION METER Connect the main sender gauge. Fuel Receiver Gauge Ignition Disconnect the connector from the sub sender gauge. Switch Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY. Wire Harness Sender HINT: Side Gauge Because of the silicon oil in the gauge, it will take a short time...
  • Page 257 BE-95 BODY ELECTRICAL COMBINATION METER INSPECT WATER TEMPERATURE RECEIVER GAUGE OPERATION (See page DI-881 INSPECT WATER TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals with fixing pointer to the stopper. Tester connection Resistance (Ω) A - D B - C If resistance value is not as specified, replace the receiver I11351 gauge.
  • Page 258 BE-96 BODY ELECTRICAL COMBINATION METER INSPECT SPECIFIC FUEL CONSUMPTION GAUGE RESISTANCE (See page DI-884 Measure the resistance between terminals with fixing pointer to the stopper. Tester connection Resistance (Ω) A - D B - C If resistance value is not as specified, replace the meter. I11353 INSPECT OIL PRESSURE SENDER CONTINUITY Disconnect the connector from the oil presser sender.
  • Page 259 BE-97 BODY ELECTRICAL COMBINATION METER INSPECT PARKING BRAKE SWITCH CONTINUITY Check that continuity exists between the terminal and switch body with the switch ON (switch pin released). Check that no continuity exists between the terminal and switch body with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch or inspect ground point.
  • Page 260 BE-98 BODY ELECTRICAL COMBINATION METER INSPECT ENGINE OIL LEVEL WARNING SENSOR Wire Harness Side CIRCUIT Disconnect the switch connector and inspect the connector on wire harness side, as shown. I04104 Tester connection Condition Specified condition 2 - Ground Always Continuity If continuity is not as specified, inspect the wire harness or ground point.
  • Page 261 BE-99 BODY ELECTRICAL COMBINATION METER INSPECT SEAT BELT BUCKLE SWITCH CIRCUIT (See page DI-917 Disconnect the switch connector and inspect the connector on wire harness side, as shown. Tester connection Condition Specified condition 2 - Ground Always Continuity If continuity is not as specified, inspect the circuits connected to other parts.
  • Page 262 BE-100 BODY ELECTRICAL COMBINATION METER Tester connection Condition Specified condition 1 - Ground Always * Continuity 2 - Ground Always * Continuity 3 - Ground Taillight ON Battery Positive Voltage 9 - Ground Always * Continuity 11 - Ground Always Continuity 3 - Ground Taillight or Headlight OFF...
  • Page 263 Passenger Side Junction Block F Mirror Heater Relay Mirror Assembly F Mirror Defogger Sedan: Driver Side Junction Block F Defogger Relay F DEFOG Fuse Mirror Assembly F Mirror Defogger Wagon: Defogger Wire I27817 2005 LEXUS IS300 (RM1140U) Author : Date : 2102...
  • Page 264 Turn the defogger switch ON. Inspect the voltage at the center of each heat wire, as shown. Voltage Criteria Approx. 5V Okay (No break in wire) Approx. 10V or 0V Broken wire I01292 2005 LEXUS IS300 (RM1140U) Author : Date : 2103...
  • Page 265 Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead to terminal 4. Check that the mirror becomes warm. HINT: It will take a short time for the mirror to become warm. I23212 2005 LEXUS IS300 (RM1140U) Author : Date : 2104...
  • Page 266 DOWN operation operates during door glass AUTO UP operation. Even though a foreign object is caught, DOWN operation does not function. After ignition switch has been turned to OFF by using a key, power window function does not operate. 2005 LEXUS IS300 (RM1140U) Author : Date : 2105...
  • Page 267 Wire harness (between 20 terminal of the master switch and 2 terminal of the power window motor or 8 terminal of the master switch and 1 terminal of the power window). 2005 LEXUS IS300 (RM1140U) Author : Date : 2106...
  • Page 268 Power window regulator master switch terminal of the master switch and body ground? detective. Window lock switch NORMAL --------- 10 to 14 V Window lock switch LOCK ------------ 0 V Go to chart 3 2005 LEXUS IS300 (RM1140U) Author : Date : 2107...
  • Page 269 Wire harness (between 6 terminal of the regulator switch and 4 terminal of the power window motor or 1 terminal of the regulator switch and 1 terminal of the power window motor). 2005 LEXUS IS300 (RM1140U) Author : Date : 2108...
  • Page 270 Replace the regulator switch with the normal one from the Power window regulator switch defective. other seats, when operating by remote function, does power window operate normally? Power window regulator master switch defective. 2005 LEXUS IS300 (RM1140U) Author : Date : 2109...
  • Page 271 Connect the connector of power window motor. Connect the normal master switch or regulator switch and Master switch or regulator switch. check if AUTO UP and DOWN operates. Power window motor defective. 2005 LEXUS IS300 (RM1140U) Author : Date : 2110...
  • Page 272 Reset the power window motor (Initial position setting of limit switch), assemble the power window regulator to the vehicle. Does the door glass operates normally? Normal (Perform the function check.) Master or regulator switch defective. 2005 LEXUS IS300 (RM1140U) Author : Date : 2111...
  • Page 273 4 mm away from the door glass fully opened position. Reset the power window motor and assemble it to the vehicle. Does the door glass operates normally? Normal (After inspecting repeatedly, perform the function check.) Master or regulator switch defective. 2005 LEXUS IS300 (RM1140U) Author : Date : 2112...
  • Page 274 C2 terminal of the instrument controller and junction and body ground? Wire harness defective (between C2 terminal of the instrument controller and junction and 1 terminal of the power main relay). 2005 LEXUS IS300 (RM1140U) Author : Date : 2113...
  • Page 275 F ECU-IG Fuse F METER Fuse F D FR POWER Fuse Sedan: Power Window Regulator F Power Window Motor F Pulse Switch F Limit Switch Power Window Regulator F Power Window Motor I27818 2005 LEXUS IS300 (RM1140U) Author : Date : 2114...
  • Page 276 BODY ELECTRICAL POWER WINDOW CONTROL SYSTEM Wagon: Rear Power Window Switch Power Window Regulator F Power Window Motor F Pulse Switch Power Window Regulator F Limit Switch F Power Window Motor I27819 2005 LEXUS IS300 (RM1140U) Author : Date : 2115...
  • Page 277 Battery Positive Voltage 2, 4 - Ground Ignition switch LOCK No voltage 2, 4 - Ground Ignition switch ACC or ON Battery Positive Voltage If circuit is not as specified, replace the switch. 2005 LEXUS IS300 (RM1140U) Author : Date : 2116...
  • Page 278 1 and the negative (-) lead to terminal 2, and check that the motor turns clockwise. Reverse the polarity, check that the motor turns counter- clockwise. Clockwise If operation is not as specified, replace the motor. Driven Gear I11376 2005 LEXUS IS300 (RM1140U) Author : Date : 2117...
  • Page 279 In case of removing the glass, glass guide, regulator and etc. be sure to perform checking of the jam protection function. If the jam protection is not functioned properly, adjust power window motor reset switch and pulse switch. 2005 LEXUS IS300 (RM1140U) Author : Date : 2118...
  • Page 280 Take care that the jam protection function does not operate just after resetting. Reset the regulator again when performing the reverse operating after closing the window fully by AUTO UP operation. Check the power window function. 2005 LEXUS IS300 (RM1140U) Author : Date : 2119...
  • Page 281 F Door Unlock Detection Switch Sedan: Door Lock Assembly F Door Lock Motor F Door Unlock Detection Switch F Door Key Lock and Unlock Switch Door Courtesy Switch Door Courtesy Switch I27820 2005 LEXUS IS300 (RM1140U) Author : Date : 2120...
  • Page 282 F Door Key Lock and Unlock Switch Door Courtesy Switch Back Door Lock Assembly Door Courtesy Switch F Back Door Lock Motor F Back Door Courtesy Switch Back Door Opener Relay I27821 2005 LEXUS IS300 (RM1140U) Author : Date : 2121...
  • Page 283 Driver’s door lock and unlock switch UNLOCK Continuity If circuit is not as specified, inspect power source or wire har- ness. INSPECT POWER WINDOW MASTER SWITCH CIR- CUIT (See page DI-935 2005 LEXUS IS300 (RM1140U) Author : Date : 2122...
  • Page 284 LOCK) ON (Door Lock set to 1 - 2 (LH side) Continuity UNLOCK) 3 - 4 (RH side) LOCK If continuity is not as specified, replace the door lock assembly. I11553 2005 LEXUS IS300 (RM1140U) Author : Date : 2123...
  • Page 285 Reverse the polarity and check that the door lock link moves to UNLOCK position. LOCK If operation is not as specified, replace the door lock assembly. INSPECT DOOR LOCK MOTOR CIRCUIT I11553 (See page DI-931 2005 LEXUS IS300 (RM1140U) Author : Date : 2124...
  • Page 286 Connect positive (+) lead to the terminal 1 and negative (-) lead to the terminal 2, and check that the motor operates. If operation is not as specified, replace the motor assembly. I23197 2005 LEXUS IS300 (RM1140U) Author : Date : 2125...

  • Page 287: Theft Deterrent System

    F HORN Relay F HORN Fuse F Headlight Relay Security Horn Engine Hood Courtesy Switch Horn Theft Deterrent ECU Driver Side Junction Block F ST Fuse F Taillight Control Relay Ignition Switch I27822 2005 LEXUS IS300 (RM1140U) Author : Date : 2126...
  • Page 288 Unlock Switch Door Lock Assembly F Door Lock Motor Wagon: F Door Unlock Detection Switch F Door Key Lock and Unlock Switch Back Door Opener Switch Back Door Lock Assembly I27823 2005 LEXUS IS300 (RM1140U) Author : Date : 2127...
  • Page 289 I10745 Tester connection Condition Specified condition 2 - Ground Always Continuity If circuit is not as specified, inspect power source or wire har- ness. 2005 LEXUS IS300 (RM1140U) Author : Date : 2128...
  • Page 290 The siren battery is normal when the siren sounds for 30 seconds, stops, then after 5 seconds, seconds again. Replace the siren battery when the siren stops sounding before 30 seconds elapse the battery because the battery life has run out. 2005 LEXUS IS300 (RM1140U) Author : Date : 2129...
  • Page 291 F Door Lock Motor Door Lock Assembly F Door Unlock Detection Switch F Courtesy Switch F Door Key Lock and Unlock Switch Wireless Door Lock Door Courtesy Switches Control Receiver I27824 2005 LEXUS IS300 (RM1140U) Author : Date : 2130...
  • Page 292 Door Lock Assemblies Switch F Door Lock Motor F Door Unlock Detection Switch Back Door Lock Assembly F Door Key Lock and Unlock Switch F Courtesy Switch Door Courtesy Switches I27825 2005 LEXUS IS300 (RM1140U) Author : Date : 2131...
  • Page 293 LED or position. lights up once more. F Because weak electric wave is used, when there is strong wave or noise in the used frequency ,operation distance might be shortened. 2005 LEXUS IS300 (RM1140U) Author : Date : 2132...
  • Page 294 LOCK and UNLOCK operation and output of luggage door opener signal are not performed under the self diagnostic mode. within. within. 5 sec. 30 sec. Key plate not inserted Key plate inserted Ignition switch 1st time 9th time 2005 LEXUS IS300 (RM1140U) Author : Date : 2133...
  • Page 295 While turning the ignition switch ON in the self normally when recognition code diagnostic mode, the mode returns to normal mode. is registered. No response from room light (1) is output. 2005 LEXUS IS300 (RM1140U) Author : Date : 2134...
  • Page 296 Between the receiver terminal 2 (RDA) and body ECU terminal B7-2 (RDA). Check RDA terminal circuit. RDA terminal open circuit. Check that the voltage of RDA is 6.5 to 14 V (with transmitting). 2005 LEXUS IS300 (RM1140U) Author : Date : 2135...
  • Page 297 Body ground check: Body ground open and contact error. Check that continuity exists between the connector terminal 5 (GND) of the wireless door control receiver and body ground. Wireless door control receiver faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2136...
  • Page 298 Install the battery (lithium battery). Install a cover so that O-ring is not distorted or slipped off. Using a screwdriver, tighten the screw. 2005 LEXUS IS300 (RM1140U) Author : Date : 2137...
  • Page 299 WIRELESS DOOR LOCK CONTROL SYSTEM CHECK BATTERY CAPACITY HINT: Make sure to use the LEXUS electrical tester. With the battery unloaded, judge can not be made wheth- er the battery is available or not on the test. When the transmitter is faulty, the energy amount left in the battery might not be checked correctly.
  • Page 300 Tester connection Condition Specified condition 1 - Ground Always Continuity 5 - Ground Always Battery Positive Voltage If the circuit is not as specified, inspect the circuits connected to other parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2139...
  • Page 301 2 - Ground 0 V - 6 V Transmitter OFF If circuit is as specified, replace the receiver. If the circuit is not as specified, inspect the circuits connected to other parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2140...
  • Page 302 When the shrews are tightened loosely, it might cause faulty contact of battery (lithium battery) and terminals. Assemble the transmitter to the key plate and the cover. Using a screwdriver, tighten the screw. 2005 LEXUS IS300 (RM1140U) Author : Date : 2141...
  • Page 303 HINT: When procedure is out of the specified, the operation re- turns to normal operation. Maximum 4 recognition codes can be registered. 2005 LEXUS IS300 (RM1140U) Author : Date : 2142...
  • Page 304 LOCK/UNLOCK at approx. 1 sec. interval. 1st time 2nd time 3rd time 4th time 5th time Approx. Approx. 1 sec. 1 sec. LOCK Within 40 secs. UNLOCK Insert the key into the ignition key cylinder. 2005 LEXUS IS300 (RM1140U) Author : Date : 2143...
  • Page 305 1st time 2nd time Indicates that rewrite mode has been 2 secs. 2 secs. selected. LOCK 1 sec. 1 sec. UNLOCK LOCK UNLOCK Registration of recognition code (Confirmation mode and prohibition mode) is completed. 2005 LEXUS IS300 (RM1140U) Author : Date : 2144...
  • Page 306 F The key plate is inserted in the ignition key cylinder. F 4 type recognition codes are registration at one time. Registration of recognition codes (add mode or rewrite mode) is completed. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 307 SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM BE0O9-08 TROUBLESHOOTING Sliding Roof does not stop at correct position. Start Power Supply was disconnected during use of sliding roof. Motor was manually rotated. *Reinitialize 2005 LEXUS IS300 (RM1140U) Author : Date : 2146...
  • Page 308 (b) Release the switch, press the switch again and hold it for 10 secs. (c) The sliding roof operates in a cycle of TILT DOWN SLIDE OPEN SLIDE CLOSE TILT UP. THis completes reinitializing. 2005 LEXUS IS300 (RM1140U) Author : Date : 2147...
  • Page 309 BE-147 BODY ELECTRICAL SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM BE05Q-07 LOCATION Sedan: Sliding Roof Control Assembly F Sliding Roof ECU F Sliding Roof Motor Front Personal Light F Sliding Roof Switch Door Courtesy Switch Wagon: Sliding Roof Control Assembly F Sliding Roof ECU F Sliding Roof Motor Front Personal Light F Sliding Roof Switch...
  • Page 310 BE-148 BODY ELECTRICAL SLIDING ROOF SYSTEM BE10K-05 INSPECTION INSPECT SLIDING ROOF SWITCH CONTINUITY Switch position Tester connection Specified condition Below 10 Ω SLIDE OPEN 3 - 4 Tilt Switch Slide Switch 10k Ω or higher SLIDE OFF 3 - 4, 4 - 6 Below 10 Ω...
  • Page 311 BE-148-1 BODY ELECTRICAL SLIDING ROOF SYSTEM CHECK AUTO SLIDE-OPEN/CLOSE OPERATION NOTICE: If the sliding roof system has not been initialized, then AUTO slide open/close operation does not work. HINT: Initialize the sliding roof system after any of the following is done: The battery is disconnected.
  • Page 312 BE-148-2 BODY ELECTRICAL SLIDING ROOF SYSTEM CHECK AUTO TILT-UP/DOWN OPERATION NOTICE: If the sliding roof system has not been initialized, then AUTO slide tilt-up/down operation does not work. HINT: Initialize the sliding roof system after any of the following is done: The battery is disconnected.
  • Page 313 BE-148-3 BODY ELECTRICAL SLIDING ROOF SYSTEM CHECK KEY-OFF SLIDING ROOF OPERATION HINT: The sliding roof can be operated for approximately 45 seconds after the ignition switch is turned from ON to OFF with all doors closed. However, if the driver side door is opened during this time, the operation is can- celed.
  • Page 314 F P SEAT (D) Fuse Power Seat Memory Switch Reclining Motor Lifter Motor Power Seat Contol ECU Power Seat Switch Reclining Motor Front Vertical Motor Slide Motor Front Vertical Motor Power Seat Switch I27827 2005 LEXUS IS300 (RM1140U) Author : Date : 2153...
  • Page 315 If continuity is not as specified, replace the switch. INSPECT POWER SEAT MEMORY SWITCH Switch position Tester connection Specified condition 1 - 4 Continuity 2 - 4 Continuity 3 - 4 Continuity I27321 2005 LEXUS IS300 (RM1140U) Author : Date : 2154...
  • Page 316 I04160 Lifter switch: Switch position Tester connection Specified condition 1 - 8 Continuity 4 - 7 4 - 7 Continuity 4 - 8 1 - 7 DOWN Continuity 4 - 8 2005 LEXUS IS300 (RM1140U) Author : Date : 2155...
  • Page 317 2 (1) and the negative (-) lead to the battery negative (-) terminal, then move the seat cushion to the front position. Continue to apply voltage, check that current changes to less than 1 ampere within 4 to 90 seconds. N21866 2005 LEXUS IS300 (RM1140U) Author : Date : 2156...
  • Page 318 1 and the negative (-) lead to terminal 2, check that the motor turns counterclockwise. Reverse the polarity, check that the motor turns clock- wise. If operation is not as specified, replace the seat adjuster. N21865 2005 LEXUS IS300 (RM1140U) Author : Date : 2157...
  • Page 319 1 and the negative (-) lead to terminal 2, check that the seat back begins to fall backward. If operation is not as specified, replace the seat adjuster. N21869 2005 LEXUS IS300 (RM1140U) Author : Date : 2158...
  • Page 320 RRV- (B-5) - Body ground Manual switch (Rear vertical down) OFF Blow 1 V 10-14 V RRV+ (B-6) - Body ground Manual switch (Rear vertical up) OFF Blow 1 V 10-14 V 2005 LEXUS IS300 (RM1140U) Author : Date : 2159...
  • Page 321 FRV- (B-9) - Body ground Manual switch (Front vertical down) OFF Blow 1 V 10-14 V FRV+ (B-10) - Body ground Manual switch (Front vertical up) OFF Blow 1 V 10-14 V 2005 LEXUS IS300 (RM1140U) Author : Date : 2160...
  • Page 322 Passenger Side Junction Block F MIR HTR Relay Ignition Switch F MIR HTR Fuse Power Window Driver Side Junction Block Master Switch F RADIO No.2 Fuse F Power Mirror Switch I27828 2005 LEXUS IS300 (RM1140U) Author : Date : 2161...
  • Page 323 6 and the negative (-) lead to terminal 7, and check that the mirror turns to the inside. I11404 Reverse the polarity, and check that the mirror turns out- side. If operation is not as specified, replace the mirror assembly. 2005 LEXUS IS300 (RM1140U) Author : Date : 2162...
  • Page 324 BE-159 BODY ELECTRICAL ELECTRO CHROMIC MIRROR SYSTEM ELECTRO CHROMIC MIRROR SYSTEM BE0HC-13 LOCATION Electro Chromic Outer Mirror Electro Chromic Inner Mirror Driver Side Junction Block F ECU-IG Fuse I27829 2005 LEXUS IS300 (RM1140U) Author : Date : 2163...
  • Page 325 1 - Ground Ignition switch LOCK or ACC No voltage 1 - Ground Ignition switch ON Battery positive voltage If circuit is not as specified, inspect the circuits connected to other parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2164...
  • Page 326 4 and the negative (-) lead to terminal 5, then ”Dark” check that the mirror surface changes to ”dark”. Check the mirror turns to ”bright” after disconnecting the battery. If operation is not as specified, replace the mirror assembly. I23213 2005 LEXUS IS300 (RM1140U) Author : Date : 2165...
  • Page 327 BE2A8-03 LOCATION Seat Heater Switch Driver Side Ignition Switch Junction Block F S-HTR Fuse Seat Heater Cushion Front Side w/o Seatback table: Seat Heater Cushion Rear Side Seat Heater Back I27830 2005 LEXUS IS300 (RM1140U) Author : Date : 2166...
  • Page 328 BE-163 BODY ELECTRICAL SEAT HEATER SYSTEM Seat Heater Cushion Front Side w/ Seatback table: Seat Heater Cushion Rear Side Seat Heater Back I27831 2005 LEXUS IS300 (RM1140U) Author : Date : 2167...
  • Page 329 A1 - B2 No continuity A2 - B1 Always Continuity A2 - C1 Always Continuity B2 - C2 Always Continuity If continuity is not as specified, replace the seat cushion pad. 2005 LEXUS IS300 (RM1140U) Author : Date : 2168...
  • Page 330 Inspect the seat cushion front side continuity between termi- nals, as shown. I25927 Tester connection Condition Specified condition 1 - 2 Always Continuity If continuity is not as specified, replace the seat cushion pad. 2005 LEXUS IS300 (RM1140U) Author : Date : 2169...
  • Page 331 Inspect the seat back continuity between terminals, as shown. I25521 Tester connection Condition Specified condition 1 - 2 Always Continuity If continuity is not as specified, replace the seat back pad. 2005 LEXUS IS300 (RM1140U) Author : Date : 2170...
  • Page 332 These radio waves then interfere with the signals from the same transmitter that reach the vehicle’s antenna directly. This type of interference is called ”fading”. BE2819 2005 LEXUS IS300 (RM1140U) Author : Date : 2171...
  • Page 333 If the disc gets dirty, clean the disc by wiping the surface from the center to outside in the radial directions with a soft cloth. NOTICE: Do not use a conventional record cleaner or anti-static pre- servative. BE4331 2005 LEXUS IS300 (RM1140U) Author : Date : 2172...
  • Page 334 The car audio system using AVC-LAN circuit has a diagnosis function. Each product has its own specified numbers called physical address. Numbers are also allotted to each function in one product, which are called logical address. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 335 System check and diagnosis memory check is performed in the Service Check Mode and the check result is displayed in ascending order of the component codes. It may take about 40 sec. to complete these checks. DISC Button SEEK ”UP” or ”DOWN” Switch PRESET Switch I23259 2005 LEXUS IS300 (RM1140U) Author : Date : 2174...
  • Page 336 DTC. To restart the Service Check, press the preset button ”1”. To exit the diagnosis mode, press ”DISC” or ”CD” for 2 sec. or more, or turn the ignition switch OFF. 2005 LEXUS IS300 (RM1140U) Author : Date : 2175...
  • Page 337 By the ”SEEK” switch operation, ”the system check result (SYS)” and ”the diagnosis memory re- sponse result (COdE)” can be displayed. Refer to the diagnosis code list and inspect the defective part(s). Press the preset button ”3” to return to the Service Check Mode. 2005 LEXUS IS300 (RM1140U) Author : Date : 2176...
  • Page 338 In the Detail Display Mode, a system check result is displayed before the diagnosis memory response result. If a DTC does not have any auxiliary code, no auxiliary code is displayed. I18571 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 339 When DTC memory is completely deleted, a beep sounds once. Pressing the preset button ”1”, perform the Service Check again and confirm that no error is dis- played for all component codes. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 340 . Error occurs in communica- tion system of power amplifier. F Check harness for communica- tion between sub-master (audio) and master component. tion system between power amplifi- er and sub-master component. 2005 LEXUS IS300 (RM1140U) Author : Date : 2179...
  • Page 341 (Communication Error by auxiliary code has been failed. for power supply and communica- Control) (Detecting this DTC does not nec- tion system of components shown essary mean actual failure.) sub code. 2005 LEXUS IS300 (RM1140U) Author : Date : 2180...
  • Page 342 *5: It may be stored when the engine key is turned again after engine start. *6: When 210 sec. has passed after pulling out the power supply connector of the master component with the ignition switch in ACC or ON, this code is stored. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 343 Any speaker does not work. Noise Noise occurs Noise produced by vibration or shock while driving. Noise produced when engine starts. The term ”AM” includes LW, MW and SW, and the term ”FW” includes UKW. 2005 LEXUS IS300 (RM1140U) Author : Date : 2182...
  • Page 344 Replace fuse. + B wire harness faulty. Is power supplied to +B terminal of radio assembly? GND faulty. Check if GND (wire harness side) to radio assembly is OK? Radio assembly faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2183...
  • Page 345 Does continuity exist in speaker wire harness? Speaker wire harness faulty. Temporarily install another speaker. Functions OK? Speaker faulty. Hiss noise from speaker? Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. 2005 LEXUS IS300 (RM1140U) Author : Date : 2184...
  • Page 346 Radio assembly faulty. Recheck system after repair. Does continuity exist in speaker wire harness? Speaker wire harness faulty. Temporarily install another speaker? Functions OK? Speaker faulty. Power amplifier faulty. Recheck system after repair. 2005 LEXUS IS300 (RM1140U) Author : Date : 2185...
  • Page 347 Is tape player operating normally? Radio assembly faulty. Speaker faulty. Temporarily install another speaker. Functions OK? Power amplifier faulty. Hiss noise from speaker? Recheck system after repair. Radio assembly faulty. Recheck system after repair. 2005 LEXUS IS300 (RM1140U) Author : Date : 2186...
  • Page 348 Replace the choke coil. Does the condition get better by replacing the choke coil? Does the condition get better by replacing the Replace the antenna cord. antenna cord? Exchange the glass. 2005 LEXUS IS300 (RM1140U) Author : Date : 2187...
  • Page 349 Check if RADIO No.1 fuse is OK? Replace fuse. +B wire harness faulty. Is power supplied to +B terminal of radio assembly? Check if GND (wire harness side) of radio assembly grounded normally? Radio assembly faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2188...
  • Page 350 Is power supplied to ACC terminal of radio assembly? Replace fuse. Check if RADIO No.1 fuse is OK? Is power supplied to +B terminal of radio assembly? +B wire harness faulty. Radio assembly faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2189...
  • Page 351 Is hiss noise produced by non-functioning speaker. Recheck system after repair. Speaker wire harness faulty. Does continuity exist in speaker wire harness? Temporarily install another speaker. Speaker faulty. Function OK? Radio assembly or power amplifier faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2190...
  • Page 352 Function OK if different tape (less than 120 mins.) is inserted? Cassette tape faulty. Is there a foreign object inside tape player? Remove foreign object. Operates normally after cleaning the heads? Head dirty. Radio assembly faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2191...
  • Page 353 Replace fuse. +B wire harness faulty. Is power supplied to +B terminal of radio assembly? Check if GND (wire harness side) of radio assembly GND faulty. grounded normally? Radio assembly faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2192...
  • Page 354 Dose continuity exist in speaker wire harness? Speaker wire harness faulty. Temporarily install another speaker. Speaker faulty. Functions OK? Power amplifier faulty. Hiss noise from speaker? Recheck system after repair. Radio assembly faulty. Recheck system after repair. 2005 LEXUS IS300 (RM1140U) Author : Date : 2193...
  • Page 355 Function OK if different CD inserted? CD faulty. Is radio operating normally? Radio assembly faulty. Is speaker property installed? Install properly. Temporarily install another speaker. Speaker faulty. Functions OK? Radio assembly or power amplifier faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2194...
  • Page 356 Is auto search button of radio operating normally? Check if RADIO No.1 fuse is OK? Replace fuse. Is power supplied to +B terminal of radio assembly? +B wire harness faulty. Radio assembly faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2195...
  • Page 357 ACC wire harness faulty. Is power supplied to +B terminal of radio assembly? +B wire harness faulty. GND faulty. Check if GND (wire harness side) of radio assembly grounded normally? Radio assembly faulty. 2005 LEXUS IS300 (RM1140U) Author : Date : 2196...
  • Page 358 Is there continuity in speaker wire harness? Speaker wire harness faulty. Temporarily install another speaker. Functions OK? Speaker faulty. Hiss noise from speaker? Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. 2005 LEXUS IS300 (RM1140U) Author : Date : 2197...
  • Page 359 Radio assembly faulty. Recheck system after repair. Does continuity exist in speaker wire harness? Speaker wire harness faulty. Speaker faulty. Temporarily install another speaker. Function OK? Power amplifier faulty. Recheck system after repair. 2005 LEXUS IS300 (RM1140U) Author : Date : 2198...
  • Page 360 Does the condition get better by replacing the Pole antenna? Replace the antenna cord. Does the condition get better by replacing the antenna cord. Noise radiates directly to the antenna from the generation source. 2005 LEXUS IS300 (RM1140U) Author : Date : 2199...
  • Page 361 Scratching noise occurs while engine is running, Engine coolant temp. gauge noise. and continues a while even after engine stops. Scraping noise in line with wiper beat. Wiper noise. Other type of noise 2005 LEXUS IS300 (RM1140U) Author : Date : 2200...
  • Page 362 BE-197 BODY ELECTRICAL AUDIO SYSTEM BE2A9-02 LOCATION Tweeter Power Amplifier Radio Assembly Driver Side Junction Block F RADIO No. 2 Fuse Rear Speakers Sedan: Front Speakers I27832 2005 LEXUS IS300 (RM1140U) Author : Date : 2201...
  • Page 363 BE-198 BODY ELECTRICAL AUDIO SYSTEM wagon: Squawker Squawker Rear Speaker Box Woofer Front Speaker I27833 2005 LEXUS IS300 (RM1140U) Author : Date : 2202...
  • Page 364 5 - 7 V (WR-) A16 - Ground Ignition switch ACC Battery voltage (ACC) B1 - Ground Constant Battery voltage (TX+) B2 - Ground Radio power switch ON Battery voltage (CTX+) 2005 LEXUS IS300 (RM1140U) Author : Date : 2203...
  • Page 365 Audio sounding 1 V or below (L-) B18 - Ground Audio sounding 1 V or below (R-) If the circuit is not as specified, inspect the circuits connected to other parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2204...
  • Page 366 B9 - Ground System check mode (TX-) B10 - Ground System check mode (TX+) *: w/ LEXUS navigation system If the circuit is not as specified, inspect the circuits connected to other parts. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 367 INSPECT GLASS IMPRINTED ANTENNA Use same procedure as for ”INSPECT DEFOGGER WIRES” on page BE-102 REPAIR GLASS IMPRINTED ANTENNA Use same procedure as for ”REPAIR DEFOGGER WIRES” on page BE-102 2005 LEXUS IS300 (RM1140U) Author : Date : 2206...
  • Page 368 BE-203 BODY ELECTRICAL ANTENNA ANTENNA BE16N-04 LOCATION Sedan: Pole Antenna Glass Printed Antenna Radio Assembly Pole Antenna Wagon: Radio Assembly Glass Printed Antenna I27834 2005 LEXUS IS300 (RM1140U) Author : Date : 2207...
  • Page 369 BE-204 BODY ELECTRICAL ANTENNA BE2AA-01 COMPONENTS Instrument Panel Assembly Combination Meter Instrument Cluster w/ LEXUS navigation system: Finish Panel Cover Steering Column Upper Cover Horn Combination Switch Assembly Center Cluster Finish Panel Steering Wheel Radio Assembly Steering Column Lower Cover...
  • Page 370 Scuff Plate LH Front Door Opening Trim Weatherstrip LH Rear Door Opening Trim Weatherstrip LH Center Pillar Garnish LWR LH Rear Door Inner Scuff Plate LH Bench Type Rear Seat Back Assembly I23230 2005 LEXUS IS300 (RM1140U) Author : Date : 2209...
  • Page 371 Front Door Opening Trim Weatherstrip LH Center Pillar Garnish LWR LH Rear Seat Rear Door Opening Rear Door Inner Scuff Back Side RH Trim Weatherstrip Rear Seat Plate LH Back Side LH I23231 2005 LEXUS IS300 (RM1140U) Author : Date : 2210...
  • Page 372 REMOVE FRONT PILLAR GARNISH RH REMOVE FRONT PILLAR GARNISH LH DISCONNECT PASSENGER AIRBAG CONNECTOR REMOVE INSTRUMENT PANEL ASSEMBLY REMOVE INSTRUMENT PANEL REINFORCEMENT BRACKET Remove the bolt and nut and pull instrument panel reinforce- ment. I11415 2005 LEXUS IS300 (RM1140U) Author : Date : 2211...
  • Page 373 Remove the 2 nuts and disconnect the connector. Remove the antenna assembly. REMOVE ANTENNA COED Remove the clamp and the antenna cord. REMOVE ANTENNA POLE Turn the antenna pole counterclockwise to remove. I11561 2005 LEXUS IS300 (RM1140U) Author : Date : 2212...
  • Page 374 Wire Harness Side Connector ”B” PS/B Seat Occupant Connector ”A” Detection Sensor 1 2 3 4 5 6 7 8 Ground 9 10 11 1213 14 1516 17 1819 20 I11820 2005 LEXUS IS300 (RM1140U) Author : Date : 2213...
  • Page 375 Wire Harness Side Seat Occupant Connector ”B” PS/B Detection Connector ”A” Sensor 1 2 3 4 5 6 7 8 Ground 9 10 11 1213 14 1516 17 1819 20 I11820 2005 LEXUS IS300 (RM1140U) Author : Date : 2214...
  • Page 376 Locate cause and repair, or recharge battery. body ground? Bellow 10 V Is there battery positive voltage between terminal ACC and Locate cause and repair, or recharge battery. body ground? Adjust or replace clock. 2005 LEXUS IS300 (RM1140U) Author : Date : 2215...
  • Page 377 BE-212 BODY ELECTRICAL CLOCK BE0G1-13 LOCATION A/C Control Assembly F Clock Passenger Side Junction Block F MPX-B Fuse Ignition Switch Driver Side Junction Block F RADIO No. 2 Fuse I27835 2005 LEXUS IS300 (RM1140U) Author : Date : 2216...
  • Page 378 In the condition of (a), bring the original transmitter to with- in 1-inch area around the garage door opener and press the switch. (code transmitting). HINT: When code registration completes correctly, LED (red) blinks in 5.6 Hz cycle. I17842 2005 LEXUS IS300 (RM1140U) Author : Date : 2217...
  • Page 379 HINT: Press the switch until blinking in 6 Hz cycle stops, so that the default code for check is set. 2005 LEXUS IS300 (RM1140U) Author : Date : 2218...
  • Page 380 (Switch at both end) Enter erase mode to erase all 3 channels RELEASE LOAD DEFAULT CLEAR/DEFAULT 10 SEC. 20 SEC. MODE OPERATION LED flashes at a rate of 6 HZ I03488 2005 LEXUS IS300 (RM1140U) Author : Date : 2219...
  • Page 381 BE-216 BODY ELECTRICAL GARAGE DOOR OPENER SYSTEM BE0L7-05 LOCATION Garage Door Opener Switch (in LH side Sun Visor) Sedan: Wagon: Garage Door Opener Switch (in LH side Sun Visor) I27836 2005 LEXUS IS300 (RM1140U) Author : Date : 2220...
  • Page 382 BE-217 BODY ELECTRICAL GARAGE DOOR OPENER SYSTEM BE0L8-02 REMOVAL REMOVE LH SIDE SUN VISOR Remove the 2 screws. Disconnect the garage door opener switch connector. 2005 LEXUS IS300 (RM1140U) Author : Date : 2221...
  • Page 383 Press the switch which an inspection code has been reg- istered for and check that LED (green) of the home link tester lights up. If the LED (green) does not light up, replace the garage door opener. I17843 2005 LEXUS IS300 (RM1140U) Author : Date : 2222...
  • Page 384 Tester connection Condition Specified condition 2 - Ground Always Continuity 1 - Ground Always Battery positive voltage If the circuit is not as specified, inspect the circuits connected to other parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2223...
  • Page 385 BE-220 BODY ELECTRICAL GARAGE DOOR OPENER SYSTEM BE0LA-02 INSTALLATION INSTALL GARAGE DOOR OPENER SWITCH Connect the garage door opener switch connector. Install the 2 screws and the LH side sun visor. 2005 LEXUS IS300 (RM1140U) Author : Date : 2224...

