POWER BRAKE UNIT REMOVAL/INSTALLATION (R.H.D.)

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

2.  Remove the front fender molding. (See FRONT FENDER PANEL REMOVAL/INSTALLATION.)

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

4.  Remove the windshield wiper motor. (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)

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

6.  Remove the installation nut from the cooler hose (LO) bracket and set the cooler hose (LO) aside.

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7.  Disconnect the cooler pipe (HI) from the clip.

8.  Remove the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION [R.H.D.].)

9.  Remove the insulator. (MZR 1.8, MZR 2.0, MZR 2.0 DISI, MZR 2.5)

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10.  Remove in the order indicated in the table.

11.  Remove the brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION.)

12.  Install in the reverse order of removal.

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

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1
Vacuum hose
2
Snap pin
3
Clevis pin
4
Fork
5
Locknut
6
Power brake unit
(See Power Brake Unit Removal Note.)
7
Gasket, plate


Power Brake Unit Removal Note

1.  Perform the following procedure to move the brake pipes.

(1)  Disconnect the clutch pipe from the master cylinder. (MZR-CD 2.2) (See CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION [A26M-R].)
(2)  Remove the brake pipes and clutch pipe (MTX) from the brake pipe bracket A as shown in the figure.
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(3)  Remove the brake pipe bracket B.
1)  Set the flathead screwdriver and fastener remover as shown in the figure.
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2)  Remove the brake pipe bracket B from the vehicle.
(4)  Disconnect the brake pipe (2 places) from the brake pipe joint.
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(5)  Remove the ABS HU/CM or DSC HU/CM component installation bolts. (See ABS HU/CM REMOVAL/INSTALLATION.) (See DSC HU/CM REMOVAL/INSTALLATION.)
(6)  Move the ABS HU/CM or DSC HU/CM component towards the vehicle front.

2.  Remove the power brake unit while moving the brake pipes located around the power brake unit towards the vehicle front.