Clutch Master Cylinder Installation

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

  1. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY (for LHD)

  2. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY (for RHD)

  3. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN

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

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

  6. CONNECT CLUTCH LINE

  7. CONNECT CLUTCH RESERVOIR TUBE (for LHD)

  8. CONNECT CLUTCH RESERVOIR TUBE (for RHD)

  9. INSTALL WIRE HARNESS (for LHD)

  10. INSTALL WIRE HARNESS (for RHD)

  11. BLEED CLUTCH LINE

  12. CHECK FOR BRAKE FLUID LEAKAGE

  13. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT

  14. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY

  15. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY

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

  17. INSTALL SIDE INSTRUMENT PANEL

  18. INSTALL FRONT DOOR OPENING TRIM COVER LH

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

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

  21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  22. INSPECT BRAKE FLUID LEVEL IN RESERVOIR

  23. PERFORM INITIALIZATION

  24. INSPECT SRS WARNING LIGHT

Clutch Master Cylinder -- 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 ASSEMBLY (for LHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Install the clutch master cylinder assembly with the 2 bolts.

    Torque:
    12 N*m{120 kgf*cm, 9 ft.*lbf}

  1. Connect the clutch reservoir tube.



2. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY (for RHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Install the clutch master cylinder assembly with the 2 bolts.

    Torque:
    12 N*m{120 kgf*cm, 9 ft.*lbf}

  1. Connect the clutch reservoir tube.



3. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN


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

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

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

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

  1. Install the new clip to the pin.



4. 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}


5. 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}


6. CONNECT CLUTCH LINE


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

  1. Using SST, connect the clutch line.

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


7. CONNECT CLUTCH RESERVOIR TUBE (for LHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the clutch reservoir tube.



8. CONNECT CLUTCH RESERVOIR TUBE (for RHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the clutch reservoir tube.



9. INSTALL WIRE HARNESS (for LHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the 3 connectors and clamp.



10. INSTALL WIRE HARNESS (for RHD)


    Lexus Is250, Is220D. Gse20 Ale20

  1. Connect the 2 connectors and clamp.



11. 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}


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


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


14. 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}


15. 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.



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


    Lexus Is250, Is220D. Gse20 Ale20.Clutch.Clutch System.Clutch Master Cylinder 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>.



17. INSTALL SIDE INSTRUMENT PANEL


    Lexus Is250, Is220D. Gse20 Ale20

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



18. INSTALL FRONT DOOR OPENING TRIM COVER LH


    Lexus Is250, Is220D. Gse20 Ale20

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



19. 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.



20. 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.



21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


22. INSPECT BRAKE FLUID LEVEL IN RESERVOIR


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


24. INSPECT SRS WARNING LIGHT
(Click here)