  • Page 386: Engine Immobiliser System

    Security Indicator Registration completion Remove the key. Security Indicator ON (After the last key (sub-key) Will you register the has been registered and re- next key? move the key, the indicator blinks.) 2005 LEXUS IS300 (RM1140U) Author : Date : 2225...
  • Page 387 However, after the registration of the additional master key, as the original master key and the original sub-key is not necessary any more, so erase registra- tion of those key codes. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 388 The registration mode completes when pulling out the key and depressing and releasing the brake pedal once or more within 10 secs. after indicator has been off or 10 sec. have passed. 2005 LEXUS IS300 (RM1140U) Author : Date : 2227...
  • Page 389 10 sec. after in- dicator has been off or 10 sec. have passed. HINT: Please follow the screen of the hand-held tester for more detailed procedure. 2005 LEXUS IS300 (RM1140U) Author : Date : 2228...
  • Page 390 The registration mode completes when pulling out the key and depressing and releasing the brake pedal once or more within 10 sec. after in- dicator has been off or 10 sec. have passed. 2005 LEXUS IS300 (RM1140U) Author : Date : 2229...
  • Page 391 10 sec. after in- dicator has been off or 10 sec. have passed. HINT: Please follow the screen of the hand-held tester for more detailed procedure. 2005 LEXUS IS300 (RM1140U) Author : Date : 2230...
  • Page 392 5. Leave the vehicle more than 20 sec. without any operation. (Key code erased) HINT: If the key cannot be pulled out within 30 sec. from the first brake depression in the step 3, the key code deletion is canceled. 2005 LEXUS IS300 (RM1140U) Author : Date : 2231...
  • Page 393 F When the key cannot be pulled out in the step 3, key code deletion is canceled. (Security indicator is OFF.) F Please follow the screen of the hand-held tester for more detailed procedure. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 394 BE-229 BODY ELECTRICAL ENGINE IMMOBILISER SYSTEM BE02Q-26 LOCATION Driver Side Junction Block F IGN Fuse Transponder Key Coil Transponder Key Amplifier I27837 2005 LEXUS IS300 (RM1140U) Author : Date : 2233...
  • Page 395 BODY ELECTRICAL ENGINE IMMOBILISER SYSTEM BE0G8-10 INSPECTION INSPECTION TRANSPONDER KEY COIL CONTINUITY Check that continuity exists between terminals 1 and 2. If continuity is not as specified, replace the coil. I04266 2005 LEXUS IS300 (RM1140U) Author : Date : 2234...
  • Page 396 BE-231 BODY ELECTRICAL HORN SYSTEM HORN SYSTEM BE0FY-31 LOCATION Engine Room Junction Block F HORN Relay F HORN Fuse Horn Horn Switch I27838 2005 LEXUS IS300 (RM1140U) Author : Date : 2235...
  • Page 397 (-) lead to the horn body and check that the horn blows. If operation is not as specified, replace the horn. INSPECT HORN SWITCH CIRCUIT (See page DI-800 N10342 2005 LEXUS IS300 (RM1140U) Author : Date : 2236...
  • Page 398 1 - 2 Continuity Apply B+ between 3 - 5 Continuity terminals 1 and 2. If continuity is not as specified, replace the relay. INSPECT HORN RELAY CIRCUIT (See page DI-800 I01200 2005 LEXUS IS300 (RM1140U) Author : Date : 2237...
  • Page 399 Protective Tape Screwdriver Remove clips from front or rear using clip remover or pliers. Protective Tape Scraper Remove clips from front or rear using clip remover or pliers. V00005 2005 LEXUS IS300 (RM1140U) Author : Date : 2238...
  • Page 400 Remove rivet by unscrewing the center pin and prying out the rivet shell. Removal Installation Push Screwdriver Clip Remover Small Clip Remover Remove rivet by prying out the pin and then prying out the rivet shell. V30002 2005 LEXUS IS300 (RM1140U) Author : Date : 2239...

  • Page 401: Srs Airbag

    BO0VV-13 PRECAUTION The LEXUS IS300 is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag and side airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during the servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary no- tices in the RS section.

  • Page 402: Front Bumper

    5.4 (55, 48 in.·lbf) Front Bumper Protector License Garnish Front Bumper Cover w/ Fog light: Front Side Marker Light Assembly Fog Light Hole Cover N·m (kgf·cm, ft·lbf) : Specified torque H15124 2005 LEXUS IS300 (RM1140U) Author : Date : 2241...
  • Page 403 Headlight Washer Actuator Assembly Headlight Cleaner Headlight Cleaner Clamp Hose Front Bumper Side Mounting Bracket Front Washer Nozzle Headlight Washer Actuator Assembly Front Bumper Side Mounting Bracket Front Bumper Cover H15125 2005 LEXUS IS300 (RM1140U) Author : Date : 2242...
  • Page 404 Front Bumper Bar Reinforcement Front Side Marker Fog Light Front Bumper Protector License Garnish 5.4 (55, 48 in.·lbf) Front Bumper Cover Front Side Marker Fog Light N·m (kgf·cm, ft·lbf) : Specified torque H19276 2005 LEXUS IS300 (RM1140U) Author : Date : 2243...
  • Page 405 Headlight Washer: Front Washer Nozzle Headlight Washer Actuator Assembly Headlight Washer Actuator Assembly Front Washer Nozzle Front Bumper Mounting Bracket Headlight Cleaner Hose Front Bumper Mounting Bracket Front Bumper Cover H19436 2005 LEXUS IS300 (RM1140U) Author : Date : 2244...
  • Page 406 Side Support Rear Bumper Reinforcement Rear Bumper Side Support Rear Bumper Energy Absorber Rear Bumper Side Side Marker Lamp RH Support No.2 LH Rear Bumper Cover Side Marker Lamp LH H19269 2005 LEXUS IS300 (RM1140U) Author : Date : 2245...
  • Page 407 Rear Bumper Reinforcement Rear Bumper Energy Absorber Rear Bumper Side Support No.2 LH Side Marker Lamp RH Side Marker Lamp LH Reflex Reflector Rear Bumper Cover N·m (kgf·cm, ft·lbf) : Specified torque H19194 2005 LEXUS IS300 (RM1140U) Author : Date : 2246...
  • Page 408 Hood 13 (133, 10 ft·lbf) Hood Hinge Hood Support Rod Clip Hood Support 13 (133, 10 ft·lbf) Hood Insulator Hood Support Clamp Hood Seal N·m (kgf·cm, ft·lbf) : Specified torque H19469 2005 LEXUS IS300 (RM1140U) Author : Date : 2247...
  • Page 409 Using a screwdriver, remove the hood lock bolt cap. HINT: Tape the screwdriver tip before use. Adjust the hood lock by loosening the bolts. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) H10362 2005 LEXUS IS300 (RM1140U) Author : Date : 2248...
  • Page 410 Hood Lock Bolt Cap 8.0 (82, 71 in.·lbf) Lower Finish Panel Hood Lock Control Cable Cover Hood Lock Control Cable Clip Front Fender Liner N·m (kgf·cm, ft·lbf) : Specified torque H19470 2005 LEXUS IS300 (RM1140U) Author : Date : 2249...
  • Page 411 Tape the screwdriver tip before use. Remove the 3 bolts and hood lock. H10362 Using a screwdriver, open the cover, then disconnect the hood lock control cable. HINT: Tape the screwdriver tip before use. H15117 2005 LEXUS IS300 (RM1140U) Author : Date : 2250...
  • Page 412 REMOVE HOOD LOCK CONTROL CABLE Using a screwdriver, disconnect the cable from the clamps. HINT: Tape the screwdriver tip before use. Wire Harness H15118 Pull the cable from the engine room to remove it. H10990 2005 LEXUS IS300 (RM1140U) Author : Date : 2251...
  • Page 413 Push the cable stopper to the clamp. Position to be clamped H10989 Wire Harness H15118 INSTALL HOOD LOCK Connect the hood lock control cable to the hood lock, then close the cover. H15117 2005 LEXUS IS300 (RM1140U) Author : Date : 2252...
  • Page 414 CHECK HOOD LOCK CONTROL FOR PROPER OP- ERATION After checking for proper operation, tighten the 3 bolts to install the lock. 3 Clips Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) H15138 INSTALL FRONT FENDER LINER 2005 LEXUS IS300 (RM1140U) Author : Date : 2253...

  • Page 415: Front Door

    Front Door Belt Moulding Window Regulator Motor Lower Frame Bracket Garnish Inside Handle Service Hole Cover Bezel Door Trim Courtesy Light N·m (kgf·cm, ft·lbf) : Specified torque F Precoated part H21515 2005 LEXUS IS300 (RM1140U) Author : Date : 2254...
  • Page 416 Using a screwdriver, remove the front armrest as shown in the illustration. HINT: Tape the screwdriver tip before use. Clip H10369 REMOVE LOWER FRAME BRACKET GARNISH Remove the lower frame bracket garnish. H10367 2005 LEXUS IS300 (RM1140U) Author : Date : 2255...
  • Page 417 Using a vacuum cleaner, remove the drilled rivet and their dust from the inside of the door. REMOVE INSIDE HANDLE Remove the screw and inside handle, disconnect the 2 cables from the inside handle. H06185 2005 LEXUS IS300 (RM1140U) Author : Date : 2256...
  • Page 418 Open the door glass until the bolts appear in the service hole. Remove the 2 bolts and door glass. NOTICE: Do not damage the door glass. H15120 HINT: Pull the glass upward to remove it. 2005 LEXUS IS300 (RM1140U) Author : Date : 2257...
  • Page 419 Remove the 2 bolts and outside handle with the key cylin- der. Remove the retainer from the outside handle. Remove the bolt, key cylinder and protector from the out- side handle. REMOVE CUSHIONS H10376 2005 LEXUS IS300 (RM1140U) Author : Date : 2258...
  • Page 420 Adjust the striker position by slightly loosening the striker mounting screws, and hitting the striker with a hammer. Tighten the striker mounting screws again. Torque: 23 N·m (235 kgf·cm, 17 ft·lbf) Install the striker cover. N17571 2005 LEXUS IS300 (RM1140U) Author : Date : 2259...
  • Page 421 If only the motor is rotated, reset the motor (See page BE-1 18). HINT: Driver’s side: Never rotate the motor to the down direction mention of the win- dow glass until completing the installation. 2005 LEXUS IS300 (RM1140U) Author : Date : 2260...
  • Page 422 INSTALL NO.2 SERVICE HOLE COVER Install the No.2 service hole cover with the 2 screws. INSTALL FRONT DOOR INSIDE PANEL PLATE Install the front door inside panel plate with the 2 screws. H10467 2005 LEXUS IS300 (RM1140U) Author : Date : 2261...
  • Page 423 Do not tilt the riveter when fastening the rivet to the material to avoid loose fitting. Riveter Do not allow gap spacing between the rivet head and the material. Riveter H02441 2005 LEXUS IS300 (RM1140U) Author : Date : 2262...
  • Page 424 8 Clips H15780 INSTALL LOWER FRAME BRACKET GARNISH Install the lower frame bracket garnish to the door panel. H10367 INSTALL FRONT ARMREST Install the front armrest with the screw. Clip H10369 2005 LEXUS IS300 (RM1140U) Author : Date : 2263...
  • Page 425 FRONT DOOR INSTALL POWER WINDOW SWITCH Connect the connectors. Install the power window switch. INSTALL INSIDE HANDLE BEZEL Install the inside handle bezel with the screw. Close the screw cap. Clip H16412 2005 LEXUS IS300 (RM1140U) Author : Date : 2264...

  • Page 426: Rear Door

    8.0 (82, 71in.·lbf) Window Rear Armrest Switch Door Lock Rear Door Belt Moulding Service Hole Cover Inside Handle Bezel Door Trim N·m (kgf·cm, ft·lbf) : Specified torque F Precoated part H21514 2005 LEXUS IS300 (RM1140U) Author : Date : 2265...
  • Page 427 Tape the screwdriver tip before use. Clip H10380 REMOVE DOOR TRIM Using a screwdriver, disengage the clips, then pull the trim up- ward to remove it. HINT: Tape the screwdriver tip before use. 6 Clips H10381 2005 LEXUS IS300 (RM1140U) Author : Date : 2266...
  • Page 428 H10384 REMOVE DIVISION BAR Remove the 2 bolts and screw. Pull the division bar forward. H10471 Rotate the division bar 90° and pull it upward as shown in the illustration. H10472 2005 LEXUS IS300 (RM1140U) Author : Date : 2267...
  • Page 429 HINT: Remove the door lock through the service hole. Disconnect the connector. H10386 REMOVE OUTSIDE HANDLE Remove the 2 bolts, rear door outside reinforcement extension and outside handle. REMOVE CUSHIONS H15789 2005 LEXUS IS300 (RM1140U) Author : Date : 2268...
  • Page 430 ADJUST DOOR LOCK STRIKER Check that the door fit and door lock linkages are adjusted correctly. H10377 Using a screwdriver, remove the striker cover. HINT: Tape the screwdriver tip before use. BO3880 2005 LEXUS IS300 (RM1140U) Author : Date : 2269...
  • Page 431 Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a hammer. Tighten the striker mounting screws again. Torque: 23 N·m (235 kgf·cm, 17 ft·lbf) Install the striker cover. Z06435 2005 LEXUS IS300 (RM1140U) Author : Date : 2270...
  • Page 432 Connect the 2 links to the outside handle and key cylinder. Install the child protection cover. INSTALL WINDOW REGULATOR HINT: Apply MP grease to the sliding and rotating parts of the window regulator. H10478 2005 LEXUS IS300 (RM1140U) Author : Date : 2271...
  • Page 433 Install the rear door quarter window glass as shown in the illustration. H10474 INSTALL DIVISION BAR Insert the division bar to the door panel, then rotate it 90°. H10473 Install the 2 bolts and screw. INSTALL DOOR GLASS RUN H10471 2005 LEXUS IS300 (RM1140U) Author : Date : 2272...
  • Page 434 Hold the lock knob to the LOCK position by hand, and do not pull the cable while connecting the locking H06185 cable. INSTALL DOOR TRIM Install the door trim to the door panel. 6 Clips H10381 2005 LEXUS IS300 (RM1140U) Author : Date : 2273...
  • Page 435 INSTALL POWER WINDOW SWITCH Connect the connector. Install the power window switch to the door trim. INSTALL DOOR INSIDE HANDLE BEZEL Install the door inside handle bezel with the screw. Close the cap. H10379 2005 LEXUS IS300 (RM1140U) Author : Date : 2274...

