Brake Master Cylinder Installation

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

  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

  2. CONNECT CLUTCH RESERVOIR HOSE (for Manual Transmission)

  3. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK

  4. FILL RESERVOIR WITH BRAKE FLUID

  5. BLEED MASTER CYLINDER

  6. BLEED BRAKE LINE

  7. BLEED BRAKE ACTUATOR ASSEMBLY

  8. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)

  9. INSPECT FLUID LEVEL IN RESERVOIR

  10. INSPECT FOR BRAKE FLUID LEAKAGE

  11. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

  12. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH

  13. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH

  14. INSTALL FRONT WIPER ARM HEAD CAP

  15. INSTALL ROOF DRIP SIDE FINISH MOULDING RH

  16. INSTALL ROOF DRIP SIDE FINISH MOULDING LH

  17. INSTALL FRONT UPPER FENDER PROTECTOR LH

  18. INSTALL FRONT UPPER FENDER PROTECTOR RH

  19. INSTALL ENGINE ROOM SIDE COVER RH

  20. INSTALL ENGINE ROOM SIDE COVER LH

  21. INSTALL COOL AIR INTAKE DUCT SEAL

Brake Master Cylinder -- Installation



1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
  1. Install a new O-ring to the brake master cylinder sub-assembly.



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Install the brake master cylinder sub-assembly to the booster assembly with the 2 nuts.

    Torque:
    12.5 N*m{127 kgf*cm, 9 ft.*lbf}


  1. Install the brake actuator assembly to the actuator bracket with the 2 cap nuts.

    Torque:
    5.5 N*m{55 kgf*cm, 48 in.*lbf}


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Using SST, connect the 2 brake lines to the brake master cylinder sub-assembly.

    SST
    09023-00101
    Torque:
    15 N*m{155 kgf*cm, 11 ft.*lbf}
  1. Engage the clamp and connect the warning switch connector.



2. CONNECT CLUTCH RESERVOIR HOSE (for Manual Transmission)
  1. Connect the clutch reservoir hose with the clamp.



3. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Install the No. 3 engine room relay block with the bolt and nut.

    Torque:
    12.5 N*m{127 kgf*cm, 9 ft.*lbf}


4. FILL RESERVOIR WITH BRAKE FLUID


    Lexus Is250, Is220D. Gse20 Ale20
  1. Fill the reservoir with brake fluid.

    Fluid:
    SAE J1703 or FMVSS No. 116 DOT3


5. BLEED MASTER CYLINDER
HINT:
  1. If the master cylinder is reinstalled or if the reservoir becomes empty, bleed the air from the master cylinder.
  2. To prevent paint damage due to brake fluid, cover the painted surface with a shop rag or a piece of cloth.


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Disconnect the 2 brake lines from the master cylinder.

  1. Slowly depress the brake pedal and hold it (*1).



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Cover the 2 outer holes with fingers, and release the brake pedal (*2).

  1. Repeat (*1) and (*2) 3 or 4 times.

  1. Using SST, connect the brake lines to the master cylinder.

    SST
    09023-00101
    Torque:
    15 N*m{155 kgf*cm, 11 ft.*lbf}


6. BLEED BRAKE LINE
NOTICE:
Bleed the brake line at the wheel furthest from the master cylinder.


    Lexus Is250, Is220D. Gse20 Ale20
  1. Connect the vinyl tube to the bleeder plug.

  1. Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed (*3).



    Lexus Is250, Is220D. Gse20 Ale20
  1. When fluid no longer comes out, tighten the bleeder plug, then release the brake pedal (*4).

  1. Repeat (*3) and (*4) until all the air in the fluid is completely bled out.

  1. Using SST, tighten the bleeder plug completely.

    SST
    09023-00101
    Torque:
    11 N*m{110 kgf*cm, 8 ft.*lbf}
  1. Repeat the above procedures for each wheel to bleed the air from the brake line.



7. BLEED BRAKE ACTUATOR ASSEMBLY
NOTICE:
After bleeding the air from the brake system, if the correct height or feel of the brake pedal cannot be obtained, bleed the air from the brake actuator assembly with the intelligent tester by following the procedures below.
  1. Depress the brake pedal more than 20 times with the engine switch off.



