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Power Brake Unit Removal/Installation: Notes

WARNING: This page is about a different car, the 2017 Mazda CX-9. However, it is still accessible from the selected car via links, so may be relevant.
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.
  • 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.
  1. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  2. Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T] .)
    • Air hose
    • Air cleaner cover
    • Air cleaner element
    • Fresh-air duct
    • Air cleaner case
    • Air inlet pipe
  3. Remove the following parts:
    1. Battery and battery tray (See BATTERY REMOVAL/INSTALLATION .)
    2. Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION .)
    3. Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION .)
    4. Windshield wiper motor and link (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION .)
    5. Keyless beeper (With advanced keyless entry system) (See KEYLESS BEEPER REMOVAL/INSTALLATION .)
    6. Cowl panel (See COWL PANEL REMOVAL/INSTALLATION .)
    7. Master cylinder (See MASTER CYLINDER REMOVAL/INSTALLATION .)
    8. Front under cover No. 2 (See FRONT UNDER COVER No. 2 REMOVAL/INSTALLATION .)
  4. Remove the nuts.
    Fig 1: Removing Insulator Nuts
    G11433074Courtesy of MAZDA MOTORS CORP.
  5. Remove the insulator.
    Fig 2: Removing Insulator
    G11433075Courtesy of MAZDA MOTORS CORP.
  6. Remove the nuts.
  7. Set the heater pipe and hose component out of the way as shown in the figure.
    Fig 3: Moving Heater Pipe And Hose Component
    G11433076Courtesy of MAZDA MOTORS CORP.
    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.
  8. Detach the brake pipes from the pipe holder.
    Fig 4: Detaching Brake Pipes From Pipe Holder
    G11433077Courtesy of MAZDA MOTORS CORP.
  9. Remove in the order indicated in the table.
  10. Install in the reverse order of removal.
  11. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See BRAKE FLUID AIR BLEEDING .)
  12. Remove the brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION .)
  13. Inspect the brake pedal. (See BRAKE PEDAL INSPECTION .)
  14. Install a new brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION .)
Fig 5: Locating Power Brake Unit Components
G11433078Courtesy of MAZDA MOTORS CORP.
COMPONENT DESCRIPTION

1 Vacuum hose
(See VACUUM HOSE REMOVAL/INSTALLATION .)
2 Snap pin
3 Clevis pin
4 Nut
5 Power brake unit
6 Gasket
7 Fork
(See Fork Installation Note .)
8 Nut
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