1994 lexus es300 maintenance

8/6/2019 1994 Lexus ES300 Maintenance

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MAINTENANCE

MAINTENANCEMA1


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* marks indicates maintenance which is part of the warranty conditions for the Emission ControlSystems. The warranty period is in accordance with the owners guide or the warranty booklet,*; California and New York specification vehicles

(1) Includes inspection of fuel tank band and vapor vent system.(2) Nonmaintenance item except for California and New York.(3) Also applicable to drum lining for parking brake.(4) Check for leakage.(5) Check for oil leaks from steering gear housing.(6) The applicable parts are listed below.

Front and rear suspension member to cross body. Strut bar bracket to body bolt.

Bolts for seat installation.

SCHEDULE BCONDITIONS:Conditions others than those listed for SCHEDULE A.

Maintenance operation: A = Check and adjust if necessary.R = Replace, change or lubricate.

I = Inspect and correct or replace if necessary.

Maintenance services beyond 96,000 km (60,000 miles) should continue to be performedat the same Intervals shown for each maintenance schedule.

R: First period 72,000 km (45,000 miles) or 36 months.R: After that every 48,000 km (30,000 miles) or 24 months.

I: First period 96,000 km (60,000 miles) or 72 months.I: After that every 12,000 km (7,500 miles) or 12 months.

Service interval(Use odometer reading ormonths, whichever comes first)

Man^aI transaxle, automatic transaxleand differential (4)

I: First period 10 years. I: After that every 2 years.

Brake line pipes and hoses (Front and rear)

Bolts and nuts on chassis and body (6y

Spark pluq:(Platinum tipped type)

Fuel line and connections (1)

Exhaust pipes and mountings

Steering goof housing oil (5)

Brake linings end drums (3)

^aII joints and dust covers

Engine oil and oil filter*

MA 14 ( item 21, 22)

Brake pads and discs

Charcoal canister (2)

Fuel tank cap gasket

I: Every 24 months

R: Every 72 months

I: Every 24 months

R: Every 12 months

R: Every 72 months

A: Every 72 months

I: Every 24 months

I: Every 24 months

I: Every 36 months

!: Every 24 months

I: Every 36 month:

I; Every 72 months

i: Every 24 months

I: Even 24 months

I: Every 24 months

R: Every 36 months MA7 (item 3, 4)

I: Every 24 months

Maintenance items

MA12 (item 16)

MA 10 (item 14)

MA1 0 (item 11)

MA1 5 ( item 23)

MA1 3 (item 19)

MA12 (item 17)

MA13 (item 18)

MA10 (item 12)

MA1 1 (item 15)

MA10 (item 13)

MA 9 (item 10)

MA 13 (item 20)

MA6 (item 2)

MA9 (item 9)

MA 8 (item 6)

MA 9 (item 8)

Drive shaft boots

Steering linkage

MA8 (item 7)

MA7 (item 5)

See page(item No.)

Engine coolant

Volvo clearance

1,000 miles

SRS airbag

1,000 km

IGNITION

Air filter*

Drive belt

CHASSIS

BRAKES

ENGINE

Monthssystem

FUEL

EVAP

22.5 37.57.6

MAINTENANCE (5SFE)MA4


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(b) Using a belt tension gauge, measure the drive belttension.

Belt tension gauge:Nippondenso BTG20 (9550600020)Borroughs No.BT 33 73F

Drive belt tension:Generator (w/ A/C)New belt

175 5 lbfUsed belt

130 10 lbfGenerator (w/o A/C)New belt

125 25 lbfUsed belt

95 20 IbfPS pump

New belt125 25 lbf

Used belt80 20 lbf

If necessary, adjust the drive belt tension.HINT: New belt refers to a belt which has been used

less than 5 minutes on a running engine. Used belt refers to a belt which has been used

on a running engine for 5 minutes or more. After installing the belt, check that it fits properly

in the ribbed grooves.

2. INSPECT DRIVE BELTS(a) Visually check the belt for excessive wear, frayedcords etc.If necessary, replace the drive belt.HINT: Cracks on the rib side of a belt are consideredacceptable. If the belt has chunks missing from theribs, it should be replaced.

MAINTENANCE OPERATIONSCold Engine Operations1. REPLACE TIMING BELT(a) Remove the timing belt.

(See page EG26 )(b) Install the timing belt.

(See page EG33 )

http://eg1.pdf/http://eg1.pdf/http://eg1.pdf/http://eg1.pdf/


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3. INSPECT AIR FILTER(a) Visually check that the air filter is not damaged orexcessively oily.If necessary, replace the air filter element.(b) Clean the air filter with compressed air.First blow from the inside thoroughly, then blow offthe outside of the air filter.

4. REPLACE AIR FILTERReplace the air filter with a new one.

(c) Check the electrode gap of new spark plugs.Correct electrode gap:

1.1 mm (0.043 In.)Recommended spark plugs:

PK20R11 for NDBKR6EP11 for NGK

NOTICE: If adjusting the gap of a now plug, bend only thebase of the ground electrode. Do NOT touch the tip.Never attempt to adjust the gap on a used plug.

Check by hand to confirm that .the belt has notslipped out of the groove on the bottom of thepulley.

