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BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.]

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Replacement Part

Warning

•  If the initialization of the sensors for the electronically controlled brake unit related parts is not completed, the electronically controlled brake unit will not operate normally which could lead to an unexpected accident. Therefore, if the electronically controlled brake unit is replaced and removed/installed, always perform the initialization of the sensors for the electronically controlled brake unit related parts so that the electronically controlled brake unit will operate normally. (With Mazda M Hybrid)

Caution

•  The 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.

•  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.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

2.  Disconnect the brake fluid level sensor connector. (Without Mazda M Hybrid) (See MASTER CYLINDER REMOVAL/INSTALLATION [R.H.D.].)

3.  Remove the electronically controlled brake unit. (With Mazda M Hybrid) (See ELECTRONICALLY CONTROLLED BRAKE UNIT REMOVAL/INSTALLATION [R.H.D.].)

4.  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

6.  If the brake pedal is replaced, perform the following procedure. (With Mazda M Hybrid)

(1)  Connect the M-MDS.

(2)  Select the following item from the screen of the M-MDS.

(3)  Press [Start] for the vehicle identification.

(4)  Press the [Toolbox] tab.

(5)  Press the [Work Support] icon.

(6)  Press the [BRAKES] icon.

(7)  Press [Run] for Calibrating Pressure Sensor for DSC.

(8)  Perform the procedure according to the directions on the screen.

(9)  Drive the vehicle.

(10)  After 5 min or more of driving, verify that the DSC system is normal.

Without Mazda M Hybrid

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1	Brake switch connector and wiring harness
2	Brake switch (See Brake Switch Installation Note.)
3	Wiring harness (MTX)
4	Snap pin (See Snap Pin Installation Note.)
5	Clevis pin
6	Nut (See Brake Pedal Installation Note.)
7	Brake pedal (See Brake Pedal Removal Note.) (See Brake Pedal Installation Note.)
8	Pedal pad

With Mazda M Hybrid

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1	Brake switch connector and wiring harness
2	Brake switch (See Brake Switch Installation Note.)
3	Wiring harness (MTX)
4	Nut (See Brake Pedal Installation Note.)
5	Brake pedal (See Brake Pedal Removal Note.) (See Brake Pedal Installation Note.)
6	Pedal pad

Brake Pedal Removal Note

1.  Remove the nuts.

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2.  Remove the bracket.

3.  Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm. (Without Mazda M Hybrid)

4.  Move the brake pedal in the direction of the arrow shown in the figure, and remove it while avoiding the hooks.

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Brake Pedal Installation Note

1.  Temporarily install the electronically controlled brake unit. (With Mazda M Hybrid) (See ELECTRONICALLY CONTROLLED BRAKE UNIT REMOVAL/INSTALLATION [R.H.D.].)

2.  Temporarily tighten nuts A.

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3.  Temporarily tighten nuts B.

4.  Tighten nuts B to the specified torque.

5.  Tighten nuts A to the specified torque.

6.  Install the bracket.

7.  Tighten the nuts in the order shown in the figure.

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Snap Pin Installation Note

1.  Install the snap pin as shown in the figure.

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Brake Switch Installation Note

1.  Inspect the brake pedal. (See BRAKE PEDAL INSPECTION [(E)].)

2.  With the brake pedal fully released, insert the brake switch into the installation hole on the brake pedal.

Caution

•  If the brake pedal arm is moved when securing the brake switch, the clearance between the brake pedal and brake switch may not be adjusted to the correct clearance. Be careful not to move the brake pedal arm when securing the brake switch.

3.  Secure the brake switch by turning it counterclockwise 45°.

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