POWER BRAKE UNIT REMOVAL/INSTALLATION [L.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 brake pedal stroke.

1. Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.3, SKYACTIV-G 1.5].) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

• Fresh-air duct

• Air hose

• Air cleaner cover

• Air cleaner element

• Resonance chamber (SKYACTIV-G 1.5)

• Air cleaner case

2. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 1.3, SKYACTIV-G 1.5].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

3. For the SKYACTIV-D 1.5 (i-ELOOP) vehicle, perform the following procedure.

(1) Remove the DC-DC converter (i-ELOOP) installation bolt. (See DC-DC CONVERTER (i-ELOOP) REMOVAL/INSTALLATION [WITH i-ELOOP (SKYACTIV-D 1.5)].)

(2) Disconnect the DC-DC converter (i-ELOOP) connector. (See DC-DC CONVERTER (i-ELOOP) REMOVAL/INSTALLATION [WITH i-ELOOP (SKYACTIV-D 1.5)].)

(3) Set the DC-DC converter (i-ELOOP) out of the way.

4. 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) Cowl panel (See COWL PANEL REMOVAL/INSTALLATION.)

(5) Master cylinder (See MASTER CYLINDER REMOVAL/INSTALLATION [L.H.D.].)

(6) Insulator (See BRAKE PEDAL REMOVAL/INSTALLATION [L.H.D.].)

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

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

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

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

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

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1

Vacuum hose, clamp

2

Power brake unit vacuum sensor connector (vehicles with i-stop)

3

Snap pin

(See Snap Pin Installation Note.)

4

Clevis pin

5

Nut

6

Power brake unit

7

Gasket

Snap Pin Installation Note

1. Install the snap pin as shown in the figure.

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1	Vacuum hose, clamp
2	Power brake unit vacuum sensor connector (vehicles with i-stop)
3	Snap pin (See Snap Pin Installation Note.)
4	Clevis pin
5	Nut
6	Power brake unit
7	Gasket