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Disc: Overhaul Mazda 3 BK

Mechanical - Hydraulic 5 illustrations ~388 words

OVERHAUL

WARNINGUse of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative.
WARNINGBrake 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.

Disassembly & Reassembly

  1. Disassemble in the order indicated in the illustration. (Scheme 24)
  2. Assemble in the reverse order of disassembly. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000).

Dust Seal Assembly Note

  1. Assemble a new dust seal to the caliper using Piston Press Rod (49-G033-102) and Socket (49-B033-001) and a press with a press-in force of 187 inch lbs. (Scheme 25)
  2. Verify that there is no gap between the dust seal and caliper body.

Piston Assembly Note

  1. Press the piston into the dust seal opening as shown in the illustration. (Scheme 26), for following steps
  2. Insert a piece of wood between the caliper body and the piston, and while supporting the piston by hand, blow compressed air through the brake hose installation hole. WARNING: When blowing compressed air into the caliper body, the piston may pop out and cause injury if not supported at the correct point. Securely support the piston friction surface by hand when blowing compressed air. NOTE: By blowing compressed air into the caliper body, the dust seal expands due to air pressure and covers the piston end.
  3. Verify that the dust seal lip covers the piston end.
  4. Press the piston into the caliper body completely.

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26
  1. Disassemble in the order indicated in the illustration. (Scheme 27)
  2. Assemble in the reverse order of disassembly. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164682-S04779945162004081200000).

Dust Seal Assembly Note

  1. While rotating the piston counterclockwise using the Caliper Piston Socket (49-F043-002) and a socket wrench, pull it out to the position shown in the illustration. (Scheme 28) As shown in the illustration, assemble a new dust seal on the piston, and rotate the piston clockwise slowly using the caliper piston socket to insert it to the caliper body completely.
  2. Assemble the dust seal to the caliper body using the Piston Press Rod (49-G033-102) and Socket (49-B026-301) and a press with a press-in force of 187 inch lbs.
  3. Verify that there is no gap between the dust seal and caliper body.

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

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