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Disc: Other Mazda 3 BK

Mechanical - Hydraulic 2 illustrations ~699 words

BLEEDING BRAKE SYSTEM

WARNINGUse of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
CAUTIONDo not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

Note. When any part of the hydraulic system has been disconnected for repair or replacement, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after components have been correctly reconnected.

Note. If vehicle is equipped with anti-lock brakes, see appropriate ANTI-LOCK article for brake bleeding procedure.

BRAKELINE BLEEDING SEQUENCE

ApplicationSequence
Without ABSRR, LR, RF & LF
With ABS(1)
(1) Information not available from manufacturer.
(1)Information not available from manufacturer.

BRAKELINE BLEEDING SEQUENCE

BLEEDING BRAKES

  1. On level ground, jack up the vehicle and support it evenly on safety stands.
  2. Remove the bleeder cap and attach a vinyl tube to the bleeder screw. (Scheme 29)
  3. Place the other end of the vinyl tube in a clear container.
  4. The first person depresses the brake pedal a few times, and then holds it in the depressed position.
  5. The second person loosens the bleeder screw, drains out the fluid and closes the bleeder screw.
  6. Repeat steps 4 and 5 until no air bubbles are seen. The reservoir should be kept about 3/4 full during bleeding to prevent air from reentering the lines.
  7. Inspect for correct brake operation.
  8. Verify that there is no fluid leakage. Wipe off any spilled fluid immediately.
  9. After bleeding the brakes, add brake fluid to the maximum level.

Scheme 29

Scheme 29
Scheme 29

BRAKE PEDAL FREE PLAY

CAUTIONOnce 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.

With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS table. Gently depress the pedal by hand and measure the pedal play. If free play is not within the specification, inspect the wear of the joint pin. Replace it if there is any malfunction.

ApplicationIn. (mm)
Brake Pedal Free Play0.16-0.33 (4.0-8.4)

BRAKE PEDAL FREE PLAY SPECIFICATIONS

BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH

CAUTIONOnce 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.

Measure the distance from the center of the upper surface of the pedal pad to the floor covering and verify that it is as specified. If not within the specification, replace the brake pedal.

ApplicationIn. (mm)
Pedal Released5.37 (136.4)

BRAKE PEDAL HEIGHT SPECIFICATIONS

PARKING BRAKE

  1. Depress brake pedal several times. Pull the parking brake lever a few times.
  2. Pull parking brake lever with a force of 22 lbs. Stroke should be 3-6 notches. If stroke is as specified, parking brake is properly adjusted. If stroke is not as specified, adjust parking brake lever.
  3. Pump the brake pedal several times.
  4. Remove the service hole cover of the rear console. (Scheme 30) Turn the adjusting nut and adjust the parking brake lever. After adjustment, turn the ignition switch to ON, pull the parking brake lever one notch, and verify that the parking brake warning light illuminates. Then verify that the rear brakes do not drag.

Scheme 30

Scheme 30
Scheme 30

POWER BRAKE UNIT

  1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal does not move as specified, go to next step.
  2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is operating. If length of strokes is equal, check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary, and go to next step.
  3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal height remains at same height, power brake unit is operating. If pedal height recedes, check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary.

PROPORTIONING VALVE

  1. Connect 2 pressure gauges and adapters to dual proportioning valve. One to input port and other to output port. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-164682-S04779945162004081200000) . Depress brake pedal until pressure gauge reads as specified and check output pressure. See «PROPORTIONING VALVE PRESSURE SPECIFICATIONS»(ref-164682-S02410806572004081200000) table.
  2. Depress brake pedal again, applying additional pressure. Recheck output pressure. See «PROPORTIONING VALVE PRESSURE SPECIFICATIONS»(ref-164682-S02410806572004081200000) table. If output pressure is not as specified, replace dual proportioning valve.
ApplicationInlet Pressure - psi (kg/cm 2 )Outlet Pressure - psi (kg/cm 2 )
Master Cylinder Pressure725 (51)508-537 (35-38)
1450 (102)718-762 (50-54)

PROPORTIONING VALVE PRESSURE SPECIFICATIONS

BRAKE PEDAL

CAUTIONThe clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch is inserted into the installation hole on the brake pedal and rotated to fix in place. If the brake switch is not properly installed, the clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the brake pedal is properly installed and fully released before installing the brake switch to the pedal.
CAUTIONOnce 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.

FRONT BRAKE CALIPER

Note. Brake rotor is also referred to as disc plate.

REAR AXLE BEARING & OIL SEAL

Note. For information on models with sealed wheel bearings, see appropriate REAR article in SUSPENSION.

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