POWER BRAKE UNIT REMOVAL/INSTALLATION (R.H.D.) [MZ-CD 1.6]

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Caution
•  Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again. Therefore, replace the switch with a new one when replacing the power brake unit or performing any procedure that changes the pedal stroke.

1.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

2.  Remove the front fender molding. (See FRONT FENDER PANEL REMOVAL/INSTALLATION.)

3.  Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

4.  Remove the windshield wiper motor. (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)

5.  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

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

7.  Remove in the order indicated in the table.

8.  Remove the brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION [MZ-CD 1.6].)

9.  Install in the reverse order of removal.

10.  After installation, inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)

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1
Vacuum hose
2
Snap pin
3
Clevis pin
4
Fork
(See Fork Installation Note.)
5
Locknut
6
Nut
7
Power brake unit
8
Gasket


Fork Installation Note

Caution
•  The brake switch may not operate normally after adjusting the pedal height. Whenever adjusting the pedal height, replace the brake switch with a new one.

1.  Install the fork and clevis pin.

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2.  Measure the height of the brake pedal. (See BRAKE PEDAL INSPECTION.)

•  If it is not within the specification, perform the following procedure:
(1)  Remove the clevis pin.
(2)  Loosen the locknut and turn the fork to adjust the pedal height.
(3)  Tighten the locknut.
(4)  Install the clevis pin and measure the height of the brake pedal.
•  If it is not within the specification, resume the procedure from Step 1.

3.  After adjustment, inspect the pedal play and the brake light operation. (See BRAKE PEDAL INSPECTION.)

•  If there is any malfunction, repair or replace the applicable part.