Conventional Brake System Location Index: Ac5uuw00008268

■ CONVENTIONAL BRAKE SYSTEM LOCATION INDEX
id041100800100
id041100800100
Vehicle Front Side
ac5uuw00008268
© 2018 Mazda Motor Corporation.

Vacuum line
(See VACUUM LINE INSPECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER
DEACTIVATION)].)
(See VACUUM LINE INSPECTION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)
(See VACUUM LINE INSPECTION [SKYACTIV-D 2.2].)
1 (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT
CYLINDER DEACTIVATION)].)
(See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER
DEACTIVATION)].)
(See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
Brake fluid
(See BRAKE FLUID INSPECTION.)
2
(See BRAKE FLUID AIR BLEEDING.)
Master cylinder
(See MASTER CYLINDER REMOVAL/INSTALLATION.)
3
(See BRAKE FLUID LEVEL SENSOR INSPECTION.)
Power brake unit

(See POWER BRAKE UNIT INSPECTION.)
4
(See POWER BRAKE UNIT REMOVAL/INSTALLATION.)
Brake switch
5
(See BRAKE SWITCH INSPECTION.)
Brake pedal
(See BRAKE PEDAL INSPECTION.)
6
(See BRAKE PEDAL REMOVAL/INSTALLATION.)

Front brake
(See FRONT BRAKE INSPECTION.)
(See FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING CALIPER].)
(See FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING CALIPER].)
(See FRONT BRAKE DISC PAD REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING
CALIPER].)
(See FRONT BRAKE DISC PAD REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING CALIPER].)
(See FRONT BRAKE CALIPER REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING
7 CALIPER].)
(See FRONT BRAKE CALIPER REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING CALIPER].)
(See FRONT BRAKE CALIPER DISASSEMBLY/ASSEMBLY [WITH SINGLE PISTON FLOATING
CALIPER].)
(See FRONT BRAKE CALIPER DISASSEMBLY/ASSEMBLY [WITH 2-PISTON FLOATING CALIPER].)
(See FRONT BRAKE HOSE REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING CALIPER].)
(See FRONT BRAKE MOUNTING SUPPORT REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING

CALIPER].)
Front brake hose

(See FRONT BRAKE HOSE REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING CALIPER].)
8
(See FRONT BRAKE HOSE REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING CALIPER].)
Vacuum pump
(See VACUUM PUMP INSPECTION.)
(See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT
9
(See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER
DEACTIVATION)].)
(See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
Vehicle Rear Side

ac5uuw00004286
Rear brake hose

1
(See REAR BRAKE HOSE REMOVAL/INSTALLATION.)
Rear brake
(See REAR BRAKE INSPECTION.)
(See REAR BRAKE DISC REMOVAL/INSTALLATION.)
(See REAR BRAKE DISC PAD REMOVAL/INSTALLATION.)
2
(See REAR BRAKE CALIPER REMOVAL/INSTALLATION.)
(See REAR BRAKE CALIPER DISASSEMBLY/ASSEMBLY.)
(See REAR BRAKE MOUNTING SUPPORT REMOVAL/INSTALLATION.)

■ VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH
CYLINDER DEACTIVATION)]
id0411008036x5
id0411008036x5
Replacement Part
O-ring
Quantity: 1
Location of use: Vacuum pump
Warning
• A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they
are cool before removing the intake air system.
1.Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL

DISCONNECTION/CONNECTION.)
2.Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5
(WITH CYLINDER DEACTIVATION)].)
3.Remove the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER
DEACTIVATION)].)
4.Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
[SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)
• Air hose
• Air cleaner cover
• Air cleaner element
• Fresh-air duct
• Air cleaner case
5.Disconnect the clip from the bracket.

ac5wzw00010542
6.Remove the bolts
7.Move the battery tray, PCM and wiring harness toward the front of the vehicle to the position where the
vacuum pump can be removed.
8.Pinch open the clamp using pliers and disconnect the vacuum hose from the vacuum pump. (See
VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)
9.Remove in the order indicated in the table.
10.Install in the reverse order of removal.

ac5wzw00011209
1 Bolt
Vacuum pump
(See Vacuum Pump Removal Note.)
2
(See Vacuum Pump and O-ring Installation Note.)
O-ring
3
(See Vacuum Pump and O-ring Installation Note.)
Vacuum Pump Removal Note
1.When removing the vacuum pump, set a cloth to the underside of the vacuum pump installation surface
so that engine oil does not adhere to other parts.
2.Remove the vacuum pump.
Vacuum Pump and O-ring Installation Note

1.Rotate the vacuum pump by hand to drain the remainder of the engine oil in the vacuum pump.
2.Degrease the O-ring installation groove and installation surface.
3.Install the new O-ring to the vacuum pump.
4.Install the vacuum pump.

■ VACUUM PUMP INSPECTION
id041100811000
id041100811000
SKYACTIV-G 2.0, SKYACTIV-G 2.5
VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT
CYLINDER DEACTIVATION)].) (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.5
2.Install the vacuum gauge.
ac5uuw00007502
3.Warm up the engine.
4.Switch the ignition off.
5.Depress the brake pedal several times and decrease the vacuum of the vacuum gauge to 0 kPa {0
mmHg, 0 inHg}.
6.Switch the ignition ON (engine on).
Caution
• If the brake pedal is released after switching the ignition ON (engine on), the vacuum in the vacuum
pump may decrease and result in an incorrect reading when performing the inspection for the degree
of vacuum in the vacuum pump. Depress and hold the brake pedal after switching the ignition ON
(engine on).
7.Perform the inspection for the degree of vacuum in the vacuum pump.
(1)Measure the time from the measurement-start vacuum to the measurement-stop vacuum while
taking readings on the vacuum gauge.

