Lexus ES300 (2002 year). Service manual — part 250

0305U-01

6N

8N

10N

11N

12N

B06432

Nut Type

Present Standard
Hexagon Nut

Cold Forging Nut

Cutting Processed Nut

Class

4N

5N (4T)

6N

7N (5T)

8N

10N (7T)

11N

12N

Old Standard Hexagon Nut

No Mark (w/ Washer)

No Mark

*

No Mark (w/ Washer)

No Mark

No Mark

*: Nut with 1 or more marks on one side surface of the nut.

-

SERVICE SPECIFICATIONS

STANDARD BOLT

03-3

104

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

HOW TO DETERMINE NUT STRENGTH

HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more

030HJ-01

03-34

-

SERVICE SPECIFICATIONS

BRAKE

135

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

BRAKE

SERVICE DATA

Brake pedal height (from asphalt sheet)

144.1 - 154.1 mm (5.673 - 6.067 in.)

Brake pedal free play

Pedal free play:

1 - 6 mm (0.04 - 0.24 in.)

Stop light switch clearance

0.5 - 2.5 mm (0.020 - 0.098 in.)

Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf)

More than 70 mm (2.76 in.)

Brake booster push rod to piston clearance (w/ SST)

Clearance:

0 mm (0 in.)

Front brake pad thickness (Single piston type)

Standard thickness:
Minimum thickness:

12.0 mm (0.472 in.)
1.0 mm (0.039 in.)

Front brake pad thickness (Twin piston type)

Standard thickness:
Minimum thickness:

10.6 mm (0.417 in.)
1.0 mm (0.039 in.)

Front brake disc thickness

Standard thickness:

Minimum thickness:

28.0 mm (1.102 in.)
26.0 mm (1.024 in.)

Front brake disc runout

Maximum disc runout:

0.05 mm (0.0020 in.)

Rear brake pad thickness (USA, Canada models)

Standard thickness:
Minimum thickness:

10.0 mm (0.394 in.)
1.0 mm (0.039 in.)

Rear brake pad thickness (Brazil models)

Standard thickness:
Minimum thickness:

11.0 mm (0.433 in.)
1.0 mm (0.039 in.)

Rear disc brake thickness (USA, Canada models)

Standard thickness:
Minimum thickness:

12.0 mm (0.472 in.)
10.5 mm (0.413 in.)

Rear disc brake thickness (Brazil models)

Standard thickness:

Minimum thickness:

10.0 mm (0.394 in.)
8.5 mm (0.335 in.)

Rear brake disc runout

Maximum disc runout:

0.15 mm (0.0059 in.)

030HK-01

-

SERVICE SPECIFICATIONS

BRAKE

03-35

136

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

TORQUE SPECIFICATION

Part Tightened

N

⋅

m

kgf

⋅

cm

ft

⋅

lbf

Bleeder plug

8.3

85

74 in.

⋅

lbf

Brake booster clevis lock nut

26

265

19

Brake pedal sub-assy set bolt

37

375

27

Stop lamp lock nut

26

265

19

Brake pedal support assy x Reinforcement

20

204

15

Brake pedal support assy x Body

13

130

9

Master cylinder piston stopper bolt

w/o VSC

10

100

7

Brake master cylinder x Brake booster

13

130

9

Brake line union nut

15

155

11

Vacuum hose bracket set bolt

5.4

55

48 in.

⋅

lbf

Chacoal canister bracket set bolt

43

440

32

Wheel nut

103

1,050

76

Front brake cylinder mounting x Steering knuckle

106.9

1,090

79

Front brake cylinder x Front brake cylinder mounting

34.3

350

25

Front brake cylinder x Flexible hose

29.4

300

22

Rear disc brake cylinder mounting set bolt

61.8

630

46

Rear disc brake cylinder slide pin x Rear disc brake cylinder mounting

Upper side:
Lower side:

39.2
34.3

400
350

29
25

Rear disc brake cylinder x Flexible hose

29.4

300

22

Brake actuator assy x Actuator bracket

5.4

55

48 in.

⋅

lbf

Brake actuator bracket x Body

19

194

14

ABS & TRAC actuator assy x Actuator bracket

5.4

55

48 in.

⋅

lbf

ABS & TRACTION actuator bracket x Body

19

194

14

Front speed sensor x Steering knuckle

8.0

82

71 in.

⋅

lbf

Front speed sensor wire harness clamp x shock absorber

Bolt A:
Bolt B:

5.0

18.8

51

192

44 in.

⋅

lbf

14

Rear axle hub set bolt

80

816

59

Yawrate sensor x Body

12.5

127

9

Skid control ECU x Body

5.5

56

49 in.

⋅

lbf

030HZ-01

03-36

-

SERVICE SPECIFICATIONS

PARKING BRAKE

137

2002 LEXUS ES300 REPAIR MANUAL (RM911U)

PARKING BRAKE

SERVICE DATA

Parking brake pedal travel at 300 N (31 kgf, 68.3 lbf):

3 - 6 clicks

Rear brake disc inside diameter

Standard inside diameter:

Maximum inside diameter:

170 mm (6.69 in.)
171 mm (6.73 in.)

Parking brake shoe lining thickness

Standard thickness:
Minimum thickness:

2.0 mm (0.079 in.)
1.0 mm (0.039 in.)

Parking brake shoe clearance between rear shoe and lever

Less than 0.35 mm (0.0138 in.)