Brake Booster - Removal

Lexus IS250 IS220d GSE20 ALE20 - BRAKE

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)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Remove the 5 clips and side cover.

5. REMOVE ENGINE ROOM SIDE COVER RH (for 4GR-FSE)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Remove the 2 clips and side cover.

6. REMOVE ENGINE ROOM SIDE COVER LH (for 2AD-FHV)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Remove the 4 clips and side cover.

7. REMOVE ENGINE ROOM SIDE COVER RH (for 2AD-FHV)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Remove the 2 clips and side cover.

8. REMOVE FRONT UPPER FENDER PROTECTOR LH (for 4GR-FSE)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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.

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)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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.

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

Put protective tape around the roof drip side finish moulding.

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

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

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

  • HINT:
Use the same procedures for the RH side and the LH side.
Tape the screwdriver tip before use.
15. REMOVE FRONT WIPER ARM HEAD CAP (for 2AD-FHV)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

  • HINT:
Use the same procedures for the RH side and the LH side.
Tape the screwdriver tip before use.
16. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (for 4GR-FSE)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

17. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (for 2AD-FHV)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

18. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (for 4GR-FSE)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

19. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (for 2AD-FHV)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

20. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for 4GR-FSE)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Remove the 2 clips.

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Remove the 2 clips.

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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)

Remove the clip and separate the clutch reservoir hose.

27. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 4GR-FSE)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Disengage the clamp and disconnect the warning switch connector.

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

  • SST
  • 09023-00101

Remove the 2 nuts and separate the brake actuator assembly.

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

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

28. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 2AD-FHV)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Disengage the clamp and disconnect the warning switch connector.

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

  • SST
  • 09023-00101

Remove the 2 nuts and separate the brake actuator assembly.

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

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

29. REMOVE BRAKE ACTUATOR ASSEMBLY (for 4GR-FSE)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Release the lock lever and disconnect the actuator connector.

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

  • SST
  • 09023-00101

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

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

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

  • NOTICE:
  • Do not damage the brake tube.

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

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

  • NOTICE:
  • Do not damage the brake tubes.
30. REMOVE BRAKE ACTUATOR ASSEMBLY (for 2AD-FHV)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Release the lock lever and disconnect the actuator connector.

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

  • SST
  • 09023-00101

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

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

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

  • NOTICE:
  • Do not damage the brake tube.

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

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

  • 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
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

34. REMOVE FRONT DOOR OPENING TRIM COVER RH
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

35. REMOVE INSTRUMENT SIDE PANEL LH
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Using a screwdriver, disengage the 4 claws.

  • HINT:
  • Tape the screwdriver tip before use.
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Apply protective tape to the areas shown in the illustration.

Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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.

Disconnect the connectors.

38. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Disengage the 7 clips.

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

39. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Remove the 3 bolts and front passenger side knee airbag assembly.

Disconnect the connector.

  • NOTICE:
  • When handling the airbag connector, take care not to damage the airbag wire harness.
40. REMOVE BRAKE PEDAL RETURN SPRING

Remove the brake pedal return spring.

41. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

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

42. SEPARATE VACUUM HOSE (for LHD)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Using pliers, move the clip and disconnect the vacuum hose.

43. SEPARATE VACUUM HOSE (for RHD)
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Using pliers, move the clip and disconnect the vacuum hose.

44. REMOVE BRAKE BOOSTER ASSEMBLY
Brake Booster - Removal. BRAKE. Lexus IS250 IS220d GSE20 ALE20

Remove the 4 nuts and brake booster assembly.

  • NOTICE:
  • Do not damage the brake lines.
45. REMOVE BRAKE BOOSTER GASKET

Remove the brake booster gasket from the brake booster assembly.

46. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY

Remove the check valve assembly and grommet.

47. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS

Loosen the lock nut and remove the push rod clevis.