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

  3. REMOVE ENGINE ROOM SIDE COVER LH

  4. REMOVE ENGINE ROOM SIDE COVER RH

  5. REMOVE FRONT UPPER FENDER PROTECTOR LH

  6. REMOVE FRONT UPPER FENDER PROTECTOR RH

  7. REMOVE ROOF DRIP SIDE FINISH MOULDING LH

  8. REMOVE ROOF DRIP SIDE FINISH MOULDING RH

  9. REMOVE FRONT WIPER ARM HEAD CAP

  10. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH

  11. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH

  12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

  13. REMOVE FRONT WHEEL

  14. DRAIN BRAKE FLUID

  15. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK

  16. SEPARATE CLUTCH RESERVOIR HOSE (for Manual Transmission)

  17. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

  18. REMOVE BRAKE ACTUATOR ASSEMBLY

  19. REMOVE FRONT DOOR SCUFF PLATE LH

  20. REMOVE FRONT DOOR SCUFF PLATE RH

  21. REMOVE FRONT DOOR OPENING TRIM COVER LH

  22. REMOVE FRONT DOOR OPENING TRIM COVER RH

  23. REMOVE INSTRUMENT SIDE PANEL LH

  24. REMOVE INSTRUMENT SIDE PANEL RH

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

  26. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY

  27. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY

  28. REMOVE BRAKE PEDAL RETURN SPRING

  29. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS

  30. REMOVE BRAKE BOOSTER ASSEMBLY

  31. REMOVE BRAKE BOOSTER GASKET

  32. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY

  33. 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


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



3. REMOVE ENGINE ROOM SIDE COVER LH


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



4. REMOVE ENGINE ROOM SIDE COVER RH


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



5. REMOVE FRONT UPPER FENDER PROTECTOR LH


    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 fender protector upper LH.



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


7. 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



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


9. REMOVE FRONT WIPER ARM HEAD CAP


    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.


10. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH


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



11. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH


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



12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    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.



13. REMOVE FRONT WHEEL


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


15. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK


    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.


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



17. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY


    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.



18. REMOVE BRAKE ACTUATOR ASSEMBLY


    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.


19. REMOVE FRONT DOOR SCUFF PLATE LH


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


21. 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.



22. 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.



23. 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.



24. 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.



25. 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.



26. 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.



27. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY


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



29. 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, then separate the push rod clevis.



30. REMOVE BRAKE BOOSTER ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Move the clip and disconnect the vacuum hose.



    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.


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



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



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