Lexus ES300 (2002 year). Manual — part 273

V00012

Shape (Example)

Removal/Installation

Removal

Installation

Removal

Installation

D25063

CORRECT

WRONG

D25064

01-8

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INTRODUCTION

REPAIR INSTRUCTION

8

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

(h)

REMOVAL AND INSTALLATION OF VACUUM HOSES
(1)

To disconnect vacuum hoses, pull them by holding
the end, not the middle of the hose.

(2)

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

(3)

After completing the job, make a double check
whether the vacuum hoses are properly connected.
A label under the hood shows the proper layout.

(4)

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.

L1

L2

D02612

L2

L1

D01201

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INTRODUCTION

REPAIR INSTRUCTION

01-9

9

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

(i)

TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1)

When a SST or extension tool is combined with the
torque wrench to extend its entire length, if you
tighten until the reading of the torque wrench reach-
es the specified torque value, the actual torque be-
comes excessive.

(2)

In this manual, only the specified torque is de-
scribed. In case of using SST or extension tool, cal-
culate the reading of the torque wrench by the fol-
lowing formula.

(3)

Formula T’=T x L2/(L1 + L2)

T’

Reading of torque wrench

{

N

⋅

m

(

kgf

⋅

cm

,

ft

⋅

lbf

)}

T

Torque

{

N

⋅

m

(

kgf

⋅

cm

,

ft

⋅

lbf

)}

L1

Length of SST or extension tool (cm)

L2

Length of torque wrench (cm)

2.

FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER

HINT:
LEXUS ES300 is equipped with an SRS (Supplemental Restraint System), such as the driver airbag, front
passenger airbag, side airbag, curtain shield airbag and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause the supplemental restraint
system to unexpectedly deploy during servicing. It may lead to a serious accident.
Furthermore, if a mistake is made in servicing the supplemental restraint system, it is possible that the SRS
will fail to operate when required. Before servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully. Then follow the correct procedure described in
this manual.
(a)

GENERAL NOTICE
(1)

Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diag-
nostic trouble codes become the most important source of information when troubleshooting.
When troubleshooting the supplemental restraint system, always check the diagnostic trouble
codes before disconnecting the battery (See page

05-546

).

(2)

Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK”
position and the negative (-) terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped with a back-up power source, so, if work is
started within 90 seconds after disconnecting the negative (-) terminal cable from the battery,
the SRS may deploy.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and
audio systems will be cancelled. So, before starting work, make a record of the memorized con-
tents in each memory system. Then, when work is finished, reset the clock and audio systems
as before. To avoid erasing the memory in each memory system, never use a back-up power
supply from another battery.

(3)

Even in case of a minor collision where the SRS does not deploy, the horn button assembly, the
instrument panel passenger airbag assembly, the front seat airbag assembly, the curtain shield
airbag assembly and seat belt pretensioner should be inspected (See pages

60-16

,

60-31

,

60-40

,

60-46

and

61-13

).

D26743

Mark

01-10

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INTRODUCTION

REPAIR INSTRUCTION

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2002 LEXUS ES300 REPAIR MANUAL (RM911U)

(4)

Never use SRS related parts from another vehicle. When replacing parts, replace them with new
parts.

(5)

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.

(6)

Never disassemble and repair the airbag sensor assembly, the horn button assembly, the instru-
ment panel passenger airbag assembly, the front seat airbag assembly, the curtain shield airbag
assembly or seat belt pretensioner.

(7)

If the airbag sensor assembly, the side airbag assembly, the horn button assembly, the instru-
ment panel passenger airbag assembly, the front seat airbag assembly, the curtain shield airbag
assembly or seat belt pretensioner has been dropped, or if there are cracks, dents or other de-
fects in the case, bracket or connector, replace them with new ones.

(8)

Do not directly expose the airbag sensor assembly, the horn button assembly, the instrument
panel passenger airbag assembly, the front seat airbag assembly, the curtain shield airbag as-
sembly or seat belt pretensioner to hot air or flames.

(9)

Use a volt/ohmmeter with high impedance (10 k

Ω

/V minimum) for troubleshooting of an electrical

circuit.

(10) Information labels are attached to the SRS components. Follow the instructions on the notices.
(11) After work on the supplemental restraint system is completed, check the SRS warning light (See

page

05-546

).

(b)

SPIRAL CABLE (in Combination Switch)
(1)

The steering wheel must be fitted correctly to the
steering column with the spiral cable at the neutral
position, otherwise cable disconnection and other
troubles may occur. Refer to page

60-24

on this

manual concerning the correct installation of the
steering wheel.

(c)

HORN BUTTON ASSEMBLY (with Airbag)
(1)

When removing the horn button assembly or handling a new horn button, it should be placed with
the pad top surface facing upward. Placing it with the pad surface facing downward may lead
to a serious accident if the airbag accedentally inflates. Also, do not place the horn button on top
of one another.

(2)

Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which
is very dangerous).

(3)

Grease should not be applied to the horn button assembly, and the pad should not be cleaned
with detergents of any kinds.

(4)

Store the horn button assembly where the ambient temperature remains below 93

°

C (200

°

F),

without high humidity and away from electrical noise.

(5)

When using electric welding, first disconnect the airbag connector (2 yellow pins) under the steer-
ing column near the combination switch connector before starting work.

D26746

Example:

CORRECT

WRONG

Z13950

Example:

D26600

Example:

CORRECT

WRONG

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INTRODUCTION

REPAIR INSTRUCTION

01-1 1

11

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

(6)

When disposing of the vehicle or the horn button assembly alone, the airbag should be deployed
using an SST before disposal (See page

60-16

).

Perform the operation in a safe place away from electrical noise.

(d)

INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY
(1)

Always store a removed or new instrument panel passenger airbag assembly with the airbag
inflation direction facing upward.
Placing the airbag assembly with the airbag inflation direction facing downward could cause a
serious accident if the airbag inflates.

(2)

Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which
is very dangerous).

(3)

Grease should not be applied to the instrument panel passenger airbag assembly, and the airbag
door should not be cleaned with detergents of any kind.

(4)

Store the airbag assembly where the ambient temperature remains below 93

°

C (200

°

F), without

high humidity and away from electrical noise.

(5)

When using electric welding, first disconnect the airbag connector (2 yellow pins) installed on the
assembly before starting work.

(6)

When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using
an SST before disposal (See page

60-31

).

Perform the operation in a safe place away from electrical noise.