Conventional Brake System: Removal & Installation Mazda 3 BL

BRAKE PEDAL REMOVAL/INSTALLATION

Scheme 33

Scheme 34

1. Remove the charge air cooler cover. (L3 WITH TC) (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345225-S13656146802009102000000) .)
2. Remove the battery and battery tray. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .) (See «BATTERY REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345228-S02486648752009102000000) .)
3. Disconnect the vacuum hose from the insulator pipe as shown in the figure. (L3 WITH TC)
4. Remove the insulator. (L3 WITH TC) (see «MASTER CYLINDER REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345233-S08787139262009102000000) ).
5. Disconnect the brake pipe (master cylinder side). (See «MASTER CYLINDER REMOVAL/INSTALLATION [LF, L3]»(ref-345233-S25269421762009102000000) ). (See «MASTER CYLINDER REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345233-S08787139262009102000000) ).
6. Remove the accelerator pedal. (See «ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF, L3]»(ref-345212-S01618660652009102000000) .) (See «ACCELERATOR PEDAL REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345225-S27974467802009102000000) .)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.

Brake Pedal Removal Note

1. Remove the brake pedal installation bolts and nuts.
2. Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm.
3. Remove the brake pedal.

Scheme 35

1. Install the new joint pin by aligning the pin holes of the brake pedal and power brake unit fork.
2. Verify that the joint pin touches the power brake unit fork completely.

Scheme 36

1. Inspect the brake pedal. (See «BRAKE PEDAL INSPECTION»(ref-345233-S35695149072009102000000) ).
2. With the brake pedal fully released, insert a new brake switch into the installation hole on the brake pedal.
3. Secure the brake switch by turning it counterclockwise 45° .

Reserve Hose (MTX) Installation Note

1. Insert the reserve hose to the reserve tank until a click is heard.
2. Verify that the reserve hose is firmly installed by pulling it, and push it into the reserve tank again.

Scheme 37

Scheme 38

1. Remove the battery and battery tray. (See «BATTERY REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345228-S02486648752009102000000) .)
2. Disconnect the vacuum hose from the insulator pipe as shown in the figure.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Scheme 39

1. Remove the reserve hose from the reserve tank while pressing the point indicated by the arrow in the figure.

Insulator Bracket, Master Cylinder Removal Note

1. Remove the insulator bracket and master cylinder from the power brake unit as a single unit.
2. Remove the insulator bracket from the master cylinder.

Insulator Bracket, Master Cylinder Installation Note

1. Temporarily install the insulator bracket to the master cylinder.
2. Install the insulator bracket and master cylinder to the power brake unit as a single unit.

Reserve Hose Installation Note

1. Insert the reserve hose to the reserve tank until a click is heard.
2. Verify that the reserve hose is firmly installed by pulling it, and push it into the reserve tank again.

Scheme 40

Scheme 41

1. Disconnect the brake fluid level sensor connector from the master cylinder.
2. 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.

Brake Pedal Component Removal Note

1. Remove the brake pedal installation bolt and nuts.
2. Move the power brake unit toward the vehicle front.
3. Remove the brake pedal component.

Scheme 42

1. Remove the battery and battery tray. (See «BATTERY REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345228-S02486648752009102000000) .)
2. Remove the master cylinder. (See «MASTER CYLINDER REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345233-S08787139262009102000000) ).
3. Remove the air hose and air duct. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345225-S13656146802009102000000) .)
4. Remove the brake switch connector.
5. Remove the accelerator pedal. (See «ACCELERATOR PEDAL REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345225-S27974467802009102000000) .)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. After installation, inspect the brake pedal. (See «BRAKE PEDAL INSPECTION»(ref-345233-S35695149072009102000000) ).

1. Remove the brake pedal installation bolt and nuts.
2. Move the power brake unit toward the vehicle front.
3. Remove the brake pedal component.

Scheme 43

1. Disconnect the master cylinder brake pipes, and install the SST (49 D043 0A0) to the master cylinder orientated as shown in the figure. NOTE: Use a commercially available flare nut wrench when installing the SST (49 D043 0A0) to the master cylinder. Flare nut across flat: 12 mm {0.47 in}
2. Connect the SSTs as shown in the figure, and bleed the air from the SSTs and the brake line. (Bleed the air from the SSTs using air bleed valve A.)
3. Inspect the rear brake fluid pressure when the front brake fluid pressure is adjusted to the level indicated in the table. If not within the specification, replace the master cylinder. PROPORTIONING VALVE FLUID PRESSURE Front brake fluid pressure (kPa {kgf/cm 2 , psi}) Rear brake fluid pressure (kPa {kgf/cm 2 , psi}) 5,000 {50.99, 725.2} 3,500-3,700 {35.70-37.72, 507.7-536.6} 10,000 {101.97, 1450.4} 4,950-5,250 {50.48-53.53, 718.0-761.4}

REAR BRAKE (DISC) REMOVAL/INSTALLATION

Scheme 44

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, pump the brake pedal a few times and inspect the following: Parking brake lever stroke Brake drag

Caliper & Brake Hose Removal Note

1. Remove the caliper and brake hose from the vehicle as a single unit.

Scheme 45

Scheme 46

1. Secure the caliper to the vise and install the brake hose to it. CAUTION: Insert a protective plate into the vise opening so as not to damage the caliper.
2. Tighten the brake hose to the specified torque. Tightening torque 26.0-30.0 N.m {2.66-3.05 kgf.m, 19.2-22.1 ft.lbf}

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Clean the exposed area of the piston.
2. Install the SST (49 F043 002) to the SST (49 B043 005).
3. Align the SST projection to the piston groove.
4. Rotate part A on the SST in the direction of the arrow and secure the SST to the caliper.
5. Rotate the SST in the direction of the arrow and push the piston completely into the caliper. NOTE: Even without the piston completely pushed in, the top of the piston projects from the dust seal by approximately 2 mm {0.09 in} .
6. Rotate part A on the SST in the direction of the arrow using the tool and remove the SST from the caliper.
7. Install the caliper and brake hose to the vehicle as a single unit.

Clip & Brake Pipe Installation Note

1. Install the brake hose to the vehicle-side bracket and secure it using a clip.
2. Verify that the brake hose is not twisted.
3. Tighten the brake pipe to the specified torque using a commercially available flair nut wrench.

Scheme 51

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, pump the brake pedal a few times and inspect the following: Parking brake lever stroke Brake drag

Caliper Installation Note

1. Clean the exposed area of the piston.
2. Install the SST (49 F043 002) to the SST (49 B043 005).
3. Align the SST Projection to the piston groove.

Scheme 52

1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Scheme 53

Scheme 54

Scheme 55

1. While rotating the piston counterclockwise using the SST , pull it out to the position shown in the figure.
2. As shown in the figure, assemble a new dust seal to the piston.
3. Install the SST (49 F043 002) to the SST (49 B043 005).
4. Align the SST projection to the piston groove.
5. Rotate part A on the SST in the direction of the arrow and secure the SST to the caliper.
6. Rotate the SST (49 B043 005) in the direction of the arrow and push the piston completely into the caliper. NOTE: Even with the piston completely pushed in, the top of the piston projects from the dust seal by approximately 2mm {0.9 in}.
7. Rotate part A on the SST (49 B043 005) in the direction of the arrow using the tool and remove the SST from the caliper.
8. Assemble the dust seal to the caliper body using the SSTs and a press with a press-in force of 834 N {85 kgf, 187 in.lbf}
9. Verify that there is no gap between the dust seal and caliper body.