Lexus ES manuals

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.

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.

(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}

(d) Engage the clamp to install the wire harness to the brake pedal support assembly.

5. INSTALL BRAKE MASTER CYLINDER GASKET

Click here

6. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

Click here

7. INSTALL BRAKE PEDAL LINK PIN

Click here

8. INSTALL STOP LIGHT SWITCH ASSEMBLY

Click here

9. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY

Click here

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

Click here

14. CONNECT BRAKE BOOSTER PUMP CONNECTOR

Click here

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

Click here

17. BLEED BRAKE SYSTEM

Click here

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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