Brake Booster Removal

Brake. Lexus Is250, Is220D. Gse20 Ale20
Brake. Lexus Is250, Is220D. Gse20 Ale20

  1. DISCONNECT BATTERY NEGATIVE TERMINAL

  2. REMOVE COOL AIR INTAKE DUCT SEAL (for 4GR-FSE)

  3. REMOVE COOL AIR INTAKE DUCT SEAL (for 2AD-FHV)

  4. REMOVE ENGINE ROOM SIDE COVER LH (for 4GR-FSE)

  5. REMOVE ENGINE ROOM SIDE COVER RH (for 4GR-FSE)

  6. REMOVE ENGINE ROOM SIDE COVER LH (for 2AD-FHV)

  7. REMOVE ENGINE ROOM SIDE COVER RH (for 2AD-FHV)

  8. REMOVE FRONT UPPER FENDER PROTECTOR LH (for 4GR-FSE)

  9. REMOVE FRONT UPPER FENDER PROTECTOR LH (for 2AD-FHV)

  10. REMOVE FRONT UPPER FENDER PROTECTOR RH (for 4GR-FSE)

  11. REMOVE FRONT UPPER FENDER PROTECTOR RH (for 2AD-FHV)

  12. REMOVE ROOF DRIP SIDE FINISH MOULDING LH

  13. REMOVE ROOF DRIP SIDE FINISH MOULDING RH

  14. REMOVE FRONT WIPER ARM HEAD CAP (for 4GR-FSE)

  15. REMOVE FRONT WIPER ARM HEAD CAP (for 2AD-FHV)

  16. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (for 4GR-FSE)

  17. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (for 2AD-FHV)

  18. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (for 4GR-FSE)

  19. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (for 2AD-FHV)

  20. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for 4GR-FSE)

  21. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for 2AD-FHV)

  22. REMOVE FRONT WHEEL

  23. DRAIN BRAKE FLUID

  24. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK (for 4GR-FSE)

  25. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK (for 2AD-FHV)

  26. SEPARATE CLUTCH RESERVOIR HOSE (for Manual Transmission)

  27. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 4GR-FSE)

  28. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 2AD-FHV)

  29. REMOVE BRAKE ACTUATOR ASSEMBLY (for 4GR-FSE)

  30. REMOVE BRAKE ACTUATOR ASSEMBLY (for 2AD-FHV)

  31. REMOVE FRONT DOOR SCUFF PLATE LH

  32. REMOVE FRONT DOOR SCUFF PLATE RH

  33. REMOVE FRONT DOOR OPENING TRIM COVER LH

  34. REMOVE FRONT DOOR OPENING TRIM COVER RH

  35. REMOVE INSTRUMENT SIDE PANEL LH

  36. REMOVE INSTRUMENT SIDE PANEL RH

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

  38. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY

  39. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY

  40. REMOVE BRAKE PEDAL RETURN SPRING

  41. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS

  42. SEPARATE VACUUM HOSE (for LHD)

  43. SEPARATE VACUUM HOSE (for RHD)

  44. REMOVE BRAKE BOOSTER ASSEMBLY

  45. REMOVE BRAKE BOOSTER GASKET

  46. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY

  47. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS

Brake Booster -- Removal



1. DISCONNECT BATTERY NEGATIVE TERMINAL
CAUTION:
Wait for 90 seconds after disconnecting the terminal to prevent airbag deployment.


2. REMOVE COOL AIR INTAKE DUCT SEAL (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 11 clips and intake duct seal.



3. REMOVE COOL AIR INTAKE DUCT SEAL (for 2AD-FHV)


4. REMOVE ENGINE ROOM SIDE COVER LH (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. Remove the 5 clips and side cover.



5. REMOVE ENGINE ROOM SIDE COVER RH (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. Remove the 2 clips and side cover.



6. REMOVE ENGINE ROOM SIDE COVER LH (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 4 clips and side cover.



7. REMOVE ENGINE ROOM SIDE COVER RH (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 clips and side cover.



8. REMOVE FRONT UPPER FENDER PROTECTOR LH (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20
  1. 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 upper fender protector LH.



9. REMOVE FRONT UPPER FENDER PROTECTOR LH (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20
  1. 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 upper fender protector LH.



