Mazda 3 Service Manual: Power Brake Unit Removal/Installation [Mzr 2.3 Disi Turbo]

Mazda 3 Service Manual / Brakes / General / Power Brake Unit Removal/Installation [Mzr 2.3 Disi Turbo]

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.
Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

1. Remove the battery and battery tray..

2. Remove the master cylinder..

3. Loosen the brake pipe flare nuts as shown in the figure.

4. Move the brake pipes as shown in the figure.

5. Disconnect the steering shaft from the steering gear and linkage..

6. Remove in the order indicated in the table.

7. Remove the brake switch..

8. Install in the reverse order of removal.

9. After installation, inspect the brake pedal..

1	Vacuum hose
2	Joint pin (See BRAKE PEDAL REMOVAL/INSTALLATION.)
3	Nut
4	Power brake unit
5	Gasket

Power Brake Unit Removal/Installation [Mzr 2.0, Skyactiv G 2.0, Mzr 2.5]

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 ...

Vacuum Hose Removal/Installation [Mzr 2.0, Mzr 2.5]

1. Remove the battery and battery tray.. 2. Remove the vacuum hose from the vacuum hose clip. 3. Insert a thin flathead screwdriver at the point indicated by the arrow in the figure, push th ...

Other materials:

Throttle Position (TP) Sensor Inspection [Mzr 2.0, Mzr 2.5]
Voltage Inspection CAUTION: The inspection cannot be performed with this method correctly if there is a malfunction of the APP sensor or throttle valve actuator. Verify that no DTCs related to the APP sensor or throttle valve actuator are stored before the inspection. NOTE: ...

Vacuum Pump Removal/Installation [Skyactiv G 2.0]
1. Remove the plug hole plate.. 2. Remove the battery and battery tray.. 3. Pinch open the clamp using pliers and disconnect the vacuum hose from the vacuum pump. 4. Remove in the order shown in the table. 5. Install in the reverse order of removal. 1 Vacu ...

Variable Swirl Shutter Valve Actuator Inspection [Mzr 2.3 Disi Turbo]
Operation Inspection 1. Remove the air hose.. 2. Disconnect the vacuum hose from the variable swirl control solenoid valve. 3. Connect a vacuum pump to the variable swirl shutter valve actuator. 4. Apply vacuum and verify that the rod moves. Vacuum kPa {mmHg, inHg ...