POWER BRAKE UNIT REMOVAL/INSTALLATION (R.H.D.) [ZY, Z6, MZ-CD 1.6 (Y6)]

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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 engine cover. (MZ-CD 1.6 (Y6)) (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO4 emission level)].) (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

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

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

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

5.  Remove the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION [ZY, Z6, LF, L5, MZ-CD 1.6 (Y6), MZR-CD 2.2].)

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

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7.  For ZY or Z6 vehicles, perform the following procedure:

(1)  Remove the cooler hose (LO) installation bolt.
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(2)  Move the cooler hose (LO) in the direction of the arrow.

8.  For MZ-CD 1.6 (Y6) vehicles, perform the following procedure:

(1)  Remove the cooler hose (LO) installation bolt.
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(2)  Remove the coolant reserve tank from the vehicle and move it out of the way.
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(3)  Move the cooler hose (LO) in the direction of the arrow.

9.  Disconnect the refrigerant pressure switch connector. (See REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) (See REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].)

10.  Disconnect the wiring harness connectors and set the fuel injector wiring harness out of the way. (MZ-CD 1.6 (Y6) (EURO4 emission level)) (See FUEL INJECTOR REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

11.  Remove the stiffener (RH).

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

13.  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].)

14.  Remove in the order indicated in the table.

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

16.  Install in the reverse order of removal.

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

18.  Inspect the front wheel alignment if necessary. (See FRONT WHEEL ALIGNMENT.)

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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


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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2.  Remove the vacuum hose from the vacuum hose clip. (ZY or Z6)

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3.  Set the vacuum hose out of the way.


Vacuum Hose Installation Note

1.  Install the vacuum hose to the vacuum hose clip. (ZY or Z6)

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

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

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