  • Page 436: Back Door

    Rear Floor Finish Plate .0 (40, 35 in.·lbf) License Plate Lamp Rear Combination Light License Plate Lamp Back Door Outside Handle Back Door Outside Garnish N·m (kgf·cm, ft·lbf) : Specified torque H19051 2005 LEXUS IS300 (RM1140U) Author : Date : 2275...
  • Page 437 Remove the 3 bolts and rear wiper motor. REMOVE REAR COMBINATION LIGHT Disconnect the connector. Remove the nut and rear combination light. Employ the same manner described above to the other H19059 side. 2005 LEXUS IS300 (RM1140U) Author : Date : 2276...
  • Page 438 Using a screwdriver, remove the rear spoiler cover, then disconnect the connector. HINT: Tape the screwdriver tip before use. REMOVE STOP CENTER LAMP ASSEMBLY Remove the 2 screws and the stop center lamp assembly. 3 Clips H19013 2005 LEXUS IS300 (RM1140U) Author : Date : 2277...
  • Page 439 Using a plastic hammer, tap the back door lock assembly to adjust. NOTICE: H19049 Tap the base for adjustment. ADJUST SIDE MALE STOPPER Adjust the side male stopper by loosening the stopper mounting bolt. H19050 2005 LEXUS IS300 (RM1140U) Author : Date : 2278...
  • Page 440 INSTALL REAR FLOOR FINISH PLATE Install the rear floor finish plate with the 3 clips. Install the 2 rope hook assemblies with the 2 bolts. INSTALL REAR COMBINATION LIGHTS 6 Clips H19026 2005 LEXUS IS300 (RM1140U) Author : Date : 2279...
  • Page 441 Install the back door trim cover to the body. 2 Clips H19055 INSTALL BACK DOOR TRIM BOARD UPPER Install the back door trim board upper to the body. 4 Clips H19052 2005 LEXUS IS300 (RM1140U) Author : Date : 2280...
  • Page 442 Install the back door stay to the body with the bolt. Torque: 19.5 N·m (199 kgf·cm, 14 ft.·lbf) Install the back door stay to the back door panel with the bolts. Torque: 22 N·m (224 kgf·cm, 16 ft.·lbf) 2005 LEXUS IS300 (RM1140U) Author : Date : 2281...
  • Page 443 Outside Rear View Mirror Mirror Front No.2 Speaker 8.0 (82, 71 in.·lbf) Lower Frame Bracket Garnish Inside Handle Bezel Front Armrest Courtesy Light Power Window Switch N·m (kgf·cm, ft·lbf) : Specified torque H15122 2005 LEXUS IS300 (RM1140U) Author : Date : 2282...
  • Page 444 Using a screwdriver, remove the front armrest as shown in the illustration. HINT: Tape the screwdriver tip before use. Clip H10369 REMOVE LOWER FRAME BRACKET GARNISH Remove the lower frame bracket garnish. H10367 2005 LEXUS IS300 (RM1140U) Author : Date : 2283...
  • Page 445 REMOVE FRONT NO.2 SPEAKER Disconnect the connector. Remove the 2 bolts and front No.2 speaker. REMOVE OUTSIDE REAR VIEW MIRROR Disconnect the connector. Remove the bolt and outside rear view mirror. H10462 2005 LEXUS IS300 (RM1140U) Author : Date : 2284...
  • Page 446 Fit the claws (A) in the holes and set the mirror to the mir- Claw (B) ror body. Push the mirror to fix it by fitting the claws (B) in the holes. Claw (A) H02941 2005 LEXUS IS300 (RM1140U) Author : Date : 2285...
  • Page 447 8 Clips H15780 INSTALL LOWER FRAME BRACKET GARNISH Install the lower frame bracket garnish to the door panel. H10367 INSTALL FRONT ARMREST Install the front armrest with the screw. Clip H10369 2005 LEXUS IS300 (RM1140U) Author : Date : 2286...
  • Page 448 OUTSIDE REAR VIEW MIRROR INSTALL POWER WINDOW SWITCH Connect the connectors. Install the power window switch. INSTALL INSIDE HANDLE BEZEL Install the inside handle bezel with the screws. Close the screw cap. Clip H16412 2005 LEXUS IS300 (RM1140U) Author : Date : 2287...
  • Page 449 Rear Light Rear Light Luggage Compartment Luggage Compartment Trim Rear Cover Luggage Door Lock Door Lock Opener Assembly Door Lock Striker 5.5 (56, 49 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque H15754 2005 LEXUS IS300 (RM1140U) Author : Date : 2288...
  • Page 450 Remove the 4 clips and luggage compartment trim side cover. Employ the same manner described above to the other side. REMOVE LUGGAGE COMPARTMENT FLOOR MAT Remove the 3 clips and luggage compartment floor mat. H10524 2005 LEXUS IS300 (RM1140U) Author : Date : 2289...
  • Page 451 Be careful not to damage the body. H10485 REMOVE ROOF SIDE INNER GARNISH Using a screwdriver, remove the roof side inner garnish. Employ the same manner described above to the other side. 5 Clips H15730 2005 LEXUS IS300 (RM1140U) Author : Date : 2290...
  • Page 452 Push down SST to pull the luggage compartment door hinge from the torsion bar. Slowly lift SST, and remove the torsion bar from the tor- sion bar bracket with SST. H10390 2005 LEXUS IS300 (RM1140U) Author : Date : 2291...
  • Page 453 Orange REMOVE LUGGAGE COMPARTMENT DOOR HINGE Remove the 2 bolts. Remove the hinge. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) Employ the same manner described above to the other side. H01931 2005 LEXUS IS300 (RM1140U) Author : Date : 2292...
  • Page 454 Remove the screw and luggage door lock opener assem- H10392 bly. REMOVE LUGGAGE COMPARTMENT DOOR LOCK Disconnect the connector. Remove the 2 bolts and luggage compartment door lock. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) H10529 2005 LEXUS IS300 (RM1140U) Author : Date : 2293...
  • Page 455 Using a screwdriver, remove the rear floor finish plate. HINT: Tape the screwdriver tip before use. 4 Clips H10359 Using a hammer and brass bar, tap the striker to adjust it. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) H10532 2005 LEXUS IS300 (RM1140U) Author : Date : 2294...
  • Page 456 BO-58 BODY LUGGAGE COMPARTMENT DOOR AND HINGE BO0XF-02 REASSEMBLY The reassembly procedures are the disassembly procedures in reverse order (See page BO-56 2005 LEXUS IS300 (RM1140U) Author : Date : 2295...
  • Page 457 BO-59 BODY LUGGAGE COMPARTMENT DOOR AND HINGE BO0XG-04 INSTALLATION The installation procedures are the removal procedures in reverse order (See page BO-52 2005 LEXUS IS300 (RM1140U) Author : Date : 2296...
  • Page 458 Floor Hook Fuel Tank Cap Hanger Fuel Lid Opening Spring Fuel Filler Opening Lid Fuel Filler Shield Fuel Tank Ring Fuel Filler Ring Opening Lid Lock Retainer Fuel Lid Control Retainer H15790 2005 LEXUS IS300 (RM1140U) Author : Date : 2297...
  • Page 459 REMOVE FUEL LID LOCK CONTROL Rotate the fuel lid lock right to disengage the lock, then pull it out. H10533 Rotate the retainer left to disengage the lock, then pull it out. H11537 2005 LEXUS IS300 (RM1140U) Author : Date : 2298...
  • Page 460 HINT: Tape the screwdriver tip before use. H10536 REMOVE FUEL FILLER OPENING LID Using a drill, drill out the rivet heads. Remove the fuel filler opening lid. H10537 2005 LEXUS IS300 (RM1140U) Author : Date : 2299...
  • Page 461 INSTALL FUEL FILLER OPENING SPRING Riveter H02442 INSTALL FUEL FILLER OPENING LID LOCK RETAIN- Install the fuel filler opening lid lock retainer with the nut. INSTALL FUEL TANK CAP HANGER H15792 2005 LEXUS IS300 (RM1140U) Author : Date : 2300...
  • Page 462 INSTALL LUGGAGE COMPARTMENT FLOOR HOOKS H10524 INSTALL LUGGAGE COMPARTMENT TRIM REAR COVER Install the luggage compartment trim rear cover with the 5 clips. INSTALL LUGGAGE COMPARTMENT TRIM NO.2 COVER 4 Clips H10359 2005 LEXUS IS300 (RM1140U) Author : Date : 2301...
  • Page 463 Fuel Tank Cap Hanger Fuel Filler Shield Fuel Filler Opening Lid Ring Fuel Tank Cap Fuel Filler Opening Lid Lock Retainer Retainer Fuel Lid Control : Specified torque N·m (kgf·cm, ft·lbf) H19476 2005 LEXUS IS300 (RM1140U) Author : Date : 2302...
  • Page 464 Tape the screwdriver tip before use. :5 Clips :2 Clips H19365 REMOVE ROOF SIDE INNER GARNISH Using a screwdriver, remove the roof side inner garnish. HINT: Tape the screwdriver tip before use. :7 Clips H19188 2005 LEXUS IS300 (RM1140U) Author : Date : 2303...
  • Page 465 REMOVE FUEL LID OPENING SPRING Insert a screwdriver between the spring and fuel filler opening lid to remove the spring as shown in the illustration. HINT: Tape the screwdriver tip before use. H10536 2005 LEXUS IS300 (RM1140U) Author : Date : 2304...
  • Page 466 BO-68 BODY FUEL LID (Wagon) REMOVE FUEL FILLER OPENING LID Using a drill, drill out the rivet heads. Remove the fuel filler opening lid. H10537 2005 LEXUS IS300 (RM1140U) Author : Date : 2305...
  • Page 467 INSTALL FUEL FILLER OPENING SPRING Riveter H02442 INSTALL FUEL FILLER OPENING LID LOCK RETAIN- Install the fuel filler opening lid lock retainer with the nut. INSTALL FUEL TANK CAP HANGER H10535 2005 LEXUS IS300 (RM1140U) Author : Date : 2306...
  • Page 468 Install the deck trim side panel assembly then connect the connector. Install the screw, bolt and clip. Install the 2 floor hooks with the 2 bolts. :5 Clips :2 Clips H19365 2005 LEXUS IS300 (RM1140U) Author : Date : 2307...
  • Page 469 INSTALL REAR SEAT FLOOR BOARD NO. 4 Install the rear floor board with the 2 bolts. Install the seat back board carpets. INSTALL SIDE SEAT BACK ASSEMBLY (See page BO-204 INSTALL REAR SEAT CUSHION (See page BO-204 2005 LEXUS IS300 (RM1140U) Author : Date : 2308...

  • Page 470: Front Wiper And Washer

    Cowl Top Ventilator Louver 5.5 (56, 49 in.·lbf) 5.5 (56, 49 in.·lbf) Hood to Cowl Top Seal 5.5 (56, 49 in.·lbf) Wiper Link 5.4 (55, 48 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque H15723 2005 LEXUS IS300 (RM1140U) Author : Date : 2309...
  • Page 471 Tape the screwdriver tip before use. H10542 Remove the nut. Matchmarks Place the matchmarks on the wiper link and motor. Remove the 3 screws and wiper motor from the wiper link. H10943 2005 LEXUS IS300 (RM1140U) Author : Date : 2310...
  • Page 472 Remove the hood insulator. Disconnect the washer hose. Using a screwdriver, remove the washer nozzle. HINT: Tape the screwdriver tip before use. Employ the same manner described above to the other side. H03556 2005 LEXUS IS300 (RM1140U) Author : Date : 2311...
  • Page 473 Check if the outer point where the washer fluid hits the windshield is within the range of the wiping pattern (the area of the glass which is wiped by the wiper blades). 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 474 Using a tool like the one shown in the illustration, change the direction of the nozzle hole to adjust the point where washer fluid hits the windshield. 0.6 - 0.65 mm (0.0236 - 0.0256 in.) BE3367 2005 LEXUS IS300 (RM1140U) Author : Date : 2313...
  • Page 475 Adjust the installation positions of the wiper arms to the positions as shown in the illustration. A: 20.0 mm (0.787 in.) B: 28.0 mm (1.102 in.) Torque the nuts. Torque: 26 N·m (265 kgf·cm, 19 ft·lbf) H15724 2005 LEXUS IS300 (RM1140U) Author : Date : 2314...
  • Page 476 5.5 (56, 49 in.·lbf) Wiper Arm 12 (122, 9) Washer Nozzle Rear Wiper Motor 5.5 (56, 49 in.·lbf) Back Door Handle Back Door Trim Board N·m (kgf·cm, ft·lbf) : Specified torque H19062 2005 LEXUS IS300 (RM1140U) Author : Date : 2315...
  • Page 477 H19208 REMOVE REAR WIPER MOTOR Remove the nut and washer on the outer side of the back door panel. Disconnect the connector. Remove the 3 bolts and rear wiper motor. H19059 2005 LEXUS IS300 (RM1140U) Author : Date : 2316...
  • Page 478 Check if the lower point where the washer fluid hits the back door glass is within the range of the wiping pattern Surge area (the are of the glass which is wiped by the wiper blades). Ceramic Line H19061 2005 LEXUS IS300 (RM1140U) Author : Date : 2317...
  • Page 479 Using a tool like the one shown in the illustration, change the direction of the nozzle hole to adjust the point where washer fluid hits the back door glass. 0.9 - 0.95 mm (0.035 - 0.037 in.) BE3367 2005 LEXUS IS300 (RM1140U) Author : Date : 2318...
  • Page 480 INSTALL BACK DOOR TRIM COVERS Install the trim covers to the body. 2 Clips H19055 INSTALL BACK DOOR TRIM BOARD UPPER Install the back door trim board upper to the body. 4 Clips H19052 2005 LEXUS IS300 (RM1140U) Author : Date : 2319...
  • Page 481 BO-83 BODY BODY OUTSIDE MOULDING BODY OUTSIDE MOULDING BO229-05 COMPONENTS Rear Door Outside Moulding Front Door Outside Moulding Front Fender Outside Moulding H15794 2005 LEXUS IS300 (RM1140U) Author : Date : 2320...
  • Page 482 Cut the adhesive tape by pulling the piano wire as shown N18321 in the illustration. NOTICE: If reusing the moulding, take care not to damage the moulding. Do not damage the body. Remove the moulding. 2005 LEXUS IS300 (RM1140U) Author : Date : 2321...
  • Page 483 Align the bosses with their corresponding holes in the body, and press firmly on the moulding. NOTICE: Do not apply excessive force on to the moulding, but steady pressure with thumbs. 2005 LEXUS IS300 (RM1140U) Author : Date : 2322...
  • Page 484 BO-86 BODY ROOF DRIP SIDE FINISH MOULDING (Sedan) ROOF DRIP SIDE FINISH MOULDING (Sedan) BO4DF-01 COMPONENTS Roof Drip Side Finish Moulding H10544 2005 LEXUS IS300 (RM1140U) Author : Date : 2323...
  • Page 485 REMOVE MOULDING AND ADHESIVE Pull off the moulding by cutting the adhesive with a knife at the front and rear ends. Remove the moulding. NOTICE: Do not damage the body with the knife. N18626 2005 LEXUS IS300 (RM1140U) Author : Date : 2324...
  • Page 486 A: 35 mm (1.38 in.) NOTICE: H10545 Let the primer coating dry for 3 minutes or more. Do not coat the adhesive. Do not keep any of the opened Primer M for later use. 2005 LEXUS IS300 (RM1140U) Author : Date : 2325...
  • Page 487 Temperature Minimum time prior to driving the vehicle 35 °C (95 °F) 1.5 hours 20 °C (68 °F) 5 hours 5 °C (41 °F) 24 hours 2005 LEXUS IS300 (RM1140U) Author : Date : 2326...
  • Page 488 ROOF DRIP SIDE FINISH CENTER MOULDING (Wagon) ROOF DRIP SIDE FINISH CENTER MOULDING (Wagon) BO4DI-01 COMPONENTS Roof Drip Side Finish Moulding Clip Roof Drip Side Finish Moulding Center Roof Drip Side Finish Moulding Clip H19075 2005 LEXUS IS300 (RM1140U) Author : Date : 2327...
  • Page 489 NOTICE: Do not remove the clips. H19076 In case that the clips are damaged or removed acci- dentally, replace them with new ones. 2005 LEXUS IS300 (RM1140U) Author : Date : 2328...
  • Page 490 The installation of the moulding should be carried out 30 minutes or more after press-fitting the clips. H19077 HINT: Initial hardening time: 30 minutes Perfect hardening time: 24 hours INSTALL MOULDING 2005 LEXUS IS300 (RM1140U) Author : Date : 2329...
  • Page 491 Front Door Opening Trim 26 (265, 19) Windshield Wiper Arm Head Cover Wiper Arm 26 (265, 19) Wiper Arm Cowl Top Ventilator Louver N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part H19446 2005 LEXUS IS300 (RM1140U) Author : Date : 2330...
  • Page 492 Remove the 2 screws and the map light assembly. Disconnect the connectors. REMOVE SUN VISORS Remove the 2 screws and sun visor, then disconnect the connector. Employ the same manner described above to the other H10445 side. 2005 LEXUS IS300 (RM1140U) Author : Date : 2331...
  • Page 493 REMOVE WINDSHIELD OUTSIDE MOULDING Using a knife, cut off the moulding as shown in the illustra- tion. NOTICE: Do not damage the body with the knife. Remove the remaining moulding. H10406 2005 LEXUS IS300 (RM1140U) Author : Date : 2332...
  • Page 494 Apply protective tape to the outer surface to keep the surface from being scratched. BO1689 Remove the glass. NOTICE: Leave as much of the adhesive on the body as possible when cutting off the glass. 2005 LEXUS IS300 (RM1140U) Author : Date : 2333...
  • Page 495 Attach new stoppers to the body with the notches on the body aligned with the stoppers as shown in the illustra- H10503 tion. HINT: Make sure that the stoppers are installed in the correct direc- tion. 2005 LEXUS IS300 (RM1140U) Author : Date : 2334...
  • Page 496 CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black-col- ored area around the entire glass rim. NOTICE: Do not touch the glass face after cleaning it. BO4421 2005 LEXUS IS300 (RM1140U) Author : Date : 2335...
  • Page 497 Load the cartridge into the sealer gun. Coat the glass with adhesive as shown in the illustration. A: 12.5 mm (0.492 in.) B: 8.0 mm (0.315 in.) c - c Adhesive H10550 2005 LEXUS IS300 (RM1140U) Author : Date : 2336...
  • Page 498 5°C (41°F) 24 hours APPLY ADHESIVE TO MOULDING INSTALLATION AREA Apply adhesive to the moulding installation area between the glass and the body. Part No. 08833-00030 or equivalent Adhesive Adhesive BO3671 2005 LEXUS IS300 (RM1140U) Author : Date : 2337...
  • Page 499 Turn the stay part of the mirror clockwise so that the stay comes to the original position, and then install the mirror assembly. Claw w/ Electro chromic inner mirror: Base Connect the inner rear view mirror connector. H19185 2005 LEXUS IS300 (RM1140U) Author : Date : 2338...
  • Page 500 Install the front pillar garnish to the body. Install the bolt. Install the front pillar garnish cover. Employ the same manner described above to the other Clip side. H19199 INSTALL FRONT PART OF FRONT DOOR OPENING TRIMS 2005 LEXUS IS300 (RM1140U) Author : Date : 2339...
  • Page 501 Deck Floor Box Front Roof Side Inner Garnish Rear Door Weatherstrip Quarter Window Assembly Floor Hook Rear Door Inside Scuff Plate Deck Trim Side Panel Assembly : Specified torque N·m (kgf·cm, ft·lbf) H19475 2005 LEXUS IS300 (RM1140U) Author : Date : 2340...
  • Page 502 HINT: Tape the screwdriver tip before use. Disconnect the connector. Disassemble the accessory socket from the socket cover. H19431 2005 LEXUS IS300 (RM1140U) Author : Date : 2341...
  • Page 503 Disconnect the connector. Moulding b - b a - a Moulding Moulding Moulding c - c g - g Moulding f - f Moulding e - e d - d Moulding Moulding H19027 2005 LEXUS IS300 (RM1140U) Author : Date : 2342...
  • Page 504 Remove the glass. NOTICE: Leave as much of the adhesive on the body as possible when cutting off the glass. Protective Tape H19030 2005 LEXUS IS300 (RM1140U) Author : Date : 2343...
  • Page 505 NOTICE: Let the primer coating dry for 3 minutes or more. Do not keep any of the opened Primer G for later use. 2005 LEXUS IS300 (RM1140U) Author : Date : 2344...
  • Page 506 Load the cartridge into the sealer gun. Coat the glass with adhesive as shown in the illustration on the following page. Adhesive height: 12.5 mm (0.492 in.) Adhesive width: 8.0 mm (0.315 in.) 2005 LEXUS IS300 (RM1140U) Author : Date : 2345...
  • Page 507 5 hours 5°C (41°F) 24 hours INSPECT FOR LEAK AND REPAIR Conduct a leak test after the hardening time has elapsed. Seal any leak with sealant. Part No. 08833-00030 or equivalent. 2005 LEXUS IS300 (RM1140U) Author : Date : 2346...
  • Page 508 Install the 2 tether anchor brackets with the 2 bolts. Torque: 21 N·m (214 kgf·cm, 15ft·lbf) Install the restraint seat tether anchor cover. install the 2 rope hook assemblies with the 2 bolts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2347...
  • Page 509 BO-1 11 BODY QUARTER WINDOW GLASS INSTALL REAR SEAT FLOOR BOARD NO. 4 Install the rear floor board with the 2 bolts. 7 Clips H19035 2005 LEXUS IS300 (RM1140U) Author : Date : 2348...
  • Page 510 Package Tray Trim Panel F Back Window Outside Moulding Roof Side Inner Garnish High-mounted Stop Light Rear Seat Cushion Rear Seatback 18(184,13) N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part H10411 2005 LEXUS IS300 (RM1140U) Author : Date : 2349...
  • Page 511 REMOVE BACK WINDOW OUTSIDE MOULDING Using a knife, cut off the moulding as shown in the illustra- tion. NOTICE: Do not damage the body with the knife. Remove the remaining moulding. H10412 2005 LEXUS IS300 (RM1140U) Author : Date : 2350...
  • Page 512 Do not damage the glass stoppers. H07610 Disengage the stoppers, then remove the glass. NOTICE: Leave as much of the adhesive on the body as possible when cutting off the glass. H10413 2005 LEXUS IS300 (RM1140U) Author : Date : 2351...
  • Page 513 H10503 tion. INSTALL NEW NO.2 STOPPERS Attach new stoppers to the glass with the ceramic notches on the glass aligned with the stoppers as shown in the illustration. Stopper H10408 2005 LEXUS IS300 (RM1140U) Author : Date : 2352...
  • Page 514 Let the primer coating dry for 3 minutes or more. Do not coat Primer M to the adhesive. Primer M Do not keep any of the opened Primer M for later use. Adhesive H02865 2005 LEXUS IS300 (RM1140U) Author : Date : 2353...
  • Page 515 A: 12.5 mm (0.492 in.) B: 8.0 mm (0.315 in.) Adhesive H07651 INSTALL GLASS Position the glass so that the reference marks are lined up, and press in gently along the rim. H10505 2005 LEXUS IS300 (RM1140U) Author : Date : 2354...
  • Page 516 Employ the same manner described above to the other side. INSTALL UPPER PART OF REAR DOOR OPENING TRIMS INSTALL REAR SEATBACK (See page BO-201 INSTALL REAR SEAT CUSHION (See page BO-201 5 Clips H15730 2005 LEXUS IS300 (RM1140U) Author : Date : 2355...
  • Page 517 5.5 (56, 49 in.·lbf) Rear Wiper Motor Back Door Handle Wiper Arm 12 (122, 9) 5.5 (56, 49 in.·lbf) Back Door Trim Cover Back Door Trim Board : Specified torque N·m (kgf·cm, ft·lbf) H19014 2005 LEXUS IS300 (RM1140U) Author : Date : 2356...
  • Page 518 Remove the nut and rear wiper arm. H19208 REMOVE REAR WIPER MOTOR Remove the nut and washer on the outer side of back door panel. Disconnect the connector. Remove the 3 bolts and rear wiper motor. H19059 2005 LEXUS IS300 (RM1140U) Author : Date : 2357...
  • Page 519 NOTICE: Do not damage the glass retainers. Remove the glass. NOTICE: Leave as much of the adhesive on the body as possible when cutting off the glass. Protective Tape H19018 2005 LEXUS IS300 (RM1140U) Author : Date : 2358...
  • Page 520 Let the primer coating dry for 3 minutes or more. Do not coat Primer M to the adhesive. Primer M Do not keep any of the opened Primer M for later use. Adhesive H02865 2005 LEXUS IS300 (RM1140U) Author : Date : 2359...
  • Page 521 Position the glass so that the reference marks are lined up, and press in gently along the rim. Using a spatula, apply adhesive on the glass rim. Use a scraper to remove any excess or protruding adhe- sive. H19024 2005 LEXUS IS300 (RM1140U) Author : Date : 2360...
  • Page 522 Align the machmarks on the wiper arm and wiper motor. Install the rear wiper arm with the nut. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) Install the wiper arm cover. H19208 2005 LEXUS IS300 (RM1140U) Author : Date : 2361...
  • Page 523 INSTALL BACK DOOR TRIM COVERS Install the trim cover to the body. 2 Clips H19055 INSTALL BACK DOOR TRIM BOARD UPPER Install the back door trim board upper to the body. 4 Clips H19052 2005 LEXUS IS300 (RM1140U) Author : Date : 2362...

  • Page 524: Sliding Roof

    0 + 1.0 mm (0 + 0.039 in.) Side end: 0 ± 1.5 mm (0 ± 0.059 in.) Rear end: 0 - 1.0 mm (0 - 0.039 in.) 0 + 2.0 mm (0 + 0.079 in.) 2005 LEXUS IS300 (RM1140U) Author : Date : 2363...
  • Page 525 Guide Rail Stopper Sliding Roof Rail 5.5 (56, 49 in.·lbf) Rear Frame Sliding Roof Bracket Sliding Roof Bracket Sliding Roof Bracket 5.5 (56, 49 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque H10510 2005 LEXUS IS300 (RM1140U) Author : Date : 2364...
  • Page 526 Point Mark the illustration. NOTICE: At the time of installation, if the sliding roof position and drive gear fully closed position are not matched, the sliding roof does not operate normally. H07727 2005 LEXUS IS300 (RM1140U) Author : Date : 2365...
  • Page 527 Disconnect the 4 drain hoses from the housing. Disengage the wire harness clamps. Remove the 6 nuts, then remove the housing as shown H10509 in the illustration. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) H10511 2005 LEXUS IS300 (RM1140U) Author : Date : 2366...
  • Page 528 Adjust the drive cable at the closed and tilted position. Slide the cable forward or backward to align the 2 marks as shown in the illustration. Slide the cable to the forefront with fingers. REMOVE ROOF WIND DEFLECTOR PANEL H10515 2005 LEXUS IS300 (RM1140U) Author : Date : 2367...
  • Page 529 Remove the 2 screws and guide block. Employ the same manner described above to the other side. REMOVE CUSHIONS H10516 REMOVE SLIDING ROOF HOUSING Remove the 6 screws and sliding roof housing. N21522 2005 LEXUS IS300 (RM1140U) Author : Date : 2368...
  • Page 530 Remove the drive gear with sliding roof fully closed. BO3396 Adjust by sliding the cable forward or rearward to align the 2 marks as shown in the illustration. Install the drive gear and sliding roof glass. H10515 2005 LEXUS IS300 (RM1140U) Author : Date : 2369...
  • Page 531 BO-133 BODY SLIDING ROOF BO22O-03 REASSEMBLY The reassembly procedures are the disassembly procedures in reverse order (See page BO-130 2005 LEXUS IS300 (RM1140U) Author : Date : 2370...
  • Page 532 BO-134 BODY SLIDING ROOF BO0M7-04 INSTALLATION The installation procedures are the removal procedures in reverse order (See page BO-128 2005 LEXUS IS300 (RM1140U) Author : Date : 2371...