Degree of vacuum in vacuum pump standard (reference)
Measurement condition Specification

Brake Measurement- Measurement-
Engine rotation speed
pedal start vacuum stop vacuum
While idling
(See ENGINE TUNE-UP
[SKYACTIV-G 2.0, SKYACTIV-G 2.5
60 kPa
(WITHOUT CYLINDER
{450 67 kPa {503
DEACTIVATION)].) Depressed Within 8 s
mmHg, 18 mmHg, 20 inHg}
inHg}
(See ENGINE TUNE-UP
[SKYACTIV-G 2.5 (WITH CYLINDER
DEACTIVATION)].)
(2)Verify that the measured time matches the standard.
• If they do not match, repair or replace the following malfunctioning locations.
― Vacuum pump malfunction
― Engine oil pressure decrease
• If they match, go to the next step.
8.Perform the inspection for the degree of maximum attained vacuum in the vacuum pump.
Note
• The inspection for the degree of maximum attained vacuum in the vacuum pump can be performed
normally even if the brake pedal is released.
(1)Read the vacuum on the vacuum gauge.
Degree of maximum attained vacuum in vacuum pump standard (reference)
Measurement condition Specification

Engine rotation speed Measurement time
While idling
(See ENGINE TUNE-UP [SKYACTIV-G 2.0, SKYACTIV-
G 2.5 (WITHOUT CYLINDER DEACTIVATION)].) No time 93.3 kPa {700 mmHg,
designation 27.6 inHg} or more
(See ENGINE TUNE-UP [SKYACTIV-G 2.5 (WITH
(2)Verify that the measured vacuum matches the standard.
• If they do not match, repair or replace the following malfunctioning locations.

SKYACTIV-D 2.2
1.Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
3.Install the vacuum gauge.
ac5wzw00009822
4.Warm up the engine.
6.Depress the brake pedal several times and decrease the vacuum of the vacuum gauge to 0 kPa {0
mmHg, 0 inHg}.
7.Switch the ignition ON (engine on).
Caution
• If the brake pedal is released after switching the ignition ON (engine on), the vacuum in the vacuum
pump may decrease and result in an incorrect reading when performing the inspection for the degree
of vacuum in the vacuum pump. Depress and hold the brake pedal after switching the ignition ON
(engine on).
8.Perform the inspection for the degree of vacuum in the vacuum pump.
(1)Measure the time from the measurement-start vacuum to the measurement-stop vacuum while
taking readings on the vacuum gauge.
Degree of vacuum in vacuum pump maximum (reference)

Measurement condition Maximum value
Measurement-start Measurement-stop
Engine rotation speed Brake pedal
vacuum vacuum
While idling
0 kPa {0
67 kPa {503 mmHg, 15 s + Engine
Depressed mmHg, 0
(See ENGINE TUNE- 20 inHg} completely warmed up
inHg}
UP [SKYACTIV-D 2.2].)
(2)Verify if the measured time is the maximum value or less.
• If it exceeds the maximum value, repair or replace the following malfunctioning locations.

■ VACUUM LINE INSPECTION [SKYACTIV-G 2.5 (WITH CYLINDER
DEACTIVATION)]
id0411008015x5
id0411008015x5
Airflow Inspection
Between intake manifold and vacuum pump
2.Remove the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.5
3.Blow air into the vacuum hose from the vacuum pump side using your mouth and verify that the air
flows to the intake manifold side, then blow air from the intake manifold side and verify that the air does
not flow to the vacuum pump side.
ac5uuw00007493
• If there is any malfunction of the inner check valve, replace it together with the vacuum hose as a
single unit. (SeeVACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER
DEACTIVATION)].)
Between vacuum pump and power brake unit
1.Remove the vacuum hose on the vacuum pump side. (See VACUUM HOSE
REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)
2.Blow air into the vacuum hose from the power brake unit side using your mouth and verify that the air
flows to the vacuum pump side, then blow air from the vacuum pump side and verify that the air does not
flow to the power brake unit side.

ac5uuw00008269
• If there is any malfunction of the inner check valve, replace it together with the vacuum hose as a
single unit. (SeeVACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER
DEACTIVATION)].)

■ REAR BRAKE MOUNTING SUPPORT REMOVAL/INSTALLATION
id041100001300
id041100001300
Replacement Part
Dust boot
Quantity: 2
Location of use: Rear brake mounting support
Oil and Chemical Type
Rubber grease (Orange)
Type: NIGLUBE RX-2
Note
• When in maintenance mode, the clearance between the disc pad and the disc plate expands.
• When the maintenance mode is completed, perform the electric parking brake automatic
adjustment.
• With the electric parking brake automatic adjustment, the electric parking brake motor gear unit
operation time is longer than normal.
1.Switch to the maintenance mode. (See MAINTENANCE MODE.)

3.Remove the wheel and tire. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)
4.Disconnect the electric parking brake motor gear unit connector.

ac5uuw00007480
7.End the maintenance mode. (See MAINTENANCE MODE.)
8.After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See BRAKE FLUID AIR
BLEEDING.)
9.After installation, pump the brake pedal a few times and inspect the following:
― Disc pad projection does not contact piston and caliper
― Brake drag

ac5uuw00007481
1 Bolt
Rear brake caliper, Electric parking brake motor gear unit

2
(See Rear Brake Caliper, Electric Parking brake motor gear unit Removal Note.)
3 Slide pin (main)
4 Slide pin (sub)
5 Dust boot
6 Disc pad component
7 Guide plate
8 Bolt
9 Mounting support

Rear Brake Caliper, Electric Parking brake motor gear unit Removal Note
1.Remove the rear brake caliper and electric parking brake motor gear unit as a single unit, and suspend
them in a place out of the way using a cable.
ac5jjw00011374

■ VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH
CYLINDER DEACTIVATION)]
id0411008016x5
id0411008016x5
Between Intake Manifold and Vacuum Pump
2.Disconnect the vacuum hose from the clip.
ac5wzw00011205
3.Pinch open the clamps using pliers and disconnect the vacuum hose.
4.Install in the reverse order of removal. (See Vacuum hose (between intake manifold and vacuum pump)
installation note.)
Vacuum hose (between intake manifold and vacuum pump) installation note

1.Install the vacuum hose as shown in the figure.
ac5wzw00011206
Between Vacuum Pump and Power Brake Unit
1.Pinch open the clamps using pliers and disconnect the vacuum hose.

ac5wzw00011207
2.Install in the reverse order of removal. (See Vacuum hose (between vacuum pump and power brake
unit) installation note.)
Vacuum hose (between vacuum pump and power brake unit) installation note
1.Install the vacuum hose as shown in the figure.

