Mazda CX 7. Manual - part 208

CONVENTIONAL BRAKE SYSTEM 

04-11–3

04-11

AIR BLEEDING

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Caution

• Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is 

spilled, wipe it off immediately.

Note

• Keep the fluid level in the 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, FMVSS 116 DOT-3

1. Remove the bleeder cap on the brake caliper, and attach a vinyl tube to the bleeder screw.
2. Place the other end of the vinyl tube in a clear container and fill the container with fluid during air bleeding.
3. Working with two people, one should pump the brake pedal several times and depress and hold the pedal 

down.

4. While the brake pedal is depressed, the other 

should loosen the bleeder screw using the SST, 
drain out any fluid containing air bubbles, and 
tighten the bleeder screw.

Tightening torque

Front: 5.9— 9.8 N·m {61— 99 kgf·cm, 53— 86 

in·lbf}

Rear: 6.9— 9.8 N·m {71— 99 kgf·cm, 61— 86 

in·lbf}

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

seen.

6. Perform air bleeding as described in the above 

procedures for all brake calipers.

7. After air bleeding, inspect the following:

• Brake operation

• Fluid leakage

• Fluid level

End Of Sie

WM: VACUUM LINE

VACUUM LINE INSPECTION

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1. Remove the vacuum hose. (See 04-11-4 VACUUM HOSE REMOVAL/INSTALLATION.)
2. Verify that air can be blown from the power brake 

unit side of the vacuum hose towards the engine 
side, and that air cannot be blown in the opposite 
direction.

• If there is any malfunction of the inner check 

valve, replace it together with the vacuum 
hose as a single unit.

End Of Sie

49 0259 770B

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CHECK VALVE

TO INTAKE MANIFOLD

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CONVENTIONAL BRAKE SYSTEM 

04-11–4

VACUUM HOSE REMOVAL/INSTALLATION

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1. Remove the clamps and vacuum hose (power brake unit side).
2. Insert a thin flathead screwdriver at the point 

indicated by the arrow in the figure, push the ring 
down and disconnect the vacuum hose from the 
intake manifold.

3. Remove the vacuum hose.
4. Install in the reverse order of removal.

5. Verify that the vacuum hose is inserted so that the 

joint contacts the intake manifold ring.

End Of Sie

WM: BRAKE PEDAL

BRAKE PEDAL INSPECTION

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Pedal Height Inspection

1. Measure the distance from the center of the 

upper surface of the pedal pad to the insulator 
and verify that it is as specified.

• 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.

Brake pedal height (reference value)

204.3 mm {8.043 in}

JOINT

RING

INTAKE MANIFOLD

POWER BRAKE UNIT

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JOINT

RING

INTAKE MANIFOLD

POWER BRAKE UNIT

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PEDAL HEIGHT

INSULATOR

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CONVENTIONAL BRAKE SYSTEM 

04-11–5

04-11

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.

• If not within the specification, inspect the wear of the clevis pin. Replace it if there is any malfunction.

Brake pedal play

2— 5 mm {0.08— 0.19 in}

Note

• 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.

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.

• If it is less than the specification, inspect for 

air in the brake line.

Brake pedal-to-floor clearance (Brake pedal 

when depressed at 147 N {15.0 kgf, 33.0 
lbf})

99.1 mm {3.91 in} or more

End Of Sie

PEDAL-TO-FLOOR
CLEARANCE

FLOOR
COVERING

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CONVENTIONAL BRAKE SYSTEM 

04-11–6

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 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.

1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
2. Remove the battery tray bracket as shown in the 

figure.

3. Disconnect the brake fluid level sensor connector.
4. Remove the master cylinder reserve tank bracket 

installation nuts. (See 04-11-10 MASTER 
CYLINDER REMOVAL/INSTALLATION.)

5. Remove the accelerator pedal. (See 01-13-17 

ACCELERATOR PEDAL REMOVAL/
INSTALLATION[L3 WITH TC].)

6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.

.

BATTERY TRAY BRACKET

18—26 N·m 
{1.9—2.6 kgf·m,
 14—19 ft·lbf}

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5

B

B

7

7

2

1

3

9

6

8

A

A

C

C

4

18.6—25.5 
{1.90—2.60,
13.8—18.8}

18.6—25.5 
{1.90—2.60,
13.8—18.8}

R

N·m {kgf·m, ft·lbf}

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1

Brake switch connector
(See 04-11-8 Brake Switch Connector Installation 
Note.)

2

Brake switch
(See 04-11-8 Brake Switch Installation Note.)

3

Interlock cable
(See 05-18-2 INTERLOCK CABLE ADJUSTMENT.)

4

Noise filter

5

Snap pin 

6

Clevis pin

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