Mazdamanuals.com

POWER BRAKE UNIT REMOVAL/INSTALLATION [R.H.D.]

Home  id041100801852

Replacement Part

Oil and Chemical Type

Caution

•  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 performing any procedure that changes the brake pedal stroke.

•  Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. In addition, if there is any brake fluid on the wiring harness, the wire insulation may corrode causing a malfunction such as a short circuit. If brake fluid gets on a painted surface or wiring harness, wash and flush it off completely with water immediately.

Note

•  Tighten the brake pipe flare nut using any commercially available flare nut wrench.

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

2.  Remove the following parts:

(1)  Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

(2)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)

(3)  Windshield wiper motor and link (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

(4)  Side cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)

(5)  Cowl panel (See COWL PANEL REMOVAL/INSTALLATION [(E)].)

3.  Remove the insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)(See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)(See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

4.  For SKYACTIV-G 2.0 or SKYACTIV-G 2.5 perform the following procedure:

(1)  Remove the cooler hose (LO) installation bolt. (See REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-G].) (See REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

ac30zw00003447

(2)  Detach the cooler pipe from the clip.

5.  Remove the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION [R.H.D.].)

6.  Detach the brake pipes from the clip.

am3zzw00029772

7.  For SKYACTIV-D 1.8, perform the following procedure:

(1)  Disconnect the brake pipes from the DSC HU/CM.

am3zzw00029771

(2)  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

(3)  Remove the catalytic converter (diesel particulate filter) insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

8.  Remove in the order indicated in the table.

9.  Install in the reverse order of removal.

10.  After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See BRAKE FLUID AIR BLEEDING [(E)].) (See CLUTCH FLUID REPLACEMENT/AIR BLEEDING [C66M-R, C66MX-R] (MTX).)

11.  Remove the brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.].)

12.  Inspect the brake pedal. (See BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.].)

13.  Install a new brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.].)

ac30zw00004082

1	Vacuum hose (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].) (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].) (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
2	Power brake unit vacuum sensor connector (With i-stop)
3	Snap pin (See BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.].)
4	Clevis pin
5	Nut
6	Fork (See Fork Installation Note.)
7	Locknut
8	Power brake unit (See Power Brake Unit Removal Note [SKYACTIV-D 1.8].) (See Power Brake Unit Installation Note [SKYACTIV-D 1.8].)
9	Gasket

Power Brake Unit Removal Note [SKYACTIV-D 1.8]

1.  Remove the fork and locknut.

2.  Remove the power brake unit.

Power Brake Unit Installation Note [SKYACTIV-D 1.8]

1.  Install the power brake unit.

2.  Install the fork and locknut. (See Fork Installation Note.)

Fork Installation Note

1.  Install the fork as shown in the figure.

am3zzw00025072