ac5wzw00011208

■ REAR BRAKE INSPECTION
id041100000800
id041100000800
Brake Judder Repair Hints
Description
1.Brake judder concern has the following 3 characteristics:
Steering wheel vibration
1.The steering wheel vibrates in the rotation direction. This characteristic is most noticeable when
applying brakes at a vehicle speed of 100—140 km/h {62.2—86.9 mph}.
Floor vibration
1.When applying the brakes, the vehicle body shakes back and forth. The seriousness of the shaking is
not influenced by vehicle speed.
Brake pedal vibration
1.When applying the brakes, a pulsating force tries to push the brake pad back. The pulsation is
transmitted to the brake pedal.
2.The following are the main possible causes of brake judder:
Due to an excessive runout (side-to-side wobble) of the disc plate, the thickness of the disc plate is
uneven.
1.If the runout is more than 0.1 mm {0.004 in} at the position 10 mm {0.39 in} from the disc plate edge,
uneven wear occurs on the disc plate because the pad contacts the plate unevenly.
2.If the runout is less than 0.1 mm {0.004 in}, uneven wear does not occur.
The disc plate is deformed by heat.
1.Repeated panic braking may raise the temperature in some portions of the disc plate by approx.
1,000 °C {1,832 °F}. This results in a deformed disc plate.
Due to corrosion, the thickness and friction coefficient of the disc plate change.
1.If the vehicle is parked in damp conditions for a long time, corrosion occurs on the friction surface of the
disc plate.

2.The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the
friction coefficient and causes a reaction force.
Inspection and repair procedure
ac5uuw00007531
Lateral runout inspection
2.Remove the rear brake caliper component and suspend it out of the way using a cable. (See REAR
BRAKE DISC REMOVAL/INSTALLATION.)

ac5uuw00008040
3.To secure the disc plate and the hub, insert the washer (thickness 10 mm {0.39 in}, inner diameter more
than 12 mm {0.47 in}) between each hub bolt and the hub nut, then tighten all the hub nuts.
Note
• The component parts of theSST(49 B017 001 or 49 G019 003) can be used as a suitable washer.
4.After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of the disc
plate 10 mm {0.39 in} from the disc plate edge.
ac5jjw00010808
5.Rotate the disc plate one time and measure the runout.
Rear disc plate runout limit
0.1 mm {0.004 in}
Thickness variation inspection

2.Clean the disc plate-to-pad friction surface using a brake cleaner.
3.Measure the points indicated in the illustration using a caliper (micrometer).
ac5uuw00007532
4.Subtract the minimum value from the maximum, and if the result is not within the specification, machine
the disc plate using a lathe.
Thickness variation limit
0.015 mm {0.00059 in}
Warning
• Do not exceed minimum disc plate thickness.
Disc Plate Thickness Inspection
Caution
• Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine
the disc plate while installed on the vehicle.
2.Measure the thickness of the disc plate.
Minimum rear disc plate thickness
8.0 mm {0.3 in}
Minimum rear disc plate thickness after machining using a brake lathe on-vehicle
8.8 mm {0.35 in}
• If the thickness is not within the specification, replace the disc plate. (SeeREAR BRAKE DISC
REMOVAL/INSTALLATION.)
Disc Pad Thickness Inspection
1.Jack up the front of the vehicle and support it with safety stands.

3.Verify the remaining thickness of the pads.
ac5jjw00011142
Minimum rear disc pad thickness
2.0 mm {0.079 in}
• Replace the pads as a set (right and left wheels) if either one is at or less than the minimum
thickness. (SeeREAR BRAKE DISC PAD REMOVAL/INSTALLATION.)

■ REAR BRAKE HOSE REMOVAL/INSTALLATION
id041100001400
id041100001400
Replacement Part
Gasket
Quantity: 2
Location of use: Rear brake hose
Brake fluid type
Type: SAE J1703 or FMVSS116 DOT-3
Caution
• 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.
BLEEDING.)

ac5uuw00007482
1 Brake pipe
Clip
2
(See Clip Installation Note.)
3 Bolt
4 Brake hose
Clip Installation Note
1.Install a clip to the position shown in the figure.

ac5uuw00007483

■ REAR BRAKE DISC REMOVAL/INSTALLATION
id041100000900
id041100000900
Note
adjustment.

ac5uuw00007463
― Brake drag

ac5uuw00007464
1 Bolt
Rear brake caliper component

(See Rear Brake Caliper Component Removal Note.)
2
(See Rear Brake Caliper Component Installation Note.)
3 Disc plate
Rear Brake Caliper Component Removal Note
1.Remove the rear brake caliper component and suspend it in a place out of the way using a cable.

ac5uuw00007465
Rear Brake Caliper Component Installation Note
1.Push the piston in using the commercially available disc brake expand tool.
ac5uuw00007466
2.Install the rear brake caliper component.

■ REAR BRAKE CALIPER REMOVAL/INSTALLATION
id041100001100
id041100001100
Special Service Tool (SST)
49 F043 002
Wrench
Replacement Part
Bolt O-ring Gasket
Quantity: 2 Quantity: 1 Quantity: 2
Location of use: Electric parking Location of use: Electric parking Location of use: Rear
brake motor gear unit brake motor gear unit brake hose
Note
adjustment.


ac5uuw00007471
BLEEDING.)
― Brake drag

ac5uuw00007472
1 Bolt
2 Electric parking brake motor gear unit
3 Bolt
4 Brake hose
5 Bolt
Rear brake caliper

6
(See Rear Brake Caliper Installation Note.)
Rear Brake Caliper Installation Note
1.Clean the exposed area of the piston.

Caution
• When pressing the piston into the rear brake caliper, the rear brake caliper internal parts could be
damaged while rotating and pressing the piston. Be careful not to rotate the piston when pressing the
piston into the rear brake caliper.
2.Press in the piston using a commercially available disc brake expander tool.
ac5uuw00007473
3.Verify that the piston grooves are at the positions shown in the figure.
ac5uuw00007474
• If the piston grooves are not at the positions shown in the figure, rotate the piston clockwise slowly
using theSSTand adjust the piston grooves at the positions shown in the figure.

ac5uuw00007475
4.Install the rear brake caliper.