  • Page 533: Instrument Panel

    20 (205, 15) Column Upper Cover Steering Wheel 35 (360, 26) Cover Combination Switch Center Cluster Finish Panel w/ LEXUS Navigation System Column Lower Cover Cover Lower Finish Panel A/C Control with Radio Receiver Assembly Center Cluster Finish Panel : Specified torque N·m (kgf·cm, ft·lbf)
  • Page 534 Box Side No. 1 Panel Box Side No. 2 Panel Console Box 30 (306, 22) Cover Rear Console Box Console Box Rear Rear Console Armrest Hinge : Specified torque N·m (kgf·cm, ft·lbf) H22779 2005 LEXUS IS300 (RM1140U) Author : Date : 2373...
  • Page 535 No. 2 Heater to Register Duct No. 1 Pin Solar Sensor Auto Light Control Sensor No. 1 Pin Instrument Side Panel No. 1 Register Instrument Panel Center Bracket No. 2 Register H19464 2005 LEXUS IS300 (RM1140U) Author : Date : 2374...
  • Page 536 ø = 5 ø = 5 ø = 5 (0.20) (0.20) (0.20) L = 14 L = 16 L = 16 (0.55) (0.63) (0.63) ø = 8 ø = 6 (0.31) (0.24) H11337 2005 LEXUS IS300 (RM1140U) Author : Date : 2375...
  • Page 537 Remove the 2 screws. Using a screwdriver, disengage the 4 clips and remove the center cluster finish panel. HINT: Tape the screwdriver tip before use. w/ LEXUS navigation system: Disconnect the connectors. 4 Clips H22782 REMOVE LOWER CENTER CLUSTER FINISH PANEL Using a screwdriver, disengage the 2 clips and remove the lower center cluster finish panel.
  • Page 538 H15133 w/o Arm rest: REMOVE CONSOLE BOX Remove the 6 screws. w/o LEXUS navigation system: Pull the console box rearward to remove it. w/ LEXUS navigation system: Pull the console box rearward to remove it, then discon- nect the connector.
  • Page 539 H22935 Remove the console box cover rear. H22934 Remove the 6 screws. w/o LEXUS navigation system: Pull the console box rearward to remove it. w/ LEXUS navigation system: Pull the console box rearward to remove it, then discon- nect the connector.
  • Page 540 Using a screwdriver, disengage the 4 clips and remove the cluster finish panel. HINT: Tape the screwdriver tip before use. 4 Clips H15715 REMOVE COMBINATION METER Remove the 3 screws and combination meter. Disconnect the connector. H15716 2005 LEXUS IS300 (RM1140U) Author : Date : 2379...
  • Page 541 Torque: 9.8 N·m (100 kgf·cm, 87in.·lbf) Clip H19277 Cover the airbag with protective cover as shown in the il- lustration.. REMOVE FRONT PILLAR GARNISH RH HINT: Use the same procedures described for the LH side. H19278 2005 LEXUS IS300 (RM1140U) Author : Date : 2380...
  • Page 542 Disengage the wire harness clamps. Remove the 3 bolts, 2 screws and 2 nuts. Pull the instrument panel rearward to remove it. NOTICE: Be careful not to damage the instrument panel and wire harness H15720 2005 LEXUS IS300 (RM1140U) Author : Date : 2381...
  • Page 543 <F> <D> <E> No. 2 Mounting Bracket <B> <B> <E> <C> Lower Molding <A> Bracket LH Lower Pad Insert No. 1 Brace Panel to Floor Brace No. 1 Mounting Bracket H23169 2005 LEXUS IS300 (RM1140U) Author : Date : 2382...
  • Page 544 REMOVE NO. 2 INSTRUMENT PANEL WIRE Disconnect the connectors. Disengage the wire harness clamps and remove the instrument panel wire. REMOVE SOLAR SENSOR REMOVE LIGHT CONTROL SWITCH SENSOR AND HOLE COVER H10436 2005 LEXUS IS300 (RM1140U) Author : Date : 2383...
  • Page 545 Using a heat light, heat the end pad between 20 to 30°C H15722 (68 to 86°F). NOTICE: Do not heat the end pad excessively. Remove the end pad. HINT: When replacing the end pad, use a new pad. 2005 LEXUS IS300 (RM1140U) Author : Date : 2384...
  • Page 546 BO-149 BODY INSTRUMENT PANEL BO2CX-03 INSTALLATION The installation procedures are the removal procedures in reverse order (see page BO-139 2005 LEXUS IS300 (RM1140U) Author : Date : 2386...
  • Page 547 Compartment Door Shift Lever w/ Armrest: Knob Box Side Console Box No.2 Panel Upper Console Panel Console Box Console Box Cover Rear Floor Carpet : Specified torque N·m (kgf·cm, ft·lbf) H19068 2005 LEXUS IS300 (RM1140U) Author : Date : 2387...
  • Page 548 Remove the clip and cowl side trim board. Employ the same manner described above to the other side. REMOVE FRONT DOOR OPENING TRIMS REMOVE REAR DOOR OPENING TRIMS REMOVE FRONT SEAT OUTER BELT FLOOR AN- CHORS H15718 2005 LEXUS IS300 (RM1140U) Author : Date : 2388...
  • Page 549 H15133 w/o Arm Rest: REMOVE CONSOLE BOX Remove the 6 screws. w/o LEXUS navigation system: Pull the console box rearward to remove it. w/ LEXUS navigation system: Pull the console box rearward to remove it, then discon- nect the connector.
  • Page 550 Remove the 2 bolts and console compartment door. Remove the console box cover rear. Remove the 6 screws. H19279 w/o LEXUS navigation system: Pull the console box rearward to remove it. w/ LEXUS navigation system: Pull the console box rearward to remove it, then discon- nect the connector.
  • Page 551 BO-154 BODY FLOOR CARPET BO0WK-03 INSTALLATION The installation procedures are the removal procedures in reverse order (See page BO-151 2005 LEXUS IS300 (RM1140U) Author : Date : 2391...
  • Page 552 Front Door Opening Trim Rear Door Opening Trim Cowl Side Trim Board Rear Door Inside Scuff Plate Center Pillar Lower Garnish Front Door Inside Scuff Plate : Specified torque N·m (kgf·cm, ft·lbf) H19202 2005 LEXUS IS300 (RM1140U) Author : Date : 2392...
  • Page 553 REMOVE CENTER PILLAR LOWER GARNISH Using a screwdriver, remove the center pillar lower gar- nish. HINT: Tape the screwdriver tip before use. Employ the same manner described above to the other side. 4 Clips H15727 2005 LEXUS IS300 (RM1140U) Author : Date : 2393...
  • Page 554 Remove the bolt. Using a screwdriver, remove the front pillar garnish. Clip H19277 Remove the bolt. Pack the airbag with protection cover. Employ the same manner described above to the other side. H19278 2005 LEXUS IS300 (RM1140U) Author : Date : 2394...
  • Page 555 Remove the mirror assembly by turning the stay part of the mirror counterclockwise. REMOVE ASSIST GRIPS Using a screwdriver, remove the caps. HINT: Tape the screwdriver tip before use. Remove the 6 bolts and 3 assist grips. H19184 2005 LEXUS IS300 (RM1140U) Author : Date : 2395...
  • Page 556 Remove the 4 screws and pull the sun visors downward. Disconnect the connectors. REMOVE SUN VISOR HOLDERS Remove the 2 screws and 2 holders. REMOVE ROOF HEADLINING Remove the 2 clips. Pull the roof headlining downward to remove it. H10554 2005 LEXUS IS300 (RM1140U) Author : Date : 2396...
  • Page 557 BO-160 BODY ROOF HEADLINING (Sedan) BO4DW-02 INSTALLATION The installation procedures are the removal procedures in reverse order (See page BO-156 2005 LEXUS IS300 (RM1140U) Author : Date : 2397...
  • Page 558 Front Pillar Garnish Deck Trim Side Panel Assembly Rear Door Center Pillar Cowl Side Trim Board Inside Scuff Plate Lower Garnish : Specified torque N·m (kgf·cm, ft·lbf) Front Door Inside Scuff Plate H19190 2005 LEXUS IS300 (RM1140U) Author : Date : 2398...
  • Page 559 Assist Grip Cover Assist Grip Cover Map Light Assembly Sun Visor Cover Room Light Assembly Assist Grip Inner Rear View Mirror Shoulder Belt Anchor Cover Upper Lens Sun Visor Holder Sun Visor H19082 2005 LEXUS IS300 (RM1140U) Author : Date : 2399...
  • Page 560 BO-163 BODY ROOF HEADLINING (Wagon) w/ Sliding Roof: Roof Headlining Sliding Roof Opening Trim Room Light Assembly Lens H19083 2005 LEXUS IS300 (RM1140U) Author : Date : 2400...
  • Page 561 REMOVE CENTER PILLAR LOWER GARNISH Using a screwdriver, remove the center pillar lower gar- nish. HINT: Tape the screwdriver tip before use. Employ the same manner described above to the other side. 4 Clips H15727 2005 LEXUS IS300 (RM1140U) Author : Date : 2401...
  • Page 562 Remove the 2 bolts and 2 rope hook assemblies. Remove the 3 clips. Using a screwdriver, remove the rear floor finish plate. HINT: Tape the screwdriver tip before use. 4 Clips H19026 2005 LEXUS IS300 (RM1140U) Author : Date : 2402...
  • Page 563 Using a screwdriver, remove the front pillar garnish cover. HINT: Tape the screwdriver tip before use. Remove the bolt. Using a screwdriver, remove the front pillar garnish. Remove the bolt. Clip H19277 2005 LEXUS IS300 (RM1140U) Author : Date : 2403...
  • Page 564 REMOVE SLIDING ROOF OPENING TRIM H10446 REMOVE INNER REAR VIEW MIRROR Using a screwdriver, remove the inner rear view mirror stay holder cover. HINT: Tape the screwdriver tip before use. H19183 2005 LEXUS IS300 (RM1140U) Author : Date : 2404...
  • Page 565 REMOVE SHOULDER BELT ANCHOR COVER UPPER Remove the 2 screws and shoulder belt anchor cover upper. REMOVE ROOF HEADLINING Remove the 3 clips. Pull the roof headlining downward to remove it. H19063 2005 LEXUS IS300 (RM1140U) Author : Date : 2405...
  • Page 566 BO-169 BODY ROOF HEADLINING (Wagon) BO4DZ-02 INSTALLATION The installation procedures are the removal procedures in reverse order (See page BO-164 2005 LEXUS IS300 (RM1140U) Author : Date : 2406...
  • Page 567 38 (387, 28) Front Seat Cushion Inner Shield Seat Track Cover Seat Cushion Front Shield Front Seat Inner Belt : Specified torque N·m (kgf·cm, ft·lbf) 42 (420, 31) F Non-reusable part H19455 2005 LEXUS IS300 (RM1140U) Author : Date : 2407...
  • Page 568 38 (387, 28) Outer Shield Seat Track Cover Power Seat 38 (387, 28) Seat Cushion Front Shield Switch Knob Power Seat Switch : Specified torque N·m (kgf·cm, ft·lbf) F Non-reusable part H19456 2005 LEXUS IS300 (RM1140U) Author : Date : 2408...
  • Page 569 BO-172 BODY FRONT SEAT (Power Adjuster Type) Reclining Motor Adjuster Assembly Power Seat Switch Sliding Motor Lifter Motor Front Vertical Motor H15132 2005 LEXUS IS300 (RM1140U) Author : Date : 2409...
  • Page 570 Using a screwdriver, remove the 4 seat track covers. HINT: Tape the screwdriver tip before use. REMOVE FRONT SEAT H19458 Remove the 4 bolts. Disconnect the connectors. Remove the front seat. NOTICE: Be careful not to damage the body. 2005 LEXUS IS300 (RM1140U) Author : Date : 2410...
  • Page 571 Disconnect the connectors and unlatch the wire harness clamps. Remove the 4 bolts and seat cushion assembly with wire harness. Unlatch the wire harness clamps to remove the wire har- ness from seat cushion assembly. H15737 2005 LEXUS IS300 (RM1140U) Author : Date : 2411...
  • Page 572 H15739 REMOVE SEATBACK COVER Using a screwdriver, remove the No. 1 and No. 2 airbag covers. HINT: Tape the screwdriver tip before use. H15740 2005 LEXUS IS300 (RM1140U) Author : Date : 2412...
  • Page 573 REMOVE FRONT SEAT INNER BELT Remove the bolt, washer and front seat inner belt. REMOVE RECLINING MOTOR Remove the 2 screws, then disconnect the reclining motor. H15743 2005 LEXUS IS300 (RM1140U) Author : Date : 2413...
  • Page 574 Remove the 2 screws, then disconnect the front vertical motor. H15745 REMOVE SLIDING MOTOR Remove the 2 screws, then disconnect the sliding motor. H15746 REMOVE POWER SEAT SWITCH Remove the 3 screws and power seat switch. H15747 2005 LEXUS IS300 (RM1140U) Author : Date : 2414...
  • Page 575 Connect the reclining motor, then install the 2 screws. INSTALL FRONT SEAT INNER BELT Install the front seat inner belt with the bolt and washer. Torque: 42 N·m (428 kgf·cm, 31 ft·lbf) H15743 2005 LEXUS IS300 (RM1140U) Author : Date : 2415...
  • Page 576 H15742 Slide the airbag door downward to install it. Install the 2 bolts. Torque: 4.7 N·m (48 kgf·cm, 42 in.·lbf) H15741 Install the No.1 and No.2 airbag covers. H15740 2005 LEXUS IS300 (RM1140U) Author : Date : 2416...
  • Page 577 INSTALL SEAT CUSHION ASSEMBLY Install the seat cushion assembly with the 4 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) Attach the wire harness clamps. Attach the side airbag assembly wire harness clamps. H15737 2005 LEXUS IS300 (RM1140U) Author : Date : 2417...
  • Page 578 Install the front seat cushion inner shield with the 2 screws. H15735 INSTALL FRONT SEAT CUSHION OUTER SHIELD Install the front seat cushion outer shield with the 4 screws. INSTALL POWER SEAT SWITCH KNOBS INSTALL HEADREST H15734 2005 LEXUS IS300 (RM1140U) Author : Date : 2418...
  • Page 579 Temporarily tighten the bolts on the rear side. Then, tight- en them to the final torque starting from the inner side. Torque: 38 N·m (387 kgf·cm, 28 ft·lbf) INSTALL SEAT TRACK COVERS H19191 2005 LEXUS IS300 (RM1140U) Author : Date : 2419...
  • Page 580 21 (210, 15) Inner Track Seat Track Cover Seat Track Handle Front Seat Inner Belt Front Seat Cushion 38 (387, 28) Inner Shield : Specified torque N·m (kgf·cm, ft·lbf) F Non-reusable part H19461 2005 LEXUS IS300 (RM1140U) Author : Date : 2420...
  • Page 581 Seat Track Handle 38 (387, 28) Front Seat Seat Track Cover Cushion Outer Shield Reclining Adjuster Vertical Adjuster Knob Release Handle : Specified torque N·m (kgf·cm, ft·lbf) F Non-reusable part H19457 2005 LEXUS IS300 (RM1140U) Author : Date : 2421...
  • Page 582 Using a screwdriver, remove the 4 seat track covers. HINT: Tape the screwdriver tip before use. REMOVE FRONT SEAT H19459 Remove the 4 bolts. Disconnect the connector. Remove the front seat. NOTICE: Be careful not to damage the body. 2005 LEXUS IS300 (RM1140U) Author : Date : 2422...
  • Page 583 Unlatch the seat cushion cover hooks and remove the seat cushion frame from the seat cushion cover with pad. Remove the hog rings and seat cushion cover from the seat cushion pad. H15763 2005 LEXUS IS300 (RM1140U) Author : Date : 2423...
  • Page 584 Using a screwdriver, remove the No.1 and No.2 airbag covers. HINT: Tape the screwdriver tip before use. H15740 Remove the 2 bolts. Slide the airbag door upward to remove it. H15741 2005 LEXUS IS300 (RM1140U) Author : Date : 2424...
  • Page 585 Remove the 4 nuts and the reclining adjuster rod assembly. DISASSEMBLE OUTER TRACK AND INNER TRACK H15751 Using a screwdriver, remove the 2 E-rings from the outer side on the inner track. HINT: Tape the screwdriver tip before use. 2005 LEXUS IS300 (RM1140U) Author : Date : 2425...
  • Page 586 When sliding the seat, inspect that the outer and inner tracks are locked at the same time. HINT: When sliding lock positions slip off, loosen the bolts to adjust the position. 2005 LEXUS IS300 (RM1140U) Author : Date : 2426...
  • Page 587 Install the 2 headrest supports. w/ Table: Install the front seatback lock with the 2 bolts and employ the same manner described above to the other side. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 2005 LEXUS IS300 (RM1140U) Author : Date : 2427...
  • Page 588 Set the side airbag assembly wire harness to the reclining adjuster inside covers. Install the reclining adjuster inside cover with the 2 screws and employ the same manner described above to the oth- er side. H15750 2005 LEXUS IS300 (RM1140U) Author : Date : 2428...
  • Page 589 Attach the wire harness clamps. Attach the side airbag assembly wire harness clamps. H15762 INSTALL FRONT SEAT CUSHION INNER SHIELD Install the front seat cushion inner shield with the 2 screws. H15761 2005 LEXUS IS300 (RM1140U) Author : Date : 2429...
  • Page 590 INSTALL RECLINING ADJUSTER RELEASE HANDLE Install the reclining adjuster release handle with the screw. INSTALL VERTICAL ADJUSTER KNOBS Install the 2 vertical adjuster knobs with the 2 clips. INSTALL HEADREST H15760 2005 LEXUS IS300 (RM1140U) Author : Date : 2430...
  • Page 591 Temporarily tighten the bolts on the rear side. Then, tight- en them to the final torque starting from the inner side. Torque: 38 N·m (387 kgf·cm, 28 ft·lbf) INSTALL SEAT TRACK COVERS H19192 2005 LEXUS IS300 (RM1140U) Author : Date : 2431...
  • Page 592 Seat Cushion Cover Rear Seat Belt Shoulder Guide F Hog Ring 7.8 (80, 69 in.·lbf) F Hog Ring Seat Cushion Pad N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part H15755 2005 LEXUS IS300 (RM1140U) Author : Date : 2432...
  • Page 593 Remove the 4 bolts, then raise the seatback assembly upward to remove the seatback assembly. REMOVE REAR SEAT CENTER ARMREST BOX AS- SEMBLY Remove the 6 bolts and rear seat center armrest box assembly. H10485 2005 LEXUS IS300 (RM1140U) Author : Date : 2433...
  • Page 594 Remove the hog rings and seatback cover on the front of seatback assembly. H10928 REMOVE SEAT CUSHION COVER Remove the hog rings on the back of seat cushion assem- bly. Leather seat only H10929 2005 LEXUS IS300 (RM1140U) Author : Date : 2434...
  • Page 595 Take care as the cut rivet is hot. NOTICE: Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill. Remove the rear seat center armrest brackets. 2005 LEXUS IS300 (RM1140U) Author : Date : 2435...
  • Page 596 Install the 2 door stoppers. Install the patch with the 2 screws. Install the door lock with the 2 screws. Install the rear seat center armrest door to the rear seat H02442 center armrest box. 2005 LEXUS IS300 (RM1140U) Author : Date : 2436...
  • Page 597 Install the rear seat center armrest with the bracket to the seatback assembly with the 2 nuts. INSTALL REAR SEAT BELT SHOULDER GUIDES Install the rear seat belt shoulder guides with the 4 screws to the seatback assembly. INSTALL HEADRESTS H10925 2005 LEXUS IS300 (RM1140U) Author : Date : 2437...
  • Page 598 Install the rear seat belts to the belt guides, then close the belt guides. H10485 INSTALL SEAT CUSHION ASSEMBLY Push down the front portion of the seat cushion assembly to install it. H10484 2005 LEXUS IS300 (RM1140U) Author : Date : 2438...
  • Page 599 Deck Floor Box Front Rear Seat Belt Assembly Outer 42 (428, 31) Rear Seat Back Assembly Rear Seat Belt Rear Seat Cushion Assembly Outer : Specified torque N·m (kgf·cm, ft·lbf) 42 (428, 31) H19474 2005 LEXUS IS300 (RM1140U) Author : Date : 2439...
  • Page 600 Rear Seat Cushion Cover F Hog Ring Rear Seat Cushion Pad 18 (184, 13) Side Seatback Assembly Side Seatback Assembly : Specified torque N·m (kgf·cm, ft·lbf) 18 (184, 13) F Non-reusable part H19169 2005 LEXUS IS300 (RM1140U) Author : Date : 2440...
  • Page 601 REMOVE REAR FLOOR BOARD NO.3 (See page BO-164 REMOVE TONNEAU COVER ASSEMBLY (See page BO-164 REMOVE REAR FLOOR FINISH PLATE (See page BO-164 REMOVE DECK TRIM SIDE PANEL ASSEMBLY (See page BO-164 2005 LEXUS IS300 (RM1140U) Author : Date : 2441...
  • Page 602 BO-205 BODY REAR SEAT (Wagon) REMOVE SEAT BACK ASSEMBLY Remove the 7 bolts and seat back assembly. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) H19040 2005 LEXUS IS300 (RM1140U) Author : Date : 2442...
  • Page 603 Remove the 3 screws and rear seat back lock cover RH. Using a screwdriver, remove the rear seat back board car- pet RH. HINT: Tape the screwdriver tip before use. 6 Clips H19037 2005 LEXUS IS300 (RM1140U) Author : Date : 2443...
  • Page 604 REMOVE REAR SEAT BACK LOCK ASSEMBLY RH Remove the 2 bolts and rear seat back lock assembly RH. REMOVE REAR SEAT CUSHION COVER Remove the hog rings and rear seat cushion cover from the seat cushion pad. 2005 LEXUS IS300 (RM1140U) Author : Date : 2444...
  • Page 605 Install the center armrest hinge cover with the screw. H19041 INSTALL SEATBACK BOARD CARPET RH Install the seatback board carpet RH. Install the rear seatback lock cover RH. INSTALL REAR SEATBACK LOCK ASSEMBLY LH 6 Clips H19037 2005 LEXUS IS300 (RM1140U) Author : Date : 2445...
  • Page 606 Install the rear seatback lock cover LH. 4 Clips H19038 INSTALL REAR SEATBACK CENTER HINGE Install the rear seat center hinge with the 2 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) INSTALL REAR SEAT HEADRESTS H19036 2005 LEXUS IS300 (RM1140U) Author : Date : 2446...
  • Page 607 BO-210 BODY REAR SEAT (Wagon) BO4EF-02 INSTALLATION The installation procedures are the removal procedures in reverse order (See page BO-204 2005 LEXUS IS300 (RM1140U) Author : Date : 2447...
  • Page 608 38 (387, 28) CRS Anchor Bracket 13.2 (135, 10) 42 (428, 31) Rear Seat Cushion Power seat: Front Seat Inner Belt Front Seat Cushion Inner Shield : Specified torque N·m (kgf·cm, ft·lbf) H19081 2005 LEXUS IS300 (RM1140U) Author : Date : 2448...
  • Page 609 Pull out the whole belt and measure the length of the BO0633 whole belt. Then retract the belt slightly and pull it out again Make sure that the belt cannot be extended further. If a problem is found, replace the assembly. 2005 LEXUS IS300 (RM1140U) Author : Date : 2449...
  • Page 610 Make sure that the belt can be pulled out at a tilt of 15 de- 15° grees or less, and cannot be pulled out at over 45 degrees 45° of tilt. If a problem is found, replace the assembly. BO0633 2005 LEXUS IS300 (RM1140U) Author : Date : 2450...
  • Page 611 13.2 (135, 10) CRS Anchor Bracket Rear Seat Inner w/ CTR Belt Assembly Rear Door Inside Scuff Plate Deck Trim Side Panel Assembly Rear Seat Cushion N·m (kgf·cm, ft·lbf) : Specified torque H19473 2005 LEXUS IS300 (RM1140U) Author : Date : 2451...
  • Page 612 Pull out the whole belt and measure the length of the BO0633 whole belt. Then retract the belt slightly and pull it out again. Make sure that the belt cannot be extended further. If a problem is found, replace the assembly. 2005 LEXUS IS300 (RM1140U) Author : Date : 2452...
  • Page 613 Make sure that the belt can be pulled out at a tilt of 15 de- 15° grees or less, and cannot be pulled out at over 45 degrees 45° of tilt. If a problem is found, replace the assembly. BO0633 2005 LEXUS IS300 (RM1140U) Author : Date : 2453...

  • Page 614: Seat Belt Pretensioner

    Tape the screwdriver tip before use. Remove the bolt and shoulder anchor. Using a screwdriver, remove the floor anchor cover. HINT: Tape the screwdriver tip before use. Remove the bolt and floor anchor. H15728 2005 LEXUS IS300 (RM1140U) Author : Date : 2454...
  • Page 615 Remove the upper bolt and retractor of front seat outer belt. H15788 NOTICE: Except when disposing of the seat belt pretensioner, do not remove the shoulder belt anchor plate from the retractor. 2005 LEXUS IS300 (RM1140U) Author : Date : 2455...
  • Page 616 Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. Check for deformation of the center pillar. Check for damage on the connector and wire har- ness. H10932 2005 LEXUS IS300 (RM1140U) Author : Date : 2456...
  • Page 617 Always wash your hands with water after completing the operation. Do not apply water, etc. to the front seat outer belt with activated pretensioner. 2005 LEXUS IS300 (RM1140U) Author : Date : 2457...
  • Page 618 Remove the rear door inside scuff plate. H01580 Remove the rear part of front door opening trim. Remove the front part of rear door opening trim. Remove the center pillar lower garnish. 2005 LEXUS IS300 (RM1140U) Author : Date : 2458...
  • Page 619 Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner. 2005 LEXUS IS300 (RM1140U) Author : Date : 2459...
  • Page 620 Place the front seat outer belt as shown in the illustration. Move the SST at least 10 m (33 ft) away from the disc wheel. NOTICE: Take care not to damage the SST wire harness. Activate the seat belt pretensioner. H15786 2005 LEXUS IS300 (RM1140U) Author : Date : 2460...
  • Page 621 Remove the disc wheel and SST. Place the front seat outer belt in a vinyl bag, and tie the end tightly and dispose of it in the same way as other general parts. 2005 LEXUS IS300 (RM1140U) Author : Date : 2461...
  • Page 622 BO-219 If the front seat outer belt has been dropped. CAUTION: For removal and installation of the seat belt pretensioner, see page BO-217 BO-226 Be sure to follow the correct procedure. 2005 LEXUS IS300 (RM1140U) Author : Date : 2462...
  • Page 623 Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) H15788 Install the floor anchor cover. Install the shoulder anchor with the bolt. Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) Install the shoulder anchor cover. H15728 2005 LEXUS IS300 (RM1140U) Author : Date : 2463...
  • Page 624 INSTALL REAR DOOR INSIDE SCUFF PLATE Install the rear door inside scuff plate to the body. H15726 INSTALL FRONT DOOR INSIDE SCUFF PLATE Install the front door inside scuff plate to the body. H15717 2005 LEXUS IS300 (RM1140U) Author : Date : 2464...
  • Page 625 BO-228 BODY SPOILER (Sedan) SPOILER (Sedan) BO4EK-01 COMPONENTS Rear Spoiler Cover High-mounted Stop Light Door Inside Handle Bezel Luggage Compartment Door Trim Luggage Compartment Door Assist Grip H19280 2005 LEXUS IS300 (RM1140U) Author : Date : 2465...
  • Page 626 BO-229 BODY SPOILER (Wagon) SPOILER (Wagon) BO4EL-01 COMPONENTS Rear Spoiler Cover Stop Center Lamp Assembly Back Door Trim Board Upper Back Door Trim Cover Back Door Trim Cover H19205 2005 LEXUS IS300 (RM1140U) Author : Date : 2466...

