BRAKE PEDAL REMOVAL/INSTALLATION [EXCEPT MZ-CD 1.6 (Y6)]

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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.

1.  Remove the charge air cooler cover. (L3 Turbo) (See INTAKE AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

2.  Remove the exhaust insulator. (R.H.D. L3 Turbo) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

3.  Remove the charge air cooler. (R.H.D. L3 Turbo) (See INTAKE AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

4.  Remove the battery and battery tray. (L.H.D.) (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY, Z6].) (See BATTERY REMOVAL/INSTALLATION [LF, L3].) (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].) (See BATTERY REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

5.  Disconnect the vacuum hose from the insulator pipe as shown in the figure. (L.H.D. L3 Turbo)

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6.  Remove the insulator. (L.H.D. L3 Turbo) (see MASTER CYLINDER REMOVAL/INSTALLATION [L.H.D. L3 Turbo].)

7.  Disconnect the brake pipe (master cylinder side). (L.H.D.) (See MASTER CYLINDER REMOVAL/INSTALLATION [L.H.D. EXCEPT L3 Turbo].) (See MASTER CYLINDER REMOVAL/INSTALLATION [L.H.D. L3 Turbo].)

8.  Remove the accelerator pedal. (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [ZJ, ZY, Z6].) (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF, L3].) (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [L3 Turbo].) (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

9.  Remove in the order indicated in the table.

10.  Install in the reverse order of removal.

11.  Adjust the accelerator cable. (without throttle valve actuator) (See ACCELERATOR CABLE INSPECTION/ADJUSTMENT [ZJ, ZY, Z6].)

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1	Brake switch connector
2	Brake switch (See Brake Switch Installation Note.)
3	Joint pin (See Joint Pin Installation Note.)
4	Bolt (L.H.D.)
5	Brake pedal (See Brake Pedal Removal Note.)
6	Pedal pad

Brake Pedal Removal Note

1.  Remove the brake pedal installation 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.

Joint Pin Installation Note

1.  For L.H.D., install the new joint pin by aligning the pin holes of the brake pedal and power brake unit fork.

2.  For R.H.D., install the new joint pin by aligning the pin holes of the brake pedal bracket and power brake unit fork.

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

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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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