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) for A25A-FKS:

(1) 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}

(2) Engage the 4 clamps to the battery clamp sub-assembly.

(b) for 2GR-FKS:

(1) 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}

(2) Engage the 5 clamps to the battery clamp sub-assembly.

6. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE (for A25A-FKS)

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7. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for A25A-FKS)

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8. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE (for 2GR-FKS)

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9. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

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10. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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11. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

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12. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

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13. INSPECT AND ADJUST BRAKE PEDAL

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