POWER BRAKE UNIT REMOVAL/INSTALLATION (L.H.D.) [MZR 1.6, MZR 2.0, MZR 2.0 DISI i-stop, MZ-CD 1.6, MZR-CD 2.2]

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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 battery and battery tray. (except MZR 2.0 DISI i-stop) (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].) (See BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].) (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].) (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.  For MZR 1.6 vehicles, remove the following parts:

(1)  Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)
(2)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)
(3)  Windshield wiper motor (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
(4)  Cowl panel (See COWL PANEL REMOVAL/INSTALLATION.)

4.  Remove the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.0, MZR 2.5, MZ-CD 1.6, MZR-CD 2.2].) (See MASTER CYLINDER REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop, SKYACTIV-G 2.0].)

5.  For MZR-CD 2.2 vehicles, perform the following procedure:

(1)  Detach the clutch pipe from the bracket.
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(2)  Remove the bolt.
(3)  Remove the bracket from the vehicle.

6.  Disconnect the brake pipes from the brake pipe joint.

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7.  Loosen the brake pipe flare nuts shown in the figure.

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8.  For MZR 1.6 vehicles, remove the brake pipes shown in the figure from the vehicle.

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9.  Move the brake pipes as shown in the figure. (except MZR 1.6)

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

11.  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].)

12.  Remove in the order indicated in the table.

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

14.  Install in the reverse order of removal.

15.  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 [L.H.D.].)
3
Nut
4
Power brake unit
5
Gasket
6
Power brake unit vacuum sensor


Vacuum Hose Removal Note

1.  Remove the vacuum hose from the vacuum hose clip.

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2.  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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3.  Install the vacuum hose to the vacuum hose clip.

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