Lexus ES300 (1997 year). Service manual - part 278

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BRAKE

TROUBLESHOOTING

BR–3

1118

1997 LEXUS ES300   (RM511U)

Symptom

Suspect Area

See page

Noise from brake

1. Pad (Cracked or distorted)

2. Installation bolt (Loosen)

3. Disc (Scored)

4. Pad support plate (Loosen)

5. Sliding pin (Worn)

6. Pad (Dirty)

7. Pad (Glazed)

8. Tension or return spring (Faulty)

9. Anti–squeal shim (Damage)

10. Hold–down spring (Damage)

BR–23

BR–32

BR–26

BR–35

BR–26

BR–35

BR–23

BR–32

BR–26

BR–35

BR–23

BR–32

BR–23

BR–32

BR–41

BR–23

BR–32

BR–41

BR063–01

R11401

R11402

R11403

R00699

BR–4

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BRAKE

BRAKE FLUID

1119

1997 LEXUS ES300   (RM511U)

BRAKE FLUID

BLEEDING

HINT:
If any work is done on the brake system or if air is suspected in
the brake lines, bleed the system of air.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.

1.

FILL BRAKE RESERVOIR WITH BRAKE FLUID

Check the fluid level in the reservoir after bleeding each wheel.
Add fluid, if necessary.

Fluid: SAEJ1703 or FMVSS No.116 DOT 3

2.

BLEED MASTER CYLINDER

HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air from the master cylinder.
(a)

Disconnect the brake lines from the master cylinder.

(b)

Slowly depress the brake pedal and hold it.

(c)

Block off the outlet plugs with your fingers, and release
the brake pedal.

(d)

Repeat (b) and (c) 3 or 4 times.

3.

CONNECT VINYL TUBE TO BRAKE CALIPER BLEED-
ER PLUG

Insert the other end of the tube in a half–full container of brake
fluid.
NOTICE:
Bleed air of the rear brake first. If front brake is bled first,
rear brake air cannot be bled.
4.

BLEED BRAKE LINE

(a)

Slowly depress the brake pedal several times.

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BRAKE

BRAKE FLUID

BR–5

1120

1997 LEXUS ES300   (RM511U)

(b)

While an assistant depresses the pedal, loosen the
bleeder plug until fluid starts to run out. Then tighten the
bleeder plug.

(c)

Repeat this procedure until there are no more air bubbles
in the fluid.
Torque: (Bleeder plug)
8.3 N·m (85 kgf·cm, 74 in.·lbf)

5.

REPEAT PROCEDURE FOR EACH WHEEL

R00954

Push Rod

Pedal Height

Stop Light 
Switch

BR064–01

BR4980

A

R00935

Pedal Freeplay

BR–6

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BRAKE

BRAKE PEDAL

1121

1997 LEXUS ES300   (RM511U)

BRAKE PEDAL

ON–VEHICLE INSPECTION

1.

CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
152.0 – 162.0 mm (5.984 – 6.378 in.)

2.

IF NECESSARY, ADJUST PEDAL HEIGHT

(a)

Disconnect the connector from the stop light switch.

(b)

Loosen the stop light switch lock nut and remove the stop
light switch.

(c)

Loosen the push rod lock nut.

(d)

Adjust the pedal height by turning the pedal push rod.

(e)

Tighten the push rod lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

(f)

Install the stop light switch and turn it until it lightly con-
tacts the pedal stopper.

(g)

Turn the stop light switch back one turn.

(h)

Check the clearance (A) between the stop light switch
and pedal.
Clearance: 0.5 – 2.4 mm (0.020 – 0.094 in.)

(i)

Tighten the stop light switch lock nut.

(j)

Connect the connector to the stop light switch.

(k)

Check that the stop lights come on when the brake pedal
is depressed, and go off when the brake pedal is re-
leased.

(l)

After adjusting the pedal height, check the pedal freeplay.

HINT:
If clearance (A) between the stop light switch and the pedal
stopper has been adjusted correctly, the pedal freeplay will
meet the specifications.

3.

CHECK PEDAL FREEPLAY

(a)

Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.

(b)

Push in the pedal by hand until the resistance begins to
be felt, then measure the distance.
Pedal freeplay:
1 – 6 mm (0.04 – 0.24 in.)