  • Page 627: Brake System

    It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 628 Hard pedal but brake inefficient 5. Pad (Oily) BR-23 BR-32 6. Pad (Glazed) BR-23 BR-32 7. Disc (Scored) BR-29 BR-38 8. Booster push rod (Out of adjustment) BR-21 9. Booster system (Vacuum leaks) BR-18 2005 LEXUS IS300 (RM1140U) Author : Date : 1804...
  • Page 629 Noise from brake 6. Pad (Dirty) BR-23 BR-32 7. Pad (Glazed) BR-23 BR-32 8. Tension or return spring (Faulty) BR-41 9. Anti-squeal shim (Damaged) BR-23 BR-32 10.Shoe hold-down spring (Damaged) BR-41 2005 LEXUS IS300 (RM1140U) Author : Date : 1805...

  • Page 630: Brake Fluid

    At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. Repeat (b) and (c) until all the air in the fluid has been bled out. N00759 2005 LEXUS IS300 (RM1140U) Author : Date : 1806...
  • Page 631 Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. F12338 Fluid: SAE J1703 or FMVSS NO. 116 DOT3 2005 LEXUS IS300 (RM1140U) Author : Date : 1807...
  • Page 632 If incorrect, check the stop light switch clearance. If the clear- ance is OK, then troubleshoot the brake system. Stop light switch clearance: 1.5 - 2.5 mm (0.059 - 0.098 in.) 2005 LEXUS IS300 (RM1140U) Author : Date : 1808...
  • Page 633 Pedal reserve distance from asphalt sheet at 490 N (50 Kgf, 110.2 Ibf): More than 99 mm (3.90 in.) If the reserve distance is incorrect, troubleshoot the brake sys- tem. R00135 2005 LEXUS IS300 (RM1140U) Author : Date : 1809...
  • Page 634 Collar 37 (377, 27) ABS & TRAC / VSC ECU F Bushing Brake Pedal N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part Pedal Pad Lithium soap base glycol grease F12308 2005 LEXUS IS300 (RM1140U) Author : Date : 1810...

  • Page 635: Parking Brake Lever

    Loosen the lock nut and the turn adjusting nut until the le- Adjusting Nut Lock Nut ver travel is correct. Tighten the lock nut. F12310 Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Install the parking brake lever hole cover. 2005 LEXUS IS300 (RM1140U) Author : Date : 1811...

  • Page 636: Brake Master Cylinder

    Straight Pin No. 2 Piston and Spring No. 1 Piston and Spring Cylinder Body N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part F14146 Lithium soap base glycol grease F14147 F14157 2005 LEXUS IS300 (RM1140U) Author : Date : 1812...
  • Page 637 Disconnect the 2 brake hoses. Remove the 2 nuts, and pull out the check valve bracket, brake hose clamp, master cylinder and gasket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) F14149 2005 LEXUS IS300 (RM1140U) Author : Date : 1813...
  • Page 638 HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 in.). R12236 2005 LEXUS IS300 (RM1140U) Author : Date : 1814...
  • Page 639 At the time of reassembly, be careful not to damage the rubber lips on the pistons. HINT: At the time of reassembly, insert the pistons with elliptic hole facing vertically. W03590 2005 LEXUS IS300 (RM1140U) Author : Date : 1815...
  • Page 640 BRAKE MASTER CYLINDER BR0MP-01 INSPECTION HINT: Clean the disassembled parts with compressed air. INSPECT CYLINDER BORE FOR RUST OR SCORING INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. 2005 LEXUS IS300 (RM1140U) Author : Date : 1816...
  • Page 641 BR0MQ-04 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR-12 HINT: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page BR-10 2005 LEXUS IS300 (RM1140U) Author : Date : 1817...
  • Page 642 Before installation, adjust length of brake booster push rod (See page BR-21 After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ), and check for leaks. Check and adjust brake pedal (See page BR-6 2005 LEXUS IS300 (RM1140U) Author : Date : 1818...

  • Page 643: Brake Booster Assembly

    Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air-tight. BR2238 2005 LEXUS IS300 (RM1140U) Author : Date : 1819...
  • Page 644 4.9 (50, 43 in.·lbf) 4.9 (50, 43 in.·lbf) Clamp Front LH Brake Line Grommet 4.9 (50, 43 in.·lbf) 15 (155, 11) N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part F14155 2005 LEXUS IS300 (RM1140U) Author : Date : 1820...
  • Page 645 Remove the 3 bolts and disconnect the 3 clamps. Remove the lower finish panel (See page BO-135 Remove the return spring, clip and clevis pin. F12325 Remove the clevis and 4 nuts. BR3753 2005 LEXUS IS300 (RM1140U) Author : Date : 1821...
  • Page 646 BR-20 BRAKE BRAKE BOOSTER ASSEMBLY Move the brake line as illustrated and ensure sufficient space. Pull out the booster and gasket. F12326 2005 LEXUS IS300 (RM1140U) Author : Date : 1822...
  • Page 647 Turn the SST upside down, and set it on the booster. Gasket 09737-0001 1 Measure the clearance between the booster push rod and pin head (SST). F03918 Clearance: 0 mm (0 in.) 2005 LEXUS IS300 (RM1140U) Author : Date : 1823...
  • Page 648 BLEED BRAKE SYSTEM (See page BR-4 N00744 CHECK FOR FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL (See page BR-6 INSTALL LOWER FINISH PANEL (See page BO-135 DO OPERATIONAL CHECK (See page BR-17 2005 LEXUS IS300 (RM1140U) Author : Date : 1824...

  • Page 649: Front Brake Pad

    Anti-squeal Shim Anti-squeal Spring Inner Pad Outer Pad Inner Anti-squeal Shim Anti-squeal Shim Pad Support Plate Inner Anti-squeal Shim 34 (350, 25) N·m (kgf·cm, ft·lbf) : Specified torque Disc brake grease F07909 2005 LEXUS IS300 (RM1140U) Author : Date : 1825...
  • Page 650 Direction of disc rotation for for- HINT: ward movement Make sure the arrows on the inner anti-squeal shims facing to the direction of disc rotation as shown in the illustration. F12332 2005 LEXUS IS300 (RM1140U) Author : Date : 1826...
  • Page 651 W00744 Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) INSTALL FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) DEPRESS BRAKE PEDAL SEVERAL TIMES CHECK THAT FLUID LEVEL IS AT MAX LINE 2005 LEXUS IS300 (RM1140U) Author : Date : 1827...

  • Page 652: Front Brake Caliper

    Inner Anti-squeal Shim F Dust Boot Sliding Bushing 118 (1,200, 87) Torque Plate Disc N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part Lithium soap base glycol grease Disc brake grease F07580 2005 LEXUS IS300 (RM1140U) Author : Date : 1828...
  • Page 653 Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) Remove the 2 installation bolts. Remove the caliper from the torque plate. REMOVE 2 ANTI-SQUEAL SPRINGS REMOVE 2 BRAKE PADS WITH 4 ANTI- SQUEAL SHIMS REMOVE 4 PAD SUPPORT PLATES 2005 LEXUS IS300 (RM1140U) Author : Date : 1829...
  • Page 654 Confirm that the metal plate portion of the dust boot fits snugly in the torque plate. HINT: At the time of reassembly, use a 21 mm socket and tap in new F01629 dust boots into the torque plate. 2005 LEXUS IS300 (RM1140U) Author : Date : 1830...
  • Page 655 If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. Install the torque plate and torque the 2 bolts. Torque: 118 N·m (1,200 kgf·cm, 87 ft·lbf) 2005 LEXUS IS300 (RM1140U) Author : Date : 1831...
  • Page 656 FRONT BRAKE CALIPER BR0JN-05 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR-28 HINT: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR-26 2005 LEXUS IS300 (RM1140U) Author : Date : 1832...
  • Page 657 Installation is in the reverse order of removal (See page BR-27 HINT: After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR-4 Check for leaks. 2005 LEXUS IS300 (RM1140U) Author : Date : 1833...

  • Page 658: Rear Brake Pad

    REAR BRAKE PAD REAR BRAKE PAD BR0JP-12 COMPONENTS Anti-squeal Shim Anti-squeal Spring Inner Pad Inner Anti-squeal Shim Clip Pad Guide Pin Inner Anti-squeal Shim Outer Pad Anti-squeal Shim Disc brake grease F12333 2005 LEXUS IS300 (RM1140U) Author : Date : 1834...
  • Page 659 INSTALL NEW PADS NOTICE: F04917 When replacing worn pads, the anti-squeal shims must be replaced together with the pads. Apply disc brake grease to both sides of inner anti-squeal shims (See page BR-32 2005 LEXUS IS300 (RM1140U) Author : Date : 1835...
  • Page 660 Ensure that ”A” and ”B” portions of anti-squeal spring are attached to the pad. INSTALL REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) F07232 DEPRESS BRAKE PEDAL SEVERAL TIMES CHECK THAT FLUID LEVEL IS AT MAX LINE 2005 LEXUS IS300 (RM1140U) Author : Date : 1836...

  • Page 661: Rear Brake Caliper

    11 (110, 8) 30 (310, 22) FGasket Brake Caliper 104 (1,065, 77) Brake Disc N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part Lithium soap base glycol grease Disc brake grease F12335 2005 LEXUS IS300 (RM1140U) Author : Date : 1837...
  • Page 662 Torque: 104 N·m (1,065 kgf·cm, 77 ft·lbf) Remove the caliper. REMOVE BRAKE PADS (See page BR-33 Remove the anti-squeal spring. Remove the clip and pad guide pin. Remove the 2 pads with the 4 anti-squeal shims. 2005 LEXUS IS300 (RM1140U) Author : Date : 1838...
  • Page 663 CAUTION: Do not place your fingers in front of the piston when using compressed air. F01641 REMOVE PISTON SEALS Using a screwdriver, remove the 2 piston seals from the caliper. F01642 2005 LEXUS IS300 (RM1140U) Author : Date : 1839...
  • Page 664 0.05 mm (0.0020 in.), install the disc in that position. If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. 2005 LEXUS IS300 (RM1140U) Author : Date : 1840...
  • Page 665 REAR BRAKE CALIPER BR0JV-04 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR-37 HINT: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR-35 2005 LEXUS IS300 (RM1140U) Author : Date : 1841...
  • Page 666 Installation is in the reverse order of removal (See page BR-36 HINT: After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR-4 Check for leaks. 2005 LEXUS IS300 (RM1140U) Author : Date : 1842...

  • Page 667: Parking Brake

    Rear Shoe Shoe Strut Shoe Hold-down Spring Spring (Color: Pink) Front Shoe Adjuster Tension Spring Shoe Hold-down Spring (Color: Blue) N·m (kgf·cm, ft·lbf) : Specified torque Disc Plug High temperature grease F12336 2005 LEXUS IS300 (RM1140U) Author : Date : 1843...
  • Page 668 Slide out the rear shoe. Remove the tension spring from the rear shoe. F01650 Disconnect the parking brake cable from the parking brake shoe lever. Remove the 2 cups, shoe hold-down spring and pin. R00310 2005 LEXUS IS300 (RM1140U) Author : Date : 1844...
  • Page 669 Standard clearance: Less than 0.35 mm (0.0138 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Thickness mm (in.) Thickness mm (in.) Clearance (0.012) (0.035) BR5333 (0.024) 2005 LEXUS IS300 (RM1140U) Author : Date : 1845...
  • Page 670 BR-44 BRAKE PARKING BRAKE IF NECESSARY, REPLACE SHIM Using a screwdriver, remove the C-washer and shim. Install the correct size shim with a new C-washer. Remeasure the clearance. R15060 2005 LEXUS IS300 (RM1140U) Author : Date : 1846...
  • Page 671 88 N (9 kgf, 20 lbf) of force. Drive the vehicle for about 400 meters (0.25 mile) in this condition. Repeat this procedure 2 or 3 times. CHECK AND ADJUST PARKING BRAKE LEVER TRAVEL (See page BR-9 2005 LEXUS IS300 (RM1140U) Author : Date : 1847...
  • Page 672 Select the ACTIVE TEST mode on the LEXUS DLC3 hand-held tester. D09381 HINT: Please refer to the LEXUS hand-held tester operator’s manual for further details. Inspect the actuator motor operation. With the motor relay ON, check the actuator motor operation noise.
  • Page 673 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 Clear the DTC (See page DI-437 DI-505 2005 LEXUS IS300 (RM1140U) Author : Date : 1849...
  • Page 674 Brake Hose ABS & TRAC / VSC Actuator Cushion Cushion Bolt 5.4 (55, 48 in.·lbf) Cushion 19 (195, 14) Actuator Bracket 19 (195, 14) N·m (kgf·cm, ft·lbf) : Specified torque F14154 2005 LEXUS IS300 (RM1140U) Author : Date : 1850...
  • Page 675 REMOVE ABS & TRAC & VSC ACTUATOR Remove the 2 nuts and ABS & TRAC / VSC actuator from the bracket. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Remove the 2 cushion bolts and 3 cushions. 2005 LEXUS IS300 (RM1140U) Author : Date : 1851...
  • Page 676 INSTALLATION Installation is in the reverse order of removal (See page BR-49 HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 Check for leaks. 2005 LEXUS IS300 (RM1140U) Author : Date : 1852...

  • Page 677: Front Speed Sensor

    COMPONENTS LH side: RH side: Fender Liner Harness Clamp 5.0 (51, 44 in.·lbf) 5.0 (51, 44 in.·lbf) 8.0 (82, 71 in.·lbf) Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque F12321 2005 LEXUS IS300 (RM1140U) Author : Date : 1853...
  • Page 678 Remove the resin clip and 2 clamp bolts holding the sen- sor harness to the body. Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf) Remove the bolt and speed sensor from the steering knuckle. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) F12322 2005 LEXUS IS300 (RM1140U) Author : Date : 1854...
  • Page 679 BR-53 BRAKE FRONT SPEED SENSOR BR0K3-11 INSTALLATION Installation is in the reverse order of removal (See page BR-52 HINT: After installation, check speed sensor signal (See page DI-437 DI-507 2005 LEXUS IS300 (RM1140U) Author : Date : 1855...

  • Page 680: Rear Speed Sensor

    REAR SPEED SENSOR REAR SPEED SENSOR BR0K4-11 COMPONENTS Seatback Seat Cushion Rear Speed Sensor 5.0 (51, 44 in.·lbf) 5.0 (51, 44 in.·lbf) 8.0 (82, 71 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque F07578 2005 LEXUS IS300 (RM1140U) Author : Date : 1856...
  • Page 681 Remove the clamp nut holding the sensor wire harness to the body. Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf) Remove the sensor installation bolt and speed sensor from the axle carrier. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) F02818 2005 LEXUS IS300 (RM1140U) Author : Date : 1857...
  • Page 682 BR-56 BRAKE REAR SPEED SENSOR BR0K6-11 INSTALLATION Installation is in the reverse order of removal (See page BR-55 HINT: After installation, check speed sensor signal (See page DI-437 DI-507 2005 LEXUS IS300 (RM1140U) Author : Date : 1858...

  • Page 683: Charging System

    CHECK BATTERY TERMINALS AND FUSES Check that the battery terminals are not loose or cor- roded. If the terminals are corroded, clean the terminals. Check the fusible link and fuses for continuity. 2005 LEXUS IS300 (RM1140U) Author : Date : 1539...
  • Page 684 CORRECT WRONG WRONG TEN FOR ABNORMAL NOISES Check that the wiring is in good condition. Check that there is no abnormal noise from the generator while the engine is running. Z05963 2005 LEXUS IS300 (RM1140U) Author : Date : 1540...
  • Page 685 Standard amperage: 30 A or more If the ammeter reading is less than the standard amperage, re- pair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. 2005 LEXUS IS300 (RM1140U) Author : Date : 1541...
  • Page 686 Generator Connector Drive Belt Generator A/T Oil Cooler Pipe Pipe Bracket Drive Belt Tensioner Absorber (M/T) 20 (200, 14) Engine Under Cover x 18 N·m (kgf·cm, ft·lbf) : Specified torque B15229 2005 LEXUS IS300 (RM1140U) Author : Date : 1542...
  • Page 687 F Front Bearing Brush Holder Cover Terminal Insulator Voltage Regulator Rectifier End Frame Wire Clip Plate Terminal Rear End Cover Brush Holder Seal Plate Rectifier Holder Rubber Insulator F Non-reusable part B01642 2005 LEXUS IS300 (RM1140U) Author : Date : 1543...
  • Page 688 Remove the bolt and pipe clamp, and disconnect the 2 A/T oil cooler pipes from the generator. Pipe Clamp B01962 Remove the bolt, nut, pipe bracket and generator. Torque: 40 N·m (400 kgf·cm, 30 ft·lbf) Pipe Bracket B01963 2005 LEXUS IS300 (RM1140U) Author : Date : 1544...
  • Page 689 Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. 09820-6301 1 Turn SST (A) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the rotor shaft. SST (B) P10835 2005 LEXUS IS300 (RM1140U) Author : Date : 1545...
  • Page 690 Remove the 4 nuts and wire clip. Wire Clip B01648 Using SST, remove the rectifier end frame. 09950- 40011 (09951- 04020, 09952- 04010, 09953-04030, 09954-04010, 09955-04041) Remove the generator washer. REMOVE ROTOR FROM DRIVE END FRAME B02021 2005 LEXUS IS300 (RM1140U) Author : Date : 1546...
  • Page 691 Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. CH1023 2005 LEXUS IS300 (RM1140U) Author : Date : 1547...
  • Page 692 Reverse the polarity of the tester probes and repeat step (a). Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. B01933 2005 LEXUS IS300 (RM1140U) Author : Date : 1548...
  • Page 693 CH-1 1 CHARGING GENERATOR INSPECT BEARING Check the bearing is not rough or worn. If necessary, replace the bearing (See page CH-12 2005 LEXUS IS300 (RM1140U) Author : Date : 1549...
  • Page 694 Using SST, remove the bearing cover (outside) and bear- ing. 09820-00021 NOTICE: Be careful not to damage the fan. N00581 Remove the bearing cover (inside). Place the bearing cover (inside) on the rotor. Bearing Cover P13567 2005 LEXUS IS300 (RM1140U) Author : Date : 1550...
  • Page 695 CH-13 CHARGING GENERATOR Using SST and a press, press in a new bearing. 09820-00031 N00578 Using SST, push in the bearing cover (outside). 09285-76010 Bearing Cover P00074 2005 LEXUS IS300 (RM1140U) Author : Date : 1551...
  • Page 696 Hold SST (A) with a torque wrench, and tighten SST (B) Turn SST (A) clockwise to the specified torque. 09820-6301 1 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the pulley shaft. SST (B) P10835 2005 LEXUS IS300 (RM1140U) Author : Date : 1552...
  • Page 697 Install the rectifier holder while pushing it with the 4 Push screws. Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) B01650 INSTALL VOLTAGE REGULATOR AND BRUSH HOLD- Place the seal plate on the rectifier end frame. Seal Plate B01651 2005 LEXUS IS300 (RM1140U) Author : Date : 1553...
  • Page 698 4.4 N·m (45 kgf·cm, 39 in.·lbf) for nut 3.9 N·m (39 kgf·cm, 35 in.·lbf) for bolt Install the terminal insulator with the nut. Torque: 6.5 N·m (67 kgf·cm, 58 in.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY B01654 2005 LEXUS IS300 (RM1140U) Author : Date : 1554...
  • Page 699 CH-17 CHARGING GENERATOR CH04A-04 INSTALLATION Installation is in the reverse order of removal (See page CH-6 2005 LEXUS IS300 (RM1140U) Author : Date : 1555...
  • Page 700 11. Clutch disc (Oily) CL-14 12. Clutch disc (Lack of spline grease) CL-18 13. Diaphragm spring (Damaged) CL-14 14. Diaphragm spring (Out of tip alignment) CL-18 15. Pressure plate (Distortion) CL-14 2005 LEXUS IS300 (RM1140U) Author : Date : 1556...

  • Page 701: Clutch Pedal

    Loosen the lock nut and turn the push rod until the free play and push rod play are correct. Tighten the lock nut. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) After adjusting the pedal free play, check the pedal height. 2005 LEXUS IS300 (RM1140U) Author : Date : 1557...
  • Page 702 Check that there is no continuity between the terminals when the switch is OFF (free). If continuity is not as specified, replace the switch. 8.0 ± 0.5 mm (0.315 ± 0.020 in.) D11485 2005 LEXUS IS300 (RM1140U) Author : Date : 1558...

  • Page 703: Clutch Master Cylinder

    Push Rod Piston F Grommet Spring Clip Master Cylinder Body Clevis Washer Lock Nut Washer 12 (120, 9) Boot Snap Ring N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part D10563 2005 LEXUS IS300 (RM1140U) Author : Date : 1559...
  • Page 704 REMOVE CLIP AND PIN Using needle nose pliers, remove the clip. Remove the pin and washer. REMOVE 2 MOUNTING NUTS AND PULL OUT MAS- D05119 TER CYLINDER Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) 2005 LEXUS IS300 (RM1140U) Author : Date : 1560...
  • Page 705 Remove the boot. D05126 REMOVE PUSH ROD While pushing the push rod, using snap ring pliers remove the snap ring. Remove the push rod and washer. REMOVE PISTON AND SPRING D05127 2005 LEXUS IS300 (RM1140U) Author : Date : 1561...
  • Page 706 Install the reservoir tank and a new grommet. Using a pin punch (5 mm) and a hammer, drive in the slotted spring pin. Protrusion 1.5 - 3.5 mm (0.059 - 0.138 in.) D05689 2005 LEXUS IS300 (RM1140U) Author : Date : 1562...
  • Page 707 CL-8 CLUTCH CLUTCH MASTER CYLINDER CL0D4-01 INSTALLATION Installation is in the reverse order of removal (See page CL-5 HINT: After installation, adjust the clutch pedal and bleed the clutch system. 2005 LEXUS IS300 (RM1140U) Author : Date : 1563...

  • Page 708: Clutch Release Cylinder

    CLUTCH RELEASE CYLINDER CL0D5-01 COMPONENTS Bleeder Plug 10.7 (109, 8) Release Cylinder Body Spring Piston Push Rod Boot Clutch Line 15.2 (155, 11) 12 (120, 9) N·m (kgf·cm, ft·lbf) : Specified torque D11475 2005 LEXUS IS300 (RM1140U) Author : Date : 1564...
  • Page 709 Using SST, disconnect the clutch line. Use a container to catch the fluid. 09023-00101 Torque: 15.2 N·m (155 kgf·cm, 11 ft·lbf) REMOVE 2 BOLTS AND PULL OUT RELEASE CYL- INDER Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) D10564 2005 LEXUS IS300 (RM1140U) Author : Date : 1565...
  • Page 710 CLUTCH RELEASE CYLINDER CL0D7-01 DISASSEMBLY PULL OUT PUSH ROD WITH BOOT REMOVE PISTON WITH SPRING Using compressed air, remove the piston and spring from the cylinder. REMOVE BLEEDER PLUG AND CAP D11476 2005 LEXUS IS300 (RM1140U) Author : Date : 1566...
  • Page 711 Torque: 10.7 N·m (109 kgf·cm, 8 ft·lbf) COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN INSTALL PISTON WITH SPRING INTO CYLINDER INSTALL BOOT WITH PUSH ROD TO CYLINDER Z07291 2005 LEXUS IS300 (RM1140U) Author : Date : 1567...
  • Page 712 CL-13 CLUTCH CLUTCH RELEASE CYLINDER CL0D9-01 INSTALLATION Installation is in the reverse order of removal (See page CL-10 2005 LEXUS IS300 (RM1140U) Author : Date : 1568...

  • Page 713: Clutch Unit

    Clutch Release Bearing Clutch Release Fork Boot 19.1 (195, 14) Flywheel See page EM-95 Clutch Cover F Pilot Bearing Clutch Disc N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part D10565 2005 LEXUS IS300 (RM1140U) Author : Date : 1569...
  • Page 714 REMOVE BOOT, RELEASE BEARING AND FORK FROM TRANSMISSION Remove the boot from the transmission. Remove the release bearing together with the fork and then separate them. Remove the clip from the release bearing. D10567 2005 LEXUS IS300 (RM1140U) Author : Date : 1570...
  • Page 715 Turn the bearing by hand while applying force in the axial direc- tion. If the bearing sticks or has much resistance, replace the pilot bearing. D10571 IF NECESSARY, REPLACE PILOT BEARING Remove the 2 bolts at diametrically opposite points. D10572 2005 LEXUS IS300 (RM1140U) Author : Date : 1571...
  • Page 716 Turn the bearing by hand while applying force in the axial direc- tion. HINT: The bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the release bearing. N00414 2005 LEXUS IS300 (RM1140U) Author : Date : 1572...
  • Page 717 Q01140 Apply clutch spline grease to the clutch disc spline. HINT: Recommended grease part number 08887-01706 (100 g). CL0653 2005 LEXUS IS300 (RM1140U) Author : Date : 1573...
  • Page 718 Install the clip to the release bearing. Install the release bearing to the release fork, and then install them to the transmission. Install the boot to the transmission. INSTALL TRANSMISSION TO ENGINE (See page MT-8 2005 LEXUS IS300 (RM1140U) Author : Date : 1574...
  • Page 719 Check for any excessive deposits of rust or scale around the radiator cap and radiator filler hole; the coolant should be free of oil. If excessively dirty, replace the coolant. Reinstall the radiator cap. 2005 LEXUS IS300 (RM1140U) Author : Date : 1458...
  • Page 720 Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine until the cooling fan operates. Squeeze the inlet and outlet radiator hoses several times by hand while warning up the engine. Stop the engine and wait until the coolant cools down. 2005 LEXUS IS300 (RM1140U) Author : Date : 1459...
  • Page 721 CHECK FOR ENGINE COOLANT LEAKS Fill the radiator with engine coolant and attach a radiator cap tester. Pump it to 177 kPa (1.8 kgf/cm , 26 psi) and check for leakage. 2005 LEXUS IS300 (RM1140U) Author : Date : 1460...