■ REAR BRAKE DISC PAD REMOVAL/INSTALLATION
id041100001000
id041100001000
49 F043 002
Wrench
Note
adjustment.

ac5uuw00007467

― Brake drag
ac5uuw00008102
Rear brake caliper

(See Caliper Removal Note.)
1
(See Rear Brake Caliper Installation Note.)
2 Disc pad
3 Shim
4 Guide plate
Caliper Removal Note

1.Remove the bolt shown in the figure and lift up the rear brake caliper.
ac5jjw00011152
Rear Brake Caliper Installation Note
Caution
• When pressing the piston into the rear brake caliper, the rear brake caliper internal parts could be
damaged while rotating and pressing the piston. Be careful not to rotate the piston when pressing the
piston into the rear brake caliper.
2.Press in the piston using a commercially available disc brake expander tool.
ac5uuw00007468

ac5uuw00007469
ac5uuw00007470
4.Return the rear brake caliper to the original position and install the bolt.
ac5jjw00011154

■ REAR BRAKE CALIPER DISASSEMBLY/ASSEMBLY
id041100001200
id041100001200
49 F043 002
Wrench
Replacement Part
Dust seal Piston seal
Quantity: 1 Quantity: 1
Location of use: Caliper body Location of use: Piston
Brake fluid type Rubber grease (Pink)
Type: SAE J1703 or FMVSS116 DOT-3 Type: RENOLIT RUBBER GREASE JP
Caution

ac5uuw00007476
1 Bleeder cap
2 Bleeder screw
Piston
(See Piston Disassembly Note.)
3
(See Dust Seal, Piston Assembly Note.)
Dust seal
4
(See Dust Seal, Piston Assembly Note.)
5 Piston seal
6 Caliper body
Piston Disassembly Note
Warning
• When compressed air is blown into the caliper body, injury to a finger or other part from pinching
could result from the piston springing up. When blowing in compressed air, do not place your fingers
between the piston and caliper body when performing the work.
Caution

• The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.
1.Insert a piece of wood in the caliper as shown in the figure and blow compressed air through the hole to
remove the piston from the caliper body.
ac5jjw00006613
Caution
• If the piston is removed from the caliper while rotating the piston, the caliper internal parts could be
damaged. Be careful not to rotate the piston when removing the piston from the caliper.
Dust Seal, Piston Assembly Note
1.Assemble the dust seal to the piston.
2.Assemble the lip of the dust seal to the groove of the caliper body with the dust seal is assembled to the
piston as shown in the figure.
ac5uuw00007477
Caution
• If the piston is pushed into the caliper while rotating the piston, the caliper internal parts could be
damaged. Be careful not to rotate the piston when pushing the piston into the caliper.

3.Align the head of the spindle nut with the inner shape of the piston and press the piston into the caliper
body completely.
4.Verify that the dust seal is installed into the caliper body groove.
ac5uuw00007478
ac5uuw00007479

■ POWER BRAKE UNIT REMOVAL/INSTALLATION
id041100801800
id041100801800
Replacement Part
Gasket Brake switch
Location of use: Power brake unit Location of use: Brake pedal
Brake fluid 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 pedal stroke.
Note
1.Disconnect the negative battery terminal.(See NEGATIVE BATTERY TERMINAL

2.Remove the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5
(WITHOUT CYLINDER DEACTIVATION)].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G
2.5 (WITH CYLINDER DEACTIVATION)].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D
2.2].)
3.Remove the following parts:
(1)Windshield wiper arm and brade (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)Keyless beeper (With advanced keyless entry system) (See
KEYLESS BEEPER REMOVAL/INSTALLATION.) (5)Cowl panel (See COWL PANEL
4.Remove the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION.)
5.For SKYACTIV-D 2.2 vehicles, remove the following parts:
• Air inlet pipe (SeeINTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
• Battery tray (SeeBATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
BLEEDING.)
9.Remove the brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION.)
10.Inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)
11.Install a new brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION.)
ac5uuw00007499

Vacuum hose
(See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT
1 (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER
DEACTIVATION)].)
(See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
2 Snap pin
3 Clevis pin
4 Nut
5 Power brake unit
6 Gasket

■ POWER BRAKE UNIT INSPECTION
id041100883000
id041100883000
49 U043 49 U043 49 U043

004A 005 006
Oil pressure Joint Hose

gauge
(Part of 49 (Part of 49
(Part of 49 U043 U043
U043 0A0A) 0A0A) 0A0A)
Caution
Note
• The following inspection methods are simple inspection methods to judge the function of the power
brake unit.
• If there is any malfunction in the power brake unit, replace the power brake unit as a single unit.
(SeePOWER BRAKE UNIT REMOVAL/INSTALLATION.)
Without Using SST
Operation inspection
1.With the engine stopped, pump the pedal a few times.
2.With the pedal depressed, start the engine.
3.If the pedal moves down slightly immediately after starting the engine, the unit is normal.
Vacuum function inspection
1.Start the engine.
2.Stop the engine after driving the vehicle for 1—2 min.
3.Depress the pedal with normal force.

4.If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is normal.
• If a problem is found, inspect for damage to or improper installation of the check valve and vacuum
hose. After repairing, inspect again.
Vacuum loss function inspection
1.Start the engine.
2.Depress the pedal with normal force.
3.With the pedal depressed, stop the engine.
4.Hold the pedal depressed for approx. 30 s.
5.If the pedal height does not change during this time, the unit is normal.
Using SST
Note
• When performing the inspection using the SST, inspect the brake pipe on the left or right front
wheel.
• The following procedure and figures show the inspection for the brake pipe on the left front wheel.
Pre-inspection preparation
1.Remove the clips.
ac5uuw00007503
2.Set the splash shield out of the way.
3.Disconnect the brake pipe from the brake hose.

ac5uuw00007504
4.Remove the clip.
5.Remove the brake hose from the bracket.
Caution
• When removing the brake pipe, the pipe holder may detach from the body. Remove the brake pipe
while pressing the pipe holder to prevent it from detaching from the body. The pipe holder cannot be
reused if it detaches from the body.
6.Detach the brake pipe from the pipe holder.
7.Install the SSTs to the brake pipe as shown in the figure.
ac5jjw00010685
8.Bleed the brake line and the SSTs of air. Bleed the air form the SSTs using bleeder screw A.
9.Install the pedal force gauge to the brake pedal.
10.Connect the vacuum gauge to the vacuum line.
Vacuum loss inspection
1.Start the engine.
2.Depress the brake pedal with a force of 200 N {20.4 kgf, 45.0 lbf}.