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Connect the intelligent tester to the DLC3, then turn the engine switch on (IG).

    NOTICE:
    Do not start the engine.
  1. Turn the intelligent tester power on and select "AIR BLEEDING" on the screen.

    NOTICE:
    1. Refer to the intelligent tester operator's manual for further details.
    2. Bleed the brake actuator assembly by following the steps displayed on the intelligent tester.


  1. Bleed the air from the actuator according to "Step 1: Increase" on the intelligent tester display.

    NOTICE:
    Make sure that the master cylinder reservoir tank does not become empty of brake fluid.



      Lexus Is250, Is220D. Gse20 Ale20
    1. Connect a vinyl tube to either one of the bleeder plugs.

    2. Depress the brake pedal several times, then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*5).



    3. Lexus Is250, Is220D. Gse20 Ale20
    4. When fluid no longer comes out, tighten the bleeder plug, then release the brake pedal (*6).

    5. Repeat (*5) and (*6) until all the air in the fluid is completely bled.

    6. Using SST, tighten the bleeder plug completely.

      SST
      09023-00101
      Torque:
      11 N*m{110 kgf*cm, 8 ft.*lbf}
    7. Repeat the above procedures for the rest of the wheels to bleed the air from the brake lines.



  1. Bleed the air from the suction line according to "Step 2: Inhalation" on the intelligent tester display.

    NOTICE:
    1. Bleed the suction line by following the steps displayed on the intelligent tester.
    2. Make sure that the master cylinder reservoir tank does not become empty of brake fluid.



      Lexus Is250, Is220D. Gse20 Ale20
    1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug.

    2. Operate the brake actuator assembly to bleed the air using the intelligent tester (*7).

      NOTICE:
      1. The operation stops automatically in 4 seconds.
      2. At this time, be sure to release the brake pedal.


    3. Lexus Is250, Is220D. Gse20 Ale20
    4. Check that the operation has stopped by referring to the intelligent tester display and tighten the bleeder plug (*8).

    5. Repeat (*7) and (*8) until all the air in the fluid is completely bled out.

    6. Using SST, tighten the bleeder plug completely.

      SST
      09023-00101
      Torque:
      11 N*m{110 kgf*cm, 8 ft.*lbf}
    7. For the rest of the wheels, bleed the air in the same way as stated in the above procedures.



  1. Bleed the air from the pressure reduction line according to "Step 3: Decrease" on the intelligent tester display.

    NOTICE:
    1. Bleed the pressure reduction line by following the steps displayed on the intelligent tester.
    2. Make sure that the master cylinder reservoir tank does not become empty of brake fluid.



      Lexus Is250, Is220D. Gse20 Ale20
    1. Connect a vinyl tube to either one of the bleeder plugs.

    2. Loosen the bleeder plug (*9).

    3. Using the intelligent tester, operate the brake actuator assembly, completely depress the brake pedal and hold it.

      NOTICE:
      1. The operation stops automatically after 4 seconds. When this operation will be repeated continuously, allow an interval of at least 20 seconds between each bleeding operation.
      2. When the operation is completed, the brake pedal will go down slightly. This is a normal phenomenon due to the opening of the solenoid.
      3. During this procedure, the brake pedal will seem heavy. It is necessary to completely depress it, so that brake fluid will come out of the bleeder plug.
      4. Be sure to keep the brake pedal depressed. Never depress and release the pedal repeatedly.


    4. Lexus Is250, Is220D. Gse20 Ale20
    5. Tighten the bleeder plug, then release the brake pedal (*10).

    6. Repeat steps (*9) to (*10) until all the air in the fluid is completely bled out.

    7. Using SST, tighten the bleeder plug completely.

      SST
      09023-00101
      Torque:
      11 N*m{110 kgf*cm, 8 ft.*lbf}
    8. Repeat the above procedures for the rest of the brakes to bleed the air from the brake line.