  • Page 722: Water Pump

    Water Pump Pulley 58 (590, 43) Drive Belt 52 (530, 38) Tensioner PS Vane Pump Absorber (M/T) 20 (200, 14) Engine Under Cover x 18 N·m (kgf·cm, ft·lbf) : Specified torque B15230 2005 LEXUS IS300 (RM1140U) Author : Date : 1461...
  • Page 723 Drive Belt Tensioner (M/T) 21 (210, 15) No. 1 Timing Belt Cover Timing Belt Guide Crankshaft Pulley Gasket 330 (3,300, 243) N·m (kgf·cm, ft·lbf) : Specified torque f Non-reusable part F Precoated part B15232 2005 LEXUS IS300 (RM1140U) Author : Date : 1462...
  • Page 724 Remove the bolt, and disconnect the connector bracket (for crankshaft position sensor connector). Connector Bracket B01638 Remove the 2 nuts, and disconnect the No. 2 water by- pass pipe from the water pump. No.2 Water Bypass Pipe B01572 2005 LEXUS IS300 (RM1140U) Author : Date : 1463...
  • Page 725 CO-7 COOLING WATER PUMP Remove the 6 bolts, water pump and gasket. Remove the drain hose. Remove the O-ring from the cylinder block. Drain Hose B01941 2005 LEXUS IS300 (RM1140U) Author : Date : 1464...
  • Page 726 COOLING WATER PUMP CO0A0-06 INSPECTION INSPECT WATER PUMP Turn the pulley seat, and check that the water pump bearing is not rough or noisy. If necessary, replace the water pump. B01574 2005 LEXUS IS300 (RM1140U) Author : Date : 1465...
  • Page 727 Torque: 9.0 N·m (90 kgf·cm, 80 in.·lbf) INSTALL IDLER PULLEY AND TIMING BELT (See page EM-24 INSTALL WATER PUMP PULLEY AND DRIVE BELT B01614 Torque: 14 N·m (140 kgf·cm, 10 ft·lbf) 2005 LEXUS IS300 (RM1140U) Author : Date : 1466...
  • Page 728 CO-10 COOLING WATER PUMP M/T: INSTALL DRIVE BELT TENSIONER ABSORBER Install the absorber with the 2 nuts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) INSTALL RADIATOR ASSEMBLY (See page CO-24 2005 LEXUS IS300 (RM1140U) Author : Date : 1467...
  • Page 729 CO-1 1 COOLING THERMOSTAT THERMOSTAT CO0A2-05 COMPONENTS Thermostat Water Inlet F Gasket F Non-reusable part B11922 2005 LEXUS IS300 (RM1140U) Author : Date : 1468...
  • Page 730 Remove the 2 nuts holding the water inlet to the water pump, and disconnect the water inlet from the water pump. Remove the thermostat. Remove the gasket from the thermostat. B01940 2005 LEXUS IS300 (RM1140U) Author : Date : 1469...
  • Page 731 If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat. Valve Lift P03242 2005 LEXUS IS300 (RM1140U) Author : Date : 1470...
  • Page 732 INSTALL WATER INLET Install the water inlet with the 2 nuts. Protrusion Torque: 9.0 N·m (90 kgf·cm, 80 in.·lbf) FILL WITH ENGINE COOLANT P11117 START ENGINE AND CHECK FOR COOLANT LEAKS 2005 LEXUS IS300 (RM1140U) Author : Date : 1471...
  • Page 733 NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main- tain a distance between the cleaner nozzle and radiator core.) 2005 LEXUS IS300 (RM1140U) Author : Date : 1472...
  • Page 734 If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. B01882 REINSTALL RADIATOR CAP 2005 LEXUS IS300 (RM1140U) Author : Date : 1473...
  • Page 735 Lower Radiator Hose Air Cleaner Inlet Upper Radiator Hose Upper Radiator Support Air Cleaner Assembly Electric Cooling Fan Connector Lower Radiator Support Oil Cooler Hose for A/T Engine Under Cover x 18 B11923 2005 LEXUS IS300 (RM1140U) Author : Date : 1474...
  • Page 736 F Packing F O-Ring F Packing F O-Ring Pipe F O-Ring Pipe F Packing F Packing Plate Washer F O-Ring Oil Cooler F O-Ring Drain Plug Lower Tank F Non-reusable part B12019 2005 LEXUS IS300 (RM1140U) Author : Date : 1475...
  • Page 737 Lift out the radiator and cooling fan assembly. Remove the 2 lower radiator supports. REMOVE ELECTRIC COOLING FAN FROM RADIA- Disconnect the radiator reservoir hose from the radiator. Remove the 6 bolts and electric cooling fan. B11924 2005 LEXUS IS300 (RM1140U) Author : Date : 1476...
  • Page 738 REMOVE OIL COOLER FROM LOWER TANK Loosen the nut, and remove the cooler pipe. Remove the 2 cooler pipes. Remove the 2 nuts and 2 plate washers. Remove the oil cooler and 2 O-rings. B02033 2005 LEXUS IS300 (RM1140U) Author : Date : 1477...
  • Page 739 Install the tank without damaging the O-ring. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank. CORRECT Tank Lock WRONG Plate B01868 2005 LEXUS IS300 (RM1140U) Author : Date : 1478...
  • Page 740 (2) and bracket (3). B11959 The points shown in the illustration cannot be staked with the SST. Use pliers or similar object and be careful not to damage the core plates. B01864 B02082 B01870 2005 LEXUS IS300 (RM1140U) Author : Date : 1479...
  • Page 741 Plate merged in water. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles O-Ring disappear. INSTALL NEW PACKINGS B01871 2005 LEXUS IS300 (RM1140U) Author : Date : 1480...
  • Page 742 INSTALL AIR CLEANER AND MAF METER AS- SEMBLY INSTALL AIR CLEANER INLET FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR ENGINE COOLANT AND A/T FLUID LEAKS INSTALL ENGINE UNDER COVER 2005 LEXUS IS300 (RM1140U) Author : Date : 1481...
  • Page 743 Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.5 - 11.5 A at 20°C (68°F) Reconnect the cooling fan connector. Battery B02073 2005 LEXUS IS300 (RM1140U) Author : Date : 1482...
  • Page 744 COMPONENTS Air Cleaner Inlet Upper Radiator Hose Air Cleaner and MAF Meter Assembly MAF Meter Connector Electric Cooling Fan Assembly Radiator Reservoir Hose Electric Cooling Fan Connector ECM Outlet Duct B11925 2005 LEXUS IS300 (RM1140U) Author : Date : 1483...
  • Page 745 CO-27 COOLING ELECTRIC COOLING FAN No. 2 Fan Motor No. 1 Fan Motor No. 2 Fan Connector Holder Fan Shroud Assembly No. 1 Fan B11958 2005 LEXUS IS300 (RM1140U) Author : Date : 1484...
  • Page 746 Disconnect the wire for electric cooling fan from the clamp on the electric cooling fan. Disconnect the 2 electric cooling fan connectors. Disconnect the radiator reservoir hose from the radiator. Remove the 6 bolts and electric cooling fan. B11957 2005 LEXUS IS300 (RM1140U) Author : Date : 1485...
  • Page 747 Remove the nut and fan. Remove the 2 fans. B00919 REMOVE FAN MOTORS Disconnect the wires and connector holders from the fan shroud. Remove the 3 screws and fan motor. Remove the 2 fan motors. B00921 2005 LEXUS IS300 (RM1140U) Author : Date : 1486...
  • Page 748 B00921 Install the wires and connector holders to the fan shroud as shown in the illustration. B11956 INSTALL FANS Install the fan with the nut. Install the 2 fans. B00919 2005 LEXUS IS300 (RM1140U) Author : Date : 1487...
  • Page 749 Connect the radiator reservoir hose to the radiator. INSTALL AIR CLEANER AND MAF METER AS- SEMBLY INSTALL AIR CLEANER INLET FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS 2005 LEXUS IS300 (RM1140U) Author : Date : 1488...
  • Page 750 If there is no continuity, replace the switch. P05962 REINSTALL ECT SWITCH Install a new O-ring to the ECT switch. Install the ECT switch. Connect the connector. REFILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS 2005 LEXUS IS300 (RM1140U) Author : Date : 1489...
  • Page 751 Reinstall the relay box cover. INSPECT NO. 2 COOLING FAN RELAY No. 2 Cooling Remove the relay box cover. Fan Relay Remove the No. 2 cooling fan relay (Marking: FAN NO.2). B06966 2005 LEXUS IS300 (RM1140U) Author : Date : 1490...
  • Page 752 Using an ohmmeter, measure the resistance be- Ohmmeter tween the terminals. If the resistance is not as specified, replace the relay. Reinstall the No. 3 cooling fan relay. Reinstall the relay box cover. Battery Continuity S04969 2005 LEXUS IS300 (RM1140U) Author : Date : 1491...

  • Page 753: Emission Control System

    (4) Sequential Multiport Fuel Injection * Injects a precisely timed, optimum amount of fuel for reduced exhaust emissions Remark: *For inspection and repair of the SFI system, refer to the SF section this manual. 2005 LEXUS IS300 (RM1140U) Author : Date : 1366...
  • Page 754 VSV for Canister Closed Valve PCV Valve Rear TWC Front TWC VSV for Vapor Pressure Sensor Fuel Tank Cap Vapor Pressure Sensor Vent Line Purge Line Air Drain Hose EVAP Line Air Inlet Line B11894 2005 LEXUS IS300 (RM1140U) Author : Date : 1367...
  • Page 755 Vent Line VSV for EVAP VSV for Canister Closed Valve Fuel Tank Air Inlet Line Charcoal Canister Purge Line Fuel Tank Air Cleaner PCV Valve Front TWC Front TWC Rear TWC B11895 2005 LEXUS IS300 (RM1140U) Author : Date : 1368...
  • Page 756 If operation is not as specified, replace the PCV valve. REMOVE CLEAN HOSE FROM PCV VALVE P02477 REINSTALL PCV VALVE 55° The port faces in the direction indicated in the illustration. Side Line B12525 2005 LEXUS IS300 (RM1140U) Author : Date : 1369...
  • Page 757 EMISSION CONTROL POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. REINSTALL ENGINE COVER Install the engine cover with the 4 nuts. S00601 2005 LEXUS IS300 (RM1140U) Author : Date : 1370...
  • Page 758 5.5 (56, 49 in.·lbf) VSV Connector for Pressure Switching Valve Charcoal Canister Assembly Vent Line Hose 5.0 (51, 44 in.·lbf) Vapor Pressure Sensor Connector N·m (kgf·cm, ft·lbf) : Specified torque B11896 2005 LEXUS IS300 (RM1140U) Author : Date : 1371...
  • Page 759 Forced driving of the VSV for the EVAP. Disconnect the VSV connector for the EVAP. Connect the positive (+) and negative (-) leads from the battery to the VSV terminals for the EVAP. Start the engine. Battery B06548 2005 LEXUS IS300 (RM1140U) Author : Date : 1372...
  • Page 760 HINT: If you can’t add pressure, you can conclude that the hose con- Pressure necting the VSV - canister - fuel tank has slipped off or the VSV is open. B06546 2005 LEXUS IS300 (RM1140U) Author : Date : 1373...
  • Page 761 If there is no stuck in hoses, replace the fuel cutoff valve and fill check valve. Reconnect the purge line hose and EVAP line hose to the charcoal canister. 2005 LEXUS IS300 (RM1140U) Author : Date : 1374...
  • Page 762 Disconnect the VSV connector for vapor pressure sensor. Remove the 2 bolts, nut and the charcoal canister assembly from the protector. INSPECT CHARCOAL CANISTER Visually check the charcoal canister for cracks or dam- age. B11901 2005 LEXUS IS300 (RM1140U) Author : Date : 1375...
  • Page 763 If operation is not as specified, replace the charcoal canister. INSPECT VSV FOR EVAP (See page SF-56 INSPECT VAPOR PRESSURE SENSOR (See page SF-67 Purge Port Vacuum REINSTALL CHARCOAL CANISTER ASSEMBLY B11905 2005 LEXUS IS300 (RM1140U) Author : Date : 1376...
  • Page 764 45 (450, 33) Heated Oxygen Sensor (Bank 1 Sensor 2) F Gasket 44 (440, 32) Pipe Support Bracket N·m (kgf·cm, ft·lbf) : Specified torque 44 (440, 32) F Non-reusable part B11916 2005 LEXUS IS300 (RM1140U) Author : Date : 1377...
  • Page 765 (Bank 2 Sensor 2) 45 (450, 33) Pipe Support Bracket 44 (440, 32) Gasket Front Exhaust Pipe (with Rear TWC) Gasket N·m (kgf·cm, ft·lbf) : Specified torque 44 (440, 32) F Non-reusable part B11907 2005 LEXUS IS300 (RM1140U) Author : Date : 1378...
  • Page 766 If any part of the protector is damaged or dented to the extent that it contacts the TWC, repair or replace INSPECT TWC HEAT INSULATOR Check the heat insulator for damage. Check for adequate clearance between the catalytic converter and heat insulator. 2005 LEXUS IS300 (RM1140U) Author : Date : 1379...
  • Page 767 Install the 2 oxygen sensors to the exhaust manifold. Torque: 45 N·m (450 kgf·cm, 33 ft·lbf) Connect the 3 oxygen sensor connectors. REINSTALL AIR CLEANER ASSEMBLY AND MAF MATER (See page EM-71 REINSTALL AIR CLEANER INLET 2005 LEXUS IS300 (RM1140U) Author : Date : 1380...
  • Page 768 EC-16 EMISSION CONTROL THREE-W AY CATALYTIC CONVERTER (TWC) SYSTEM REINSTALL ENGINE COVER 2005 LEXUS IS300 (RM1140U) Author : Date : 1381...
  • Page 769 IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regula- tions. A08542 2005 LEXUS IS300 (RM1140U) Author : Date : 1266...
  • Page 770 (Black smoke from exhaust) 2. Plugged PCV valve 3. Faulty SFI system: F Faulty fuel pressure regulator F Faulty ECM F Faulty injector F Faulty throttle position sensor F Faulty MAF meter 2005 LEXUS IS300 (RM1140U) Author : Date : 1267...
  • Page 771 RECONNECT INJECTOR CONNECTORS HINT: The Nos. 1, 3, 5 injector connectors and dark gray, and the Nos. 2, 4, 6 injector connectors are brown. 2005 LEXUS IS300 (RM1140U) Author : Date : 1268...
  • Page 772 EM-4 ENGINE MECHANICAL COMPRESSION REINSTALL SPARK PLUGS RECONNECT IGNITION COILS AND HIGH-TENSION CORD SET ASSEMBLY (See page IG-9 INSTALL ENGINE COVER Install the engine cover with the 4 nuts. 2005 LEXUS IS300 (RM1140U) Author : Date : 1269...

  • Page 773: Valve Clearance

    No. 1 vacuum pipe. Disconnect the 2 water bypass hoses from the throttle body, and remove the throttle body together with the in- take air connector and gasket. A11129 2005 LEXUS IS300 (RM1140U) Author : Date : 1270...
  • Page 774 0.25 - 0.35 mm (0.010 - 0.014 in.) Turn the crankshaft pulley 1 revolution (360°), and align the groove with the timing mark ”0” of the No. 1 timing belt cover. 2005 LEXUS IS300 (RM1140U) Author : Date : 1271...
  • Page 775 SST (A) move SST (A). 09248-55040 (09248-05410, 09248-05420) HINT: Apply SST (B) at slight angle on the side marked with ”7” or ”9”, at the position shown in the illustration. P11926 2005 LEXUS IS300 (RM1140U) Author : Date : 1272...
  • Page 776 Select a new shim with a thickness as close as pos- sible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 in.), from 2.500 mm (0.0984 in.) to 3.300 mm (0.1299 in.). 2005 LEXUS IS300 (RM1140U) Author : Date : 1273...
  • Page 777 Adjusting Shim Selection Chart (Intake) Installed Shim Thickness mm (in.) Measured Clearance mm (in.) New shim thickness mm (in.) Shim Shim Thickness Thickness Intake valve clearance (Cold): 0.15 - 0.25 mm (0.006 - 0.010 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured HINT: clearance is 0.450 mm (0.0177 in.).
  • Page 778 Adjusting Shim Selection Chart (Exhaust) Installed Shim Thickness mm (in.) Measured Clearance mm (in.) New shim thickness mm (in.) Shim Shim Thickness Thickness Exhaust valve clearance (Cold): 0.25 - 0.35 mm (0.010 - 0.014 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured HINT: clearance is 0.450 mm (0.0177 in.).
  • Page 779 Secure the engine wire with the clamp on the throttle body bracket. Install the engine wire clamp with the clamp bracket of the throttle body. Connect the accelerator cable to the throttle body. REINSTALL INTAKE AIR RESONATOR 2005 LEXUS IS300 (RM1140U) Author : Date : 1276...
  • Page 780 EM-12 ENGINE MECHANICAL VALVE CLEARANCE REINSTALL ENGINE COVER Install the engine cover with the 4 nuts. REFILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS 2005 LEXUS IS300 (RM1140U) Author : Date : 1277...

  • Page 781: Ignition Timing

    FURTHER CHECK IGNITION TIMING Ignition timing: 6 - 16° BTDC @ idle (Transmission in neutral position) HINT: A02637 The timing mark moves in a range between 6° and 16°. DISCONNECT TIMING LIGHT FROM ENGINE 2005 LEXUS IS300 (RM1140U) Author : Date : 1278...

  • Page 782: Idle Speed

    D09381 Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the throttle body. DISCONNECT HAND-HELD TESTER OR OBD II SCAN TOOL 2005 LEXUS IS300 (RM1140U) Author : Date : 1279...

  • Page 783: Timing Belt

    Drive Belt 58 (590, 43) Drive Belt Lower Radiator Support 52 (530, 38) Tensioner Absorber (M/T) 20 (200, 14) Engine Under Cover x 16 N·m (kgf·cm, ft·lbf) : Specified torque A17485 2005 LEXUS IS300 (RM1140U) Author : Date : 1280...
  • Page 784 8.0 (80, 71 in.·lbf) Timing Belt Plate 27 (270, 20) Drive Belt Tensioner Timing Belt Tensioner (with Arm) N·m (kgf·cm, ft·lbf) : Specified torque f Non-reusable part F Precoated part A17484 2005 LEXUS IS300 (RM1140U) Author : Date : 1281...
  • Page 785 Remove the 3 bolts and tensioner. NOTICE: Be careful not to drop the bolts inside the timing belt cover. A02649 LOOSEN CRANKSHAFT PULLEY BOLT Using SST, loosen the pulley bolt. 09213-7001 1, 09330-00021 A02690 2005 LEXUS IS300 (RM1140U) Author : Date : 1282...
  • Page 786 Do not turn the crankshaft pulley. A02660 REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS HINT: Re-using timing belt: Place matchmarks on the timing belt and camshaft timing pul- leys as shown in the illustration. A02653 2005 LEXUS IS300 (RM1140U) Author : Date : 1283...
  • Page 787 Remove the bolt, union bolt, oil control valve filter and 2 gas- kets, and disconnect the No. 1 oil pipe from the No. 3 camshaft bearing cap. Oil Control Valve Filter A02662 2005 LEXUS IS300 (RM1140U) Author : Date : 1284...
  • Page 788 Bolt: Part No. 90119-18001 NOTICE: Do not turn the crankshaft pulley. REMOVE NO. 1 TIMING BELT COVER A02745 Remove the 5 bolts, timing belt cover and gasket. REMOVE TIMING BELT GUIDE 2005 LEXUS IS300 (RM1140U) Author : Date : 1285...
  • Page 789 09950- 50013 (09951- 05010, 09952- 05010, 09953-05020, 09954-05011) Bolt Bolt: Part No. 90119-18001 NOTICE: Do not scratch the sensor part the crankshaft timing A02746 pulley. Do not turn the timing pulley. 2005 LEXUS IS300 (RM1140U) Author : Date : 1286...
  • Page 790 Visually check tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace tensioner. P02075 2005 LEXUS IS300 (RM1140U) Author : Date : 1287...
  • Page 791 Using a drill, make a hole in the cylinder as shown to release the gas inside. CAUTION: The gas coming out is harmless, but the careful of the chips which may fly up when drilling. A17483 2005 LEXUS IS300 (RM1140U) Author : Date : 1288...
  • Page 792 HINT: When re-using timing belt: Align the matchmarks of the crankshaft timing pulley and timing belt, and install the belt with the arrow pointing in the direction of engine revolution. A02642 2005 LEXUS IS300 (RM1140U) Author : Date : 1289...
  • Page 793 Align the camshaft knock pin with the VVT-i pulley, and Align push the VVT-i pulley by hand until you feel it touch the bottom. A02648 Check that the outer circumference of the VVT-i pulley 30° easily rotates through 30°. A02659 2005 LEXUS IS300 (RM1140U) Author : Date : 1290...
  • Page 794 Slide the timing pulley on the camshaft, facing the front mark forward. Using SST, install the pulley bolt. 09960-10010 (09962-01000, 09963-01000) Torque: 81 N·m (810 kgf·cm, 60 ft·lbf) A02661 2005 LEXUS IS300 (RM1140U) Author : Date : 1291...
  • Page 795 Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the push rod retracted. 1.5 mm Release the press. Hexagon Wrench Z02446 Install the dust boot onto the tensioner. P04459 2005 LEXUS IS300 (RM1140U) Author : Date : 1292...
  • Page 796 INSTALL DRIVE BELT TENSIONER Install the tensioner with the 3 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) NOTICE: Be careful not to drop the bolts inside the timing belt cover. A02691 2005 LEXUS IS300 (RM1140U) Author : Date : 1293...
  • Page 797 FILL ENGINE WITH COOLANT START ENGINE CHECK FOR LEAKS INSTALL ENGINE UNDER COVER ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT LEVEL 2005 LEXUS IS300 (RM1140U) Author : Date : 1294...

  • Page 798: Cylinder Head

    Air Cleaner Inlet Drive Belt Drive Belt Tensioner Absorber (M/T) Upper Radiator Hose 20 (200, 14) Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque x 16 f Non-reusable part A17486 2005 LEXUS IS300 (RM1140U) Author : Date : 1295...
  • Page 799 No. 2 Timing Belt Cover f O-Ring Oil Dipstick and Guide for Engine PS Vane Pump 58 (590, 43) N·m (kgf·cm, ft·lbf) : Specified torque 39.2 (400, 29) f Non-reusable part A17488 2005 LEXUS IS300 (RM1140U) Author : Date : 1296...
  • Page 800 Intake Manifold Assembly Straight 8.0 (80, 71 in.·lbf) 28 (280, 21) Screw Plug 81 (810, 60) Manifold Stay Timing Belt Starter Wire N·m (kgf·cm, ft·lbf) : Specified torque f Non-reusable part A11124 2005 LEXUS IS300 (RM1140U) Author : Date : 1297...
  • Page 801 Engine Hanger Cylinder Head Camshaft Position Sensor f Gasket ECT Sensor f Gasket f Valve Guide Bushing Valve Water Outlet with Water Bypass Hose f Non-reusable part F Precoated part A14344 2005 LEXUS IS300 (RM1140U) Author : Date : 1298...
  • Page 802 DISCONNECT FRONT EXHAUST PIPE FROM EX- Wire HAUST MANIFOLD Grommet Disconnect the wire grommet and sensor wire of the heated oxygen sensor (bank 2 sensor 2) from the hole and clamp on the floor. Clamp B01935 2005 LEXUS IS300 (RM1140U) Author : Date : 1299...
  • Page 803 Disconnect the engine wire clamp from the clamp bracket of the No. 2 vacuum pipe. REMOVE NO. 3 TIMING BELT COVER REMOVE IGNITION COILS AND HIGH- TENSION A02735 CORD SET ASSEMBLY (See page IG-7 REMOVE SPARK PLUGS 2005 LEXUS IS300 (RM1140U) Author : Date : 1300...
  • Page 804 No. 2 cylinder head cover. Remove the 3 nuts, and disconnect the engine wire pro- tector from the intake manifold. REMOVE FUEL PRESSURE PULSATION DAMPER (See page SF-26 5 mm Hexagon Wrench A11123 2005 LEXUS IS300 (RM1140U) Author : Date : 1301...
  • Page 805 Remove the exhaust camshaft timing pulley. Hold the hexagon portion of the camshaft with a wrench, and remove the pulley bolt and camshaft pulley. Remove the VVT-i (intake camshaft timing) pulley (See page EM-17 S03013 2005 LEXUS IS300 (RM1140U) Author : Date : 1302...
  • Page 806 Uniformly loosen and remove the 12 camshaft bearing cap bolts, in several passes, in the sequence shown. Remove the 6 No. 2 camshaft bearing caps and cam- shaft. Remove the intake and exhaust camshafts. A02930 A17558 2005 LEXUS IS300 (RM1140U) Author : Date : 1303...
  • Page 807 If the cylinder head is difficult to lift off, pry with a screwdriver be- Lift tween the cylinder head and block projection. NOTICE: Be careful not to damage the contact surfaces of the cylin- der head and cylinder block. S03016 2005 LEXUS IS300 (RM1140U) Author : Date : 1304...
  • Page 808 Remove the spring retainer, valve spring, valve and spring seat. HINT: Store the valves, valve springs, spring seats and spring retain- ers in correct order. A02715 Using needle-nose pliers, remove the oil seal. 2005 LEXUS IS300 (RM1140U) Author : Date : 1305...
  • Page 809 Be careful not to scratch the cylinder block contact sur- face. A02706 Clean the valve guide bushings. Using a valve guide bushing brush and solvent, clean all the guide bushings. P02072 2005 LEXUS IS300 (RM1140U) Author : Date : 1306...
  • Page 810 If cracked, replace the cylinder head. A02708 CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM0580 2005 LEXUS IS300 (RM1140U) Author : Date : 1307...
  • Page 811 Standard margin thickness: 0.8 - 1.2 mm (0.031 - 0.047 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. Margin Thickness EM0181 2005 LEXUS IS300 (RM1140U) Author : Date : 1308...
  • Page 812 Check that the seat contact is in the middle of the valve face with the following width: Intake 1.0 - 1.4 mm (0.039 - 0.055 in.) Exhaust 1.2 - 1.6 mm (0.047 - 0.063 in.) 2005 LEXUS IS300 (RM1140U) Author : Date : 1309...
  • Page 813 Free length: Pink painted mark 43.71 mm (1.7209 in.) Yellow painted mark 44.10 mm (1.7362 in.) If the free length is not as specified, replace the valve spring. EM0801 2005 LEXUS IS300 (RM1140U) Author : Date : 1310...
  • Page 814 Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft jour- nals. Install the bearing caps (See page EM-53 NOTICE: Do not turn the camshaft. Remove the bearing caps. A02817 2005 LEXUS IS300 (RM1140U) Author : Date : 1311...
  • Page 815 Using a precision straight edge and feeler gauge, measure the surfaces contacting the intake manifold for warpage. Maximum warpage: 0.15 mm (0.0059 in.) If warpage is greater than maximum, replace the chamber. A02830 2005 LEXUS IS300 (RM1140U) Author : Date : 1312...
  • Page 816 10.8 - 11.0 mm (0.425 - 0.433 in.) Minimum outside diameter: 10.7 mm (0.421 in.) Compressed If the diameter is less than minimum, replace the bolt. Thread About 50 mm A02828 2005 LEXUS IS300 (RM1140U) Author : Date : 1313...
  • Page 817 Exhaust 11.4 - 11.8 mm (0.449 - 0.465 in.) A02744 HINT: Exhaust Intake Different bushings are used for the intake and exhaust. 38.5 mm 40.5 mm (1.516 in.) (1.594 in.) P04791 2005 LEXUS IS300 (RM1140U) Author : Date : 1314...
  • Page 818 Using a sharp 6 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM-41 ) between the guide bushing and valve stem. Sharp 6 mm Reamer A02687 2005 LEXUS IS300 (RM1140U) Author : Date : 1315...
  • Page 819 Install a new oil seal on the valve guide bushing. Install the valve, spring seat, valve spring and spring re- tainer. A02704 Using SST, compress the valve spring and place the 2 keepers around the valve stem. 09202-70020 (09202-00010) A02715 2005 LEXUS IS300 (RM1140U) Author : Date : 1316...
  • Page 820 Torque: 40 N·m (400 kgf·cm, 30 ft·lbf) INSTALL WATER OUTLET WITH WATER BYPASS HOSE Install a new gasket and the water outlet with the bolt and 2 nuts. Torque: 28 N·m (280 kgf·cm, 21 ft·lbf) 2005 LEXUS IS300 (RM1140U) Author : Date : 1317...
  • Page 821 S02643 INSTALL CAMSHAFTS Knock Pin Apply engine oil to the thrust portion of the camshaft. Place the camshaft on the cylinder head with the cam lobe facing up as shown. A02699 2005 LEXUS IS300 (RM1140U) Author : Date : 1318...
  • Page 822 Torque: 20 N·m (200 kgf·cm, 15 ft·lbf) Using a 5 mm hexagon wrench, the 2 No. 3 camshaft bearing cap bolts. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) S03018 2005 LEXUS IS300 (RM1140U) Author : Date : 1319...
  • Page 823 Slide the timing pulley on the camshaft, facing the front mark forward. Front Mark Hold the hexagon portion of the camshaft with a wrench, and tighten the timing pulley bolt. Torque: 81 N·m (810 kgf·cm, 60 ft·lbf) A02727 2005 LEXUS IS300 (RM1140U) Author : Date : 1320...
  • Page 824 Install the manifold stay with the 2 bolts. Torque: 40 N·m (400 kgf·cm, 30 ft·lbf) Install the starter wire to the manifold stay. A11122 INSTALL FUEL PRESSURE PULSATION DAMPER (See page SF-27 2005 LEXUS IS300 (RM1140U) Author : Date : 1321...
  • Page 825 Install the ground strap to the cylinder head. INSTALL SPARK PLUGS INSTALL IGNITION COILS AND HIGH- TENSION A02732 CORD SET ASSEMBLY (See page IG-9 2005 LEXUS IS300 (RM1140U) Author : Date : 1322...
  • Page 826 Torque: 40 N·m (410 kgf·cm, 30 ft·lbf) Connect the 3 heated oxygen sensor connectors and clamp. A09752 Install a new clamp and the case clamp as shown in the illustration. Case Clamp New Clamp A11121 2005 LEXUS IS300 (RM1140U) Author : Date : 1323...
  • Page 827 FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS INSTALL ENGINE UNDER COVER ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT LEVEL 2005 LEXUS IS300 (RM1140U) Author : Date : 1324...