3.Stop the engine when the vacuum gauge reading reaches 68 kPa {510 mmHg, 20 inHg} with the pedal
depressed.
4.With the engine off, observe the vacuum gauge for 15 s.
5.If the gauge has dropped 3.3 kPa {25 mmHg, 0.97 inHg} or less, the unit is normal.
Lack of hydraulic pressure inspection
1.If the pedal force and fluid pressure correlation is within the specification with the engine stopped and a
vacuum amount of 0 kPa {0 mmHg, 0 inHg}, the system is normal.
Master cylinder fluid pressure (SKYACTIV-G 2.0, SKYACTIV-G 2.5)
Vacuum amount at 0 kPa {0 mmHg, 0 inHg}

Pedal force Fluid pressure
2
200 N {20.4 kgf, 45.0 lbt} 890 kPa {9.08 kgf/cm , 129 psi} or more
Master cylinder fluid pressure (SKYACTIV-D 2.2)
Vacuum amount at 0 kPa {0 mmHg, 0 inHg}

2
200 N {20.4 kgf, 45.0 lbf} 770 kPa {7.85 kgf/cm , 112 psi} or more
Hydraulic pressure inspection
1.Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa {500 mmHg, 19.7 inHg}.
2.At this time, apply the indicated pedal force and if the fluid pressure is within the specification, the unit is
normal.
Master cylinder fluid pressure (SKYACTIV-G 2.0, SKYACTIV-G 2.5)
Vacuum amount at 66.7 kPa {500 mmHg, 19.7 inHg}

2
200 N {20.4 kgf, 45.0 lbt} 6,810 kPa {69.44 kgf/cm , 987.7 psi} or more
Master cylinder fluid pressure (SKYACTIV-D 2.2)
Vacuum amount at 66.7 kPa {500 mmHg, 19.7 inHg}

2
200 N {20.4 kgf, 45.0 lbf} 6,710 kPa {68.42 kgf/cm , 973.2 psi} or more
After-inspection procedure

1.After the inspection, remove the SSTs, install the brake hose, clamp, and brake pipe to the original
positions, and then bleed the air from the brake line. (See FRONT BRAKE HOSE
REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING CALIPER].) (See FRONT BRAKE
HOSE REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING CALIPER].) (See BRAKE FLUID AIR
BLEEDING.)

■ FRONT BRAKE MOUNTING SUPPORT REMOVAL/INSTALLATION [WITH
SINGLE PISTON FLOATING CALIPER]
id0411000005w4
id0411000005w4
Replacement Part
Dust boot
Quantity: 2
Location of use: Front brake mounting support
Rubber grease (Orange) Brake grease (Brown)
Type: NIGLUBE RX-2 Type: Molykote 7439
4.Depress the brake pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.

ac5uuw00007458

1 Bolt
Front brake caliper

2
(See Front Brake Caliper Removal Note.)
3 Slide pin (main)
4 Slide pin (sub)
5 Dust boot
Guide plate
7
(See Guide Plate Installation Note.)
8 Bolt
9 Mounting support
Front Brake Caliper Removal Note
1.Remove the front brake caliper and suspend it in a place out of the way using a cable.
ac5uuw00007459
Guide Plate Installation Note

Caution
• When assembling the guide plates to the mounting support, securely assemble them on the leading
side and trailing side to each position shown in the figure. If the guide plates are assembled to the
incorrect positions, it could become a source of noise.
1.Install the guide plate as shown in the figure.
ac5uuw00007460

■ MASTER CYLINDER REMOVAL/INSTALLATION
id041100801300
id041100801300
Replacement Part
Nut Set bolt Bush
Quantity: 2 Quantity: 1 Quantity: 2
Location of use: Cylinder Location of use: Brake fluid Location of use: Cylinder
component reserve tank component
O-ring
Quantity: 1
— —
Location of use: Cylinder

component
Brake fluid type
Caution
Note


2.2].)
(1)Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE
BLEEDING.)
ac5uuw00007491

1 Brake fluid level sensor connector
Clutch reserve hose (MTX)

(See Clutch Reserve Hose Removal Note (MTX).)
2
(See Clutch Reserve Hose Installation Note (MTX).)
3 Hose holder
4 Brake pipe
5 Nut
6 Bracket
7 Master cylinder
8 Cap
9 Brake fluid reserve tank
10 Cylinder component
Clutch Reserve Hose Removal Note (MTX)
1.Disconnect the clutch reserve hose in the order shown in the figure.
ac5uuw00007492
Clutch Reserve Hose Installation Note (MTX)
1.Insert the clutch reserve hose into the master cylinder.
2.Pull the clutch reserve hose to verify that it does not come off, and reinsert it completely.

■ FRONT BRAKE MOUNTING SUPPORT REMOVAL/INSTALLATION [WITH 2-
PISTON FLOATING CALIPER]
id0411000005w5
id0411000005w5
Replacement Part
Dust boot
Quantity: 2
Location of use: Front brake mounting support
Rubber grease (Pink)
Type: Cosmo rubber grease

ac5wzw00009652

1 Bolt (main)
2 Bolt (sub)
Front brake caliper

3
(See Front Brake Caliper Removal Note.)
4 Dust boot
6 Guide plate
7 Bolt
8 Mounting support
Front Brake Caliper Removal Note
1.Remove the front brake caliper and suspend it in a place out of the way using a cable.
ac5wzw00009828