After installing a new belt, run the engine forabout 5 minutes and recheck the belt tension.

5. REPLACE SPARK PLUGS(a) Disconnect the spark plug cords at the rubber boot.DO NOT pull on the cords.

(b) Using a 16 mm plug wrench, remove the spark plugs.



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7. REPLACE ENGINE COOLANT(See page EG241 )HINT: Use a good brand of ethyleneglycol base

engine coolant and mix it according to themanufacturers instructions.

Using engine coolant which includes more than5096 ethyleneglycol (but not more than 70%) isrecommended.

NOTICE: Do not use alcohol type coolant. The engine coolant should be mixed with demineral

ized water or distilled water.Capacity (w/ Heater):6.3 liters (6.7 US qts, 5.5 Imp. qts)

6. REPLACE ENGINE OIL AND OIL FILTER(See page EG274 )Oil grade:

API grade SG or SH, EnergyConserving II multigrade engine oil or ILSAC multigrade engine oil.Recommended viscosity Is as shown in the illustration.

Drain and refill capacity:M/T

w/ Oil filter change3.6 liters (3.8 US qts, 3.2 Imp. qts)

w/o Oil filter change3.4 liters (3.6 US qts, 3.0 Imp. qts )

A/Tw/ Oil filter change

3.6 liters (3.8 US qts, 3.2 Imp. qts)w/o Oil filter change

3.4 liters (3.6 US qts, 3.0 Imp. qts)

(d) Using a 16 mm plug wrench, reinstall the sparkplugs.

Torque: 18 Nm (180 kgfcm, 13 ftlbf)(e) Reconnect the spark plug cords.



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11. INSPECT EXHAUST PIPES AND MOUNTINGSVisually check the pipes, hangers and connections forsevere corrosion, leaks or damage.12. ADJUST VALVE CLEARANCE(See page EG 12)Valve clearance (Cold):Intake0.19 0.29 mm (0.007 0.011 In.)Exhaust0.28 0.38 mm (0.011 0.015 In.)

BRAKES13. INSPECT BRAKE LINE PIPES AND HOSESHINT: Check in a well lighted area. Check the entirecircumference and length of the brake hoses using amirror as required. Turn the front wheels fully right orleft before checking the front brake.

(a) Check all brake lines and hoses for: Damage Wear Deformation Cracks Corrosion Leaks Bends Twists(b) Check all clamps for tightness and connections for

leakage.(c) Check that the hoses and lines are clear of sharp

edges, moving parts and the exhaust system.(d) Check that the lines installed in grommets pass thr

ough the center of the grommets.

14. INSPECT FRONT AND REAR BRAKE PADS AND DISCS(a) Check the thickness of the disc brake pads and check

for irregular wear. Minimum pad thickness:

1.0 mm (0.039 in.)



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15. INSPECT BRAKE LININGS AND DRUMS(a) Check the lining to drum contact condition and

lining wear.Minimum lining thickness:

1.0 mm (0.0039 in.)(b) Check the brake drums for scoring or wear.

Maximum drum inside diameter:Drum brake

230.6 mm (9.079 in.)Disc brake

171.0 mm (6.732 in.)(c) Clean the brake parts with a damp cloth.NOTICE: Do not use compressed air to clean the brakeparts.(d) Disc brake:

Settle the parking brake shoes and drum. When per forming the road test in item 25, do the following: Drive the vehicle at approx. 50 km/h (30 mph) on

a safe, level and dry road. With the parking brake release knob pushed in,

pull on the lever with 88 N (9 kgf, 20 lbf) of force. Drive the vehicle for approx. 400 m (1 /4 mile) in

this condition. Repeat this procedure 2 or 3 times.Check parking lever travel.If necessary, adjust the parking brake.

HINT: If a squealing or scraping noise comes from thebrake during driving, check the pad wear indicator tosee if it is contacting the disc rotor. If so, the disc padshould be replaced.

(b) Check the disc for wear or runout.Minimum disc thickness:

Front26.0 mm (1.024 in.)

Rear9.0 mm (0.354 In.)

Maximum disc runout:Front

0.05 mm (0.0020 in.)Rear

0.15 mm (0.0059 in.)



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17. INSPECT SRS AIRBAGDriver Airbag:Visually inspect the steering wheel pad (airbag andinflater). Use the diagnosis check to check if there are

abnormalities. Check that there are no cuts, cracks or noticeable

color changes on the surface of the steering

wheel pad or in the center groove of the pad. Remove the steering wheel pad from the vehicle

and check the wiring and steering wheel fordamage and corrosion due to rusting, etc.

If necessary, replace the steering wheel pad.

CHASSISI6. INSPECT STEERING LINKAGE

(a) Check the steering wheel freeplay.Maximum steering wheel freeplay:30 mm (1.18 In.)With the vehicle stopped and the front wheels point

ing straight ahead, rock the steering wheel gentlyback and forth with light finger pressure.

Front Passenger Airbag:Visually inspect the front passenger airbag assembly(airbag and inflater). Use the diagnosis check to check if there are


color changes in the front passenger airbag door.

(b) Check the steering linkage for looseness or damage.Check that:

Tie rod ends do not have excessive play. Dust seals and boots are not damaged. Boot clamps are not loose.



