POWER BRAKE UNIT REMOVAL/INSTALLATION (R.H.D.) [MZR 2.0 DISI i-stop]

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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.

•  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 master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

2.  Detach the brake pipes from the brake pipe brackets.

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3.  Remove the coolant reserve tank from the vehicle and move the coolant reserve tank in the direction of the arrow.

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4.  Remove the cooler hose (HI) from the clip.

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5.  Disconnect the refrigerant pressure sensor connector. (See REFRIGERANT PRESSURE SENSOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].)

6.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

7.  Remove the A/F sensor from the exhaust manifold insulator.

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8.  Disconnect the connectors shown in the figure.

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9.  Remove the wiring harness from the cylinder head cover.

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10.  Remove the wiring harness from the bracket.

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11.  Remove the bracket from the cylinder head.

12.  Remove the wiring harness from the bracket.

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13.  Move the bracket under the vehicle.

14.  Move the wiring harness towards the right side of the vehicle.

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15.  Remove the cooler hose (LO) installation nut.

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16.  Move the cooler hose (LO) and cooler hose (HI) in the direction of the arrow.

17.  Remove the dashboard under cover. (See DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)

18.  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].)

19.  Remove in the order indicated in the table.

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

21.  Install in the reverse order of removal.

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

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1	Vacuum hose (See Vacuum Hose Removal Note.) (See Vacuum Hose Installation Note.)
2	Joint pin (See BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.].)
3	Nut
4	Power brake unit
5	Gasket
6	Power brake unit vacuum sensor

Vacuum Hose Removal Note

1.  Disconnect the vacuum hose connector from the power brake unit while pressing the tabs of the vacuum hose connector.

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Vacuum Hose Installation Note

1.  Insert the vacuum hose connector to the power brake unit.

2.  Verify that the vacuum hose is inserted so that the connector contacts the power brake unit flange.

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