POWER BRAKE UNIT REMOVAL/INSTALLATION

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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. For R.H.D., remove the insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L8, LF, L3 2WD].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

2. Remove the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION.)

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

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

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

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

7. For L.H.D., remove the A/C bracket.

8. For L.H.D. (2WD (MTX), 4WD (ATX)), remove the ABS (ABS/TCS) HU/CM or DSC HU/CM. (See ABS/TCS HU/CM REMOVAL/INSTALLATION [MTX].) (See DSC HU/CM REMOVAL/INSTALLATION [2WD (MTX), 4WD (ATX)].)

9. For R.H.D., when working on the 2WD (ATX) and 4WD (MTX), move the brake pipe aside by following procedures.

  (1) Disconnect the brake pipe (2 places) from the brake pipe joint.

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  (2) Disconnect the wiring harness, then disconnect the brake pipe (5 places).

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10. For R.H.D., remove the alternator cover.

11. For R.H.D., remove the insulator.

12. For R.H.D., remove the vacuum pipe bracket.

13. Remove in the order indicated in the table.

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1 | Vacuum hose
2 | Snap pin
3 | Clevis pin
4 | Nut
5 | Fork
6 | Power brake unit
7 | Gasket
8 | Nut

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

15. Install in the reverse order of removal.