LEXUS LS430 2003 Factory Repair Manual

Fig. 17: Checking Brake Pedal Height
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
17.CHECK PEDAL FREE PLAY
a. Stop the en
gine and depress the brake pedal several times until no vacuum remains in the booster.

b. Push in the pedal until the resistance begins to be felt, and then measure the distance as shown in
the illustration.
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If incorrect, proceed to the following step.
1. Check the stop lamp switch clearance.
Stop lamp switch clearance:
0.5 to 2.4 mm (0.020 to 0.094 in.)
If correct, the pedal free play is OK.
If incorrect, ad
just the stop lamp switch clearance.

Fig. 18: Checking Pedal Free Play
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
18.CHECK PEDAL RESERVE DISTANCE

a. Release the parking brake pedal.
b. With the engine running, depress the pedal and measure the pedal reserve distance, as shown in the
illustration.
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 105 mm (4.13 in.)
If incorrect, troubleshoot the brake system.
Fig. 19: Checking Pedal Reserve Distance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
19.INSTALL FLOOR CARPET ASSY FRONT
20.INSTALL FR DOOR SCUFF PLATE LH (SEE REPLACEMENT
)
21.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (SEE REPLACEMENT
)
22.INSTALL INSTRUMENT PANEL UNDER SAFETY PAD SUB-ASSY NO.1 (SEE
REPLACEMENT
)

23.INSTALL OUTER MIRROR SWITCH ASSY
24.INSTALL COIN BOX
25.INSTALL INSTRUMENT PANEL UNDER COVER NO.1 (SEE REPLACEMENT
)
26.INSTALL CLUSTER FINISH PANEL CENTER LOWER
27.INSTALL INSTRUMENT CLUSTER FINISH PANEL END
28.INSTALL SEAT ASSY FR LH
29.INSTALL SEAT TRACK BRACKET COVER INNER FRONT
30.INSTALL SEAT TRACK BRACKET COVER OUTER FRONT
31.INSTALL SEAT TRACK OUTER COVER LH
32.INSTALL SEAT TRACK COVER RH
33.INSTALL SEAT BELT ANCHOR COVER CAP LH
OVERHAUL
1.DISCONNECT BATTERY NEGATIVE TERMINAL
2.PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3.REMOVE SWITCH & VOLUME CASE
4.REMOVE STEERING WHEEL COVER LOWER NO.2
5.REMOVE HORN BUTTON ASSY (SEE OVERHAUL
)
6.REMOVE STEERING WHEEL ASSY (SEE OVERHAUL
)
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7.REMOVE STEERING COLUMN COVER (SEE OVERHAUL
)
8.REMOVE SPIRAL CABLE SUB-ASSY (SEE REPLACEMENT
)
9.REMOVE TURN SIGNAL SWITCH ASSY (SEE REPLACEMENT
)
10.REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
11.REMOVE INSTRUMENT CLUSTER FINISH PANEL END
12.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE REPLACEMENT
)
13.REMOVE COIN BOX ASSY
14.REMOVE OUTER MIRROR SWITCH ASSY
15.REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1 (SEE REPLACEMENT
)
16.REMOVE INSTRUMENT PANEL AIR BAG ASSY LOWER NO.1 (SEE REPLACEMENT
)
17.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (SEE REPLACEMENT
)
18.REMOVE INSTRUMENT CLUSTER FINISH PANEL (SEE REPLACEMENT
)
19.REMOVE COMBINATION METER ASSY (SEE OVERHAUL
)
20.REMOVE PUSH ROD PIN
a. Disconnect the stop lamp switch connector and brake pedal load sensing switch connector.

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24005100470003002500550044004e00480003003300480047[al Load Sensing Switch
Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Remove the brake pedal return spring.

Fig. 21: Removing Brake Pedal Return Spring
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
c. Remove the clip and push rod pin.

Fig. 22: Removing Clip And Push Rod Pin
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
21.REMOVE BRAKE PEDAL SUPPORT SUB-ASSY
a. Remove the bolt.

Fig. 23: Removing Brake Pedal Support Bolt
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Remove the brace, bolt and nut.
c. Remove the brake pedal support sub-ass
y and the 3 nuts.

Fig. 24: Removing Brake Pedal Support Sub-Assy And Nuts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
22.REMOVE BRAKE PEDAL SUB-ASSY
a. Remove the nut, the brake pedal shaft washer and the brake pedal sub-assy from the brake pedal
support sub-ass
y.