■ FRONT BRAKE INSPECTION
id041100000000
id041100000000
Brake Judder Repair Hints
Description
1.Brake judder concern has the following 3 characteristics:
Steering wheel vibration
1.The steering wheel vibrates in the rotation direction. This characteristic is most noticeable when
applying brakes at a vehicle speed of 100—140 km/h {62.2—86.9 mph}.
Floor vibration
1.When applying the brakes, the vehicle body shakes back and forth. The seriousness of the shaking is
not influenced by vehicle speed.
Brake pedal vibration
1.When applying the brakes, a pulsating force tries to push the brake pad back. The pulsation is
transmitted to the brake pedal.
2.The following are the main possible causes of brake judder:
Due to an excessive runout (side-to-side wobble) of the disc plate, the thickness of the disc plate is
uneven.
1.If the runout is more than 0.04 mm {0.002 in} at the position 10 mm {0.39 in} from the disc plate edge,
uneven wear occurs on the disc plate because the pad contacts the plate unevenly.
2.If the runout is less than 0.04 mm {0.002 in}, uneven wear does not occur.
The disc plate is deformed by heat.
1.Repeated panic braking may raise the temperature in some portions of the disc plate by approx.
1,000 °C {1,832 °F}. This results in a deformed disc plate.
Due to corrosion, the thickness and friction coefficient of the disc plate change.
1.If the vehicle is parked in damp conditions for a long time, corrosion occurs on the friction surface of the
disc plate.

2.The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the
friction coefficient and causes a reaction force.
Inspection and repair procedure
ac5uuw00007446
Lateral runout inspection
2.Remove the front brake caliper component and suspend it in a place out of the way using a cable. (See
FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING CALIPER].) (See
FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING CALIPER].)

ac5uuw00007447
3.To secure the disc plate and the hub, insert the washer (thickness 10 mm {0.39 in}, inner diameter more
than 12 mm {0.47 in}) between each hub bolt and the hub nut, then tighten all the hub nuts.
Note
• The component parts of theSST(49 B017 001 or 49 G019 003) can be used as a suitable washer.
4.After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of the disc
plate 10 mm {0.39 in} from the disc plate edge.
ac5wzw00000197
5.Rotate the disc plate one time and measure the runout.
Front disc plate runout limit
0.04 mm {0.002 in}
Thickness variation inspection

2.Clean the disc plate-to-pad friction surface using a brake cleaner.
3.Measure the points indicated in the illustration using a caliper (micrometer).
ac5uuw00007448
4.Subtract the minimum value from the maximum, and if the result is not within the specification, machine
the disc plate using a lathe.
Thickness variation limit
0.015 mm {0.00059 in}
Warning
• Do not exceed minimum disc plate thickness.
Disc Plate Thickness Inspection
Caution
• Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine
the disc plate while installed on the vehicle.
2.Measure the thickness of the disc plate.
Minimum front disc plate thickness
26.0 mm {1.02 in}
Minimum front disc plate thickness after machining using a brake lathe on-vehicle
26.8 mm {1.06 in}
• If the thickness is not within the specification, replace the disc plate. (SeeFRONT BRAKE DISC
REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING CALIPER].) (SeeFRONT BRAKE
DISC REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING CALIPER].)
Disc Pad Thickness Inspection
1.Jack up the front of the vehicle and support it with safety stands.

3.Verify the remaining thickness of the pads.
ac5wzw00009643
Minimum front disc pad thickness
2.0 mm {0.079 in}
• Replace the pads as a set (right and left wheels) if either one is at or less than the minimum
thickness.(SeeFRONT BRAKE DISC REMOVAL/INSTALLATION [WITH SINGLE PISTON
FLOATING CALIPER].) (SeeFRONT BRAKE DISC REMOVAL/INSTALLATION [WITH 2-PISTON
FLOATING CALIPER].)

■ FRONT BRAKE HOSE REMOVAL/INSTALLATION [WITH SINGLE PISTON
FLOATING CALIPER]
id0411000006w4
id0411000006w4
Replacement Part
Gasket
Quantity: 2
Location of use: Front brake hose
Brake fluid type
Caution
Note
BLEEDING.)

ac5uuw00007461
1 Brake pipe
Clip
2
3 Bolt
4 Brake hose

ac5uuw00007462

■ FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH SINGLE PISTON
FLOATING CALIPER]
id0411000001w4
id0411000001w4
ac5uuw00007449

1 Bolt
Front brake caliper component

(See Front Brake Caliper Component Removal Note.)
2
(See Front Brake Caliper Component Installation Note.)
3 Disc plate
Front Brake Caliper Component Removal Note
1.Remove the front brake caliper component and suspend it in a place out of the way using a cable.
ac5uuw00007450
Front Brake Caliper Component Installation Note

ac5uuw00007451
2.Install the front brake caliper component.

■ FRONT BRAKE HOSE REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING
CALIPER]
id0411000006w5
id0411000006w5
Replacement Part
Gasket
Quantity: 2
Brake fluid type
Caution
Note
BLEEDING.)

ac5wzw00009653
1 Brake pipe
Clip
2
3 Bolt
4 Brake hose

ac5uuw00007462

■ FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING
CALIPER]
id0411000001w5
id0411000001w5
ac5wzw00009644

1 Bolt
Front brake caliper component

(See Front Brake Caliper Component Removal Note.)
2
(See Front Brake Caliper Component Installation Note.)
3 Disc plate
Front Brake Caliper Component Removal Note
1.Remove the front brake caliper component and suspend it in a place out of the way using a cable.
ac5wzw00009645
Front Brake Caliper Component Installation Note

ac5wzw00009646

■ FRONT BRAKE DISC PAD REMOVAL/INSTALLATION [WITH SINGLE PISTON
FLOATING CALIPER]
id0411000002w4
id0411000002w4
Brake grease (Brown) Brake grease (Black)
Type: Molykote 7439 Type: AS880N
ac5uuw00007452

1 Bolt
2 Caliper
Disc pad
3
(See Disc Pad, Bolt Installation Note.)
4 Shim
Guide plate
5
(See Guide Plate Installation Note.)
Guide Plate Installation Note
Caution
• When assembling the guide plates to the mounting support, securely assemble them on the leading
side and trailing side to each position shown in the figure. If the guide plates are assembled to the
incorrect positions, it could become a source of noise.
1.Install the guide plate as shown in the figure.
ac5uuw00007453
Disc Pad, Bolt Installation Note

ac5uuw00007454
3.Install the disc pads to the mounting support.
4.Return the caliper to the original position and install the bolt.