  • Page 828: Engine Unit

    Member Brace (M/T) 20 (200, 14) 58 (590, 43) 119 (1,120, 88) Stabilizer Bar Engine Under Cover 49 (500, 36) x 18 18 (180, 13) N·m (kgf·cm, ft·lbf) : Specified torque A17487 2005 LEXUS IS300 (RM1140U) Author : Date : 1325...
  • Page 829 (Bank1 Sensor 1) Engine Wire Radiator Upper Hose f 3 ECU Connectors f 4 Wire Harness Connectors f 2 Junction Connectors Generator Connector Generator Wire Oxygen Sensor Connector (Bank1 Sensor 2) A17494 2005 LEXUS IS300 (RM1140U) Author : Date : 1326...
  • Page 830 Heated Oxygen Sensor (Bank 1 Sensor 2) Ring Center Exhaust Pipe 43 (438, 32) Gasket Front Exhaust Pipe Gasket 43 (438, 32) Retainer N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part A17107 2005 LEXUS IS300 (RM1140U) Author : Date : 1327...
  • Page 831 12 (120, 9) Shift Lever Fuel Inlet Hose Gasket 29 (300, 22) Rear Engine Mounting Member 13.5 (135, 10) N·m (kgf·cm, ft·lbf) : Specified torque 25.5 (260, 19) Non-reusable part A17000 2005 LEXUS IS300 (RM1140U) Author : Date : 1328...
  • Page 832 14 mm Bolt 19 (195, 14) 37 (380, 27) Starter Hole Plug Starter Connector 72 (730, 53) Clutch Cover N·m (kgf·cm, ft·lbf) : Specified torque Clutch Disc Non-reusable part F Precoated part A17489 2005 LEXUS IS300 (RM1140U) Author : Date : 1329...
  • Page 833 REMOVE DRIVE BELT TENSIONER ABSORBER Remove the 2 nuts and absorber. REMOVE DRIVE BELT (See page CH-1 REMOVE FRONT SUSPENSION MEMBER BRACE Remove the 8 bolts and brace. M/T: REMOVE TRANSMISSION SHIFT LEVER A13976 2005 LEXUS IS300 (RM1140U) Author : Date : 1330...
  • Page 834 Remove the ECM hood and ECM cover. Disconnect the 3 ECM connectors. Disconnect the 4 wire harness connectors. Disconnect the 2 junction connectors. Disconnect the grommet and engine wire from the ECM box. A02786 2005 LEXUS IS300 (RM1140U) Author : Date : 1331...
  • Page 835 DISCONNECT CLUTCH RELEASE CYLINDER FROM TRANSMISSION REMOVE PROPELLER SHAFT (See page PR-4 A/T: REMOVE TRANSMISSION CONTROL ROD Remove the 2 nuts and control rod. REMOVE FRONT AND CENTER EXHAUST PIPES A02791 2005 LEXUS IS300 (RM1140U) Author : Date : 1332...
  • Page 836 Remove the 2 bolts, and disconnect the lower arm from the steering knuckle. A13977 SET ENGINE JACK NOTICE: Using chain, hold the engine tightly. A13978 DISCONNECT REAR ENGINE MOUNTING MEMBER Remove the 4 bolts and rear engine mounting member. A13979 2005 LEXUS IS300 (RM1140U) Author : Date : 1333...
  • Page 837 Pull A02743 REMOVE EXHAUST MANIFOLD Case Clamp Remove the case clamp. Disconnect the heated oxygen sensor (bank 2 sensor 1) connector. Remove the 8 nuts, exhaust manifold and 2 gaskets. A09755 2005 LEXUS IS300 (RM1140U) Author : Date : 1334...
  • Page 838 Remove the transmission together with the torque con- verter clutch from the engine. A/T: REMOVE DRIVE PLATE Remove the 8 bolts, rear plate, drive plate and front spacer. M/T: REMOVE CLUTCH COVER AND DISC A13982 2005 LEXUS IS300 (RM1140U) Author : Date : 1335...
  • Page 839 Connect the VSS connector. Connect the back-up light switch connector. INSTALL STARTER Install the starter and clamp bracket with the 2 bolts. Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) Connect the starter connector. 2005 LEXUS IS300 (RM1140U) Author : Date : 1336...
  • Page 840 Push in the dipstick guide end to the dipstick tube of the oil pan. Install the dipstick guide with the bolt. Connect the engine wire clamp to the dipstick guide. Push Install the dipstick. A02761 2005 LEXUS IS300 (RM1140U) Author : Date : 1337...
  • Page 841 Torque: 245 N·m (2,500 kgf·cm, 181 ft·lbf) Connect the height level sensor to the lower arm. CONNECT SHOCK ABSORBER Connect the shock absorber with the bolt and nut. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) A13977 2005 LEXUS IS300 (RM1140U) Author : Date : 1338...
  • Page 842 Set the shift lever to the N position. While holding the shift lever lightly toward the R position side, tighten the nut. A02792 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) M/T: INSTALL CLUTCH RELEASE CYLINDER TO TRANS- MISSION 2005 LEXUS IS300 (RM1140U) Author : Date : 1339...
  • Page 843 Connect the igniter connector. Connect the ground cable to the bracket on the cylinder block. Connect the engine wire clamp to the wire clip of the gen- erator. Connect the generator wire. A02759 2005 LEXUS IS300 (RM1140U) Author : Date : 1340...
  • Page 844 Connect the engine wire clamp to the air cleaner case. Connect the PCV hose to the No.2 cylinder head cover. CONNECT RADIATOR UPPER AND LOWER HOSES CONNECT BRAKE BOOSTER VACUUM HOSE A13975 INSTALL AIR CLEANER INLET 2005 LEXUS IS300 (RM1140U) Author : Date : 1341...
  • Page 845 Be careful not to damage the body or glass with the hood end. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT AND OIL LEVELS 2005 LEXUS IS300 (RM1140U) Author : Date : 1342...
  • Page 846 Gasket LH Engine Mounting Bracket and Insulator Assembly f Gasket No. 2 Oil Pan Drain Plug N·m (kgf·cm, ft·lbf) : Specified torque x 16 f Non-reusable part F Precoated part A02768 2005 LEXUS IS300 (RM1140U) Author : Date : 1343...
  • Page 847 Rear Oil Seal Retainer Crankshaft Crankshaft Thrust Washer Main Bearing Main Bearing Cap See page EM-95 1st: 45 (450, 33) 2nd: Turn 90° N·m (kgf·cm, ft·lbf) : Specified torque f Non-reusable part A02806 2005 LEXUS IS300 (RM1140U) Author : Date : 1344...
  • Page 848 0.250 - 0.402 mm (0.0098 - 0.0158 in.) Maximum thrust clearance: 0.50 mm (0.0197 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crank- shaft. P04467 2005 LEXUS IS300 (RM1140U) Author : Date : 1345...
  • Page 849 Install the connecting rod cap with the 2 bolts (See page EM-95 NOTICE: Do not turn the crankshaft. Remove the 2 bolts, connecting rod cap and lower bear- ing (See procedure (b) and (c) above). P02426 2005 LEXUS IS300 (RM1140U) Author : Date : 1346...
  • Page 850 1.504 - 1.507 mm (0.0592 - 0.0593 in.) Mark ”4” 1.507 - 1.510 mm (0.0593 - 0.0594 in.) Mark ”5” 1.510 - 1.513 mm (0.0594 - 0.0596 in.) Completely remove the Plastigage. 2005 LEXUS IS300 (RM1140U) Author : Date : 1347...
  • Page 851 Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. Place the crankshaft on the cylinder block. 2005 LEXUS IS300 (RM1140U) Author : Date : 1348...
  • Page 852 = Total number 7 (Use bearing ”3”) Mark 0, 1, 2, 3, 4, 5, 6 or 7 No.7 No.1 No.6 No.2 No.5 No.3 No.4 Mark 1, 2, 3, 4 or 5 A02784 2005 LEXUS IS300 (RM1140U) Author : Date : 1349...
  • Page 853 2.000 - 2.003 mm (0.0787 - 0.0789 in.) Mark ”4” 2.003 - 2.006 mm (0.0789 - 0.0790 in.) Mark ”5” 2.006 - 2.009 mm (0.0790 - 0.0791 in.) Completely remove the Plastigage. 2005 LEXUS IS300 (RM1140U) Author : Date : 1350...
  • Page 854 HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. P02278 2005 LEXUS IS300 (RM1140U) Author : Date : 1351...
  • Page 855 If the diameter is greater than maximum, replace the cylinder block. 10 mm (0.39 in.) EM0365 REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. A02684 2005 LEXUS IS300 (RM1140U) Author : Date : 1352...
  • Page 856 0.035 - 0.068 mm (0.0014 - 0.0027 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block. 2005 LEXUS IS300 (RM1140U) Author : Date : 1353...
  • Page 857 If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. INSPECT PISTON PIN FIT At 80°C (176°F), you should be able to push the piston pin into the piston pin hole with your thumb. A02680 2005 LEXUS IS300 (RM1140U) Author : Date : 1354...
  • Page 858 Standard diameter: 8.1 - 8.3 mm (0.319 - 0.327 in.) Minimum diameter: 8.0 mm (0.315 in.) If the diameter is less than minimum, replace the connecting rod bolt. About Compressed 20 mm P02459 2005 LEXUS IS300 (RM1140U) Author : Date : 1355...
  • Page 859 IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure step 16). Install new main journal and/or crank pin undersized bearings. 2005 LEXUS IS300 (RM1140U) Author : Date : 1356...
  • Page 860 There are 2 methods ((a) and (b)) to replace the oil seal. If the oil pump is removed form the cylinder block. Using a screwdriver, pry out the oil seal. P04473 2005 LEXUS IS300 (RM1140U) Author : Date : 1357...
  • Page 861 Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. 09223-15030, 09950-70010 (09951-07100) Apply MP grease to the oil seal lip. P04796 2005 LEXUS IS300 (RM1140U) Author : Date : 1358...
  • Page 862 Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. 09223-15030, 09950-70010 (09951-07100) P02363 2005 LEXUS IS300 (RM1140U) Author : Date : 1359...
  • Page 863 Position the piston rings so that the ring ends are as No. 1 Upper Side Compression shown. Rail NOTICE: Expander Do not align the piston ring ends. Front Mark (Cavity) No. 2 Lower Side Compression Rail A02672 2005 LEXUS IS300 (RM1140U) Author : Date : 1360...
  • Page 864 INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.4 main journal position of the cylinder block with the oil grooves facing outward. PLACE CRANKSHAFT ON CYLINDER BLOCK A02754 2005 LEXUS IS300 (RM1140U) Author : Date : 1361...
  • Page 865 Front Mark (Cavity) SEMBLIES Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. Front A02747 2005 LEXUS IS300 (RM1140U) Author : Date : 1362...
  • Page 866 Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket sur- faces and sealing groove. Thoroughly clean all components to remove all de- bris. Using a non-residue solvent, clean both sealing surfaces. 2005 LEXUS IS300 (RM1140U) Author : Date : 1363...
  • Page 867 INSTALL TIMING PULLEYS AND BELT (See page EM-24 INSTALL GENERATOR Install the generator and pipe bracket with the bolt and nut. Torque: 40 N·m (400 kgf·cm, 30 ft·lbf) REMOVE ENGINE STAND FROM ENGINE 2005 LEXUS IS300 (RM1140U) Author : Date : 1364...

  • Page 868: Exhaust System

    Heated Oxygen Sensor (Bank 1 Sensor 2) 45 (450, 33) Heat Insulator f Gasket Front Exhaust Pipe f Gasket 43 (438, 32) Retainer N·m (kgf·cm, ft·lbf) : Specified torque f Non-reusable part A13983 2005 LEXUS IS300 (RM1140U) Author : Date : 1365...

  • Page 869: Ignition System

    REPAIR WIRING BETWEEN IGNITION COIL AND ECM Using a 16 mm plug wrench, reinstall the spark plug. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) Reinstall the ignition coil (See page IG-9 2005 LEXUS IS300 (RM1140U) Author : Date : 1507...
  • Page 870 Reconnect the high-tension cord set to the ignition coils. Assemble the holder and grommet. Align the spline of the ignition coil with the spline of the holder, and push in the cord. Push S02492 2005 LEXUS IS300 (RM1140U) Author : Date : 1508...
  • Page 871 Using a 16 mm plug wrench, remove the 6 spark plugs. Visually check the spark plug for thread damage and insu- B02629 lator damage. If abnormal, replace the spark plug. Recommended spark plug: DENSO made SK16R-P11 2005 LEXUS IS300 (RM1140U) Author : Date : 1509...
  • Page 872 Secondary coil resistance: Cold 8.5 - 14.7 kΩ 10.8 - 17.2 kΩ If the resistance is not as specified, replace the ignition coil. Reinstall the ignition coil assembly (See page IG-9 S02336 2005 LEXUS IS300 (RM1140U) Author : Date : 1510...
  • Page 873 2,065 - 3,225 Ω B01627 If the resistance is not as specified, replace the sensor. Reinstall the bolt holding the connector bracket to the wa- ter pump. Reconnect the sensor connector. 2005 LEXUS IS300 (RM1140U) Author : Date : 1511...

  • Page 874: Ignition Coil

    Throttle Position Sensor Connector Connector 21 (210, 15) High-Tension Cord Set Engine Wire No. 1 No. 3 No. 2 Ignition Coil Water Bypass Hose N·m (kgf·cm, ft·lbf) : Specified torque Hose Clamp B11954 2005 LEXUS IS300 (RM1140U) Author : Date : 1512...
  • Page 875 Slightly slide the throttle body away from the intake air Slide connector. Disconnect B01617 REMOVE THROTTLE BODY GASKET Remove the 3 bolts and throttle body gasket. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) B01618 2005 LEXUS IS300 (RM1140U) Author : Date : 1513...
  • Page 876 B01623 Remove the 3 bolts, the ignition coils and high-tension cord set assembly. Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf) B01624 REMOVE IGNITION COILS FROM HIGH- TENSION CORD SET S02493 2005 LEXUS IS300 (RM1140U) Author : Date : 1514...
  • Page 877 IG-9 IGNITION IGNITION COIL IG00X-04 INSTALLATION Installation is in the reverse order of removal (See page IG-7 2005 LEXUS IS300 (RM1140U) Author : Date : 1515...

  • Page 878: Camshaft Position Sensor

    Oil Dipstick and Guide for Engine Camshaft Position 21 (210, 15) Sensor Connector 9.0 (90, 80 in.·lbf) Camshaft Position Sensor Knock Sensor 2 Connector Starter Connector N·m (kgf·cm, ft·lbf) :Specified torque F Non-reusable part B11949 2005 LEXUS IS300 (RM1140U) Author : Date : 1516...
  • Page 879 Torque: 39.2 N·m (400 kgf·cm, 29 ft·lbf) REMOVE INTAKE MANIFOLD ASSEMBLY (See page EM-34 REMOVE CAMSHAFT POSITION SENSOR Remove the 2 bolts and sensor. Torque: 9.0 N·m (90 kgf·cm, 80 in.·lbf) B01625 2005 LEXUS IS300 (RM1140U) Author : Date : 1517...
  • Page 880 IG-12 IGNITION CAMSHAFT POSITION SENSOR IG05X-03 INSTALLATION Installation is in the reverse order of removal (See page IG-1 2005 LEXUS IS300 (RM1140U) Author : Date : 1518...

  • Page 881: Crankshaft Position Sensor

    Crankshaft Position Sensor 9.0 (90, 80 in.·lbf) Generator A/T Oil Cooler Pipe Pipe Bracket Drive Belt Tensioner Absorber 20 (200, 14) Engine Under Cover x 18 N·m (kgf·cm, ft·lbf) : Specified torque B15231 2005 LEXUS IS300 (RM1140U) Author : Date : 1519...
  • Page 882 Remove the bolt holding the connector bracket to the wa- ter pump. REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and sensor. Torque: 9.0 N·m (90 kgf·cm, 80 in.·lbf) Remove the connector bracket from the connector. B01984 2005 LEXUS IS300 (RM1140U) Author : Date : 1520...
  • Page 883 IG-15 IGNITION CRANKSHAFT POSITION SENSOR IG05Z-04 INSTALLATION Installation is in the reverse order of removal (See page IG-14 2005 LEXUS IS300 (RM1140U) Author : Date : 1521...
  • Page 884 242 or equivalent Using SST, install the oil pressure switch. 09268-46021 Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Connect the oil pressure switch connector. START ENGINE AND CHECK FOR LEAKS P12478 2005 LEXUS IS300 (RM1140U) Author : Date : 1492...
  • Page 885 Reinstall the engine under cover with the 3 screws. FILL WITH ENGINE OIL Addition 3/4 Turn Clean and install the oil drain plug with a new gasket. Torque: 38 N·m (380 kgf·cm, 28 ft·lbf) B02226 2005 LEXUS IS300 (RM1140U) Author : Date : 1493...
  • Page 886 5.1 liters (5.4 US qts, 4.5 lmp. qts) Dry fill 6.5 liters (6.9 US qts, 5.7 lmp. qts) Reinstall the oil filler cap. START ENGINE AND CHECK FOR OIL LEAKS RECHECK ENGINE OIL LEVEL 2005 LEXUS IS300 (RM1140U) Author : Date : 1494...

  • Page 887: Oil Pump

    Dust Boot Timing Belt Tensioner No. 2 Oil Pan 27 (270, 20) N·m (kgf·cm, ft·lbf) : Specified torque f Gasket x 16 f Non-reusable part Drain Plug F Precoated part B15228 2005 LEXUS IS300 (RM1140U) Author : Date : 1495...
  • Page 888 LU-5 LUBRICATION OIL PUMP Plug f Gasket Compression Spring x 10 Relief Valve Oil Pump Body Cover Drive Rotor Driven Rotor Oil Pump Body f Non-reusable part B01643 2005 LEXUS IS300 (RM1140U) Author : Date : 1496...
  • Page 889 No. 2 oil pan. 09032-00100 NOTICE: Be careful not to damage the No. 2 oil pan contact surface of the No.1 oil pan. Be careful not to damage the oil pan Z02375 flange. 2005 LEXUS IS300 (RM1140U) Author : Date : 1497...
  • Page 890 Remove the 9 bolts. Using a hammer and a brass bar, remove the oil pump by carefully tapping the oil pump body. Remove the 2 O-rings from the cylinder block. P02152 2005 LEXUS IS300 (RM1140U) Author : Date : 1498...
  • Page 891 Remove the plug, gasket, compression spring and relief valve. NOTICE: Be careful not to damage the pump body. P02148 REMOVE DRIVE AND DRIVEN ROTORS Remove the 10 screws, pump body cover, the drive and driven rotors. P02443 2005 LEXUS IS300 (RM1140U) Author : Date : 1499...
  • Page 892 Maximum side clearance: 0.12 mm (0.0047 in.) If the side clearance is greater than maximum, replace the ro- tors as a set. If necessary, replace the oil pump assembly. P02156 Remove the rotors. 2005 LEXUS IS300 (RM1140U) Author : Date : 1500...
  • Page 893 LU-10 LUBRICATION OIL PUMP LU05M-04 REPLACEMENT REPLACE FRONT CRANKSHAFT OIL SEAL (See page EM-92 2005 LEXUS IS300 (RM1140U) Author : Date : 1501...
  • Page 894 Be careful not to damage the pump body. Insert the relief valve and compression spring into the oil Relief pump body hole. Valve Install the plug with a new gasket. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) S01373 2005 LEXUS IS300 (RM1140U) Author : Date : 1502...
  • Page 895 Immediately remove nozzle from the tube and rein- stall cap. Seal Width 2 - 3 mm Z02385 Install the oil pump with the 9 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) Long Bolt P03936 2005 LEXUS IS300 (RM1140U) Author : Date : 1503...
  • Page 896 Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket sur- faces and sealing groove. Thoroughly clean all components to remove all the debris. 2005 LEXUS IS300 (RM1140U) Author : Date : 1504...
  • Page 897 Install the dipstick guide with the bolt. Push Install the dipstick. Connect the engine wire clamp to the dipstick guide. INSTALL CRANKSHAFT TIMING PULLEY, IDLER A02760 PULLEY AND TIMING BELT (See page EM-24 2005 LEXUS IS300 (RM1140U) Author : Date : 1505...
  • Page 898 OIL PUMP INSTALL CRANKSHAFT POSITION SENSOR Torque: 9.0 N·m (90 kgf·cm, 80 in.·lbf) REMOVE ENGINE STAND FROM ENGINE ASSEMBLY ENGINE AND TRANSMISSION (See page EM-71 INSTALL ENGINE WITH TRANSMISSION (See page EM-71 2005 LEXUS IS300 (RM1140U) Author : Date : 1506...