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20. INSPECT BALL JOINTS AND DUST COVERS(a) Inspect the ball joints for excessive looseness. Jack up the front of the vehicle and place

wooden blocks with a height of 180200 mm(7.097.87 in.) under the front tires.

Lower the jack until there is about half a load onthe front coil spring. Place stands under the vehi cle for safety.

Check that the front wheels are in a straightforward position, and block them with chocks.Using a lever, pry up the end of the lower arm,

and check the amount of play.Maximum ball joint vertical play:

0 mm (0 in.)If there is play, replace the ball joint.

(b) Check the dust cover for damage.

Remove the front passenger airbag assemblyfrom the vehicle and check the wiring and frontpassenger airbag door for damage and corrosiondue to rusting, etc.If necessary, replace the front passenger airbag as sembly.

CAUTION: For removal and replacement of the steering wheel

pad or front passenger airbag assembly, see pageRS19 or 31 and be sure to perform the operationin the correct order.

Before disposing of the steering wheel pad or frontpassenger airbag assembly, it must first be deployedby using SST (See page RS22 or 35).

18. INSPECT STEERING GEAR HOUSING OILCheck the steering gear housing for oil leakage.

19. INSPECT DRIVE SHAFT BOOTSCheck the drive shaft boots for clamp looseness, leak age or damage.

http://rs.pdf/http://rs.pdf/http://rs.pdf/http://rs.pdf/


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22. REPLACE TRANSAXLE OIL (FLUID)A. M/T:

Replace transaxle oil(a) Remove the filler and drain plugs, and drain the oil.(b) Reinstall the drain plug securely.(c) Add new oil until it begins to run out of the filler hole.Recommended transaxle oil:

Oil grade API GL3Viscosity SAE 75W90Capacity:

2.6 liters (2.7 US qts, 2.3 Imp. qts)In case the above oil grade is unavailable, use type Aor B.Type A:Oil grade API GL4Viscosity SAE 75W90Type B:Oil grade API GL5

Viscosity SAE 75W90(d) Reinstall the filler plug securely.

B. A/T:Replace transaxle fluidTransmission:

(a) Using a 10 mm hexagon wrench, remove the drainplug and drain the fluid.

(b) Reinstall the drain plug securely.

(c) With the engine OFF, add new fluid through the dip stick tube.Transmission fluid:ATF DEXRON IIDrain and refill capacity:2.5 liters (2.6 US qts, 2.2 Imp. qts)

(d) Start the engine and shift the selector into all posi tions from P through L, and then shift into P.

21. CHECK TRANSAXLE OIL (FLUID)(a) Visually check the transaxle for oil (fluid) leakage.

If leakage is found, check for the cause and repair.



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Differential:(a) Remove the filler plug.(b) Using a 10 mm hexagon wrench, remove the drain

plug and drain the fluid.(c) Reinstall the drain plug securely.(d) Add new fluid until it begins to run out of the filler

hole.

Differential fluid:ATF DEXRON IICapacity:1.6 liters (1.7 US qts, 1.4 Imp. qts)

(e) Reinstall the filler plug securely.

(e) With the engine idling, check the fluid level. Add fluidup to the COOL level on the dipstick.

NOTICE: Do not overfill. The transmission and differential are separate units.(f) Recheck the fluid level at the normal operating tem

perature (70 80 @ C (158 176 @ F)) and add as neces sary.

23. TIGHTEN BOLTS AND NUTS ON CHASSIS ANDBODYTighten the following parts: Front seat mount bolts

Torque: 37 Nm (375 kgfcm, 27 ftlbf)

Front suspension membertobody mountingbolts

Torque: 181 Nm (1,850 kgfcm, 134 ftlbf)



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24. BODY INSPECTION(a) Check the body exterior for dents, scratches and rust.(b) Check the underbody for rust and damage.

If necessary, replace or repair.25. ROAD TEST

(a) Check the engine and chassis for abnormal noises.(b) Check that the vehicle does not wander or pull to one

side.(c) Check that the brakes work properly and do not drag.26. FINAL INSPECTION

(a) Check the operation of the body parts:Hood:

Auxiliary catch operates properlyHood locks securely when closed

Front and rear doors:Door lock operates properlyDoors close properly

Luggage compartment door and back door:

Door lock operates properlySeats:Seat adjusts easily and locks securely in anypositionFront seat back locks securely in any positionFoldingdown rear seat backs lock securely

(b) Be sure to deliver a clean car. Especially check: Steering wheel Shift lever knob All switch knobs Door handles Seats

Rear suspension member to body mountingnuts




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Check that all warning lights and buzzersfunction properly.9. HORNCheck that it is working.10. WINDSHIELD GLASSCheck for scratches, pits or abrasions.11. WINDSHIELD WIPER AND WASHER

(a) Check operation of the wipers and washer.(b) Check that the wipers do not streak.12. WINDSHIELD DEFROSTERCheck that the air comes out from thedefroster outlet when operating the heateror air conditioner at defroster mode.13. REAR VIEW MIRRORCheck that it is mounted securely.14. SUN VISORSCheck that they more freely and mountedsecurely.

