Lexus ES: Installation
INSTALLATION
PROCEDURE
1. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster assembly.
2. INSTALL BRAKE BOOSTER ASSEMBLY
(a) Temporarily install the brake booster assembly to the vehicle body.
NOTICE:
Do not apply excessive force to the brake lines.
(b) Temporarily install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.
NOTICE:
Fully tighten the lock nut when adjusting the brake pedal height.
(c) Install the 4 nuts to secure the brake booster assembly.
Torque:
12.8 N·m {131 kgf·cm, 9 ft·lbf}
(d) Connect the connector to the vacuum warning switch assembly.
3. INSTALL BRAKE PEDAL LINK PIN
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4. CONNECT UNION TO CHECK VALVE HOSE
(a) Connect the union to check valve hose to the brake booster assembly, and slide the clip to secure it.
5. INSTALL BATTERY CLAMP SUB-ASSEMBLY
| (a) Install the battery clamp sub-assembly with the 3 bolts and nut. Torque: Bolt : 18.5 N·m {189 kgf·cm, 14 ft·lbf} Nut : 8.0 N·m {82 kgf·cm, 71 in·lbf} |
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(b) Engage the 5 clamps to the battery clamp sub-assembly.
6. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE
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7. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY
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8. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
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9. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
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10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
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11. INSPECT AND ADJUST BRAKE PEDAL
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Installation
INSTALLATION PROCEDURE 1. INSTALL BRAKE BOOSTER GASKET (a) Install a new brake booster gasket to the brake booster assembly. 2. INSTALL BRAKE BOOSTER ASSEMBLY (a) Temporarily install the brake booster
On-vehicle Inspection
ON-VEHICLE INSPECTION PROCEDURE 1. INSPECT BRAKE BOOSTER ASSEMBLY (a) Airtightness check (1) Start the engine and stop it after 1 or 2 minutes. Slowly depress the brake pedal several times. HINT: I
Reassembly
REASSEMBLY PROCEDURE 1. INSTALL VACUUM WARNING SWITCH ASSEMBLY (a) Install a new check valve grommet to the brake booster assembly. (b) Install the vacuum warning switch assembly to the brake booster
SEE MORE:
EPS Warning Light Circuit
CAUTION / NOTICE / HINT NOTICE:
Perform this troubleshooting procedure when no DTCs are output, including DTCs related to CAN communication system malfunctions.
If the customer reports that the steering feels heavy, refer to the "Heavy steering" item in the Problem Symptoms Table.
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Problem Symptoms Table
PROBLEM SYMPTOMS TABLE HINT:
Inspect the fuses and relays related to this system before inspecting the suspected areas below.
Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of