  1. Bleed the air from the brake line again according to "Step 4: Increase" on the intelligent tester display.

    NOTICE:
    1. Bleed the brake line by following the steps displayed on the intelligent tester.
    2. Make sure that the master cylinder reservoir tank does not become empty of brake fluid.



      Lexus Is250, Is220D. Gse20 Ale20
    1. Connect a vinyl tube to either one of the bleeder plugs.

    2. Depress the brake pedal several times, then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*11).



    3. Lexus Is250, Is220D. Gse20 Ale20
    4. When fluid no longer comes out, tighten the bleeder plug, then release the brake pedal (*12).

    5. Repeat (*11) and (*12) until all the air in the fluid is completely bled out.

    6. Using SST, tighten the bleeder plug completely.

      SST
      09023-00101
      Torque:
      11 N*m{110 kgf*cm, 8 ft.*lbf}
    7. Repeat the above procedures for each brake to bleed the air from the brake line.

  1. Finish "AIR BLEEDING" on the intelligent tester and turn off the power.

  1. Disconnect the intelligent tester from the DLC3.

  1. Turn the engine switch off.



8. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the bleeder plug cap.

  1. Connect a vinyl tube to the bleeder plug.

  1. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

  1. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

  1. Repeat the previous 2 steps until all the air in the fluid is completely bled.

  1. Tighten the bleeder plug.

    Torque:
    11 N*m{112 kgf*cm, 8 ft.*lbf}
  1. Install the bleeder plug cap.

  1. Check that all the air has been bled from the clutch line.



9. INSPECT FLUID LEVEL IN RESERVOIR
  1. Check the fluid level and add fluid if necessary.

    Fluid:
    SAE J1703 or FMVSS No. 116 DOT3
    HINT:
    If fluid leaks, tighten or replace the leaking part.


10. INSPECT FOR BRAKE FLUID LEAKAGE


11. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Engage the 11 claws.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Install the cowl top ventilator louver sub-assembly with the 2 clips.



12. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
  1. Operate the wiper, and stop the windshield wiper motor at the automatic stop position.



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Install the front wiper arm and blade assembly RH with the nut at the position as shown in the illustration.

    Torque:
    22 N*m{224 kgf*cm, 16 ft.*lbf}
    HINT:
    Hold the arm hinge by hand to fasten the nut.
    Area
    Measurement
    A
    18.5 to 33.5 mm (0.73 to 1.32 in.)
    B
    Approx. 20 mm (0.79 in.)
  1. Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and there is no interference with the vehicle body.



13. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
  1. Operate the wiper, and stop the windshield wiper motor at the automatic stop position.



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

    Torque:
    22 N*m{224 kgf*cm, 16 ft.*lbf}
    HINT:
    Hold the arm hinge by hand to fasten the nut.
    Area
    Measurement
    A
    15 to 30 mm (0.59 to 1.18 in.)
    B
    Approx. 40 mm (1.57 in.)


14. INSTALL FRONT WIPER ARM HEAD CAP


    Lexus Is250, Is220D. Gse20 Ale20
  1. Install the front wiper arm head cap.

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


15. INSTALL ROOF DRIP SIDE FINISH MOULDING RH


16. INSTALL ROOF DRIP SIDE FINISH MOULDING LH


17. INSTALL FRONT UPPER FENDER PROTECTOR LH


    Lexus Is250, Is220D. Gse20 Ale20
  1. Engage the claw and the 3 clips, then install the front upper fender protector LH.

  1. Engage the clip on the rubber portion of the cowl top ventilator louver sub-assembly to the front fender protector upper LH.



18. INSTALL FRONT UPPER FENDER PROTECTOR RH
HINT:
Use the same procedures for the RH side and the LH side.


19. INSTALL ENGINE ROOM SIDE COVER RH


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Install the side cover with the 2 clips.



20. INSTALL ENGINE ROOM SIDE COVER LH


    Lexus Is250, Is220D. Gse20 Ale20.Brake.Brake System.Brake Master Cylinder  Installation
  1. Install the side cover with the 5 clips.



21. INSTALL COOL AIR INTAKE DUCT SEAL


    Lexus Is250, Is220D. Gse20 Ale20
  1. Install the intake duct seal with the 11 clips.