Lexus ES: Installation
INSTALLATION
PROCEDURE
1. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad to the brake pedal support assembly.
HINT:
Installation is easier after applying a small amount of soapy water.
2. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER
(a) Engage the 2 claws to install the stop light switch mounting adjuster.
3. INSTALL BRAKE PEDAL RETURN SPRING
| (a) Install the brake pedal return spring to the brake pedal support assembly. NOTICE: Attach the bottom part of the brake pedal return spring first, making sure that the open part of the hook is facing the front of the vehicle. Attach the top part of the brake pedal return spring second, making sure that the open part of the hook is facing the rear of the vehicle. |
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4. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY
(a) Install the brake pedal support assembly while avoiding the stud bolts of the brake booster support base.
NOTICE:
Be careful not to deform the bracket of the instrument panel reinforcement assembly.
| (b) for TMC Made: Install 2 new clips. |
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| (c) Install the brake pedal support assembly to the instrument panel reinforcement assembly with the bolt. Torque: 15 N·m {153 kgf·cm, 11 ft·lbf} |
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| (d) Engage the clamp to install the wire harness to the brake pedal support assembly. |
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5. INSTALL BRAKE MASTER CYLINDER GASKET
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6. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY
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7. INSTALL BRAKE PEDAL LINK PIN
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8. INSTALL STOP LIGHT SWITCH ASSEMBLY
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9. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY
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10. CONNECT BRAKE LINE
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11. CONNECT NO. 1 BRAKE ACTUATOR HOSE
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12. CONNECT ENGINE ROOM MAIN WIRE
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13. BLEED NO. 1 BRAKE ACTUATOR TUBE
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14. CONNECT BRAKE BOOSTER PUMP CONNECTOR
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HINT:
Perform this operation only when the accumulator pressure zero down operation could not be performed using the Techstream.
15. FILL RESERVOIR WITH BRAKE FLUID
16. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL
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17. BLEED BRAKE SYSTEM
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18. INSPECT AND ADJUST BRAKE PEDAL
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19. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
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20. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY
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21. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
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Removal
REMOVAL CAUTION / NOTICE / HINT The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during brake
Precaution
PRECAUTION NOTICE:
This vehicle is equipped with an SRS (Supplemental Restraint System). Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy d
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Precaution
PRECAUTION PRECAUTION FOR DISCONNECTING CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTICE: When disconnecting the cable from the negative (-) auxiliary battery terminal, initialize the following systems after the cable is reconnected. System Name See Procedure Lane Control System (for H
Inspection
INSPECTION PROCEDURE 1. INSPECT CYLINDER HEAD SUB-ASSEMBLY (a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head sub-assembly contacts the cylinder block sub-assembly, intake manifold and exhaust manifold (TWC: Front Catalyst). *
