Lexus Car ES, IS, LS 1998-06

Actuator

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the brake fluid. Wash off the brake fluid immediately if it comes into contact with a painted surface.
  6.  
  7. If equipped, slide the clip and disconnect the actuator No.1 hose from the actuator.
  8.  
  9. If equipped, disconnect the master cylinder pressure sensor connector and harness clamp.
  10.  
  11. Disconnect the 6 brake lines from the actuator. Use tags or make a memo to identify the place to reconnect.
  12.  
  13. Disconnect the brake actuator connector.
  14.  
  15. Remove the 3 nuts and brake actuator with mounting bracket.
  16.  
  17. Remove the 2 nuts and brake actuator from the mounting bracket.
  18.  
  19. Remove the 2 holders and 3 cushions from the brake actuator.
  20.  

To install:

  1. Install the 3 cushions and 2 holders to the actuator assembly.
  2.  
  3. Install the actuator to the bracket with the 2 nuts and tighten to 48 inch lbs. (5.4 Nm).
  4.  
  5. Install the brake actuator with the 3 nuts and tighten to 14 ft. lbs. (19 Nm).
  6.  
  7. Connect the brake actuator connector.

    Click image to see an enlarged view

    Fig. Correct brake line locations to the brake actuator assembly.-ES 300 and ES 330 w/VSC



    Click image to see an enlarged view

    Fig. Correct brake line locations to the ABS & Traction actuator assembly.-ES 300

  8.  
  9. Connect each brake line to the correct position of brake actuator, as shown in the illustration. Tighten the fittings to 11 ft. lbs. (15 Nm).
  10.  
  11. If equipped, connect the actuator No.1 hose to the actuator and slide the clip.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fill the reservoir with brake fluid.
  16.  
  17. Bleed the master cylinder and the brake lines.
  18.  
  19. Bleed the ABS & Traction actuator assembly (ES 300).
  20.  
  21. If equipped VSC, bleed the brake actuator assembly (ES 330).
  22.  
  23. Check the fluid level.
  24.  
  25. Check for brake fluid leaks.
  26.  
  27. Check the operation of the brake actuator.
  28.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner inlet and air cleaner.
  6.  
  7. Disconnect the 6 brake lines from the ABS & TRAC / VSC actuator.
  8.  
  9. Disconnect the brake hose and connector.
  10.  
  11. Remove the nut, 2 bolts and ABS & TRAC / VSC actuator assembly.
  12.  
  13. Remove the 2 nuts and ABS & TRAC / VSC actuator from the bracket.
  14.  
  15. Remove the 2 cushion bolts and 3 cushions.
  16.  

To install:

  1. Install the 3 cushions and 2 holders to the actuator assembly.
  2.  
  3. Install the actuator to the bracket with the 2 nuts and tighten to 48 inch lbs. (5.4 Nm).
  4.  
  5. Install the actuator assembly with the nut and 2 bolts and tighten to 14 ft. lbs. (19 Nm).
  6.  
  7. Connect the brake hose and connector.
  8.  
  9. Connect each brake line to the actuator. Tighten the fittings to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the air cleaner inlet and air cleaner.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fill the reservoir with brake fluid.
  16.  
  17. Bleed the brake system.
  18.  
  19. Check for brake fluid leaks.
  20.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the cool air intake duct seal.
  6.  
  7. Remove the left and right engine room side covers.
  8.  
  9. Remove left and right front upper fender protectors.
  10.  
  11. Remove the left and right front windshield wiper arm assemblies.
  12.  
  13. Remove the cowl top ventilator louver sub-assembly.
  14.  
  15. Remove the bolt, nut and No. 3 engine room relay block. Cover the relay block with a shop rag or a piece of cloth to prevent brake fluid from getting on it.
  16.  
  17. Remove the front wheel.
  18.  
  19. Drain the brake fluid. Wash off the brake fluid immediately if it comes into contact with a painted surface.
  20.  
  21. Disengage the clamp and disconnect the warning switch connector.
  22.  
  23. Disconnect the 2 brake tubes from the brake master cylinder sub-assembly.
  24.  
  25. Remove the 2 nuts and separate the brake actuator assembly.
  26.  
  27. Remove the 2 nuts and brake master cylinder sub-assembly from the brake booster assembly.
  28.  
  29. Remove the O-ring from the brake master cylinder sub-assembly.
  30.  
  31. Release the lock lever and disconnect the actuator connector.
  32.  
  33. Disconnect the 6 brake tubes from the brake actuator assembly with bracket. Use tags or make a memo to identify the places to reconnect.

