brake LEXUS ES300 2005 Manual PDF
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 267 of 969
C69097
R12236
(A)
F41707
F09717
R12236
(A) 32-22
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
2456 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Push in the piston and remove the piston stopper bolt and
gasket.
(e) Remove the No.1 piston sub-assy, pulling straight out not
at an angle.
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
(f) Place a waste cloth and 2 wooden blocks on the work
table and lightly edges until the No.2 piston sub-assy
drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag the top of the blocks
is at least 100 mm (3.94 in.).
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
9. REMOVE BRAKE MASTER CYLINDER KIT (W/ VSC)
(a) Place master cylinder in vise.
(b) Remove the O-ring.
(c) Push in the piston and remove the snap ring with snap
ring pliers.
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
(d) Push in the piston with a screwdriver, and remove the
straight pin by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(e) Remove the No.1 piston sub-assy, pulling straight out not
at an angle.
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
(f) Place a waste cloth and 2 wooden blocks on the work
table and lightly edges until the No.2 piston sub-assy
drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag the top of the blocks
is at least 100 mm (3.94 in.).
NOTICE:
If pulled out at an angle, there is a possibility that the cylin-
der bore could be damaged.
Page 268 of 969
C69097
F40004
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-23
2457 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. INSPECT MASTER CYLINDER BODY
(a) Check the cylinder bore for rust or scoring.
11. INSTALL BRAKE MASTER CYLINDER KIT (W/O VSC)
(a) Place master cylinder in vise.
(b) Apply the lithium soap base glycol grease on new No.1
and No.2 piston sub-assy.
(c) Install the No.2 and No.1 piston sub-assy.
NOTICE:
If the piston is inserted at an angle, there is a possibil-
ity that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pis-
tons.
(d) Push in the piston and install a new gasket and a new pis-
ton stopper bolt.
Torque: 10 NVm (100 kgfVcm, 7 ftVlbf)
(e) Push in the piston and install the snap ring with snap ring
pliers.
(f) Apply the lithium soap base glycol grease on a new O-
ring and install the O-ring to the master cylinder.
12. INSTALL BRAKE MASTER CYLINDER KIT (W/ VSC)
(a) Place master cylinder in vise.
(b) Apply the lithium soap base glycol grease on new No.1
and No.2 piston sub-assy.
(c) Install the No.2 and No.1 piston sub-assy.
NOTICE:
If the piston is inserted at an angle, there is a possibil-
ity that the cylinder bore could be damaged.
Be careful not to damage the rubber lips on the pis-
tons.
Page 269 of 969
F09718
F41707
F42650
SST 32-24
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
2458 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Install a straight pin.
HINT:
Insert the No.2 piston with the groove positioning horizontally.
(e) Push in the piston and install the snap ring with snap ring
pliers.
(f) Apply the lithium soap base glycol grease on a new O-
ring and install the O-ring to the master cylinder.
13. INSTALL MASTER CYLINDER RESERVOIR GROMMET
(a) Apply the lithium soap base glycol grease on the 2 master cylinder reservoir grommets.
(b) Install the 2 master cylinder reservoir grommets to the master cylinder reservoir sub-assy.
14. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
(a) Install the master cylinder reservoir sub-assy to the master cylinder with the screw.
15. INSTALL BRAKE MASTER CYLINDER RESERVOIR STRAINER
(a) Install the brake master cylinder reservoir strainer.
16. INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY
(a) Install the brake master cylinder reservoir filler cap assy.
17. INSPECT AND ADJUST BRAKE BOOSTER PUSH
ROD
(a) Apply SST to the master cylinder.
SST 09737-00013
(b) Set SST, on the master cylinder, lower the pin of the SST
until it slightly touches the piston.
(c) Apply the chalk to the flat surfaced tip of the SST pin.
(d) Turn SST upside down and place it clearance between
the brake booster and SST.
Clearance: 0 mm (0 in.)
HINT:
If there is a clearance between the SST main body and
the booster shell. It means that the specified value, and
no chalk attachment on the booster push rod means that
it is more than the specified value.
Brake booster push rod clearance before shipment is ad-
justed to be 0.105 mm ( 0.004 in.).
Page 270 of 969
F40006
SST
F40992
F40991
Front Brake Tube
Frame No. 1
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-25
2459 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737-00020
18. INSTALL BRAKE MASTER CYLINDER SUB-ASSY
(a) Install the master cylinder sub-assy and 2-way with the
2 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
(b) Using SST and connect the 4 front brake tubes to the
master cylinder sub-assy.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
(c) Using SST and install the front brake tube frame No.1 to
the master cylinder.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
(d) Connect the level warnig switch connector.
