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Electronically Controlled Brake Unit Removal/Installation [L.H.D.]: Notes

Replacement Part 

Brake switch
Quantity: 1
Location of use: Brake pedal

Oil and Chemical Type 

Brake fluid type
Type: Mazda Genuine Brake Fluid or equivalent
WARNING:
  • If the initialization of the sensors for the electronically controlled brake unit related parts is not completed, the electronically controlled brake unit will not operate normally which could lead to an unexpected accident. Therefore, if the electronically controlled brake unit is replaced and removed/installed, always perform the initialization of the sensors for the electronically controlled brake unit related parts so that the electronically controlled brake unit will operate normally.
  • Always end maintenance mode after performing the servicing in maintenance mode. Otherwise, driving the vehicle without ending maintenance mode could result in an accident.
CAUTION:
  • When replacing the electronically controlled brake unit, perform the configuration to assure that the system operates correctly. (See CONFIGURATION .)
  • Do not empty the brake fluid in the following brake related parts. Otherwise, the electronically controlled brake unit could be damaged.
    • Electronically controlled brake unit
    • Brake fluid reserve tank
    • Rear brake caliper
  • The internal parts of the electronically controlled brake unit could be damaged if dropped. Be careful not to drop the electronically controlled brake unit. Replace the electronically controlled brake unit if it is subjected to an impact.
  • 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.
  • 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 electronically controlled brake unit or performing any procedure that changes the brake pedal stroke.
  • When disconnecting the brake pipe from the electronically controlled brake unit, always plug and seal the electronically controlled brake unit so that brake fluid does not leak.
  • A new electronically controlled brake unit has been plugged sealing off brake fluid. For this reason, remove the plug of the electronically controlled brake unit directly before installing it to the vehicle. Other than this, do not remove the plug of the electronically controlled brake unit.
NOTE:
  • After replacing the electronically controlled brake unit and performing an operation/release of the electric parking brake, the electronically controlled brake unit performs a check of the related parts, and records the operation/release condition of the electric parking brake.
  • Tighten the brake pipe flare nut using any commercially available flare nut wrench.
  • When switching to maintenance mode, the electronically controlled brake unit and the electric parking brake functions are canceled.
  • When switching to maintenance mode, the clearance between the rear disc pad and the rear disc plate widens.
  • When the maintenance mode is ended, the electric parking brake motor gear unit operating time is longer than normal due to the automatic adjustment of the electric parking brake.
  • Bleed the air inside the brake fluid reserve tank when the fluid inside the brake fluid reserve tank is empty.
  1. To replace the electronically controlled brake unit, perform the following procedure.
    1. Connect the M-MDS to the DLC-2.
    2. Switch the ignition ON (engine off).
    3. Activate the M-MDS and perform the following procedure.
      1. Press [Start] to start the vehicle identification.
      2. Press the [Toolbox] tab.
      3. Press the [Work Support] icon.
      4. Press [Configuration].
      5. Press [Run] to perform the configuration.
      6. Press [DSC].
      7. When [Install the new ECU] is displayed, move to the electronically controlled brake unit replacement procedure.
  2. Disconnect the negative battery terminal.
  3. For VIN 7, remove the plug hole plate.
  4. For VIN 7/VIN L, perform the following procedure:
    1. Remove the engine cover.
    2. Remove the left wall (rear) and rear wall.
  5. Remove the battery.
  6. Remove the battery tray and PCM component.
  7. Set the PCM wiring harness out of the way.
  8. Remove the brake fluid reserve tank (sub) from the cowl panel.
    Fig 1: Brake Fluid Reserve Tank (Sub) Bolts With Torque Specification
    G14580999Courtesy of MAZDA MOTORS CORP.
  9. 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
  10. Remove the fuel hose holder from the body.
    G14581000Courtesy of MAZDA MOTORS CORP.
  11. Remove the insulator.
    Fig 2: Insulator Nuts With Torque Specification