    Click image to see an enlarged view

    Fig. Correct brake line locations to the brake actuator assembly.-IS 250 and IS 350

  34.  
  35. Disconnect the No. 3 front brake tube from the flexible hose.
  36.  
  37. Separate the grommet and remove the No. 3 front brake tube.
  38.  
  39. Remove the 2 bolts, nut and brake actuator assembly with bracket from the body.
  40.  
  41. Remove the 2 nuts and the brake actuator from the actuator bracket assembly.
  42.  
  43. Remove the brake actuator bolt cushion and actuator bracket.
  44.  
  45. Remove the 2 bolts and the 2 brake actuator bolt cushions from the brake actuator assembly.
  46.  

To install:

  1. Install the 2 brake actuator bolt cushions and 2 bolts to the brake actuator assembly.
  2.  
  3. Install the brake actuator bolt cushion with the actuator bracket assembly.
  4.  
  5. Install the brake actuator to the actuator bracket assembly with the 2 nuts. Tighten the 2 nuts to 48 inch lbs. (5.4 Nm).
  6.  
  7. Install the actuator assembly with bracket to the body with the 2 bolts and nut. Tighten the bolts and nut to 14 ft. lbs. (19 Nm).
  8.  
  9. Connect the No. 3 front brake tube to the flexible hose and tighten to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the grommet to the body. Make sure that the grommet is installed correctly.
  12.  
  13. Temporarily tighten each brake tube to the correct positions of the brake actuator assembly with bracket as shown in the illustration.
  14.  
  15. Fully tighten each brake tube to 11 ft. lbs. (15 Nm).
  16.  
  17. Connect the actuator connector.
  18.  
  19. Install the brake master cylinder as follows:


    1. Install a new O-ring to the brake master cylinder sub-assembly.
    2.  
    3. Install the brake master cylinder sub-assembly to the booster assembly with the 2 nuts and tighten to 9 ft. lbs. (12.5 Nm).
    4.  
    5. Connect the 2 brake lines to the brake master cylinder sub-assembly and tighten to 11 ft. lbs. (15 Nm).
    6.  
    7. Engage the clamp and connect the warning switch connector.
    8.  

  20.  
  21. Install the No. 3 engine room relay block.
  22.  
  23. Fill the reservoir with brake fluid.
  24.  
  25. Bleed the master cylinder and the brake lines.
  26.  
  27. Bleed the brake actuator assembly.
  28.  
  29. Inspect DTCs
  30.  
  31. Check the fluid level.
  32.  
  33. Check for brake fluid leaks.
  34.  
  35. Install the front wheel.
  36.  
  37. Install the cowl top ventilator louver sub-assembly.
  38.  
  39. Install the left and right front windshield wiper arm assemblies.
  40.  
  41. Install left and right front upper fender protectors.
  42.  
  43. Install the left and right engine room side covers.
  44.  
  45. Install the cool air intake duct seal.
  46.  
  47. Connect the negative battery cable.
  48.  
  49. Perform the yaw rate sensor zero point calibration.
  50.  
  51. Inspect sensor signal.
  52.  
  53. Inspect actuator with intelligent tester.
  54.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the battery clamp cover, bolt and air cleaner inlet.
  6.  
  7. Disconnect the MAF meter connector.
  8.  
  9. Remove the 3 bolts and loosen the hose clamp, pull out the air cleaner assembly with the cleaner hose.
  10.  
  11. Disconnect the 6 brake lines from the brake actuator.
  12.  
  13. Disconnect the 2 connectors from the brake actuator.
  14.  
  15. Remove the bolt, 2 nuts and brake actuator assembly.
  16.  
  17. Remove the 2 nuts and actuator from the actuator bracket.
  18.  
  19. Remove the 2 cushion bolts and 3 cushions from the brake actuator.
  20.  

