Lexus ES300 (1997 year). Manual — part 282

BR2237

BR06F–01

BR2238

GOOD

NO GOOD

1st

2nd

3rd

–

BRAKE

BRAKE BOOSTER ASSEMBLY

BR–19

1134

1997 LEXUS ES300 (RM511U)

BRAKE BOOSTER ASSEMBLY

ON–VEHICLE INSPECTION

1.

OPERATING CHECK

(a)

Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.

(b)

Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.

2.

AIR TIGHTNESS CHECK

(a)

Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.

If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b)

Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.

BR06G–04

Z19273

Z19273

Master Cylinder

Vacuum Hose

Brake Booster

2–way

N·m (kgf·cm, ft·lbf)

: Specified torque

Non–reusable part

Gasket

15 (155, 11)

13 (130, 9)

Pin

Clevis

Clip

25 (260, 16)

Gasket

13 (130, 9)

BR–20

–

BRAKE

BRAKE BOOSTER ASSEMBLY

1135

1997 LEXUS ES300 (RM511U)

COMPONENTS

BR06H–01

R00257

–

BRAKE

BRAKE BOOSTER ASSEMBLY

BR–21

1136

1997 LEXUS ES300 (RM511U)

REMOVAL

1.

REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE

2.

REMOVE MASTER CYLINDER (See page

BR–13

)

3.

REMOVE CHARCOAL CANISTER

4.

DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER

5.

REMOVE PEDAL RETURN SPRING

6.

REMOVE CLIP AND CLEVIS PIN

7.

REMOVE BRAKE BOOSTER, GASKET AND CLEVIS

(a)

Remove the 4 nuts and clevis.

(b)

Pull out the brake booster and gasket.

BR06I–05

BR3976

SST

Gasket

R11347

SST

BR–22

–

BRAKE

BRAKE BOOSTER ASSEMBLY

1137

1997 LEXUS ES300 (RM511U)

INSTALLATION

1.

INSTALL BRAKE BOOSTER

(a)

Install the booster and a new gasket.

(b)

Install the clevis to the operating rod.

(c)

Install and torque the booster installation nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

(d)

Install the clevis, and torque the lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

(e)

Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.

(f)

Install the pedal return spring.

2.

ADJUST LENGTH OF BOOSTER PUSH ROD

(a)

Install a new gasket on the master cylinder.

(b)

Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST

09737–00010

(c)

Turn the SST upside down, and set it on the booster.
SST

09737–00010

(d)

Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)

(e)

Adjust the booster push rod length until the push rod light-
ly touches the pin head.

3.

INSTALL CHARCOAL CANISTER TO ORIGINAL POSI-
TION

4.

INSTALL MASTER CYLINDER (See page

BR–18

)

5.

INSTALL AIR CLEANER COVER WITH AIR CLEANER
HOSE

6.

CONNECT VACUUM HOSE TO BRAKE BOOSTER

7.

FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page

BR–4

)

8.

CHECK FOR FLUID LEAKAGE

9.

CHECK AND ADJUST BRAKE PEDAL
(See page

BR–6

)

10.

DO OPERATIONAL CHECK (See page

BR–19

)