POWER BRAKE UNIT REMOVAL/INSTALLATION [R.H.D.]

id041100801852

Replacement part

Pipe holder
 
Quantity: 1
 
Location of use: Brake pipe
Gasket
 
Quantity: 1
 
Location of use: Power brake unit
Brake switch
 
Quantity: 1
 
Location of use: Brake pedal

Oil and chemical type

Brake fluid
 
Type: SAE J1703 or FMVSS116 DOT-3

Caution
•  When performing the work which the pedal stroke changes, such as power brake unit or brake pedal replacement, always replace the brake switch with a new one because the brake switch cannot adjust the clearance which has already been adjusted again.
•  Be careful not to let brake fluid get on the paint surface. Otherwise, it could cause paint peeling. If brake fluid gets on the paint surface, wash and flush it off completely with water immediately.
Note
•  Tighten the brake pipe flare nut using a commercially available flare nut wrench.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the following parts.

(1)  Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)
(2)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)
(3)  Windshield wiper motor and link (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)
(4)  Keyless beeper (See KEYLESS BEEPER REMOVAL/INSTALLATION.)
(5)  Cowl panel (See COWL PANEL REMOVAL/INSTALLATION.)

3.  Remove the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION [R.H.D.].)

4.  Remove the power brake unit vacuum sensor. (See POWER BRAKE UNIT VACUUM SENSOR REMOVAL/INSTALLATION [R.H.D.].)

5.  Remove the washer tank bracket. (See WASHER TANK REMOVAL/INSTALLATION.)

6.  Remove front under cover No.2. (SKYACTIV-D 2.2) (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

7.  Remove the insulator.

ac5wzw00009812

8.  Disconnect the brake pipes from the DSC HU/CM.

ac5wzw00009813

9.  Disconnect the brake pipe holder from the vehicle.

ac8wzw00003227

10.  Remove in the order shown in the figure.

11.  Install in the reverse order of removal.

12.  After installation, add brake fluid and perform the air bleeding/fluid leakage inspection. (See BRAKE FLUID AIR BLEEDING.)

13.  Remove the brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.].)

14.  Inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)

15.  Install a new brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.].)

ac5wzw00009815

1
Vacuum hose
(See VACUUM HOSE REMOVAL/INSTALLATION [R.H.D. (SKYACTIV-G 2.5)].)
(See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
2
Snap pin
3
Clevis pin
4
Nut
5
Power brake unit
6
Gasket