10. REMOVE FRONT UPPER FENDER PROTECTOR RH (for 4GR-FSE)
HINT:
Use the same procedures for the RH side and the LH side.


11. REMOVE FRONT UPPER FENDER PROTECTOR RH (for 2AD-FHV)
HINT:
Use the same procedures for the RH side and the LH side.


12. 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.


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal



13. REMOVE ROOF DRIP SIDE FINISH MOULDING RH
HINT:
Use the same procedures for the RH side and the LH side.


14. REMOVE FRONT WIPER ARM HEAD CAP (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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.


15. REMOVE FRONT WIPER ARM HEAD CAP (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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.


16. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the nut and the front wiper arm and blade assembly LH.



17. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the nut and the front wiper arm and blade assembly LH.



18. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the nut and the front wiper arm and blade assembly RH.



19. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the nut and the front wiper arm and blade assembly RH.



20. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 clips.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Disengage the 11 claws, and pull out the cowl top ventilator louver sub-assembly.



21. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 clips.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Disengage the 11 claws, and pull out the cowl top ventilator louver sub-assembly.



22. REMOVE FRONT WHEEL


23. DRAIN BRAKE FLUID
NOTICE:
If brake fluid leaks onto any painted surface, wash it off or remove the brake fluid completely.


24. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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.


25. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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.


26. SEPARATE CLUTCH RESERVOIR HOSE (for Manual Transmission)
  1. Remove the clip and separate the clutch reservoir hose.



27. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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.


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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.



28. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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.


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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 ACTUATOR ASSEMBLY (for 4GR-FSE)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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.


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal

    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.


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal

    NOTICE:
    Do not damage the brake tubes.


30. REMOVE BRAKE ACTUATOR ASSEMBLY (for 2AD-FHV)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. 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.


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal

    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.


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal

    NOTICE:
    Do not damage the brake tubes.


31. REMOVE FRONT DOOR SCUFF PLATE LH


32. REMOVE FRONT DOOR SCUFF PLATE RH
HINT:
Use the same procedures for the RH side and the LH side.


33. REMOVE FRONT DOOR OPENING TRIM COVER LH


    Lexus Is250, Is220D. Gse20 Ale20
  1. Disengage the 6 claws and remove the front door opening trim cover LH.



34. REMOVE FRONT DOOR OPENING TRIM COVER RH


    Lexus Is250, Is220D. Gse20 Ale20
  1. Disengage the 6 claws and remove the front door opening trim cover RH.



35. REMOVE INSTRUMENT SIDE PANEL LH


    Lexus Is250, Is220D. Gse20 Ale20
  1. Using a moulding remover, disengage the 5 claws and 3 clips, and then remove the side instrument panel LH.



36. REMOVE INSTRUMENT SIDE PANEL RH


    Lexus Is250, Is220D. Gse20 Ale20
  1. Using a moulding remover, disengage the 5 claws and 3 clips, and then remove the side instrument panel RH.



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


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. Using a screwdriver, disengage the 4 claws.

    HINT:
    Tape the screwdriver tip before use.


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. Apply protective tape to the areas shown in the illustration.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Using a moulding remover, disengage the 4 claws starting from the right of the No. 3 instrument panel register assembly. Disengage the remaining 3 claws by pulling the No. 3 instrument panel register assembly by hand.

    NOTICE:
    Do not pry the lower part of the No. 3 instrument panel register assembly. Doing so may damage the assembly.
  1. Disconnect the connectors.



38. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Disengage the 7 clips.

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



39. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 3 bolts and front passenger side knee airbag assembly.

  1. Disconnect the connector.

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


40. REMOVE BRAKE PEDAL RETURN SPRING
  1. Remove the brake pedal return spring.



41. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. Remove the clip and the push rod pin, and then separate the push rod clevis.



42. SEPARATE VACUUM HOSE (for LHD)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Using pliers, move the clip and disconnect the vacuum hose.



43. SEPARATE VACUUM HOSE (for RHD)


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. Using pliers, move the clip and disconnect the vacuum hose.



44. REMOVE BRAKE BOOSTER ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Booster  Removal
  1. Remove the 4 nuts and brake booster assembly.

    NOTICE:
    Do not damage the brake lines.


45. REMOVE BRAKE BOOSTER GASKET
  1. Remove the brake booster gasket from the brake booster assembly.



46. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY
  1. Remove the check valve assembly and grommet.



47. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
  1. Loosen the lock nut and remove the push rod clevis.