15. STEERING WHEELCheck that it has the specified freeplay. Bealert for changes in steering condition,such as hard steering, excessive freeplayor strange noise.16. SEATS

(a) Check that all front seat controls such asseat adjusters, seatback recliner, etc. op erate smoothly.

(b) Check that all latches lock securely in anyposition.

(c) Check that the locks hold securely in anylatches position.

(d) Check that the head restraints move upand down smoothly and that the lockshold securely in any latched position.

(e) For foldingdown rear seat backs, checkthat the latches look securely.

17. SEAT BELTS(a) Check that the seat belt system such as

buckles, retractors and anchors operate

properly and smoothly.(b) Check that the belt webbing is not cut,frayed, worn or damaged.

18. ACCELERATOR PEDALCheck the pedal for smooth operation anduneven pedal effort or catching.19. CLUTCH PEDAL (See page CL6 )Check the pedal for smooth operation.Check that the pedal has the properfreeplay.

GENERAL MAINTENANCEThese are some maintenance and inspec tion items which are considered to be theowners responsibility. They can be perfo rmed by the owner or he can have themdone at a service shop. These items in clude those which should be checked on adaily basis, those which, in most cases, donot require (special) tools and those whichare considered to be reasonable for theowner to perform. Items and proceduresfor general maintenance are as follows:

OUTSIDE VEHICLE1. TIRES

(a) Check the pressure with a gauge. Adjust ifnecessary.

(b) Check for cuts, damage or excessive wear.2. WHEEL NUTSWhen checking the tires, check the nutsfor looseness or for missing nuts. If neces sary, tighten them.3. TIRE ROTATIONIt is recommended that tires be rotatedevery 12,000 km (7,500 miles).4. WINDSHIELD WIPER BLADESCheck for wear or cracks whenever theydo not wipe clean. Replace if necessary.6. FLUID LEAKS

(a) Check underneath for leaking fuel, oil,water or other fluid.

(b) If you smell gasoline fumes or notice anyleak, have the cause found and corrected.

6. DOORS AND ENGINE HOOD(a) Check that all doors including the trunk lid

and back door operate smoothly, and thatall latches lock securely.

(b) Check that the engine hood secondary

latch secures the hood from openingwhenthe primary latch is released.

INSIDE VEHICLE7. LIGHTS

(a) Check that the headlights, stop lights,taillights, turn signal lights, and otherlights are all working.

(b) Check the headlight aim.6. WARNING LIGHTS AND BUZZERS

http://cl.pdf/http://cl.pdf/


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29. ENGINE DRIVE BELTSCheck all drive belts for fraying, cracks,wear or oiliness.30. ENGINE OIL LEVELCheck the level on the dipstick with theengine turned off.31. POWER STEERING FLUID LEVELCheck the level.The level should be in the HOT or COLDrange depending on the fluid temperature.32. AUTOMATIC TRANSMISSION FLUID

LEVEL(a) Park the vehicle on a level surface.(b) With the engine idling and the parking

brake applied, shift the selector into allpositions from P to L and then shiftinto P.

(c) Pull out the dipstick and wipe off the fluidwith a clean rag. Reinsert the dipstickand check that the fluid level is in the HOTran nge.

(d) Perform this check with the fluid at normaldriving temperature (70 80 @ C or 158 176 F).NOTE: Wait about 30 minutes before che cking the fluid level after extended drivingat high speeds in hot weather, driving inheavy traffic or with a trailer.

33. EXHAUST SYSTEMVisually inspect for cracks, holes or loosesupports.If any change in the sound of the exhaustor smell of the exhaust fumes is noticed,have the cause located and corrected.

UNDER HOOD24. WINDSHIELD WASHER FLUIDCheck that there is sufficient fluid in thetank.25. ENGINE COOLANT LEVELCheck that the coolant level is betweenthe FULL and LOW lines on the see through reservoir.28. RADIATOR AND HOSES

(a) Check that the front of the radiator isclean and not blocked with leaves, dirt orbugs.

(b) Check the hoses for cracks, kinks, rot orloose connections.

27. BATTERY ELECTROLYTE LEVELCheck that the electrolyte level of all bat

tery cells is between the upper and lowerlevel lines on the case. If level low, adddistilled water only.28. BRAKE AND CLUTCH FLUID LEVELS

(a) Check that the brake fluid level is near theupper level line on the see through reser voir.

(b) Check that the clutch fluid level is within 5 mm (0.20 in.) of the reservoir fillingline.

20. BRAKE PEDAL (See page BR8 )(a) Check the pedal for smooth operation.(b) Check that the pedal has the proper re

serve distance and freeplay.(c) Check the brake booster function.

21. BRAKESAt a safe place, check that the brakes donot pull to one side when applied.22. PARKING BRAKE (See page BR10 )

(a) Check that the lever has the proper travel.(b) On a safe incline, check that the vehicle is

help securely with only the parking brakeapplied.