To install:

  1. Install the 3 cushions and 2 cushion bolts to the brake actuator.
  2.  
  3. Install the brake actuator to the actuator bracket assembly with the 2 nuts. Tighten the 2 nuts to 48 inch lbs. (5.4 Nm).
  4.  
  5. Install the actuator assembly with bracket to the body with the bolt and 2 nuts. Tighten the bolt and nuts to 14 ft. lbs. (19 Nm).
  6.  
  7. Connect the 2 connectors to the brake actuator.
  8.  
  9. Connect each brake line to the brake actuator. Tighten the fittings to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the air cleaner assembly with the cleaner hose.
  12.  
  13. Connect the MAF meter connector.
  14.  
  15. Install the battery clamp cover and air cleaner inlet.
  16.  
  17. Fill the reservoir with brake fluid.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Bleed the brake system.
  22.  
  23. Check for brake fluid leaks.
  24.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine room side cover.
  6.  
  7. Remove the bolt and separate the engine room No.3 R/B.
  8.  
  9. Remove the front wheel.
  10.  
  11. Remove the front fender outside moulding, front fender splash shield and left front fender liner.
  12.  
  13. Draw out brake fluid with syringe. Wash brake fluid off immediately if it adheres to any painted surfaces.

    Click image to see an enlarged view

    Fig. Correct brake line locations to the brake actuator assembly.-LS 430

  14.  
  15. Disconnect the 6 brake tubes from the ABS & TRACTION actuator assy with bracket. Use tags or make a memo to identify the places to reconnect.

    Click image to see an enlarged view

    Fig. Certain brake actuator assembly bolt locations.-LS 430

  16.  
  17. Disconnect the connector from the ABS & TRACTION actuator assy.
  18.  
  19. Remove bolt A.
  20.  
  21. Remove nut B, then nut C.
  22.  
  23. Remove the ABS & TRACTION actuator assy with actuator bracket assy.
  24.  
  25. Remove the 2 nuts and the ABS & TRACTION actuator assy from the actuator bracket assy.
  26.  

To install:

  1. Place the ABS & TRACTION actuator assy on the actuator bracket assy and tighten the 2 nuts to 48 inch lbs. (5.4 Nm).
  2.  
  3. Place the ABS & TRACTION actuator with bracket on the body.
  4.  
  5. Tighten bolt A to 14 ft. lbs. (19 Nm).
  6.  
  7. Tighten nut C, then B to 14 ft. lbs. (19 Nm).
  8.  
  9. Connect the ABS & TRACTION actuator assy connector.
  10.  
  11. Connect each brake line to the brake actuator. Tighten the fittings to 11 ft. lbs. (15 Nm).
  12.  
  13. Fill the reservoir with brake fluid.
  14.  
  15. Bleed the master cylinder and the brake lines.
  16.  
  17. Check the fluid level and add fluid, if necessary. If fluid leaks, tighten or replace the leaking part.
  18.  
  19. Check the ABS & Traction actuator with hand-held tester.
  20.  
  21. Clear DTCs.
  22.  
  23. Install the left front fender liner, front fender splash shield and front fender outside moulding.
  24.  
  25. Install the front wheel.
  26.  
  27. Install the engine room No.3 R/B and bolt.
  28.  
  29. Install the engine room side cover.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Perform the yaw rate sensor zero point calibration and test mode.
  34.  

 
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