LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2002 >> IS 300 Base, Standard >> Repair and Diagnosis (Single Page) >> Brakes >> Mechanical - Hydraulic >> Disc Brakes >> Overhaul >> Master Cylinder >> Assembly (SC 430)

Assembly (SC 430)

  1. Place booster pump with a cloth under it in vise.
  2. Install brake booster accumulator pipe, compression spring and NEW O-ring. Ensure no foreign matter enters pump.
  3. Using special tool (09318-12010), install accumulator. Tighten to specification. See TORQUE SPECIFICATIONS .
  4. Using hexagon wrench, install brake booster pump No. 2 bracket and 2 bolts. Tighten to specification. See TORQUE SPECIFICATIONS .
  5. Install shaft, collars, bushes and washers. Install brake booster pump bracket No. 1 with bolt and tighten to specification. See TORQUE SPECIFICATIONS .
  6. Install brake booster with accumulator pump assembly.
  7. Using hexagon wrench, install brake booster pump bracket No. 1 and brake booster pump bracket No. 2 with bolt. Tighten to specification. See TORQUE SPECIFICATIONS .
  8. Using hexagon wrench, install brake booster pump bracket No. 3 with bolts. When installing brake booster bracket, measure clearances "A", "B", "D" and "E". See Figure. Ensure clearances correspond to each value in Figure. Using a thickness gauge, ensure that "C" range is .004-.016" (.1-.4 mm). See Figure. Tighten to specification. See TORQUE SPECIFICATIONS .
  9. Install a new brake control wire with screws. Tighten master cylinder side and booster pump side to their respective specifications. See TORQUE SPECIFICATIONS . Connect wire harness clamp.
  10. Install NEW gaskets and union No. 1 with union bolt. Tighten to specification. See TORQUE SPECIFICATIONS .
  11. Install NEW gaskets and union No. 2 with union bolt. Tighten to specification. See TORQUE SPECIFICATIONS .
  12. Install brake actuator hose and clips.
  13. Using special tool (09023-00100), install brake actuator No. 1 tube. Tighten to specification. See TORQUE SPECIFICATIONS .
  14. Using hexagon wrench, install brake actuator No. 1 bracket with bolt. Tighten to specification. See TORQUE SPECIFICATIONS .
  15. Using hexagon wrench, install brake actuator No. 3 bracket with bolt. Tighten to specification. See TORQUE SPECIFICATIONS .
  16. Connect level warning switch connector to brake actuator No. 3 bracket.
  17. Apply lithium soap base glycol grease to new brake booster piston and plug. Install piston and brake booster plug. Press in brake booster plug, and install a NEW snap ring.
  18. Apply lithium soap base glycol grease to NEW grommets and install to reservoir assembly.
  19. Install master cylinder reservoir assembly with screws and tighten to specification. See TORQUE SPECIFICATIONS .
  20. Install brake master cylinder reservoir filler cap assembly and master cylinder boot.
  21. Install lock nut and master cylinder push rod clevis.
  22. Install NEW brake booster gasket to master cylinder and install brake master cylinder. See MASTER CYLINDER  under REMOVAL & INSTALLATION.
scientia non olet · About LEMON Manuals