23. AUTOMATIC TRANSMISSION PARKMECHANISM

(a) Check that lock release button of the se lector lever for proper and smooth opera

tion.(b) On a safe incline, check that the vehicle isheld securely with the selector lever inthe P position and all brakes released.

http://br.pdf/http://br.pdf/http://br.pdf/http://br.pdf/


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@ .mark indicates maintenance which is part of the warranty conditions for the Emission ControlSystems. The warranty period is in accordance with the owners guide or the warranty booklet.(@ : California and New York specification vehicles)(1) Applicable to vehicles operated under conditions of extensive idling and/or low speed driving forlong distances such as police, taxi or doortodoor delivery use.(2) Applicable when operating mainly on dusty roads. If not, apply SCHEDULE B.(3) Includes inspection of fuel tank band and vapor vent system.

(4) Non maintenance item except for California and New York.(5) Also applicable to drum lining for parking brake. For other usage conditions, refer to SCHEDULEB.(6) Check for oil leaks from steering gear housing.(7) Applicable only when operating mainly on rough, muddy roads. The applicable parts are listedbelow. For other usage conditions, refer to SCHEDULE B. Front and rear suspension member to cross body. Strut bar bracket to body. Bolts for seat installation.

MAINTENANCE (1MZFE)MA21


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* mark indicates maintenance which is part of the warranty conditions for the Emission ControlSystems. The warranty period is in accordance with the owners guide or the warranty booklet.(*: California and New York specification vehicles)

(1) Includes inspection of fuel tank band and vapor vent system.(2) Nonmaintenance item except for California and New York.(3) Also applicable to drum lining for parking brake.(4) Check for leakage.(5) Check for oil leaks from steering gear housing.(6) The applicable parts are listed below.

Front and rear suspension member to cross body.Strut bar bracket to body.Bolts for seat installation.

SCHEDULE B CONDITIONS:

Conditions others than those listed for SCHEDULE A.

Maintenance operation: A = Check and adjust if necessary.R = Replace, change or lubricate.I = Inspect and correct or replace if necessary.

Maintenance services beyond 98,000 km (84,000 mile:) should continue to be performedat the same Intervals shown for each maintenance schedule,

R: First period 72,000 km (46,000 miles) or 36 months.R: After that every 48,000 km (30,000 miles) or 24 months.

I: First period 98,000 km (60,000 miles) or 72 months.I: After that every 12,000 km (7,600 miles) or 12 months.

Service interval(Use odometer reading ormonths, whichever comes first)

I; First period 10 years. I: After that every 2 years.

Automatic transmission and differential oil (4)

Brake pads and disc (Front and rear)

Fuel lines and connections (1)

Exhaust pipes and mountings

Steering gear housing oil (6)

Broke linings and drums (3)

Stake line pipes and hoses

Drive shaft boots

Ball Jolnta and dust covers

Engine oil and oil filter*

Charcoal canister (2)

Fuel tank cap gasket

R; Every 12 months

R: Every 72 months

A; Every 72 months

R; Every 72 months

I; Every 24 months

I: Every 24 months

R: Every 36 months

I: Every 24 months

I: Every 24 months

I; Every 24 month:

I; Every 72 months

I; Every 36 month:

I: Every 24 months

I: Every 36 months

I: Every 24 months

MA30 (item 14)

MA31 (item 17)

MA29 (item 12)

MA24 (item 11)

i: Every 24 months MA32 (item 18)

MA33 (item 20)

MA29 (item 10)

MA31 (item 16)

MA33 (item 22)

MA32 (item 19)

MA30 (item 15)

MA29 (item 13)

MA27 (item6)

MA28 (item 8)

MA27 (item 7)

MA28 (item 9)

MA25 (item 4)

MA25 (item 5)

MA24 (item 2)

Steering linkage

See page(item No.)

Engine coolant

Valve clearance

1,000 miles

1,000 km

IGNITION

CHASSIS

Drive belt

nk filter*

BRAKES

ENGINE

Monthssystem

EVAP

FUEL

52.537.522.67.5Maintenance Items

I; Every 24 monthsBolts end nuts on chassis end body (6) MA34 (item 23)

spark plugs (Platinum tipped type)



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API grade SG or SH, Energy Conserving

or ILSAC multigrede and recommendedviscosity oil with SAE bW30being the preferred engine oil

Engine oilDrain and refillw/ Oil filter changew/o Oil filter change

PREPARATIONEQUIPMENT

4.7 liters (5.0 US qts, 4.1 Imp. qts)4.5 liters (4.8 US qts, 4.0 Imp. qts)


Automatic transaxle fluidDrain end refill


Dial indicator with magnetic base

8.7 liters (9.2 US qts. 7.7 Imp. qts)

LUBRICANT

Ethyleneglycol base

Belt tension gauge

COOLANT

Vernier calipers

Torque wrench

ATF DEXRON

ATF DEXRON Differential fluid

Engine coolant

Steel square

Thermometer

Micrometer

Claasifioation

Classification

Brake hose

Capacity

Capacity

Mirror

Item

Item



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(b) Using a belt tension gauge, measure the drive belttension.Belt tension gauge:Nippondenso BTG20 (9550800020)Borroug hs No. BT3373FDrive belt tension:GeneratorNew belt

175 5 lbfUsed belt

115 + 20 lbfPS pump

New belt150 185 lbf

Used belt115 20 lbf

If nesessary, adjust the drive belt tension.HINT:New belt refers to a belt which has been used 5miniutes or less on a running engine.Used belt refers to a belt which has been usedon a running engine for 5 minutes or more.After installing the belt, check that it fits properlyin the ribbed grooves.Check by hand to confirm that the belt has notslipped out of the groove on the bottom of thepulley.After installing a new belt, run the engine forabout 5 minutes and recheck the belt tension.

