Lexus IS250 · Service Manual BRAKE

REMOVAL

Removal / installation


1. PRECAUTION

HINT:
(Click here)


2. REMOVE COOL AIR INTAKE DUCT SEAL

  1. A127530
    Remove the 11 clips and intake duct seal.


3. REMOVE ENGINE ROOM SIDE COVER LH

  1. A123702E01
    Remove the 5 clips and side cover.


4. REMOVE ENGINE ROOM SIDE COVER RH

  1. A123703E01
    Remove the 2 clips and side cover.


5. REMOVE FRONT UPPER FENDER PROTECTOR LH

  1. E119591
    Using a clip remover, separate the clip on the rubber portion of the cowl top ventilator louver sub-assembly from the front upper fender protector LH.

  1. Disengage the 3 clips and the claw to remove the front fender protector upper LH.


6. REMOVE FRONT UPPER FENDER PROTECTOR RH

HINT:
Use the same procedures for the RH side and the LH side.


7. REMOVE ROOF DRIP SIDE FINISH MOULDING LH

  1. Put protective tape around the roof drip side finish moulding.

  1. Using a moulding remover, disengage the 6 clips and remove the roof drip side finish moulding.

    NOTICE:
    1. Do not remove the clips.
    2. If the clips are damaged or fall off, replace them with new clips.


    B125564E01


8. REMOVE ROOF DRIP SIDE FINISH MOULDING RH

HINT:
Use the same procedures for the RH side and the LH side.


9. REMOVE FRONT WIPER ARM HEAD CAP

  1. E119593E01
    Using a screwdriver, remove the front wiper arm head cap.

    HINT:
    1. Use the same procedures for the RH side and the LH side.
    2. Tape the screwdriver tip before use.


10. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH

  1. E119604
    Remove the nut and the front wiper arm and blade assembly LH.


11. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH

  1. E119605
    Remove the nut and the front wiper arm and blade assembly RH.


12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

  1. E119595
    Remove the 2 clips.

  1. E119597
    Disengage the 11 claws, and pull out the cowl top ventilator louver sub-assembly.


13. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:
Wait for 90 seconds after disconnecting the terminal to prevent airbag deployment (Click here).


14. SEPARATE NO. 3 ENGINE ROOM RELAY BLOCK

  1. C110241E02
    Remove the bolt, nut and No. 3 engine room relay block.

    NOTICE:
    Cover the No. 3 engine room relay block with a shop rag or a piece of cloth to prevent brake fluid from getting on it.


15. REMOVE FRONT WHEEL

16. DRAIN BRAKE FLUID

NOTICE:
If brake fluid leaks onto any painted surface, wash off or remove the brake fluid completely.


17. REMOVE FRONT DOOR SCUFF PLATE LH

18. REMOVE FRONT DOOR SCUFF PLATE RH

HINT:
Use the same procedures for the RH side and the LH side.


19. REMOVE FRONT DOOR OPENING TRIM COVER LH

  1. B123347
    Disengage the 6 claws and remove the front door opening trim cover LH.


20. REMOVE FRONT DOOR OPENING TRIM COVER RH

  1. B123353
    Disengage the 6 claws and remove the front door opening trim cover RH.


21. REMOVE INSTRUMENT SIDE PANEL LH

  1. B123348
    Using a moulding remover, disengage the 5 claws and 3 clips, and then remove the side instrument panel LH.


22. REMOVE INSTRUMENT SIDE PANEL RH

  1. B123354
    Using a moulding remover, disengage the 5 claws and 3 clips, and then remove the side instrument panel RH.


23. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

  1. B123349E01
    Remove the 2 screws <E>.

  1. Push the 2 claws in the direction indicated by the arrow to disengage them.

  1. Remove the No. 1 instrument panel under cover sub-assembly from the guide as shown in the illustration and pull the cover toward the rear of the vehicle.

  1. Disconnect the connectors and remove the No. 1 instrument panel under cover sub-assembly.


24. REMOVE NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

  1. B123350
    Disengage the 7 clips.

  1. Disconnect the connectors and remove the lower instrument panel finish panel sub-assembly.


25. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY

26. REMOVE BRAKE ACTUATOR ASSEMBLY

  1. C113029E01
    Release the lock lever and disconnect the actuator connector.

  1. Using SST, disconnect the 6 brake tubes from the brake actuator assembly with bracket.

    SST
    09023-00101  

  1. Use tags or make a memo to identify the places to reconnect.

    C113030E02

    HINT:
    1. *1: To Front Wheel Cylinder RH
    2. *2: To Front Wheel Cylinder LH
    3. *3: To Rear Wheel Cylinder RH
    4. *4: To Rear Wheel Cylinder LH
    5. *5: From Front Master Cylinder
    6. *6: From Rear Master Cylinder

  1. Separate the grommet and remove the No. 3 front brake tube.

    NOTICE:
    Do not damage the brake tube.

  1. Remove the 2 bolts, nut and brake actuator assembly with bracket from the body.

    C130366E01

    NOTICE:
    Do not damage the brake tubes.


27. SEPARATE CLUTCH RESERVOIR HOSE (for Manual Transmission)

  1. Remove the clip and separate the clutch reservoir hose.


28. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

  1. C110239E02
    Disengage the clamp and disconnect the warning switch connector.

  1. Using SST, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

    SST
    09023-00101  

  1. Remove the 2 nuts and separate the brake actuator assembly.

    C110234E03

  1. C110236E01
    Remove the 2 nuts and brake master cylinder sub-assembly from the brake booster assembly.

  1. Remove the O-ring from the brake master cylinder sub-assembly.


29. REMOVE BRAKE PEDAL RETURN SPRING

  1. C110239E02
    Disengage the clamp and disconnect the warning switch connector.

  1. Using SST, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

    SST
    09023-00101  

  1. Remove the 2 nuts and separate the brake actuator assembly.

    C110234E03

  1. C110236E01
    Remove the 2 nuts and brake master cylinder sub-assembly from the brake booster assembly.

  1. Remove the O-ring from the brake master cylinder sub-assembly.


30. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS

  1. C113043E03
    Remove the clip and the push rod pin, then separate the push rod clevis.


31. REMOVE BRAKE BOOSTER ASSEMBLY

  1. C110198
    Move the clip and disconnect the vacuum hose.

  1. C110235E01
    Remove the 4 nuts and brake booster assembly.

    NOTICE:
    Do not damage the brake lines.


32. REMOVE BRAKE BOOSTER GASKET

  1. Remove the brake booster gasket from the brake booster assembly.


33. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY

  1. C110240E01
    Disconnect the 2 connectors.

  1. C128561E01
    Remove the bolt and brake pedal support assembly.


34. REMOVE STOP LIGHT SWITCH ASSEMBLY

  1. Loosen the lock nut and remove the stop light switch assembly.


35. REMOVE CUSHION

  1. Remove the cushion.


36. REMOVE BRAKE PEDAL PAD

  1. Remove the brake pedal pad.

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