    G14581001Courtesy of MAZDA MOTORS CORP.
  12. Disconnect the connectors and clips. (See Connector Removal Note .) (See Connector Installation Note .)
    G14581002Courtesy of MAZDA MOTORS CORP.
  13. Remove in the order indicated in the table.
  14. Install in the reverse order of removal.
  15. Remove the brake switch.
  16. Inspect the brake pedal.
  17. Install a new brake switch.
  18. If the electronically controlled brake unit is replaced, perform the following procedure.
    1. Return to the M-MDS operation and press [Continue].
    2. When the M-MDS processing is completed, press [Next].
    3. When the M-MDS processing is completed, press [Next].
    4. Verify that the following conditions/operations are met/completed, mark the check boxes, and then press [Next].
      • Ignition is switched ON (engine off)
      • Install battery charger to vehicle
      • Battery voltage: 11.6 V or more
      • Connect power cable to M-MDS
      • Front doors on both sides and trunk lid (4SD) or liftgate (5HB) are open
    5. Press [Finish].
    6. Switch the ignition OFF.
    7. Switch the ignition ON (engine off) to complete global central configuration (GCC) for the electronically controlled brake unit.
    8. Clear the DTC. (See CLEARING DTC .)
    9. Perform the sensor initialization for the DSC-related parts.
    10. Operate the electric parking brake switch using the following procedure to verify the operation of the electric parking brake and perform the automatic adjustment.
      1. Switch the ignition ON (engine off).
      2. Operate the electric parking brake.
        • If the electric parking brake cannot be operated, release it once and then try to re-operate it.
          • If the electric parking brake cannot be operated/released, perform a DTC inspection as a malfunction of the electric parking brake may have occurred. (See DTC INSPECTION .)
      3. Verify that the electric parking brake indicator light turns on and the brake control system warning light turns off.1 
        G14581003Courtesy of MAZDA MOTORS CORP.
        • If the electric parking brake indicator light does not turn on, the electric parking brake indicator light flashes, or the brake control system warning light does not turn off, perform a DTC inspection as a malfunction of the electric parking brake may have occurred. (See DTC INSPECTION .)
      4. Release the electric parking brake.
      5. Verify that the electric parking brake indicator light and the brake control system warning light turn off.
        • If the electric parking brake indicator light and the brake control system warning light do not turn off, perform a DTC inspection as a malfunction of the electric parking brake may have occurred. (See DTC INSPECTION .)
      6. Operate the electric parking brake.
    11. Clear the DTC. (See CLEARING DTC .)
    12. Verify that the following warning/indicator lights turn off.
      • Brake system warning light
      • ABS warning light
      • TCS/DSC indicator light
      • DSC OFF indicator light
      • Brake control system warning light
      G14580988Courtesy of MAZDA MOTORS CORP.
      • If the warning/indicator lights do not turn off, perform a DTC inspection. (See DTC INSPECTION .)
  19. Switch to the maintenance mode.
  20. Add brake fluid, bleed the air, and inspect for fluid leakage.
  21. End the maintenance mode.
  22. If the electronically controlled brake unit is replaced, perform the following procedure.
    1. Connect the M-MDS to the DLC-2.
    2. Switch the main power ON (READY off).
    3. Activate the M-MDS and perform the following procedure.
      1. Press [Start] to start the vehicle identification.
      2. Press the [Toolbox] tab.
      3. Press the [Work Support] icon.
      4. Press [BRAKES].
      5. Press [Self-Diagnosing Brake Line].
    4. Clear the DTC. (See CLEARING DTC .)
Fig 3: Electronically Controlled Brake Unit Components With Torque Specification
G14581005Courtesy of MAZDA MOTORS CORP.
PART DESCRIPTION

Component No. Refer to
1 Clutch reserve hose (MTX)
(See Clutch Reserve Hose Removal Note (MTX) ).)
(See Clutch Reserve Hose Installation Note (MTX) ).)
2 Brake pipe
(See Brake Pipe Removal Note .)
(See Brake Pipe Installation Note .)
3 Snap pin
4 Clevis pin
5 Nut
6 Electronically controlled brake unit component
(See Electronically Controlled Brake Unit Component Installation Note .)
7 Gasket
8 Bolt
9 Bracket
10 Reserve hose
(See Reserve Hose Installation Note .)
11 Cap
12 Reserve tank (sub)
13 Electronically controlled brake unit
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