2. INSPECT DRIVE BELT(a) Visually check the belt for excessive wear, frayed

cords etc.If necessary, replace the drive belt.

HINT: Cracks on the rib side of a belt are consideredacceptable. If the belt has chunks missing from theribs, it should be replaced.

MAINTENANCE OPERATIONSCold Engine Operations1. REPLACE TIMING BELT

(a) Remove the timing belt.(See page EG41 )

(b) Install the timing belt.(See page EG49 )



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3. INSPECT AIR FILTER(a) Visually check that the air filter is not excessively

damaged or oily.(b) Clean the element with compressed air.

First blow from the inside thoroughly, then blow offthe outside of the air filter.

4. REPLACE AIR FILTERReplace the air filter with a new one.

5. REPLACE SPARK PLUGS(a) Using a 5 mm hexagon wrench, remove the 2 nuts and

Vbank cover.

(c) Remove the6 bolts and6 ignition coils from the RHand LH cylinder heads.

(b) Disconnect the 6 ignition coil connectors from the RHand LH cylinder heads.

HINT: Arrange the ignition coils in the correct order.

MAINTENANCE (1MZ FE)MA25


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(f) Check the electrode gap of new spark plugs.Correct electrode gap:1.1 mm (0.043 In.)Recommended spark plugs:PKZOR11 for NDBKR6EP11 for NGK

NOTICE: If adjusting the gap of a new plug, bend only the

base of the ground electrode. DO NOT touch the tip.Never attempt to adjust the gap on a used plug.(g) Using a 16 mm plug wrench, reinstall the 6 spark

plugs.Torque: 18 Nm (180 kgf.cm, 13 ftlbf)

(e) Using a 16 mm plug wrench, remove the 6 spark plugsfrom the RH and LH cylinder heads.

(h) Reinstall the6 ignition coil with the6 bolts.Torque: 8 Nm (80 kgfcm, 89 in.lbf)

(i) Reconnect the 6 ignition coil connectors.



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7. REPLACE ENGINE COOLANT(See page EG319 )HINT: Use a good brand of ethyleneglycol base

engine coolant and mix it according to themanufacturers instructions.

Using engine coolant which includes more than5096 ethyleneglycol (but not more than 7096) isrecommended.

NOTICE:Do not use alcohol type coolant.The engine coolant should be mixed with demineralized water or distilled water.Capacity:8.7 liters (9.2 US qts, 7.7 Imp. qts)

6. REPLACE ENGINE OIL AND OIL FILTER(See page EG372 )Oil grade:

API grade SG or SH, EnergyConserving orILSAC multigrade engine oil. Recommended viscosity is as shown in the Illustration with SAE 5W30being the preferred engine oil.

Capacity:Drain and refillw/ 0il filter change

4.7 liters (5.0 US qts, 4.1 Imp. qts)w/o Oil filter change


(j) Using a 5 mm hexagon wrench, reinstall the V bank cover with the 2 nuts.



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(c) Clean filter in canister.Clean the filter by blowing 294 kPa (3 kgf/cm @,43 psi) of compressed air into port A while hold ing port B closed.

NOTICE: Do not attempt to wash the canister. No activated carbon should come out.

9. REPLACE GASKET IN FUEL TANK CAP(a) Remove the old gasket from the tank cap. Do not

damage the cap.(b) Install a new gasket by hand.(c) Check the cap for damage or cracks.(d) Install the cap and check the torque limiter.

(b) Check for clogged filter and stuck check valve.Blow low pressure compressed air (4.71 kPa, 48gf/cm @, 0.68 psi) into port A and check that airflows without resistance from the other ports.

Blow low pressure compressed air (4.71 kPa, 48gf/cm @, 0.68 psi) into port B and check that airdoes not flow from the other ports.

If a problem is found, replace the charcoal canister.

8. INSPECT CHARCOAL CANISTER(a) Visually inspect the canister case.



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BRAKES13. INSPECT BRAKE LINE PIPES AND HOSESHINT: Check in a well lighted area. Check the entirecircumference and length of the brake hoses using amirror as required. Turn the front wheels fully right orleft before checking the front brake.

(a) Check all brake lines and hoses for: Damage Wear Deformation Cracks Corrosion Leaks Bends Twists (b) Check all clamps for tightness and connections for

leakage.(c) Check that the hoses and lines are clear of sharp

edges, moving parts and the exhaust system.(d) Check that the lines installed in grommets pass

through the center of the grommets.

10. INSPECT FUEL LINES AND CONNECTIONSVisually check the fuel lines for cracks, leakage, looseconnections, deformation or tank band looseness.11. INSPECT EXHAUST PIPES AND MOUNTINGSVisually check the pipes, hangers and connections forsevere corrosion, leaks or damage.12. ADJUST VALVE CLEARANCE(See page EG 13)Valve clearance (Cold):Intake

0.15 0.25 mm (0.006 0.010 in.)Exhaust

0.25 0.35 mm (0.010 0.014 in.)



