engine LEXUS LS430 2003 Factory Manual Online

34.CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE ON-VEHICLE INSPECTION )
35.CHECK PEDAL FREE PLAY (SEE ON
-VEHICLE INSPECTION )
36.CHECK PEDAL RESERVE DISTANCE (SEE ON
-VEHICLE INSPECTION )
37.INSTALL COMBINATION METER ASSY (SEE OVERHAUL
)
38.INSTALL INSTRUMENT CLUSTER FINISH PANEL (SEE REPLACEMENT
)
39.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (SEE REPLACEMENT
)
40.INSTALL INSTRUMENT PANEL AIR BAG ASSY LOWER NO.1 (SEE REPLACEMENT
)
41.INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1 (SEE REPLACEMENT
)
42.INSTALL OUTER MIRROR SWITCH ASSY
43.INSTALL COIN BOX ASSY
44.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE REPLACEMENT
)
45.INSTALL INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
46.INSTALL INSTRUMENT CLUSTER FINISH PANEL END
47.INSTALL TURN SIGNAL SWITCH ASSY (SEE REPLACEMENT
)
48.INSTALL SPIRAL CABLE SUB-ASSY (SEE REPLACEMENT
)
49.INSTALL STEERING COLUMN COVER (SEE OVERHAUL
)
50.INSTALL STEERING WHEEL ASSY (SEE OVERHAUL
)
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51.INSTALL HORN BUTTON ASSY (SEE OVERHAUL
)
52.INSTALL STEERING WHEEL COVER LOWER NO.2
53.INSTALL SWITCH & VOLUME CASE
54.CONNECT BATTERY NEGATIVE TERMINAL
55.INSPECT SRS WARNING LIGHT (SEE DIAGNOSIS SYSTEM
)
56.PERFORM INITIALIZATION (SEE PRECAUTION
)
OVERHAUL
1.REMOVE ENGINE ROOM SIDE COVER
2.SEPARATE ENGINE ROOM NO.3 R/B
a. Remove the bolt and separate the engine room No.3 R/B.
3.DRAIN BRAKE FLUID
a. Draw out fluid with syringe.
4.REMOVE BRAKE MASTER CYLINDER SUB-ASSY
a. Remove the clamp from the 2 brake tubes.

Fig. 47: Installing Snap Ring
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
10.INSTALL MASTER CYLINDER RESERVOIR GROMMET
a. Apply lithium soap base glycol grease to the 2 master cylinder reservoir grommets.
b. Install the 2 master cylinder reservoir grommets to the master cylinder reservoir sub-assy.
11.INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
a. Install the master cylinder reservoir sub-assy to the master cylinder sub-assy with the set screw.
b. Install the master cylinder reservoir strainer and master cylinder reservoir filler cap.
c. Connect the brake fluid warning switch connector.
12.INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
a. Depress the brake pedal several times while the engine is stopped to release the pressure.
b. Set SST on the brake master cylinder sub-assy and lower the pin of the SST until it slightly touches
the piston.
c. Apply chalk to the flat surfaced tip of the SST pin.
SST 09737-00013

Fig. 53: Installing Brake Tube To Brake Master Cylinder Sub-Assy And ABS & TRACTION
Actuator Assy
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
14.FILL RESERVOIR WITH BRAKE FLUID
15.BLEED MASTER CYLINDER (SEE BLEEDING
)
16.BLEED BRAKE LINE (SEE BLEEDING
)
17.CHECK FLUID LEVEL IN RESERVOIR
18.CHECK FOR BRAKE FLUID LEAKAGE
If fluid leaks, tighten or replace the leaking part.
19.INSTALL ENGINE ROOM NO.3 R/B
a. Install the engine room No.3 R/B with a bolt.
20.INSTALL ENGINE ROOM SIDE COVER
COMPONENTS

pedal reserve distance.
b. Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal.
If not, replace the brake booster.
Fig. 55: Identifying Brake Pedal Operation Check

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2.AIR TIGHTNESS CHECK
a. Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly.
If the pedal can be depressed to the floor the first time, but on the 2nd or 3rd time cannot be
depressed as far, the booster is airtight.
If not, replace the brake booster.
b. Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed.
If there is no change in the pedal reserve travel after the pedal is held for 30 seconds, the booster is
air tight.
If not, replace the brake booster.

Fig. 56: Identifying Air Tightness Check
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3.INSPECT VACUUM CHECK VALVE
a. Check that there is ventilation from the booster to engine, and no ventilation from the engine to the
booster.
b.If any fault is found, replace the vacuum check valve.

Fig. 57: Inspecting Vacuum Check Valve
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REPLACEMENT
1.REMOVE ENGINE ROOM SIDE COVER
2.SEPARATE ENGINE ROOM NO.3 R/B
a. Remove the bolt and separate the engine room No.3 R/B.
3.DRAIN BRAKE FLUID
a. Draw out fluid with syringe.
4.REMOVE BRAKE MASTER CYLINDER SUB-ASSY
a. Remove the clamp from the 2 brake tubes.

35.INSTALL INSTRUMENT CLUSTER FINISH PANEL END
36.INSTALL INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
37.INSTALL ENGINE ROOM NO.3 R/B
a. Install the engine room No.3 R/B with the bolt and bracket.
38.INSTALL ENGINE ROOM SIDE COVER
COMPONENTS

1.CONNECT HAND-HELD TESTER:
a. Connect the hand-held tester to the DLC3.
b. Start the engine and run at idle.
c. Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operators manual for further details.
Fig. 109: Connecting Hand
-Held Tester To DLC3
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2.INSPECT ACTUATOR MOTOR OPERATION
a. With the motor relay on, check the actuator motor operation noise.
b. Turn the motor relay off.
c. Depress the brake pedal and hold it for approximately 15 seconds. Check that the brake pedal
cannot be depressed.
d. With the motor rela
y on, check that the pedal does not pulsate.

REPLACEMENT
1.REMOVE ENGINE ROOM SIDE COVER
2.SEPARATE ENGINE ROOM NO.3 R/B
a. Remove the bolt and separate the engine room No.3 R/B.
3.REMOVE FRONT WHEEL
4.REMOVE FRONT FENDER LINER
Remove the front fender outside moulding, front fender splash shield and front fender liner LH.
5.DRAIN BRAKE FLUID
a. Draw out fluid with syringe.
6.REMOVE ABS & TRACTION ACTUATOR ASSY WITH BRACKET
a. Using SST, disconnect the 6 brake tubes from the ABS & TRACTION actuator assy with bracket.
SST 09751-36011
Fig. 110: Disconnecting Brake Tubes From ABS & TRACTION ACTUATOR ASSY WITH

18.INSTALL FRONT WHEEL
19.CONNECT ENGINE ROOM NO.3 R/B
a. Install the engine room No.3 R/B and bolt.
20.INSTALL ENGINE ROOM SIDE COVER
21.PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION AND TEST MODE
COMPONENTS