POWER BRAKE UNIT REMOVAL/INSTALLATION [R.H.D.]

id041100801852

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.
•  Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. In addition, if there is any brake fluid on the wiring harness, the wire insulation may corrode causing a malfunction such as a short circuit. If brake fluid gets on a painted surface or wiring harness, wash and flush it off completely with water immediately.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  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 and link (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)
(4)  Keyless beeper (With advanced keyless entry system) (See KEYLESS BEEPER REMOVAL/INSTALLATION.)
(5)  Cowl panel (See COWL PANEL REMOVAL/INSTALLATION.)
(6)  Master cylinder (See MASTER CYLINDER REMOVAL/INSTALLATION [R.H.D.].)
(7)  Front under cover No.2 (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

3.  Remove the nuts.

ac9wzw00004532

4.  Remove the insulator.

ac9wzw00004533

5.  Set the heater hoses out of the way as shown in the figure.

ac9wzw00004542

6.  Remove in the order indicated in the table.

7.  Install in the reverse order of removal.

8.  After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See BRAKE FLUID AIR BLEEDING.)

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

10.  Inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)

11.  Install a new brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.].)

ac9wzw00004534

1
Vacuum hose
(See VACUUM HOSE REMOVAL/INSTALLATION [R.H.D.].)
2
Power brake unit vacuum sensor connector (vehicles with i-stop)
3
Snap pin
4
Clevis pin
5
Nut
6
Power brake unit
7
Gasket
8
Fork
(See Fork Installation Note.)
9
Nut
10
Power brake unit vacuum sensor (vehicles with i-stop)

Fork Installation Note

1.  Install the fork as shown in the figure.

ac9uuw00009728
Standard
128.35—129.35 mm {5.0532—5.0925 in}