BRAKE PEDAL REMOVAL/INSTALLATION [L.H.D.]

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Caution

•  The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch is inserted into the installation hole on the brake pedal and rotated to fix in place. If the brake switch is not properly installed, the clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the brake pedal is properly installed and fully released before installing the brake switch to the pedal.

•  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 the pedal, or performing any procedure that changes the pedal stroke.

•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

1.  Remove the battery and battery tray. (except MZR 2.0 DISI i-stop) (See BATTERY REMOVAL/INSTALLATION [ZY, Z6].) (See BATTERY REMOVAL/INSTALLATION [LF, L5].) (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].) (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].) (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.  Remove the main battery, sub battery and battery tray. (MZR 2.0 DISI i-stop) (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

3.  Disconnect the vacuum hose from the insulator bracket as shown in the figure. (L3 Turbo)

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4.  Remove the wiring harness from the air duct. (L3 Turbo)

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5.  Remove the dashboard under cover. (If equipped) (See DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)

6.  Remove the side wall (driver side). (See SIDE WALL REMOVAL/INSTALLATION.)

7.  Disconnect the steering shaft from the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM].) (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM].)

8.  Remove the accelerator pedal. (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [ZY, Z6].) (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF, L5].) (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].) (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [L3 Turbo].) (See ACCELERATOR PEDAL (APP) REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].) (See ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION [MZR-CD 2.2].)

9.  Remove in the order indicated in the table.

10.  Install in the reverse order of removal.

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1	Connector, wiring harness
2	Brake switch (See Brake Switch Installation Note.)
3	Brake pedal position (BPP) switch (See Brake Pedal Position (BPP) Switch Installation Note.)
4	Joint pin (See Joint Pin Installation Note.)
5	Nut, bolt
6	Brake pedal (See Brake Pedal Removal Note.)
7	Pedal pad
8	Bracket (See Bracket Removal Note.) (See Bracket Installation Note.)

Brake Pedal Removal Note

1.  Remove the brake pedal installation bolt and nuts.

2.  Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm.

3.  Remove the brake pedal.

Bracket Removal Note

1.  Remove the bracket as shown in the figure.

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Bracket Installation Note

1.  Install the bracket as shown in the figure.

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Joint Pin Installation Note

1.  Install the new joint pin by aligning the pin holes of the brake pedal and power brake unit fork.

2.  Verify that the joint pin touches the power brake unit fork completely.

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Brake Pedal Position (BPP) Switch Installation Note

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

2.  With the brake pedal fully released, insert a new brake pedal position (BPP) switch into the installation hole on the brake pedal.

3.  Secure the brake pedal position (BPP) switch by turning it clockwise 45°.

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Brake Switch Installation Note

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

2.  With the brake pedal fully released, insert a new brake switch into the installation hole on the brake pedal.

3.  Secure the brake switch by turning it counterclockwise 45°.

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