19. FILL RESERVOIR WITH BRAKE FLUID
20. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
21. BLEED BRAKE LINE (SEE PAGE 32-4)
22. INSTALL AIR CLEANER ASSY
23. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
24. CHECK BRAKE FLUID LEAKAGE
Page 271 of 969
3203F-08
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
C16481
Ventilation
No Ventilation 32-26
- BRAKEBRAKE BOOSTER ASSY
2460 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE BOOSTER ASSY (From July, 2003)
ON-VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Air tightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press the brake pedal several times slowly.
HINT:
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is air tight.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion switch OFF and check that there is no change
in the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Check vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.
Page 272 of 969
320DZ-05
F46404
Vacuum Hose Assy
Clip
Brake Master
Cylinder Sub-AssyGasket Push Rod Pin
Push Rod Clevis
Clip
Brake Booster
Front Brake
Tube No.5Front Brake Tube Frame No.1
Non-reusable part
NVm (kgfVcm, ftVlbf): Specified torque
15 (155, 11)
13 (130, 9)
5.4 (55, 48 in.Vlbf)
13 (130, 9)
15 (155, 11)
13 (130, 9)
Vacuum Hose Bracket
15 (155, 11)
2-W ay
15 (155, 11)
Front Brake
Tube No.2
15 (155, 11)
Front Brake
Tube No.3
- BRAKEBRAKE BOOSTER ASSY
32-27
2461 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS
Page 273 of 969
3211X-04
F40995
F40996
BR3753
32-28
- BRAKEBRAKE BOOSTER ASSY
2462 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. REMOVE AIR CLEANER ASSY
2. DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluid immediately if it comes into contact with a painted surface.
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
4. REMOVE VACUUM HOSE ASSY
(a) Remove the bolt and separate the vacuum hose from the
vacuum hose bracket.
(b) Slide the clip and disconnect the vacuum hose from the
brake booster.
5. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
6. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
7. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
8. REMOVE BRAKE PEDAL RETURN SPRING
9. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
10. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Loosen the lock nut and remove the push rod clevis.
11. REMOVE FRONT BRAKE TUBE NO.5
(a) Using SST and remove the front brake tube No.5.
SST 09023-00101
12. REMOVE BRAKE BOOSTER ASSY
(a) Remove the 4 nuts.
(b) Pull out the brake booster assy.
Page 274 of 969
BR3753
F40996
F40995
- BRAKEBRAKE BOOSTER ASSY
32-29
2463 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. REMOVE BRAKE BOOSTER GASKET
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster.
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster with the 4 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
16. INSTALL FRONT BRAKE TUBE NO.5
(a) Using SST and install the front brake tube No.5.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
17. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the push rod clevis and lock nut.
18. INSTALL PUSH ROD PIN
(a) Install the push rod pin and clip.
HINT:
Apply the lithium soap base glycol grease to the part indicate by arrow (see page 32-27).
19. INSTALL BRAKE PEDAL RETURN SPRING
20. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
21. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
22. INSTALL FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
23. INSTALL VACUUM HOSE ASSY
(a) Install the vacuum hose and vacuum hose bracket to the
body with a bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(b) Connect the vacuum hose to the brake booster with the
clip.
24. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE PAGE 32-21)
SST 09737-00013, 09737-00020
25. INSTALL BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
26. FILL RESERVOIR WITH BRAKE FLUID
Page 275 of 969
32-30
- BRAKEBRAKE BOOSTER ASSY
2464 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
27. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
28. BLEED BRAKE LINE (SEE PAGE 32-4)
29. INSTALL AIR CLEANER ASSY
30. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
31. CHECK BRAKE FLUID LEAKAGE
32. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8 or 32-12)
Page 276 of 969
320E5-02
F41863
Front Disc
Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt
Gasket
Front Disc Brake
Bleeder Plug Cap
Disc Brake
Cylinder Assy LH
Set Ring
Cylinder BootFront Disc
Brake Piston
Piston Seal
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Disc brake grease Lithium soap base glycol grease
Non-reusable part
NVm (kgfVcm, ftVlbf)
: Specified torque Single Piston Type:
Anti Squeal
Shim No.1
Disc Brake
Pad Kit Front Anti Squeal
Shim No.1
Anti Squeal
Shim No.2
Anti Squeal
Shim No.2
Wear Indicator
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)34.3 (350, 25)
34.3 (350, 25)
106.9 (1,090, 79)
106.9 (1,090, 79)
- BRAKEFRONT BRAKE
32-31
2465 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT BRAKE
COMPONENTS