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Mazda 6. Manual - part 237

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GENERAL PROCEDURES, CONVENTIONAL BRAKE SYSTEM

PRECAUTION (BRAKES)

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Wheels and Tires Removal/Installation

1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a

wheel is removed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}.

Brake Lines Disconnection/Connection

Caution

• Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off

immediately.

1. Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut

tightening torque to allow for use of a torque wrench-SST combination.

• If any brake line has been disconnected anytime during the procedure, add brake fluid, bleed the brakes,

and inspect for leakage after the procedure has been completed.

Connectors Disconnection

1. Disconnect the negative battery cable before doing any work that requires handling of connectors. Reconnect

the negative battery cable only after the work is completed.

ABS, ABS/TCS, or DSC Components Operations

1. Make sure that there are no DTCs in the ABS, ABS/TCS, or DSC memory after working on ABS, ABS/TCS or

DSC components.

• If there are any DTCs in the memory, clear them.

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AIR BLEEDING

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Caution

• Maintain the fluid level in the reservoir tank properly while bleeding the air.

Specified fluid

Note

• The brakes should be bled whenever a brake line is disconnected. If a hydraulic line is disconnected at

the master cylinder, start at the slave cylinder farthest from the brake master cylinder, and move to the
next farthest slave cylinder until all four cylinders have been bled. If the disconnection point is anywhere
except the master cylinder, start at the point closest to the disconnection, and move to the next closest
slave cylinder until all four cylinders have been bled.

1. Remove the bleeder cap and attach a vinyl tube to the bleeder screw.
2. Place the other end of the vinyl tube in a clear, fluid-filled container.
3. One person should depress the brake pedal a few times, and then hold it in the depressed position.

GENERAL PROCEDURES

CONVENTIONAL BRAKE SYSTEM

European
(L.H.D. U.K.)
specs.

SAE J1703, FMVSS 116 DOT3 OR DOT4

GCC specs.

SAE J1703, FMVSS 116 DOT3

CONVENTIONAL BRAKE SYSTEM

P–7

4. A second person should loosen the bleeder

screw, drain out the fluid and close the screw

using the SST.

Tightening torque

Front:6.9—9.8 N·m

{71—99 kgf·cm, 62—86 in·lbf}

Rear:5.9—8.8 N·m

{61—89 mgf·cm, 53—77 in·lbf}

5. Repeat steps 3 and 4 until no air bubbles are

seen.

6. Bleed air from each component by following the

procedure above.

7. After air bleeding, check the following:

• Brake operation

• fluid leakage

• fluid level

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VACUUM HOSE CHECK VALVE INSPECTION (POWER BRAKE UNIT)

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1. Remove the clamps and vacuum hose (power brake unit side).
2. For engine side, insert a small flathead

screwdriver in the direction of the arrow shown in
the figure, push the ring down and remove the
vacuum hose.

3. Apply both suction and pressure to the engine-

side hose, and verify that air blows only toward
that side.

• If air flows in both directions or not at all,

replace the vacuum hose.

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BRAKE PEDAL INSPECTION

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Brake Pedal Height Inspection

1. Verify that the distance from the carpet to the center of the upper surface of the pedal pad is as specified.

Pedal height (reference value)

Brake Pedal Height Adjustment

Caution

• The brake switch may not operate normally after adjusting the pedal height. Whenever adjusting

the pedal height, replace the brake switch with a new one.

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JOINT

RING

INTAKE MANIFOLD

POWER BRAKE UNIT

TO ENGINE

CHECK VALVE

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R.H.D.

172 mm {6.77 in}

L.H.D.

187 mm {7.36 in}

P–8

CONVENTIONAL BRAKE SYSTEM

1. Loosen locknut B and turn the bolt A until it does

not contact the pedal.

2. Loosen locknut D and turn rod C to adjust the

height.

3. Tighten the bolt with locknut B .

Tightening torque

9.8—14.7 N·m

{100—149 kgf·cm, 116—130 in·lbf}

4. After adjustment, inspect the pedal play and the

brake light operation.

Brake Pedal Play Inspection

1. Depress the pedal a few times to eliminate the vacuum in the system.
2. Remove the spring pin, verify that the holes in the fork and in the pedal are aligned, and reinstall the pin. (See

P–9 BRAKE PEDAL REMOVAL/INSTALLATION

3. Gently depress the pedal by hand until resistance is felt, and check the pedal play.

Pedal play

0—3 mm {0—0.1 in}

Brake Pedal Play Adjustment

1. Remove the spring pin and clevis pin. (See

P–9 BRAKE PEDAL REMOVAL/INSTALLATION

2. Loosen locknut D and turn rod C to align the

holes in the fork and in the pedal.

3. Install the clevis pin and the spring pin.
4. Tighten locknut D.

Tightening torque

15.7—21.6 N·m

{1.61—2.20 kgf·m, 11.6—15.9 ft·lbf}

5. Check the pedal height and the brake light

operation.

Pedal-to-floor Clearance Inspection

1. Start the engine and depress the brake pedal with

a force of 588 N {60 kgf, 132 lbf}

2. Verify that the distance from the floor panel to the

pedal pad center is as specified when the pedal is
depressed.

• If the distance is less than specified, check for

the air in brake system.

Specification

68 mm {2.7 in} min.

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BRAKE SWITCH INSPECTION

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1. Disconnect the negative battery cable.
2. Disconnect the brake switch connector harness.

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CONVENTIONAL BRAKE SYSTEM

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3. Inspect for continuity between the brake switch connector terminals.

• If not as specified, replace the brake switch.

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BRAKE PEDAL REMOVAL/INSTALLATION

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Caution

• The clearance between the brake switch and the brake pedal is automatically adjusted to the

correct amount when the brake switch connector is connected after the brake switch has been
properly installed. If the brake switch is not properly installed or the connector is connected
before installation, the clearance may be incorrect, causing a brake light malfunction. Therefore,
always verify that the brake switch is properly installed before connecting the connector.

• 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. For ATX model, remove the lock unit with brake switch (R.H.D. only).
2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

Brake switch Installation Note

1. Fix the brake switch on a bracket with pressing down at 50 N {5.1 kgf·m, 37 ft·lbf}.
2. Rotate the brake switch 45

° counterclockwise.

3. Verify that the brake switch is locked securely.

Brake Switch Connector Installation Note

1. Inspect the brake pedal. (See

P–7 BRAKE PEDAL INSPECTION

2. With the brake pedal in its original position, install the brake switch to the brake switch connector.

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