POWER BRAKE UNIT REMOVAL/INSTALLATION [R.H.D. ZJ, ZY, Z6, LF, L3, MZR-CD (RF Turbo)]

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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.  Perform the following procedure and move the cooler hose (LO) to the position shown in the figure. (ZJ, ZY, Z6)

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(1)  Remove the suction hose.

(2)  Detach the accelerator cable and move it out of the way. (without throttle valve actuator)

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(3)  Remove the coolant reserve tank from the vehicle and move it out of the way.

(4)  Remove the cooler hose (LO) installation nuts.

2.  Perform the following procedure and move the cooler hose (LO) under the vehicle. (LF, L3)

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(1)  Disconnect the A/F sensor connector.

(2)  Remove the bracket.

(3)  Remove the cooler hose bracket.

3.  Perform the following procedure. (MZR-CD (RF Turbo))

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

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

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

(4)  Remove the stiffener (RH). (See FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION

Caution

•  If the stiffener installation bolts are removed when the vehicle is lifted, the front shock absorber could fall and cause damage to the vehicle. Therefore, always place the vehicle on the ground when removing the stiffener and stiffener installation bolts. When lifting up the vehicle after the stiffener is removed, temporarily install the removed stiffener installation bolts to the mounting rubber.

4.  Remove the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION [R.H.D. EXCEPT L3 Turbo].)

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

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

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

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

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

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1	Vacuum hose (See VACUUM HOSE REMOVAL/INSTALLATION [ZJ, ZY, Z6, LF, L3, L3 Turbo].) (See VACUUM HOSE REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6), MZR-CD (RF Turbo)].)
2	Joint pin (See BRAKE PEDAL REMOVAL/INSTALLATION [EXCEPT MZ-CD 1.6 (Y6)].)
3	Brake pedal component (See Brake Pedal Component Removal Note.)
4	Power brake unit
5	Gasket

Brake Pedal Component Removal Note

1.  Remove the brake pedal installation nuts.

2.  Move the power brake unit toward the vehicle front.

3.  Remove the brake pedal component.