Lexus ES: Installation

INSTALLATION

PROCEDURE

1. INSTALL BRAKE MASTER CYLINDER GASKET

(a) Install a new brake master cylinder gasket to the brake booster with master cylinder assembly.

2. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(a) Install the brake booster with master cylinder assembly with the 4 nuts. Torque: 12.8 N·m {131 kgf·cm, 9 ft·lbf} NOTICE: Do not kink or damage the brake lines. Do not carry the brake booster with master cylinder assembly by the parts shown in the illustration. Be careful not to allow brake fluid to enter the connector. If installing a new brake booster with master cylinder assembly, do not remove the hole plugs before connecting the brake lines because the brake booster with master cylinder assembly is filled with brake fluid.

*a Skid Control ECU *b No. 1 Reservoir Hose *c Brake Master Cylinder Push Rod Clevis *d Boot *e Master Cylinder Reservoir Assembly

3. INSTALL BRAKE PEDAL LINK PIN

(a) Apply lithium soap base glycol grease to the brake pedal link pin.

Lithium Soap Base Glycol Grease

(b) Connect the brake master cylinder push rod clevis to the brake pedal support assembly with the brake pedal link pin, and install a new clip as shown in the illustration. HINT: The brake pedal link pin can be installed in either direction.

4. CONNECT BRAKE LINE

(a) Using a union nut wrench, connect the 3 brake lines to the brake booster with master cylinder assembly. Torque: Specified tightening torque : 15.2 N·m {155 kgf·cm, 11 ft·lbf} NOTICE: Do not kink or damage the brake lines. Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening. Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts. HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

*a Torque Wrench Fulcrum Length *b Union Nut Wrench

5. CONNECT NO. 1 BRAKE ACTUATOR HOSE

(a) Connect the No. 1 brake actuator hose to the brake booster with master cylinder assembly and slide the clip to secure it.

*a	Identification Mark
	Front of the vehicle

6. CONNECT ENGINE ROOM MAIN WIRE

(a) Connect the connector to the brake booster with master cylinder assembly and lock the lock lever as shown in the illustration.

	Connect the connector
	Lock the lock lever

(b) Connect the connector to the brake booster with master cylinder assembly.

7. BLEED NO. 1 BRAKE ACTUATOR TUBE

NOTICE:

Make sure to bleed the air from the No. 1 brake actuator tube. If the air remains in the No. 1 brake actuator tube, the air will enter the brake booster pump assembly and may damage the brake booster pump assembly.

(a) Remove the brake master cylinder reservoir filler cap assembly.

(b) Add brake fluid to the reservoir until the fluid level is between the MAX and MIN lines on the brake fluid reservoir.

Brake Fluid:

SAE J1703 or FMVSS No. 116 DOT3

SAE J1704 or FMVSS No. 116 DOT4

(c) Remove the 2 nuts to separate the No. 1 brake actuator tube.

(d) Set SST to the brake master cylinder reservoir assembly. SST: 09992-00242 SST: 09992-00350

(e) Using SST, increase and then maintain the pressure in the brake master cylinder reservoir assembly for 60 seconds.(*1)

Standard Pressure:

50 to 80 kPa (0.6 to 0.8 kgf/cm2, 7.3 to 11.6 psi)

(f) Release the pressure in the brake master cylinder reservoir assembly and wait for 30 seconds.(*2)

(g) Repeat steps *1 to *2, 3 times.

(h) Remove SST.

(i) Elevate the No. 1 brake actuator tube for 10 seconds by lifting the No. 1 brake actuator tube as shown in the illustration.(*3)

Pull up

NOTICE:

Do not damage the hoses by applying excessive force.

(j) Repeat step *3, 5 times.

(k) Elevate the No. 1 brake actuator tube for 10 seconds by lifting the No. 1 brake actuator tube as shown in the illustration.(*4)

NOTICE:

Do not damage the hoses by applying excessive force.

Pull up

(l) Lower the No. 1 brake actuator tube for 10 seconds as shown in the illustration.(*5)

NOTICE:

Do not damage the hoses by applying excessive force.

Press down

(m) Repeat steps *4 to *5, 5 times.

(n) Install the No. 1 brake actuator tube with the 2 nuts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

8. CONNECT BRAKE BOOSTER PUMP CONNECTOR

HINT:

Perform this operation only when the accumulator pressure zero down operation could not be performed using the Techstream.

(a) Connect the connector to the brake booster pump assembly and lock the lock lever as shown in the illustration.

	Connect the connector
	Lock the lock lever

9. FILL RESERVOIR WITH BRAKE FLUID

10. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

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11. BLEED BRAKE SYSTEM

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12. INSPECT AND ADJUST BRAKE PEDAL

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13. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

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

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15. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

(a) Temporarily install the front center upper suspension brace sub-assembly with the 6 bolts and 4 nuts.

(b) Fully tighten the 2 nuts (A).

Torque:

50 N·m {510 kgf·cm, 37 ft·lbf}

(c) Fully tighten the 6 bolts and 2 nuts (B) to install the front center upper suspension brace sub-assembly.

Bolt:

Torque:

Nut (B) :

39 N·m {398 kgf·cm, 29 ft·lbf}

(d) Engage the 2 clamps to install the wire harness.

(e) Connect the connector.

(f) w/ Windshield Deicer System:

(1) Engage the 3 clamps to install the wire harness.

(2) Connect the connector.

16. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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