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14. INSPECT FRONT AND REAR BRAKE PADS ANDDISCS

(See BR section)(a) Check the thickness of the disc brake pads and check

for irregular wear.Minimum pad thickness:1.0 mm (0.039 in.)

HINT: If a squealing or scraping noise comes from thebrake durings driving, check the pad wear indicator tosee if it is contacting the disc. If so, the disc padshould be replaced.

(b) Check the disc for wear or runout.Minimum disc thickness:Front

26.0 mm (1.024 In.)Rear

9.0 mm (0.354 in.)

15. INSPECT PARKING BRAKE LININGS AND DRUMS(See BR section)

(a) Check the lining to drum contact condition andlining wear.Minimum lining thickness:1.0 mm (0.0039 in.)

(b) Check the brake drums for scoring or wear.Maximum drum Inside diameter:171.0 mm (8.732 in.)

(c) Clean the brake parts with a damp cloth.NOTICE: Do not use compressed sir to clean the brakeparts.

Maximum disc runout:Front

0.05 mm (0.0020 in.)Rear

0.15 mm (0.0059 in.)



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(d) Settle the parking brake shoes and drum. When per forming the road test in item 24, do the following:

Drive the vehicle at approx. 50 km/h (30 mph) ona safe, level and dry road.

Center lever type parking brake:With the parking brake release knob pushed in,pull on the lever with 88 N (9 kgf, 20 lbf) of force.

Pedal type parking brake: Depress the pedal with 147 N (15 kgf, 33 lbf) of

force. Drive the vehicle for approx. 400 m (1 /4 mile) in

this condition. Repeat this procedure 2 or 3 times.

Check parking lever travel.

17. INSPECT SRS AIRBAGDriver Airbag:Visually inspect the steering wheel pad (airbag andinflater). Use the diagnosis check to check if there are


color changes on the surface of the steeringwheel pad or in the center groove of the pad.

16. INSPECT STEERING LINKAGE(a) Check the steering wheel freeplay.

Maximum steering wheel freeplay:30 mm (1.18 In.)With the vehicle stopped and pointed straight ahead,rock the steering wheel gently back and forth withlight finger pressure.

(b) Check the steering linkage for looseness or damage.Check that:

Tie rod ends do not have excessive play. Dust seals and boots are not damaged. Boot clamps are not loose.

CHASSIS



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Front Passenger Airbag:Visually inspect the front passenger airbag assembly(airbag and inflater). Use the diagnosis check to check if there are


color changes in the front passenger airbag door. Remove the front passenger airbag assembly

from the vehicle and check the wiring and frontpassenger airbag door for damage and corrosiondue to rusting, etc.If necessary, replace the front passenger airbag as sembly.

CAUTION: For removal and replacement of the steering wheel

pad or front passenger airbag assembly, see pageRS section and be sure to perform the operation inthe correct order.

Before disposing of the steering wheel pad or frontpassenger airbag assembly the airbag must first bedeployed by using SST (See page RS section).

18. INSPECT STEERING GEAR HOUSING OILCheck the steering gear housing for oil leakage.

Remove the steering wheel pad from the vehicleand check the wiring and steering wheel fordamage and corrosion due to rusting, etc.If necessary, replace the steering wheel pad.

19. INSPECT DRIVE SHAFT BOOTSCheck the drive shaft boots for clamp looseness,grease leakage or damage.



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(e) Check that the fluid comes to within 5 mm (0.20 in.) ofthe bottom edge of the filler hole.Fluid type:ATF DEXRON Capacity:0.95 liters (1.0 US qts, 0.8 Imp. qts)

(f) Reinstall the filler plug securely.

B. Replace differential fluid(a) Remove the filler plug.(b) Using a 10 mm hexagon wrench, remove the drain

plug and drain the fluid.(c) Using a 10 mm hexagon wrench, install the drain plug

securely.

23. TIGHTEN BOLTS AND NUTS ON CHASSIS ANDBODYTighten the following parts: Front seat mount bolts


Front suspension member to body mountingbolts

Torque: 181 Nm (1,850 kgfcm, 134 ftlbf)

(d) Add new fluid until it begins to run out of the fillerhole.



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GENERAL MAINTENANCEThese are the maintenance and inspectionitems which are considered to be theowners responsibility. They can be perfo rmed by the owner or they can have themdone at a service shop. These items in

clude those which should be checked on adaily basis, those which, in most cases, donot require (special) tools and those whichare considered to be reasonable for theowner to perform. Items and proceduresfor general maintanance are as follows:

OUTSIDE VEHICLE1. TIRES(a) Check the pressure with a gauge. Adjust if

necessary.

(b) Check for cuts, damage or excessive wear.2. WHEEL NUTSWheel checking the tires, check the nutsfor looseness or for missing nuts. If neces sary, tighten them.3. TIRE ROTATIONIt is recommended that tires be rotatedevery 12,000 km (7,500 miles).4. WINDSHIELD WIPER BLADESCheck for wear or cracks whenever theydo not wipe clean. Replace if necessary.

5. FLUID LEAKS(a) Check underneath for leaking fuel, oil,

water or other fluid.(b) If you smell gasoline fumes or notice any

leak, have the cause found and corrected.6. DOORS AND ENGINE HOOD(a) Check that all doors including the trunk lid

operate smoothly, and that all latches locksecurely.