  • Page 899: Outside Vehicle

    Check that all of the doors and the trunk lid operate smoothly, and that all the latches lock securely. When the primary latch is released, check that the engine hood secondary latch prevents the hood from opening. 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 900: Inside Vehicle

    When the rear seatbacks are folded down, check if the latches lock securely. SEAT BELTS Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. Check that the belt webbing is not cut, frayed, worn or damaged. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 901 Check the lock release mechanism of the selector lever for proper and smooth operation. When the selector lever is in the ”P” position and all brakes are released on a low incline, check that the vehicle is stabilized. 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 902: Under Hood

    After extended driving under harsh conditions (high speeds, hot weather, heavy traffic or pulling a trailer), let the engine cool own for approximately 30 minutes before checking the fluid level. EXHAUST SYSTEM Check for unusual exhaust sounds or abnormal exhaust fumes. Locate the cause and correct it. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 903 Visually check the fuel lines for cracks, leakage, loose connec- tions, deformation or tank band looseness. INSPECT EXHAUST PIPES AND MOUNTINGS Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. INSPECT VALVE CLEARANCE (See page EM-5 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 904 (FRONT PADS: See page BR-24 (REAR PADS: See page BR-33 (FRONT DISCS: See page BR-29 (REAR DISCS: See page BR-38 INSPECT OR CHANGE BRAKE FLUID (See page BR-4 Fluid: SAE J1703 or FMVSS No.116 DOT3 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 905 Visually check the manual transmission and differential for oil leakage. If leakage is found, check for the cause and repair it. LSD torque sensing type: REPLACE DIFFERENTIAL OIL (See page SA-73 Except wagon model: ROTATE TIRES (See page SA-3 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 906 Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf) REPLACE AIR REFINER FILTER (See page AC-93 BODY INSPECTION Check the body exterior for dents, scratches and rust. Check the underbody for rust and damage. If necessary, replace or repair. D09260 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 907 Check the engine and chassis for abnormal noises. Check that the vehicle does not wander or pull to one side. Check that the brakes work properly and do not drag. Do setting of the parking brake shoes and drum. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 908 Apply FIPG in an approx. 1.2 mm (0.047 in.) wide bead along the sealing surface. Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied. 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 909 2. Shift key spring (Damaged) MT-30 MT-38 1. Locking ball spring (Damaged) MT-11 2. Shift fork (Worn) MT-11 Jumps out of gear 3. Gear (Worn or damaged) MT-11 4. Bearing (Worn or damaged) MT-11 2005 LEXUS IS300 (RM1140U) Author : Date : 1576...
  • Page 910 Engine Cover No. 1 Intake Air Connector 5.0 (51, 44 in.·lbf) Exhaust Manifold Case Clamp Radiator Upper Gasket 40 (408, 29) Hose No. 1 N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part D11484 2005 LEXUS IS300 (RM1140U) Author : Date : 1577...
  • Page 911 No. 2 Engine Under Cover 62 (630, 46) Pipe Support Bracket No. 1 Rear Floor Board 43 (438, 32) No. 1 Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque F Non-reusable part D11483 2005 LEXUS IS300 (RM1140U) Author : Date : 1578...
  • Page 912 Disconnect the heated oxygen sensor (bank 2 sensor 1) connector. Remove the 8 nuts, exhaust manifold and 2 gaskets. RAISE VEHICLE NOTICE: Make sure that the vehicle is securely supported. DRAIN TRANSMISSION OIL A09755 2005 LEXUS IS300 (RM1140U) Author : Date : 1579...
  • Page 913 Remove the 2 bolts and starter. JACK UP TRANSMISSION SLIGHTLY D11479 Using a transmission jack, support the transmission. REMOVE REAR ENGINE MOUNTING MEMBER Remove the 4 bolts, 4 nuts and rear engine mounting member. D05120 2005 LEXUS IS300 (RM1140U) Author : Date : 1580...
  • Page 914 After separating the transmission from the engine, turn the transmission a little in the clockwise. At the condition that the transmission housing does not contact the body, lower the jack. D11481 2005 LEXUS IS300 (RM1140U) Author : Date : 1581...
  • Page 915 Install the starter with the 2 bolts. Torque: 37.3 N·m (380 kgf·cm, 28 ft·lbf) D05120 Install the wire with the nut. Torque: 9.8 N·m (10 kgf·cm, 7 ft·lbf) Connect the connector. 2005 LEXUS IS300 (RM1140U) Author : Date : 1582...
  • Page 916 Oil grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 Capacity: 2.6 litter (2.7 US qts, 2.3 lmp. qts) INSTALL NO. 1 REAR FLOOR BOARD Drain Plug INSTALL LH FRONT FLOOR CENTER COVER D11482 LOWER VEHICLE 2005 LEXUS IS300 (RM1140U) Author : Date : 1583...
  • Page 917 Install the shift boot retainer with the 4 bolts. Connect the 2 wire harness clamps. INSTALL UPPER CONSOLE PANEL AND CONSOLE BOX (See page BO-149 DO ROAD TEST Check for abnormal noises and smooth shifting. D05108 2005 LEXUS IS300 (RM1140U) Author : Date : 1584...

  • Page 918: Manual Transmission Assembly

    Wire Harness Clamp Vehicle Speed Sensor Driven Gear Restrict Pin 41 (410, 30) 13 (130, 9) 38 (387, 28) Extension Housing N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part F Precoated part D11489 2005 LEXUS IS300 (RM1140U) Author : Date : 1585...
  • Page 919 Reverse Idler Gear Shaft Stopper Reverse Idler Gear Snap Ring Oil Separator No. 3 Clutch Hub Reverse Idler Gear Shaft N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part F Precoated part 18.5 (189, 14) D11494 2005 LEXUS IS300 (RM1140U) Author : Date : 1586...
  • Page 920 Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 24.5 N·m (250 kgf·cm, 18 ft·lbf) Using a magnetic finger, remove the compression spring and lock ball pin. D11493 2005 LEXUS IS300 (RM1140U) Author : Date : 1587...
  • Page 921 Torque: 25 N·m (255 kgf·cm, 18 ft·lbf) Remove the front bearing retainer. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent Q06715 Using a snap ring expander, remove the 2 bearing snap rings. 2005 LEXUS IS300 (RM1140U) Author : Date : 1588...
  • Page 922 Sealant: Part No.08833-00080, THREE BOND 1344, Middle LOCTITE 242 or equivalent Torque: 25 N·m (255 kgf·cm, 18 ft·lbf) Using a magnetic finger, remove the 3 springs and balls. Long Q06267 2005 LEXUS IS300 (RM1140U) Author : Date : 1589...
  • Page 923 Using a hexagon wrench (6 mm), remove the straight screw plug. D11490 Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 25 N·m (255 kgf·cm, 18 ft·lbf) Using a magnetic finger, remove the spring and ball. 2005 LEXUS IS300 (RM1140U) Author : Date : 1590...
  • Page 924 INSPECT COUNTER 5TH GEAR THRUST CLEAR- ANCE Using a feeler gauge, measure the counter 5th gear thrust clearance. Standard clearance: 0.10 - 0.41 mm (0.0039 - 0.0161 in.) Maximum clearance: 0.41 mm (0.0161 in.) WM0041 2005 LEXUS IS300 (RM1140U) Author : Date : 1591...
  • Page 925 REMOVE SYNCHRONIZER RING ASSEMBLY WITH NO. 3 HUB SLEEVE AND NO. 3 CLUTCH HUB Remove the synchronizer ring assembly with the No. 3 hub sleeve from the No. 3 clutch hub. Q00987 2005 LEXUS IS300 (RM1140U) Author : Date : 1592...
  • Page 926 09316-6001 1 (09316-00011, 09316-00071) When installing the No. 3 clutch hub, support the counter shaft in front with a 1.4 - 2.3 kg (3 - 5 lb) hammer or equiv- alent. REMOVE REAR MAGNET 2005 LEXUS IS300 (RM1140U) Author : Date : 1593...
  • Page 927 At the time of installation, please refer to the following item. Using SST, install the 5th gear and rear bearing. 09312-20012 (09313-00010, 09313-00030, 09313-00040, 09313-00050) Z07209 REMOVE REVERSE GEAR Using a snap ring expander, remove the snap ring. Z02529 2005 LEXUS IS300 (RM1140U) Author : Date : 1594...
  • Page 928 Using a snap ring expander, remove the 2 snap rings. HINT: At the time of installation, please refer to the following item. Be sure the snap ring is flush with the intermediate plate sur- face. 2005 LEXUS IS300 (RM1140U) Author : Date : 1595...
  • Page 929 Install the input shaft and counter gear together. Using SST and a hammer, install the counter gear center bearing outer race. 09316-6001 1 (09316-00011) Be careful not to damage the bearing rollers. WM0125 2005 LEXUS IS300 (RM1140U) Author : Date : 1596...
  • Page 930 MANUAL TRANSMISSION MANUAL TRANSMISSION ASSEMBLY MT0C3-02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page MT-23 HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly. 2005 LEXUS IS300 (RM1140U) Author : Date : 1597...

  • Page 931: Input Shaft

    MT-24 MANUAL TRANSMISSION INPUT SHAFT INPUT SHAFT MT0C4-02 COMPONENTS Roller Bearing Snap Ring Synchronizer Ring Input Shaft Bearing Snap Ring Non-reusable part Q00884 2005 LEXUS IS300 (RM1140U) Author : Date : 1598...
  • Page 932 If the clearance is less than the minimum, replace the synchro- nizer ring and gear cone by applying a small amount of fine lap- ping compound. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. Z02534 2005 LEXUS IS300 (RM1140U) Author : Date : 1599...
  • Page 933 2.20 - 2.25 (0.0866 - 0.0886) 2.25 - 2.30 (0.0886 - 0.0906) 2.30 - 2.35 (0.0906 - 0.0925) Q00858 2.35 - 2.40 (0.0925 - 0.0945) Using a snap ring expander, install the snap ring. 2005 LEXUS IS300 (RM1140U) Author : Date : 1600...

  • Page 934: Output Shaft

    Synchronizer Middle Ring Needle Roller Bearing Inner Race 2nd Gear 1st Gear Synchronizer Ring No. 1 Hub Sleeve Shifting Key Spring Shifting Key Synchronizer Outer Ring Synchronizer Inner Ring Non-reusable part D11501 2005 LEXUS IS300 (RM1140U) Author : Date : 1601...
  • Page 935 Using a magnetic finger, remove the locking ball. Q00859 REMOVE NO. 1 HUB SLEEVE ASSEMBLY, 2ND GEAR AND NEEDLE ROLLER BEARING Using a press, remove the parts from the shaft as an assembly. WM0053 2005 LEXUS IS300 (RM1140U) Author : Date : 1602...
  • Page 936 SPRING FROM NO. 2 CLUTCH HUB Remove the No. 2 hub sleeve from the No. 2 clutch hub. Push the shifting key spring with a screwdriver, remove the 3 shifting keys and key springs. Q00888 2005 LEXUS IS300 (RM1140U) Author : Date : 1603...
  • Page 937 Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the synchronizer ring. MT0780 2005 LEXUS IS300 (RM1140U) Author : Date : 1604...
  • Page 938 Minimum diameter: 2nd gear: 42.975 mm (1.6919 in.) 3rd gear: 31.969 mm (1.2586 in.) If the outer diameter is less than the minimum, replace the out- put shaft. Q00862 2005 LEXUS IS300 (RM1140U) Author : Date : 1605...
  • Page 939 If the outer diameter is less than the minimum, replace the inner race. Q00863 Using a dial indicator, check the shaft runout. Maximum runout: 0.03 mm (0.0012 in.) If the runout exceeds the maximum, replace the output shaft. Q00864 2005 LEXUS IS300 (RM1140U) Author : Date : 1606...
  • Page 940 Apply gear oil to the shaft. Place the synchronizer ring on the gear and align the ring slots with the shifting keys. Q00865 Using a press, install the 3rd gear and No. 2 clutch hub. WM0115 2005 LEXUS IS300 (RM1140U) Author : Date : 1607...
  • Page 941 Install the assembly on the output shaft with the synchro- nizer ring slots aligned with the shifting keys and turn the inner race to align it with the locking ball. Q00868 2005 LEXUS IS300 (RM1140U) Author : Date : 1608...
  • Page 942 HINT: Hold the 1st gear inner race to prevent it from falling. 09506-35010 INSPECT 1ST GEAR THRUST CLEARANCE (See page MT-28 WM0122 2005 LEXUS IS300 (RM1140U) Author : Date : 1609...
  • Page 943 Shifting Key Spring Spacer No. 3 Clutch Hub Needle Roller Bearing Synchronizer Cone Ring 5th Synchronizer Ring No. 3 Hub Sleeve Reverse Synchronizer Ring N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part Z15652 2005 LEXUS IS300 (RM1140U) Author : Date : 1610...
  • Page 944 Remove the 3 shifting keys and key springs by carefully levering up the shifting key spring with one screwdriver and levering the shifting key away from the reverse syn- chronizer ring with another screwdriver. Q04010 2005 LEXUS IS300 (RM1140U) Author : Date : 1611...
  • Page 945 If the clearance exceeds the maximum, replace the gear or Z02655 shaft. INSPECT 5TH GEAR SYNCHRONIZER RING Check for wear or damage. Install the synchronizer pull ring, cone ring and outer ring to the 5th gear. Q04038 2005 LEXUS IS300 (RM1140U) Author : Date : 1612...
  • Page 946 Using a feeler gauge, measure the clearance between the hub sleeves and shift forks. Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve. WM0066 2005 LEXUS IS300 (RM1140U) Author : Date : 1613...
  • Page 947 Using a snap ring expander, install the snap ring. IF NECESSARY, REPLACE COUNTER GEAR CENTER BEARING Remove the bearing from the counter gear. Install a new bearing on the counter gear. HINT: Engage the roller cages. WM0079 2005 LEXUS IS300 (RM1140U) Author : Date : 1614...
  • Page 948 COUNTER GEAR AND REVERSE IDLER GEAR Using SST and a hammer, tap out the bearing outer race. 09950-60010 (09951-00510), 09950-70010 (09951-07150) HINT: The outer race will be installed later, as the transmission is as- sembled. Q07367 2005 LEXUS IS300 (RM1140U) Author : Date : 1615...
  • Page 949 Install the synchronizer cone ring to the reverse synchro- nizer pull ring and turn the pull ring. Q00873 Install the 5th synchronizer ring. Install the reverse synchronizer ring. Q04037 Turn the reverse synchronizer pull ring. Q00874 2005 LEXUS IS300 (RM1140U) Author : Date : 1616...
  • Page 950 MT-43 MANUAL TRANSMISSION COUNTER GEAR AND REVERSE IDLER GEAR While pushing 3 shifting keys, install the synchronizer ring assembly to the No. 3 hub sleeve. Front Z08961 2005 LEXUS IS300 (RM1140U) Author : Date : 1617...
  • Page 951 MT-44 MANUAL TRANSMISSION FRONT BEARING RETAINER OIL SEAL FRONT BEARING RETAINER OIL SEAL MT0CG-02 COMPONENTS Front Bearing Retainer F Oil Seal Non-reusable part WM0295 2005 LEXUS IS300 (RM1140U) Author : Date : 1618...
  • Page 952 Using a screwdriver, pry out the oil seal. Using SST and a press, install a new oil seal. 09950-60010 (09951-00440), 09950-70010 (09951-07150) Drive in depth: 12.2 ± 0.5 mm (0.480 ± 0.020 in.) Q07368 2005 LEXUS IS300 (RM1140U) Author : Date : 1619...
  • Page 953 Shift Lever Housing Shift and Select Lever Dust Deflector Race Oil Seal Snap Ring Oil Receiver Pipe Extension Housing N·m (kgf·cm, ft·lbf) : Specified torque f Non-reusable part Precoated Part D11502 2005 LEXUS IS300 (RM1140U) Author : Date : 1620...
  • Page 954 WM0085 Using SST, remove the outer race. 09308-00010 Q07553 Using SST, install a new outer race. 09950- 60010 (09951- 00560), 09950- 70010 (09951-07150) Using a screwdriver, install the snap ring. Q07370 2005 LEXUS IS300 (RM1140U) Author : Date : 1621...
  • Page 955 WM0110 Using SST and a hammer, drive in a new oil seal. 09950- 60010 (09951- 00560), 09950- 70010 (09951-07150) Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.) Q07371 2005 LEXUS IS300 (RM1140U) Author : Date : 1622...
  • Page 956 Suspect Area See page 1. Sleeve yoke spline (Worn) Noise 2. Spider bearing (Worn or stuck) PR-6 1. Sleeve yoke spline (Stuck) Vibration 2. Propeller shaft (Runout) PR-6 3. Propeller shaft (Imbalance) 2005 LEXUS IS300 (RM1140U) Author : Date : 1658...
  • Page 957 LH Front Floor Center Cover Pipe Support Bracket 43 (438, 32) No. 2 Engine Under Cover No. 1 Rear Floor Board No. 1 Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part F10570 2005 LEXUS IS300 (RM1140U) Author : Date : 1659...
  • Page 958 74 (750, 54) Washer Intermediate Shaft Sub-assembly Propeller Shaft Dust Cover See page PR-7 Washer Plate Center Support Bearing Universal Joint Flange N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part F08147 2005 LEXUS IS300 (RM1140U) Author : Date : 1660...
  • Page 959 Place matchmarks on the differential companion flange and propeller shaft. Remove the 4 bolts, washers and nuts. Pull the yoke from the transmission. Matchmarks F08148 Install SST in the transmission to prevent oil leakage. 09325-20010 F08149 2005 LEXUS IS300 (RM1140U) Author : Date : 1661...
  • Page 960 DISASSEMBLE PROPELLER SHAFT Place matchmarks on the universal joint flange and pro- peller shaft flange. Remove the 4 bolts, washers and nuts. Separate the intermediate shaft and propeller shaft. Matchmarks F08150 2005 LEXUS IS300 (RM1140U) Author : Date : 1662...
  • Page 961 Check if the bearing turns smoothly. Check for crack in or damage to the cushion. If the center support bearing is damaged, worn or does not turn smoothly, replace it. F08146 2005 LEXUS IS300 (RM1140U) Author : Date : 1663...
  • Page 962 Remove the center support bearing. F08155 Install a new center support bearing to intermediate shaft. HINT: Install the center support bearing in the direction, as shown. Install the 2 washers. Rear Side F08158 2005 LEXUS IS300 (RM1140U) Author : Date : 1664...
  • Page 963 Mount the intermediate shaft sub-assembly in a vise. Using a screwdriver and hammer, remove the dust cover. F08156 Using SST and press, install a new dust cover. 09316-6001 1 (09316-00011) F08157 2005 LEXUS IS300 (RM1140U) Author : Date : 1665...
  • Page 964 Torque the 4 nuts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) Matchmarks F08150 HINT: Assemble the propeller shaft so that each joint faces in the direction as shown in the illustration. F08159 2005 LEXUS IS300 (RM1140U) Author : Date : 1666...
  • Page 965 Connect the heated oxygen sensor. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) INSTALL NO. 1 REAR FLOOR BOARD INSTALL LH FRONT FLOOR CENTER COVER INSTALL NO. 1 AND NO. 2 ENGINE UNDER COVERS 2005 LEXUS IS300 (RM1140U) Author : Date : 1667...
  • Page 966 R06880 Using SST, measure the installation angle of the differen- tial. 09370-50010 HINT: Measure the installation angle by placing the SST in the posi- tion, as shown in the illustration. R01139 2005 LEXUS IS300 (RM1140U) Author : Date : 1668...
  • Page 967 4.5 (0.177) 11.0 (0.433) 6.5 (0.256) 13.5 (0.531) NOTICE: Left and right washers should be the same thickness. 2 washers should not be assembled together. Some vehicles are not assembled with washers. 2005 LEXUS IS300 (RM1140U) Author : Date : 1669...
  • Page 968 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Class Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt No Mark No Mark No Mark w/ Washer w/ Washer B06431 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 969 1.25 1,100 1,250 1,750 10.5 1.25 1.25 1.25 1,050 1,500 1,700 2,300 1.25 1.25 1.25 1,100 1,250 1.25 1.25 1.25 1,300 1,450 1.25 1.25 1.25 1,450 1,600 1.25 1.25 1.25 1,600 1,800 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 970 Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas- sification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 971 SS-4 SERVICE SPECIFICATIONS MAINTENANCE MAINTENANCE SS1JW-02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front seat mount bolts Front suspension member x Body 1,000 Rear suspension member x Body 1,300 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 972: Engine Mechanical

    98.19 mm (3.8657 in.) Exhaust 98.74 mm (3.8874 in.) Valve face angle 44.5° Stem diameter Intake 5.970 - 5.985 mm (0.2350 - 0.2356 in.) Exhaust 5.965 - 5.980 mm (0.2348 - 0.2354 in.) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 973 0.005 - 0.011 mm (0.0002 - 0.0004 in.) Maximum 0.05 mm (0.0020 in.) Rod out-of alignment Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.) Rod twist Maximum per 100 mm (3.94 in.) 0.15 mm (0.0059 in.) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 974 51.745 - 51.755 mm (2.0372 - 2.0376 in.) Circle runout Maximum 0.06 mm (0.0024 in.) Main journal taper and out-of-round Maximum 0.02 mm (0.0008 in.) Crank pin taper and out-of-round Maximum 0.02 mm (0.0008 in.) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 975 PS pump rear stay x Manifold stay 39.2 Drive plate x Torque converter clutch Engine hanger x Cylinder head Rear support member x Body 25.5 Drive plate x Crankshaft Transmission x Cylinder block Starter x Transmission 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 976 No. 2 water bypass pipe x Cylinder block Generator x Water pump Generator x Cylinder block Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe Center exhaust pipe x Tailpipe Tailpipe bracket x Body 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 977: Emission Control

    Heated oxygen sensor x Exhaust manifold Exhaust manifold x Cylinder head Front exhaust pipe (with rear TWC) x Exhaust manifold Front exhaust pipe (with rear TWC) x Center exhaust pipe Pipe support bracket x Transmission 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 978 3 - 5 (Apply battery voltage to terminal 1 and 2) Circuit opening Resistance 3 - 5 10 kΩ or higher Below 1 Ω relay 3 - 5 (Apply battery voltage to terminal 1 and 2) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 979 Knock sensor x Cylinder block PS pump rear stay x Manifold stay 39.2 PS pump rear stay x PS pump bracket 39.2 Heated oxygen sensor x Exhaust manifold Heated oxygen sensor x Front exhaust pipe 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 980 3 - 5 (Apply battery voltage to terminal 1 and 2) Cooling No. 3 fan Resistance 3 - 5 10 kΩ or higher Below 1 Ω relay 3 - 5 (Apply battery voltage to terminal 1 and 2) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 981 Water inlet x Water pump 80 in.·lbf Oil cooler x Radiator lower tank 74 in.·lbf Oil cooler x Oil cooler pipe 14.7 Electric cooling fan x Radiator 44 in.·lbf Upper radiator support x Body 13.5 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 982 0.30 mm (0.0118 in.) Body clearance 0.100 - 0.175 mm (0.0039 - 0.0069 in.) Maximum 0.20 mm (0.0079 in.) Side clearance 0.030 - 0.090 mm (0.0012 - 0.0035 in.) Maximum 0.12 mm (0.0047 in.) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 983 Oil strainer x No. 1 oil pan 80 in.·lbf No. 2 oil pan x No. 1 oil pan 80 in.·lbf Oil level sensor x No. 1 oil pan 48 in.·lbf Crankshaft position sensor x Oil pump 80 in.·lbf 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 984 835 - 1,400 Ω Camshaft position Resistance at cold 1,060 - 1,645 Ω sensor at hot 1,630 - 2,740 Ω Crankshaft Resistance at cold 2,065 - 3,225 Ω position sensor at hot 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 985 PS pump rear stay x Manifold stay 39.2 PS pump rear stay x PS pump bracket 39.2 Camshaft position sensor x Cylinder head 80 in.·lbf Crankshaft position sensor x Oil pump 80 in.·lbf 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 986 Contact plate for wear Maximum 0.9 mm (0.035 in.) Starter relay Resistance 3 - 5 10 kΩ or higher Below 1 Ω 3 - 5 (Apply battery voltage to terminal 1 and 2) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 987 52 in.·lbf End cover x Field frame 13 in.·lbf Terminal nut x Terminal 30 of starter Terminal nut x Terminal C of starter Magnetic switch end cover x Magnetic switch 22 in.·lbf 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 988 14.2 - 14.4 mm (0.559 - 0.567 in.) Minimum 12.8 mm (0.504 in.) Brush exposed length 9.5 -11.5 mm (0.374 -0.453 in.) Minimum 1.5 mm (0.059 in.) Voltage regulator Regulating voltage 13.2 - 14.8 V 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 989 Brush holder x Voltage regulator 18 in.·lbf Rear end cover x Rectifier holder 39 in.·lbf Plate terminal x Rectifier holder 39 in.·lbf Bolt 35 in.·lbf Terminal insulator x Rectifier holder 58 in.·lbf 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 990 Maximum 0.1 mm (0.004 in.) Diaphragm spring finger wear Maximum depth 0.6 mm (0.024 in.) Diaphragm spring finger wear Maximum width 5.0 mm (0.197 in.) Diaphragm spring tip non-alignment Maximum 0.5 mm (0.020 in.) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 991 Pedal hight lock nut 15.7 Push rod lock nut Clutch line union 15.2 Master cylinder installation nut Release cylinder installation bolt Bleeder plug 10.7 Clutch cover x Flywheel 19.1 Release fork suppor 39.2 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 992: Manual Transmission

    2.55 - 2.60 mm (0.1004 - 0.1024 in.) Mark 13 2.61 - 2.66 mm (0.1028 - 0.1047 in.) Mark 14 2.68 - 2.73 mm (0.1055 - 0.1075 in.) Mark 15 2.74 - 2.79 mm (0.1079 - 0.1098 in.) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 993 12.2 ± 0.5 mm (0.480 ± 0.020 in.) Front bearing retainer (from retainer end) 0 ± 0.5 mm (0 ± 0.020 in.) Extension housing 16 - 17 mm (0.63 - 0.67 in.) Reverse restrict pin drive in depth 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 994 No. 1 and No. 2 shift fork set bolt Reverse idler gear shaft stopper set bolt Straight screw plug x Reverse shift head Rear bearing retainer x Intermediate plate 18.5 Straight screw plug x Extension housing 25.5 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 995: Automatic Transmission

    47 - 59 km/h (29 - 37 mph) 82 - 90 km/h (51 - 56 mph) 32 - 38 km/h (20 - 24 mph) L position (Throttle valve fully opened) 17 - 22 km/h (11 - 14 mph) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 996 Lock-up OFF 36 - 41 km/h (22 - 25 mph) 4th gear Lock-up ON 28 - 33 km/h (17 - 32 mph) Lock-up OFF 27 - 32 km/h (18 - 20 mph) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 997 Exhaust pipe assembly x Exhaust manifold Exhaust manifold with TWC x Engine Pipe support bracket x Transmission Torque converter clutch x Drive plate Propeller shaft x Differential Propeller shaft x Body Drive plate x Crankshaft 2005 LEXUS IS300 (RM1140U) Author : Date :...

  • Page 998: Propeller Shaft

    Joint angle (No. 3 joint) Center support bearing adjusting washer thickness 2.0 mm (0.079 in.) 4.5 mm (0.177 in.) 6.5 mm (0.256 in.) 9.0 mm (0.354 in.) 11.0 mm (0.433 in.) 13.5 mm (0.531 in.) 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 999 Intermediate shaft x Center support bearing x Universal joint flange 1,850 Loosen nut Center support bearing x Body Exhaust pipe assembly x Exhaust manifold Heated oxygen sensor x Exhaust pipe assembly Pipe support bracket x Transmission 2005 LEXUS IS300 (RM1140U) Author : Date :...
  • Page 1000 0°06’ ± 12’ (0.1° ± 0.2°, 1 ± 2 mm, 0.04 ± 0.08 in.) Toe-in (total) Rack end length difference 1.5 mm (0.059 in.) or less 41°01’ (39°01’ − 42°01’) Wheel angle Inside wheel 41.02° (39.02° − 42.02°) 33°23’ Outside wheel: Reference 33.38° 2005 LEXUS IS300 (RM1140U) Author : Date :...

Table of Contents