BRAKE PEDAL REMOVAL/INSTALLATION
| CAUTION | The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch connector is connected after the brake switch has been properly installed. If the brake switch is not properly installed or the connector is connected before installation, the clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the brake switch is properly installed before connecting the connector. 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 the pedal, or performing any procedure that changes the pedal stroke. When replacing the brake pedal (AT), it is possible that the installation of the interlock cable could become defective. Always refer to the interlock cable installation note when replacing the brake pedal. (See INTERLOCK CABLE INSTALLATION NOTE ). |
Note. When the brake switch connector is connected to the brake switch, the clearance between the pedal and the brake switch is adjusted automatically. However, this mechanism will only function one time.
Scheme 32
- Remove in the order indicated in the table.
- Install in the reverse order of removal.
Brake Pedal Removal Note
- Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm.
- Remove the brake pedal.
Scheme 33
Scheme 33: Brake Switch Installation Note
- Install the new brake switch to the brake pedal (MT) or the interlock cable (AT), and secure it by turning it clockwise 45° (AT) or counterclockwise 45° (MT).
Brake Switch Connector Installation Note
- Inspect the brake pedal. (See «BRAKE PEDAL INSPECTION»(ref-478576-S29283544712012061100000) ).
- With the brake pedal in its original position, install the brake switch to the brake switch connector.
Master Cylinder Installation Note
| CAUTION | If the master cylinder is installed at an angle, the master cylinder piston may push against the push rod retainer of the power brake unit causing poor air bleeding, brake drag, or other malfunctions. Be sure to install the master cylinder at a perpendicular angle to the power brake unit. |
Scheme 34
Scheme 35
Scheme 36
- Install the SST to the power brake unit and tighten to the specified torque. Tightening torque 13.7-21.6 N.m {1.4-2.2 kgf.m, 10.2-15.9 ft.lbf}
- Apply a vacuum of 66.7 kPa {500 mmHg, 19.7 inHg} to the power brake unit using a vacuum gauge. NOTE: Use any commercially available vacuum gauge.
- Using calipers, measure dimension L as shown in the illustration. Standard L dimension 30.4-30.6 mm {1.197-1.204 in}
- If dimension L is not within the standard, remove the SST (49 G043 001) and, while stopping the push rod rotation with the SST (49 E043 003A), adjust the push rod length with the SST (49 B043 004).
- Switch the SSTs and remeasure dimension L.
- Install the master cylinder to the power brake unit.
Scheme 37
Scheme 37: BRAKE FLUID LEVEL SENSOR INSPECTION
Scheme 38
- Disconnect the brake fluid level sensor connector from the master cylinder.
- Inspect for continuity according to fluid level between the brake fluid level sensor terminals. If not as indicated in the table, replace the reserve tank.
POWER BRAKE UNIT REMOVAL/INSTALLATION
| 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. |
Scheme 39
Scheme 40
- For 6MT vehicles, perform the following procedures: Disconnect the purge solenoid valve connector wiring harness from the bracket. Remove the bracket from the air intake hose and move the purge solenoid valve component out of the way. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-478572-S27568218632012061100000) ). Remove the following parts as a single unit. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-478572-S27568218632012061100000) ). Air intake hose Resonance chamber No. 2 Resonance duct No. 1 Resonance duct No. 2
- Remove the master cylinder. (See «MASTER CYLINDER REMOVAL/INSTALLATION»(ref-478576-S18947502362012061100000) ).
- For MT vehicles, remove the clutch pipe as shown in the illustration.
- Remove the nut as shown in the illustration, then remove the cooler hose (LO) bracket from the vehicle.
- Remove in the order indicated in the table
- Remove the brake switch. (See «BRAKE PEDAL REMOVAL/INSTALLATION»(ref-478576-S22316361792012061100000) ).
- Install in the reverse order of removal.
- After installation, perform brake pedal inspection. (See «BRAKE PEDAL INSPECTION»(ref-478576-S29283544712012061100000) ).
Scheme 41
