Lexus NX: Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTCs.

PROCEDURE

1. INSTALL REAR DISC

(a) Align the matchmarks of the rear disc and axle hub and install the rear disc. HINT: When replacing the disc with a new one, select the installation position where the rear disc has the smallest runout.

*a Matchmark

2. INSTALL REAR DISC BRAKE BUSH DUST BOOT

(a) Apply a light coat of lithium soap base glycol grease to the entire circumference of a new rear disc brake bush dust boot where it contacts the rear disc brake cylinder mounting, and the entire inner circumference of both of its ends. HINT: Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to the rear disc brake bush dust boot.

*a Lithium soap base glycol grease

(b) Install the 2 rear disc brake bush dust boots to the rear disc brake cylinder mounting.

3. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH

(a) Apply a light coat of lithium soap base glycol grease to a new rear disc brake rear cylinder slide pin where it contacts the rear disc brake cylinder slide bush.

*a Lithium soap base glycol grease

(b) Install the rear disc brake cylinder slide bush to the rear disc brake rear cylinder slide pin.

4. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light coat of lithium soap base glycol grease to the sliding part of the rear disc brake cylinder slide pin.

*a Lithium soap base glycol grease

(b) Install the rear No. 1 disc brake cylinder slide pin to the rear disc brake cylinder mounting LH.

(c) Push the rear No. 1 disc brake cylinder slide pin into the rear disc brake bush dust boot to align them.

5. INSTALL REAR DISC BRAKE REAR CYLINDER SLIDE PIN

(a) Apply a light coat of lithium soap base glycol grease to the sliding part and the seal surface of the rear disc brake rear cylinder slide pin.

*a Lithium soap base glycol grease

(b) Install the rear disc brake rear cylinder slide pin to the disc brake cylinder mounting LH.

(c) Push the rear disc brake rear cylinder slide pin into the rear disc brake bush dust boot to align them.

6. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH

(a) Install the rear disc brake cylinder mounting LH with the 2 bolts.

Torque:

104 N·m {1061 kgf·cm, 77 ft·lbf}

7. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE

(a) Install the 4 pad support plates to the disc brake cylinder mounting as shown in the illustration. NOTICE: The shapes of the rear disc brake pad support plates differ. Therefore, when replacing a rear disc brake pad support plate with a new plate, make sure to check the part number and shape prior to installation. When reusing a rear disc brake pad support plate, make sure to check the installation position using the matchmark placed during removal proper to installation.

*1 Rear No. 1 Disc Brake Pad Support Plate *2 Rear No. 2 Disc Brake Pad Support Plate

8. INSTALL REAR ANTI-SQUEAL SHIM KIT

(a) Apply disc brake grease to both surfaces of the inner rear No. 1 disc brake anti-squeal shim and only to the inner surface of the outer rear disc brake anti-squeal shim.

*a	Inner Side
*b	Outer Side
	Disc brake grease

NOTICE:

Make sure that disc brake grease is not applied onto the lining surface.

(b) Install the rear No. 1 disc brake anti-squeal shim and rear No. 2 disc brake anti-squeal shim to the inner rear disc brake pad. NOTICE: When replacing a worn pad, the shims must be replaced together with the pads. Install the shims in the correct positions and direction as shown in the illustration.

*1 Rear No. 1 Disc Brake Anti-squeal Shim *2 Rear No. 2 Disc Brake Anti-squeal Shim *3 Rear Disc Brake Anti-squeal Shim *4 Pad Wear Indicator Plate

(c) Install the rear disc brake anti-squeal shim to the outer rear disc brake pad.

NOTICE:

When replacing a worn pad, the shims must be replaced together with the pads.

9. INSTALL REAR DISC BRAKE PAD

(a) Install the 2 new pad wear indicator plates to the rear disc brake pads.

NOTICE:

Install the pad wear indicator plates in the correct positions and directions.

(b) Install the 2 rear disc brake pads to the rear disc brake cylinder mounting LH.

NOTICE:

Make sure there is no oil or grease on the friction surface of the pads and disc.

HINT:

If the rear disc brake pad has an identification mark, be sure to confirm the installation location.

10. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY LH

(a) Hold the rear disc brake cylinder slide pins and install the rear disc brake cylinder assembly to the disc brake cylinder mounting with 2 new bolts. Torque: 34.3 N·m {350 kgf·cm, 25 ft·lbf}

*a Hold *b Turn

11. INSTALL PARKING BRAKE ACTUATOR ASSEMBLY LH

(a) Apply a light coat of lithium soap base glycol grease to the new O-ring.