■ FRONT BRAKE DISC PAD REMOVAL/INSTALLATION [WITH 2-PISTON
FLOATING CALIPER]
id0411000002w5
id0411000002w5
Brake grease (Black)
Type: Daikalub grease

ac5wzw00009647
1 Bolt
2 Caliper
Disc pad
3
(See Disc Pad, Bolt Installation Note.)
4 Shim
5 Guide plate
Disc Pad, Bolt Installation Note

ac5wzw00009648
3.Install the disc pads to the mounting support.
4.Return the caliper to the original position and install the bolt.

■ FRONT BRAKE CALIPER REMOVAL/INSTALLATION [WITH SINGLE PISTON
FLOATING CALIPER]
id0411000003w4
id0411000003w4
Replacement Part
Gasket
Quantity: 2
Brake fluid type
Caution
BLEEDING.)

ac5uuw00007455
1 Bolt
2 Brake hose
3 Bolt
Front brake caliper

4
(See Front Brake Caliper Installation Note.)
Front Brake Caliper Installation Note

ac5uuw00007456

■ FRONT BRAKE CALIPER DISASSEMBLY/ASSEMBLY [WITH SINGLE PISTON
FLOATING CALIPER]
id0411000004w4
id0411000004w4
Replacement Part
Type: SAE J1703 or FMVSS116 DOT-3 Type: Oil mixed with rubber grease 3611560 and CCI#20
Caution

ac5uuw00007457
1 Bleeder cap
2 Bleeder screw
Piston
3
4 Dust seal
5 Piston seal
6 Caliper body
Warning
Caution

remove the piston from the caliper body.
ac5wzw00000202

■ FRONT BRAKE CALIPER REMOVAL/INSTALLATION [WITH 2-PISTON
FLOATING CALIPER]
id0411000003w5
id0411000003w5
Replacement Part
Gasket
Quantity: 2
Brake fluid type
Caution
BLEEDING.)

ac5wzw00009649
1 Bolt
2 Brake hose
3 Bolt
Front brake caliper

4
(See Front Brake Caliper Installation Note.)
Front Brake Caliper Installation Note

ac5wzw00009650

■ FRONT BRAKE CALIPER DISASSEMBLY/ASSEMBLY [WITH 2-PISTON
FLOATING CALIPER]
id0411000004w5
id0411000004w5
Caution
Replacement Part
Type: SAE J1703 or FMVSS116 DOT-3 Type: Cosmo rubber grease
1.Disassemble in the order indicated in the table.

ac5wzw00009651
1 Bleeder cap
2 Bleeder screw
Piston
3
4 Dust seal
5 Piston seal
6 Caliper body
2.Assemble in the reverse order of removal.
Warning
Caution

remove the pistons from the caliper body.
ac9uuw00008899

■ BRAKE PEDAL REMOVAL/INSTALLATION
id041100801200
id041100801200
Replacement Part
Brake switch
Quantity: 1
Location of use: Brake pedal
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.

2.2].)
(1)Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE
4.Disconnect the clutch reserve hose from the master cylinder. (MTX) (See MASTER CYLINDER
5.Disconnect the brake pipe from the master cylinder. (See MASTER CYLINDER

BLEEDING.)
ac5uuw00007486

1 Brake switch connector
2 Brake switch wiring harness
Brake switch
3
(See Brake Switch Installation Note.)
Snap pin
4
(See Snap Pin Installation Note.)
5 Clevis pin
Nut
6
(See Nut Installation Note.)
Brake pedal
7
(See Brake Pedal Removal Note.)
8 Pedal pad
Brake Pedal Removal Note
1.Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with
the brake pedal arm.
2.Move the brake pedal in the direction of the arrow shown in the figure, and remove it while avoiding the
hook.

ac5uuw00007487
Nut Installation Note
1.Temporarily tighten nuts A.
ac5uuw00007488
2.Temporarily tighten nuts B.
3.Tighten nuts B to the specified torque.
Tightening torque
19—25 Nm {2.0—2.5 kgf·m, 15—18 ft·lbf}
4.Tighten nuts A to the specified torque.
Tightening torque

19—25 Nm {2.0—2.5 kgf·m, 15—18 ft·lbf}
Snap Pin Installation Note
1.Install the snap pin as shown in the figure.
ac5uuw00007489
Brake Switch Installation Note
1.Inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)
2.With the brake pedal fully released, insert a new 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°.

ac5uuw00007490

■ BRAKE SWITCH INSPECTION
id041100801900
id041100801900
Caution
• Inspect the brake switch with it installed to the brake pedal, otherwise the brake switch may not
operate normally. If the brake switch is removed from the brake pedal, replace the brake switch with a
new one.
1.Remove the lower panel. (See LOWER PANEL REMOVAL/INSTALLATION.)
2.Remove the front heat duct (LH). (See FRONT HEAT DUCT REMOVAL/INSTALLATION.)
3.Disconnect the brake switch connector.
4.Verify that the continuity is as indicated in the table.
am3uuw00006691
• If not as indicated in the table, replace the brake switch. (SeeBRAKE PEDAL
am3zzw00010316

■ BRAKE PEDAL INSPECTION
id041100801100
id041100801100
Pedal Height Inspection
1.Measure the distance from the center of the upper surface of the pedal pad to the floor covering and
verify that it is as specified.
ac5uuw00007484
Brake pedal height (reference value)
137 mm {5.39 in}
• If not within the specification, inspect the following items and repair or replace the applicable part if
there is any malfunction.
― Power brake unit installation condition
― Deformation of or damage to the power brake unit fork
― Brake pedal installation condition
― Clevis pin wear
• If there is no malfunction in the above items, replace the brake pedal. (SeeBRAKE PEDAL
Pedal Play Inspection
1.Pump the pedal several times to release the vacuum in the power brake unit.
2.Gently depress the pedal by hand and measure the pedal play.

