Disc: Removal & Installation Mazda MX-5 NB рестайлинг

Removal & Installation

1. Disconnect the brakelight switch connector.
2. Remove brake pedal components in the order indicated in the illustration. see scheme 3
3. Install in the reverse order of removal.
4. After installation, verify and adjust the pedal height and free play, as necessary. See «BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH»(ref-139611-S34306144712004060700000) under ADJUSTMENTS, and «BRAKE PEDAL FREE PLAY»(ref-139611-S01178416362004060700000) under ADJUSTMENTS.

Note. Remove any rust or grime on the contact face of the rotor and wheel hub. Install the rotor and align the marks made before removal.

Note. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table.

Raise and support vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front rotor. See FRONT BRAKE ROTOR . Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Bleed air from system. See BLEEDING BRAKE SYSTEM .

1. Raise and support vehicle. Remove front wheel assembly. Remove in the order indicated in the illustration. (Scheme 6) NOTE: On brake pad installation, Step 3 in the illustration, use Disc brake expander (49-0221-600c) and an old pad to push the piston fully inward. (Scheme 9) Install the new brake pads in the mounting support.
2. Install in the reverse order of removal.

Scheme 6

1. Raise and support vehicle. Remove front wheel assembly. Remove in the order indicated in the illustration. (Scheme 7) NOTE: Prior to removal, mark the wheel hub bolt and rotor before removal for reference during installation. (Scheme 8)
2. Remove brake pads, shims, mounting support and guide plate. Replace brake pads if lining thickness is less than specified. See «DISC BRAKE SPECIFICATIONS»(ref-139611-S38926585902002050200000) table.
3. To install, reverse removal procedure. NOTE: On brake pad installation, use Disc Brake Expander (49-0221-600C) and an old pad push the piston fully inward. (Scheme 9) Install the new brake pads in the mounting support. NOTE: Prior to rotor installation, remove any rust or grime on the contact face of the rotor and wheel hub. Install the rotor and align the marks made before removal. NOTE: Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See «DISC BRAKE SPECIFICATIONS»(ref-139611-S38926585902002050200000) table. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-139611-S12717708312002050200000).

Scheme 7

Scheme 8

Scheme 9

1. Remove the cruise control actuator.
2. Remove in the order indicated in the illustration. (Scheme 10)
3. Install in the reverse order of removal. On master cylinder installation, see «MASTER CYLINDER INSTALLATION NOTE»(ref-139611-S34723036082004061000000).

Scheme 10

Master Cylinder Installation Note

1. Turn the nut of the Adjustment Gauge (49-B043-001) Rod clockwise to fully retract the gauge rod. Attach the adjustment gauge to the power brake unit. Tighten to specifications. See «TORQUE SPECIFICATIONS»(ref-139611-S12717708312002050200000).
2. Using a vacuum pump, apply 19.7 in. Hg (66.7 kPa) of vacuum. (Scheme 11)
3. Turn the adjusting nut of the adjustment gauge rod counterclockwise until the gauge rod just contacts the push rod end of the power brake unit. (Scheme 12) Push lightly on the end of the gauge rod to be sure it is seated. Verify that there is no gap between the adjusting nut and adjustment gauge rod body. CAUTION: When pushing the adjustment gauge rod into the master cylinder piston, only use enough pressure to push the rod to the bottom of the piston. If too much pressure is applied, a false reading will occur.
4. Remove the adjustment gauge from the power brake unit without disturbing the adjusting nut. Set the adjustment gauge onto the master cylinder as shown in the illustration. (Scheme 12)
5. Push lightly on the end of the adjustment gauge rod to be sure it has contacted the bottom of, the master cylinder piston, but do not push so hard that the piston moves. (Scheme 13) Note any clearance between the adjustment gauge body and the adjusting nut clearance at "B" or between the body and the master cylinder clearance at "C". See «ADJUSTING PUSH ROD»(ref-139611-S42751193232004061000000) table. To adjust the push rod, see «MASTER CYLINDER PUSH ROD»(ref-139611-S38991344612002050200000) under ADJUSTMENTS.

ADJUSTING PUSH ROD

Scheme 11

Scheme 12

Scheme 13

1. Remove the exhaust pipe heat insulator.
2. Remove in the order indicated in the illustration. (Scheme 14)
3. Install in the reverse order of removal.
4. After installation: Adjust the parking brake lever stroke. See «PARKING/EMERGENCY BRAKE»(ref-139611-S10411102732002050200000) under ADJUSTMENTS. Depress the brake pedal a few times. Verify that the rear brakes do not drag while the wheels are rotated by hand.

Scheme 14

1. Remove in the order indicated in the illustration. (Scheme 15) NOTE: Install the parking brake switch so that it contacts the parking brake lever when the lever is fully released. Turn the ignition switch to ON, and verify that the parking brake warning light illuminates with the lever pulled up one notch.
2. Install in the reverse order of removal. NOTE: After installation, adjust the parking lever stroke. See «PARKING/EMERGENCY BRAKE»(ref-139611-S10411102732002050200000) under ADJUSTMENTS.

Scheme 15

1. Remove the master cylinder and the proportioning valve (without ABS), and brake pipe joint (with ABS). (Scheme 10)
2. Remove in the order indicated in the illustration. (Scheme 16)
3. Install in the reverse order of removal. NOTE: Install the vacuum hose to the power brake unit and intake manifold. (Scheme 17)
4. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-139611-S12717708312002050200000). Bleed air from system.

Scheme 16

Scheme 17

Remove in the order indicated in the illustration. (Scheme 18) Install in the reverse order of removal. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Bleed air from system. See BLEEDING BRAKE SYSTEM.

Scheme 18

Raise and support rear of vehicle. Remove rear wheel assemblies. Disconnect brake flexhose from caliper. Remove components in the order indicated in the illustration. (Scheme 19) Only remove the necessary components for removing rear brake caliper.

Note. Prior to removal, mark the wheel hub bolt and rotor for reference during installation. (Scheme 8)

On brake pad installation, see REAR BRAKE PADS . To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Bleed air from system. See BLEEDING BRAKE SYSTEM .

Note. Remove any rust or grime on the contact face of the rotor and wheel hub. Install the rotor and align the marks made before removal.

Note. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table.

Scheme 19

1. Raise and support vehicle. Remove front wheel assembly. Remove components in the order indicated in the illustration. (Scheme 20) Replace brake pads if lining thickness is less than specified. See «DISC BRAKE SPECIFICATIONS»(ref-139611-S38926585902002050200000) table. NOTE: On brake pad installation: Turn the manual adjustment gear counterclockwise using an Allen wrench to pull the brake caliper piston back. (Scheme 21) Install the brake pads. Turn the manual adjustment gear clockwise until the brake pads just touch the rotor. Return the manual adjustment gear counterclockwise 1/3 turn.
2. Install in the reverse order of removal. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-139611-S12717708312002050200000).

Scheme 20

Scheme 21

1. Raise and support vehicle. Remove rear wheel assemblies. Disconnect parking brake cable. Remove rear brake caliper with brake hose connected. Support caliper using wire. Remove rotor-to-hub screws (if equipped). (Scheme 19) Remove rotor.
2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See «DISC BRAKE SPECIFICATIONS»(ref-139611-S08689886592002050200000). To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-139611-S12717708312002050200000).