(b) Install the O-ring to the rear disc brake cylinder assembly LH.

(c) Using a 5 mm hexagon socket wrench, install the parking brake actuator assembly LH with the 2 bolts.

Torque:

8.4 N·m {86 kgf·cm, 74 in·lbf}

(d) Connect the connector to the parking brake actuator assembly.

12. CONNECT REAR FLEXIBLE HOSE LH

(a) Install a new gasket and connect the flexible hose with a new union bolt.

Torque:

30.4 N·m {310 kgf·cm, 22 ft·lbf}

HINT:

Install the flexible hose lock securely in the lock hole in the cylinder.

13. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

(a) Connect the negative (-) auxiliary battery terminal and tighten the nut.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

(b) Perform the following procedure if air bleeding is not necessary:

(1) Connect the reservoir level switch connector.

(2) Clear the DTCs.

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14. INITIALIZATION AFTER RECONECTING AUXILIARY BATTERY TERMINAL

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HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

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15. INSTALL DECK FLOOR BOX LH

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16. INSTALL REAR DECK FLOOR BOX

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17. INSTALL NO. 3 DECK BOARD SUB-ASSEMBLY

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18. BLEED BRAKE LINE

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19. BLEED REAR DISC BRAKE CYLINDER ASSEMBLY

CAUTION:

If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder assembly.

(a) Perform the procedure to enter rear disc brake pad replacement mode 5 times.

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(b) Release the parking brake.

(c) Disconnect the No. 2 parking brake wire assembly connector from the parking brake actuator assembly.

(d) Disconnect the center No. 1 cowl top ventilator louver. (1) Slide the hood to cowl top seal and detach the 2 claws (A). (2) Detach the 2 claws (B) and 3 guides, and remove the center No. 1 cowl top ventilator louver.

(e) Remove the brake master cylinder reservoir filler cap assembly.

(f) Add brake fluid to the brake master cylinder reservoir assembly until the brake fluid level is between the MAX and MIN lines on the brake master cylinder reservoir assembly.

(g) Connect the Techstream to the DLC3 with the power switch off.

(h) Turn the power switch on (IG).

(i) Turn the Techstream on and enter the following menus: Chassis / ABS/VSC/TRAC / Utility / Air Bleeding.

HINT:

Do not apply the parking brake even if instructed by the Techstream.

(j) Remove the 2 bolts and separate the rear disc brake cylinder assembly with the rear disc brake cylinder mounting from the rear axle carrier sub-assembly.(*1)

(k) Hold the rear disc brake cylinder assembly with the rear disc brake cylinder mounting horizontally, then tilt it 45° toward the bleeder plug side as shown in the illustration.(*2)

(l) Temporarily install the rear disc brake cylinder assembly with the rear disc brake cylinder mounting to the rear axle carrier sub-assembly with the 2 bolts.(*3)

(m) Using the Techstream, perform air bleeding.(*4)

(n) Follow the Techstream instructions to bleed the air from the brake fluid.(*5)

NOTICE:

Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brake lines.

(o) Repeat steps (*1) through (*5) 3 times.

NOTICE:

If there is still air in the system after performing steps (*1) through (*5) 3 times, repeat the steps (*1) through (*5) until the air has been bled.

(p) Tighten the bleeder plug completely.

Torque:

8.3 N·m {85 kgf·cm, 73 in·lbf}

(q) Install the rear disc brake cylinder assembly with the rear disc brake cylinder mounting to the rear axle carrier sub-assembly with the 2 bolts.

Torque:

104 N·m {1061 kgf·cm, 77 ft·lbf}

(r) Connect the No. 2 parking brake wire assembly connector to the parking brake actuator assembly.

(s) Clear the DTCs.

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(t) Turn the Techstream off and turn the power switch off.

(u) Disconnect the Techstream from the DLC3.

(v) Inspect for brake fluid leaks.

(w) Inspect and adjust the brake fluid level in the brake master cylinder reservoir assembly.

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(x) Install the brake master cylinder reservoir filler cap assembly.

(y) Install the center No. 1 cowl top ventilator louver. (1) Attach the 2 claws (B) and 3 guides to install the center No. 1 cowl top ventilator louver. (2) Slide the hood to cowl top seal to attach the 2 claws (A).

20. INSTALL REAR WHEEL

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21. RECOVERY TO NORMAL

(a) After performing repairs, operate the integration control and panel assembly (electric parking brake switch).

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