Brake pedal play
4.8 mm {0.19 in} or less
• If not within the specification, inspect the wear of the clevis pin. Replace it if there is any
malfunction. (SeeBRAKE PEDAL REMOVAL/INSTALLATION.)
• If there is no malfunction in the clevis pin, there is a possibility that the power brake unit has some
malfunction. Verify that there are no malfunctions, and replace it if necessary. (SeePOWER BRAKE
UNIT INSPECTION.) (SeePOWER BRAKE UNIT REMOVAL/INSTALLATION.)
Pedal-to-floor Clearance Inspection
1.Start the engine and depress the brake pedal with a force of 147 N {15.0 kgf, 33.0 lbf}.
2.Measure the distance from the center of the upper surface of the pedal pad to the floor covering and
verify that it is as specified.
ac5uuw00007485
Brake pedal-to-floor clearance
86 mm {3.4 in} or more
• If it is less than the specification, inspect for air in the brake line. (SeeBRAKE FLUID AIR
BLEEDING.)

■ BRAKE FLUID LEVEL SENSOR INSPECTION
id041100801400
id041100801400
1.Disconnect the brake fluid level sensor connector. (See MASTER CYLINDER
2.Verify that the continuity is as indicated in the table.
ac5wzw00000247
• If not as indicated in the table, replace the master cylinder component. (SeeMASTER CYLINDER
ac5uuw00007365

■ BRAKE FLUID INSPECTION
id041100815200
id041100815200
Brake fluid type
Caution
1.Verify that the brake fluid level in the brake fluid reserve tank is between the MAX and MIN marks.

ac5uuw00008274
• If the brake fluid level is below the MIN mark, add brake fluid.
Brake fluid type

SAE J1703 or FMVSS116 DOT-3

■ BRAKE FLUID AIR BLEEDING
id041100815300
id041100815300
Brake fluid type
Caution
Note
• Keep the fluid level in the brake fluid reserve tank at 3/4 full or more during the air bleeding.
• Begin air bleeding with the brake caliper that is furthest from the master cylinder.
Brake fluid type

SAE J1703 or FMVSS116 DOT-3
1.Switch the ignition ON (engine off).
2.Release the electric parking brake.
4.Remove the cap from the brake fluid reserved tank and add brake fluid.
5.Remove the bleeder cap on the brake caliper, and attach a vinyl tube to the bleeder screw.
6.Place the other end of the vinyl tube in a clear container and fill the container with fluid during air
bleeding.
7.Working with two people, one should pump the brake pedal several times and depress and hold the
pedal down.

ac4ccw00001649
8.While the brake pedal is depressed, the other should loosen the bleeder screw using a commercially
available flare nut wrench, drain out any fluid containing air bubbles, and tighten the bleeder screw.
ac4ccw00001650
Tightening torque
Front (With single piston floating caliper) : 6.9—9.8 N·m {71—99 kgf·cm, 62—86
in·lbf}Front (With 2-piston floating caliper) : 9—12 N·m {92—122 kgf·cm, 80—
106 in·lbf}Rear: 6.9—9.8 N·m {71—99 kgf·cm, 62—86 in·lbf}
9.Repeat Steps 7 and 8 until no air bubbles are seen.
10.Perform air bleeding as described in the above procedures for all brake calipers.
Note
• If the air bleed from the left/right rear calipers is insufficient, air bleeding can implemented quickly by
operating/releasing the electric parking brake several times while performing the work in Steps 7 and
8.
11.Clean the brake calipers.
12.After air bleeding, inspect the following:
• Brake operation
• Fluid leakage

• Fluid level

Conventional Brake System Location Index: Ac5uuw00008268

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Conventional Brake System Location Index: Ac5uuw00008268

Uploaded by

Copyright:

Available Formats

■ CONVENTIONAL BRAKE SYSTEM LOCATION INDEX

Vehicle Front Side

© 2018 Mazda Motor Corporation.

(See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

Power brake unit

© 2018 Mazda Motor Corporation.

(See FRONT BRAKE MOUNTING SUPPORT REMOVAL/INSTALLATION [WITH 2-PISTON FLOATING

Front brake hose

(See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

Vehicle Rear Side

© 2018 Mazda Motor Corporation.

Rear brake hose

(See REAR BRAKE MOUNTING SUPPORT REMOVAL/INSTALLATION.)

© 2018 Mazda Motor Corporation.

Location of use: Vacuum pump

1.Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL

• Air cleaner cover

• Air cleaner element

• Air cleaner case

5.Disconnect the clip from the bracket.

© 2018 Mazda Motor Corporation.

6.Remove the bolts

9.Remove in the order indicated in the table.

10.Install in the reverse order of removal.

© 2018 Mazda Motor Corporation.

Vacuum Pump Removal Note

2.Remove the vacuum pump.

Vacuum Pump and O-ring Installation Note

© 2018 Mazda Motor Corporation.

2.Degrease the O-ring installation groove and installation surface.

3.Install the new O-ring to the vacuum pump.

4.Install the vacuum pump.

© 2018 Mazda Motor Corporation.

SKYACTIV-G 2.0, SKYACTIV-G 2.5

2.Install the vacuum gauge.

3.Warm up the engine.

4.Switch the ignition off.

6.Switch the ignition ON (engine on).

© 2018 Mazda Motor Corporation.

Measurement condition Specification

(2)Verify that the measured time matches the standard.

• If they do not match, repair or replace the following malfunctioning locations.

― Vacuum pump malfunction

― Engine oil pressure decrease

• If they match, go to the next step.

(1)Read the vacuum on the vacuum gauge.

Degree of maximum attained vacuum in vacuum pump standard (reference)

Measurement condition Specification

(2)Verify that the measured vacuum matches the standard.

• If they do not match, repair or replace the following malfunctioning locations.

― Vacuum pump malfunction

© 2018 Mazda Motor Corporation.

3.Install the vacuum gauge.

4.Warm up the engine.

5.Switch the ignition off.

7.Switch the ignition ON (engine on).

Degree of vacuum in vacuum pump maximum (reference)

© 2018 Mazda Motor Corporation.

(2)Verify if the measured time is the maximum value or less.

― Vacuum pump malfunction

― Engine oil pressure decrease

© 2018 Mazda Motor Corporation.

Between intake manifold and vacuum pump