Technical Instructions

1. OPERATION FLOW CHART

2. AFFECTED VIN RANGE

3. PREPARATION

A. PARTS

B. TOOLS

4. INSPECTION PROCEDURE

1. INSPECT LEFT FRONT BRAKE LINE CLEARANCES

a) Inspect the clearance of the following components around the left front brake line:

1. Front brake line and coil spring. OK, if 5 mm (0.20 in.) or more.

2. Front brake line and lower spring seat. OK, if 5 mm (0.20 in.) or more.

3. Front brake line and vehicle body/inner fender. OK, if 30 mm (1.18 in.) or less

(b) Inspect the front brake line for damage OK, if paint is not removed.

(c) Check that the grommet is correctly positioned.

NOTE:
If the clearances are not as specified or the brake line is damaged, replace the left front brake line.

(d) If the clearances are WITHIN SPECIFICATIONS, proceed to Section 7.

5. LOCATION OF COMPONENTS

6. WORK PROCEDURE

1. REMOVE LOWER RADIATOR AIR DEFLECTOR

(a) Open the hood and remove the 8 plastic clips that retain the lower radiator air deflector.

(b) Remove the lower radiator air deflector.

(c) Remove the wire harness clip and 2 vacuum lines that are secured to the air cleaner inlet assembly.

(d) Remove the 2 bolts that secure the air cleaner inlet assembly and slide the assembly out of the air cleaner housing.

2. REMOVE AIR CLEANER ASSEMBLY

(a) Mark all vacuum lines prior to removal to assure correct reconnection.

(b) Remove the vacuum lines and electrical connectors on top of the air cleaner assembly.

(c) Remove the 2 bolts that secure the top of the air cleaner housing assembly.

(d) Remove the top of the air cleaner housing assembly.

(e) Remove the air filter.

(f) Remove the vacuum lines and electrical connectors from the bottom half of the air cleaner housing. Take note of where these vacuum lines are routed to ensure proper re-assembly.

NOTE:
Some ES 300 models may have a strut support bar that could interfere with intake air hose removal. The intake air hose and plastic air box can be removed with the strut support bar installed in the vehicle.

NOTE:
To avoid wire harness damage, release the wire and hose retainers on the back of the air cleaner housing prior to air cleaner housing removal.

(g) Remove the 3 bolts in the bottom of the air cleaner assembly.

(h) Remove the bottom of the air cleaner housing.

(i) Disconnect the intake hose from the throttle body.

3. FRONT LEFT BRAKE LINE NO. 5 REPLACEMENT

(a) Attach a drain hose to the left front caliper bleeder valve.

(b) Open the bleeder valve.

(c) Loosen front brake line No. 5 from the flexible hose in the wheel well using a line wrench or SST.

SST: 09023-00100 (or equivalent)

NOTE:
Upon loosening the flare nut on the brake line brake fluid will begin to drain.

NOTE:
Wash brake fluid off vehicle immediately. If brake fluid comes into contact with any painted surface it may be permanently damaged.

(d) Drain brake fluid.

(e) Disconnect the No. 5 brake line from the flexible hose.

4. REMOVE BRAKE LINE FROM 2-WAY CONNECTOR

(a) Using a line wrench disconnect the other end of the No. 5 brake line from the 2-way connector.

(b) Carefully remove the No. 5 brake line from the vehicle. To prevent brake fluid from dripping on the vehicle, cover the ends during removal.

(c) Carefully remove any brake fluid from the brake line unions with brake cleaner.

5. INSTALLING NEW NO. 5 BRAKE LINE

(a) Install the new No. 5 brake line.

NOTE:
Ensure that the new No. 5 brake line is correctly routed, spaced, and secured.

(b) Using the SST connect the No. 5 brake line to the 2 way connector.

SST: 09023-00100

TORQUE: 15 N.m (155 kgf.cm, 11 ft.lbf)

6. BLEED THE BRAKE SYSTEM

(a) Check and correct the brake fluid level in the brake master cylinder reservoir.

NOTE:
Immediately clean off any brake fluid spilled on painted surfaces. Brake fluid will damage the vehicle's finish. Do not let the brake fluid reservoir go empty.

(b) Bleed the brake system in the following sequence to remove any air from the system.

1. Right Rear

2. Left Rear

3. Right Front

4. Left Front

(c) Tighten bleeder plug once bleeding is complete.

TORQUE: 8.3 NM (85 kgf.cm, 74 in.lbf)

(d) Reinstall the bleeder plug cover (black rubber cover)

7. CHECK FLUID LEVEL IN RESERVOIR

(a) Check the brake fluid level and add fluid if necessary.

(b) Clean off any excess fluid residue.

(c) Check for leaks on each end of the new brake line unions and at the bleeder plug.

FLUID:
SAE J1703 or FMVSS No. 116 DOT3

NOTE:
Wash brake fluid off vehicle immediately. If brake fluid comes into contact with any painted surface is may be permanently damaged.

8. REINSTALL THE BOTTOM HALF OF AIR CLEANER HOUSING

(a) Secure the wire harness to the backside of the air cleaner housing using the 2 attached wire clips.

(b) Reinstall the 3 bolts in the bottom of the air cleaner assembly.

(c) Reinstall rubber intake hose onto throttle body and tighten hose clamp.

(d) Reinstall the vacuum lines and electrical connectors to the bottom half of the air cleaner housing.

NOTE:
Some ES 300 models may have a strut support bar that could interfere with intake air hose reinstallation. The intake air hose and plastic air box can be reinstalled with the strut support bar installed in the vehicle.

9. REINSTALL TOP OF AIR CLEANER HOUSING

(a) Reinstall air filter.

(b) Reinstall vacuum lines and electrical connectors on the top of the air cleaner assembly.

10. CONFIRM VACUUM LINE ROUTING

(a) Confirm that all of the vacuum lines are properly reinstalled. Reference the diagram shown.

11. REINSTALL RADIATOR LOWER AIR DEFLECTOR

(a) Slide the air cleaner intake into the air cleaner housing and reinstall the 2 bolts that secure the air cleaner inlet assembly.

(b) Reinstall the wire harness clip and 2 vacuum lines that are secured to the air cleaner inlet assembly.

(c) Position radiator lower air deflector over mounting holes and reinstall 8 plastic clips that retain the radiator lower air deflector to vehicle.

12. TEST DRIVE VEHICLE

(a) Test drive vehicle to confirm proper brake operation.

(b) Confirm that "Check Engine Light" or any other MIL on condition does not exist.

7. SSC COMPLETION LABEL INSTALLATION

1. After completing the repair and before returning the vehicle to the owner, an SSC completion label that is enclosed in the owner's notification must be affixed to the left front door hinge post near the check strap.

2. The label is to be filled out as follows:

^ Write in SSC 1LE

^ Write in date of repair.

^ Write in your dealer code.

3. Additional SSC completion labels, in sheets of 50 (P/N 00410-01917), may be ordered through the non-parts system on a 1450 order form or through the TDN system.