Clutch Pedal Installation

Transmission. Lexus Is250, Is220D. Gse20 Ale20
Clutch. Lexus Is250, Is220D. Gse20 Ale20

  1. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING

  2. INSTALL CLUTCH PEDAL PAD

  3. INSTALL CLUTCH PEDAL CUSHION (for LHD)

  4. INSTALL CLUTCH PEDAL CUSHION (for RHD)

  5. INSTALL CLUTCH PEDAL SHAFT COLLAR

  6. INSTALL CLUTCH PEDAL TURNOVER BUSHING

  7. INSTALL CLUTCH PEDAL SUB-ASSEMBLY

  8. INSTALL CLUTCH PEDAL SPRING HOLDER

  9. INSTALL PEDAL WITH HOOK SPRING

  10. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN

  11. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY (for LHD)

  12. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY (for RHD)

  13. CONNECT CLUTCH LINE

  14. CONNECT CLUTCH RESERVOIR TUBE (for LHD)

  15. CONNECT CLUTCH RESERVOIR TUBE (for RHD)

  16. INSTALL WIRE HARNESS (for LHD)

  17. INSTALL WIRE HARNESS (for RHD)

  18. BLEED CLUTCH LINE

  19. CHECK FOR BRAKE FLUID LEAKAGE

  20. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT

  21. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY

  22. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY

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

  24. INSTALL SIDE INSTRUMENT PANEL LH

  25. INSTALL FRONT DOOR OPENING TRIM COVER

  26. INSTALL FRONT DOOR SCUFF PLATE (w/o Illumination)

  27. INSTALL FRONT DOOR SCUFF PLATE (w/ Illumination)

  28. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL

  29. CHECK BRAKE FLUID LEVEL IN RESERVOIR

  30. PERFORM INITIALIZATION

  31. INSPECT SRS WARNING LIGHT

Clutch Pedal -- Installation


HINT:
  1. Use the same procedures for the RHD and LHD.
  2. The procedures listed below are for the LHD.


1. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Pedal Installation

  1. Apply MP grease to the inside of a new clevis bushing.

  1. Install the clevis bushing to the clutch pedal.

    HINT:
    Install the clevis bushing from the left side of the vehicle.


2. INSTALL CLUTCH PEDAL PAD


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Pedal Installation

  1. Install the clutch pedal pad to the clutch pedal.



3. INSTALL CLUTCH PEDAL CUSHION (for LHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Using needle-nose pliers, install the 3 clutch pedal cushions to the clutch pedal.



4. INSTALL CLUTCH PEDAL CUSHION (for RHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Using needle-nose pliers, install the 4 clutch pedal cushions to the clutch pedal.



5. INSTALL CLUTCH PEDAL SHAFT COLLAR


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Pedal Installation

  1. Apply MP grease to the inner, outer and end surfaces of 2 new pedal bushings.

  1. Install the clutch pedal shaft collar and 2 pedal bushings to the clutch pedal.



6. INSTALL CLUTCH PEDAL TURNOVER BUSHING


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Pedal Installation

  1. Apply MP grease to the inside of the turnover bushing.

  1. Install the turnover bushing to the clutch pedal.



7. INSTALL CLUTCH PEDAL SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20

  1. Install the clutch pedal to the clutch pedal support with the pedal shaft, washer, and nut.

    Torque:
    37 N*m{375 kgf*cm, 27 ft.*lbf}


8. INSTALL CLUTCH PEDAL SPRING HOLDER


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Pedal Installation

  1. Apply MP grease to the inside of a new clutch pedal spring holder.

  1. Install the clutch pedal spring holder.



9. INSTALL PEDAL WITH HOOK SPRING


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Pedal Installation

  1. Apply MP grease to the sliding portion of the spring.

  1. Install the hook spring.



10. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Pedal Installation

  1. Apply MP grease to the contact surface of the pin and clevis bushing.

  1. Connect the clevis to the clutch pedal with the pin.

    HINT:
    Install a pin from the left side of the vehicle.

  1. Install the new clip to the pin.



11. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY (for LHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Install the clutch pedal support with the 2 nuts and bolt.

    Torque:
    19 N*m{190 kgf*cm, 14 ft.*lbf}


12. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY (for RHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Install the clutch pedal support with the 2 nuts and bolt.

    Torque:
    24 N*m{241 kgf*cm, 17 ft.*lbf}


13. CONNECT CLUTCH LINE


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Pedal Installation

  1. Using SST, connect the clutch line.

    SST
    09023-00101
    Torque:
    15 N*m{153 kgf*cm, 11 ft.*lbf}
    HINT:
    Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).


14. CONNECT CLUTCH RESERVOIR TUBE (for LHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the clutch reservoir tube.



15. CONNECT CLUTCH RESERVOIR TUBE (for RHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the clutch reservoir tube.



16. INSTALL WIRE HARNESS (for LHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the 3 connectors and clamp.



17. INSTALL WIRE HARNESS (for RHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the 2 connectors and clamp.



18. BLEED CLUTCH LINE

  1. Fill the brake reservoir with the brake fluid and bleed the clutch system (Click here).

    Torque:
    11 N*m{112 kgf*cm, 8 ft.*lbf}


19. CHECK FOR BRAKE FLUID LEAKAGE
HINT:
Check for leakage in the clutch system.


20. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT
(Click here)


21. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the connector.

    NOTICE:
    When handling the airbag connector, take care not to damage the airbag wire harness.

  1. Install the driver side knee airbag assembly with the 4 bolts.

    Torque:
    10 N*m{102 kgf*cm, 7 ft.*lbf}


22. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the connectors.

  1. Engage the 7 clips and install the lower instrument panel finish panel sub-assembly.



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


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Pedal Installation

  1. Connect the connectors.

  1. Insert the No. 1 instrument panel under cover sub-assembly into the guide as shown in the illustration.

  1. Engage the 2 claws.

  1. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <E>.



24. INSTALL SIDE INSTRUMENT PANEL LH


    Lexus Is250, Is220D. Gse20 Ale20

  1. Engage the 5 claws and 3 clips, and then install the side instrument panel LH.



25. INSTALL FRONT DOOR OPENING TRIM COVER


    Lexus Is250, Is220D. Gse20 Ale20

  1. Engage the 6 claws and install the front door opening trim cover LH.



26. INSTALL FRONT DOOR SCUFF PLATE (w/o Illumination)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Engage the 4 clips.



    Lexus Is250, Is220D. Gse20 Ale20

  1. Engage the 7 claws, and install the front door scuff plate LH.



27. INSTALL FRONT DOOR SCUFF PLATE (w/ Illumination)

  1. Connect the connector.



    Lexus Is250, Is220D. Gse20 Ale20

  1. Engage the 4 clips.



    Lexus Is250, Is220D. Gse20 Ale20

  1. Engage the 7 claws, and install the front door scuff plate LH.



28. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL


29. CHECK BRAKE FLUID LEVEL IN RESERVOIR


30. PERFORM INITIALIZATION
Some systems need initialization after reconnecting the negative battery terminal (Click here).


31. INSPECT SRS WARNING LIGHT
(Click here)