Lexus ES300 (1997 year). Service manual — part 485

FI1066

IN0GD–01

Z11554

IN–4

–

INTRODUCTION

REPAIR INSTRUCTIONS

4

1997 LEXUS ES300 (RM511U)

REPAIR INSTRUCTIONS

GENERAL INFORMATION

1.

BASIC REPAIR HINT

(a)

Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.

(b)

During disassembly, keep parts in the appropriate order
to facilitate reassembly.

(c)

Observe the following operations:
(1)

Before performing electrical work, disconnect the
negative (–) terminal cable from the battery.

(2)

If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the negative
(–) terminal cable which is grounded to the vehicle
body.

(3)

To prevent damage to the battery terminal, loosen
the cable nut and raise the cable straight up without
twisting or prying it.

(4)

Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.

(5)

Install the cable ends to the battery terminals with
the nut loose, and tighten the nut after installation.
Do not use a hammer to tap the cable ends onto the
terminals.

(6)

Be sure the cover for the positive (+) terminal is
properly in place.

(d)

Check hose and wiring connectors to make sure that they
are secure and correct.

(e)

Non–reusable parts
(1)

Always replace cotter pins, gaskets, O–rings and oil
seals etc. with new ones.

(2)

Non–reusable parts are indicated in the component
illustrations by the ”

” symbol.

(f)

Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(1)

If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.

BE1367

Medium Current Fuse and High Current Fuse

Equal Amperage Rating

V00076

Abbreviation

Part Name

Symbol

Illustration

FUSE

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

FUSIBLE LINK

CIRCUIT BREAKER

FUSE

M–FUSE

H–FUSE

FL

CB

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INTRODUCTION

REPAIR INSTRUCTIONS

IN–5

5

1997 LEXUS ES300 (RM511U)

(2)

When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.

(3)

Precoated parts are indicated in the component il-
lustrations by the ”

” symbol.

(g)

When necessary, use a sealer on gaskets to prevent
leaks.

(h)

Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.

(i)

Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in the preparation part at the front
of each section in this manual.

(j)

When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.

IN0253

WRONG

CORRECT

IN0252

WRONG

CORRECT

IN0002

Example

IN–6

–

INTRODUCTION

REPAIR INSTRUCTIONS

6

1997 LEXUS ES300 (RM511U)

(k)

Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page

IN–16

).

(1)

If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels at the opposite
end in order to ensure safety.

(2)

After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on

a vehicle raised on a jack alone, even for a small

job that can be finished quickly.

(l)

Observe the following precautions to avoid damage to the
following parts:
(1)

Do not open the cover or case of the ECU, ECM,
PCM or TCM unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by
static electricity.)

(2)

To disconnect vacuum hoses, pull off the end, not
the middle of the hose.

(3)

To pull apart electrical connectors, pull on the con-
nector itself, not the wires.

(4)

Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.

(5)

When steam cleaning an engine, protect the elec-
tronic components, air filter and emission–related
components from water.

(6)

Never use an impact wrench to remove or install
temperature switches or temperature sensors.

(7)

When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.

(8)

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.

(m)

Tag hoses before disconnecting them:
(1)

When disconnecting vacuum hoses, use tags to
identify how they should be reconnected.

(2)

After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.

N02541

DLC2

IN0247

N02505

DLC1

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INTRODUCTION

REPAIR INSTRUCTIONS

IN–7

7

1997 LEXUS ES300 (RM511U)

(n)

Unless otherwise stated, all resistance is measured at an
ambient temperature of 20

°

C (68

°

F). Because the resis-

tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.

2.

FOR VEHICLES WITH DATA LINK CONNECTOR 2
(DLC2)

The DLC2 is provided inside the cabin (located under the
left side of instrument panel) as a connector exclusively
for diagnosis of data from the engine, automatic transmis-
sion, ABS, A/C, Airbag, Traction Control and Cruise Con-
trol System to improve serviceability.

The DLC1 inside the engine compartment is used for en-
gine adjustment.

Connecting the following terminals of the DLC2 to termi-
nal E

1

selects the diagnosis mode shown in the table.

NOTICE:
Pay enough attention to the terminal connection position
as this will cause a malfunction.

Terminal

System

T

E1

Engine and automatic transmission (Normal mode)

T

E2

and T

E1

Engine and automatic transmission (Test mode)

T

C

ABS, A/C, Airbag, Traction Control and Cruise Control

System

T

T

Automatic transmission

Refer to the respective system for the inspection method.

HINT:
By connecting the DLC2 up to a monitor specifically designed
for use with the DLC2, the diagnosis result for each system can
be read easily.