(b) Check that the engine hood secondarylatch secures the hood from opening whenthe primary latch is released.

INSIDE VEHICLE7. LIGHTS(a) Check that the headlights, stop lights,

taillights, turn signal lights, and otherlights are all working.

(b) Check the headlight aiming.

8. WARMING LIGHT AND BUZZERSCheck that all warning lights and buzzersfunction properly.9. HORNCheck that it is working.10. WINDSHIELD GLASSCheck for scratches, pits or abrasions.11. WINDSHIELD WIPER AND WASHER(a) Check operation of the wipers and washer.(b) Check that the wipers do not streak.12. WINDSHIELD DEFROSTERCheck that air comes out from the defrost er outlet when operating the heater airconditioner at defroster mode.13. REAR VIEW MIRRORCheck that it is mounted securely.14. SUN VISORS

Check that they move freely and are mounted securely.15. STEERING WHEELCheck that it has the specified freeplay. Bealert for changes in steering condition,such as hard steering, excessive freeplayor strange noises.16. SEATS(a) Check that all front seat controls such as

seat adjusters, seatback recliner, etc. op erate smoothly.

(b) Check that all latches lock securely in anyposition.

(c) Check that the locks hold securely in anylatched position.

(d) Check that the head restraints move upand down smoothly and that the lockshold securely in any latched position.

(e) For foldingdown rear seat backs, checkthat the latches lock securely.

17. SEAT BELTS

(a) Check that the seat belt system such asbuckles, retractors and anchors operateproperly and smoothly.

(b) Check that the belt webbing is not cut,frayed, worn or damaged.

18. ACCELERATOR PEDALCheck the pedal for smooth operation anduneven pedal effort or catching.



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engine turned off.30. POWER STEERING FLUID LEVELCheck the level.The level should be in the HOT or COLDrange depending on the fluid temperature.31. AUTOMATIC TRANSMISSION FLUIDLEVEL(a) Park the vehicle on a level surface.(b) With the engine idling and the parking

brake applied, shift the selector into allpositions from P to L and then shiftinto P position.

(c) Pull out the dipstick and wipe off the fluidwith a clean rag.Reinsert the dipstick and check that thefluid level is in the HOT range.

(d) Perform this check with the fluid at normal

driving temperature (7080@

C, 158 176 @F).HINT: Wait about 30 minutes before che cking the fluid level after extended drivingat high speeds in hot weather, driving inheavy traffic or with a trailer.32. EXHAUST SYSTEMVisually inspect for cracks, holes or loosesupports.If any change in the sound of the exhaustor smell of the exhaust fumes is noticed,

have the cause located and corrected.

UNDER HOOD23. WINDSHIELD WASHER FLUIDCheck that there is sufficient fluid in thetank.24. ENGINE COOLANT LEVELCheck that the coolant level is between

the FULL and LOW lines on the see through reservoir.25. RADIATOR AND HOSES

(a) Check that the front of the radiator isclean and not blocked with leaves, dirtor bugs.

(b) Check the hoses for cracks, kinks, rot orloose connections.

26. BATTERY ELECTROLYTE LEVELCheck that the electrolyte level of all bat tery cells is between the upper and lower

level lines on the case.27. BRAKE FLUID LEVELCheck that the brake fluid level is near theupper level line on the seethrough reser voir.28. ENGINE DRIVE BELTSCheck all drive belts for fraying, cracks,wear or oiliness.29. ENGINE OIL LEVELCheck that level on the dipstick with the

19. BRAKE PEDAL (See BR section)(a) Check the pedal for smooth operation.(b) Check that the pedal has the proper re

serve distance and freeplay.(c) Check the brake booster function.20. BRAKESAt a safe place, check that the brakes donot pull to one side when applied.21. PARKING BRAKE (See BR section)(a) Check that the lever has the proper travel.(b) On a safe incline, check that the vehicle is

help securely with only the parking brakeapplied.

22. AUTOMATIC TRANSMISSION PARKMECHANISM(a) Check the lock release button of the selec

tor lever for proper and smooth operation.

(b) On a safe incline, check that the vehicle ishelp securely with the selector lever inthe P position and all brakes released.



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Drive belt tension

Generator

Generator

PS pumpPS pump

Spark plug Recommended spark plug

Spark plug Recommended spark plug

Spark plug Correct electrode gap

Firing order

Valve clearance

Valve clearance

Front and rear brake

Pad thickness

Disc thickness Front

Disc thickness RearDisc runout Front

Disc runout Rear

Parking brake

Lining thickness

Drum inside diameter

Front axle and suspension

Ball joint vertical play

Steering wheel freeplay

SERVICE SPECIFICATIONSSERVICE DATA

New belt

Used belt

New beltUsed belt

ND

NGK

TORQUE SPECIFICATIONS

Minimum

Minimum

MinimumMaximum

Maximum

Front suspension member x Body

Rear suspension member x Body

Front seat mount bolts

Minimum

Maximum

Maximum

Maximum

Intake

Exhaust

Pert tightened


1994 lexus es300 maintenance

Documents