Front exciter ring installation

1. Component views

Front exciter ring (2WD (Except high ride suspension specifications))

Part name

  1. Bolt
  2. Hub flange and unit bearing
  3. Brake disc
  4. Dust cover
  5. Knuckle
  6. Wheel pin

2. Exciter ring installation

Caution

  • If the exciter ring is defective, replace the unit bearing as an assembly.

As the exciter ring is integrated with the unit bearing, it cannot be replaced separately.

3. Front hub reassembly

1. 2WD (Except high ride suspension specifications)

1) Place the front hub on a wooden working table or approx. 15 x 15 mm {6 x 6 in} wooden block.

To protect the wheel pin end and threads

2) Install the wheel pin to the front hub using a hammer.

3) Secure the brake rotor using a vise and protective pad.

4) Install the front hub to the brake rotor.

Tightening torque: 93 to 113 N・m { 9.5 to 11.5 kgf・m / 69 to 83 lb・ft }

Note

  • When reusing the front hub and brake rotor, install them according to the alignment marks that were made before disassembling.

Note

  • When replacing the front hub or brake rotor with a new one, install it according to the markings as shown in the diagram.
  • Install so that the markings are as close to each other as possible.

Legend

  1. Brake rotor side marking
  2. Front hub side marking

2. 2WD (High ride suspension specifications)

1) Place the front hub on a wooden working table or approx. 15 x 15 mm {6 x 6 in} wooden block.

To protect the wheel pin end and threads

2) Install the wheel pin to the front hub using a hammer.

3) Install the front hub to the brake rotor.

Legend

  1. Screw bolt

3. 4WD

1) Place the front hub on a wooden working table or approx. 15 x 15 mm {6 x 6 in} wooden block.

To protect the wheel pin end and threads

2) Install the front hub to the brake rotor.

Legend

  1. Screw bolt

4. Front hub installation

1. 2WD (Except high ride suspension specifications)

1) Install the knuckle cap to the knuckle.

2) Install the front hub and brake rotor to the knuckle.

3) Install the bolt to the knuckle.

Tightening torque: 85 N・m { 8.7 kgf・m / 63 lb・ft }

2. 2WD (High ride suspension specifications)

1) Install the knuckle cap to the knuckle.

2) Install the front hub and brake rotor to the knuckle.

3) Install the bolt to the knuckle.

Tightening torque: 85 N・m { 8.7 kgf・m / 63 lb・ft }

3. 4WD

1) Install the front hub and brake rotor to the knuckle.

2) Install the bolt to the knuckle.

Tightening torque: 85 N・m { 8.7 kgf・m / 63 lb・ft }

3) Install the washer and lock nut to the front hub.

Tightening torque: 127 N・m { 13.0 kgf・m / 94 lb・ft }

Legend

  1. Lock nut
  2. Washer

4) Install the cotter pin to the front hub.

Caution

  • If the cotter pin hole position does not align, rotate the lock nut in the tightening direction to align it.

5) Install the hub cap to the front hub.

5. Brake caliper installation

1) Install the brake support to the knuckle.

Tightening torque: 205 to 245 N・m { 20.9 to 25.0 kgf・m / 151 to 181 lb・ft }

2) Install the disc brake pad and shim to the brake support.

3) Install the brake caliper to the brake support.

4) Install the lock bolt to the brake caliper.

Tightening torque: 32 to 42 N・m { 3.3 to 4.3 kgf・m / 24 to 31 lb・ft }

6. Brake hose connect

1) Clean dust or foreign material on the following parts.

  • Bolt
  • Brake side screw

2) Install the following parts to the brake hose, and connect the brake hose to the brake caliper.

  • Bolt
  • Gasket

Caution

  • Insert the brake hose end into the detent hole.
  • Do not reuse the gasket.

Tightening torque: 29 to 39 N・m { 3.0 to 4.0 kgf・m / 21 to 29 lb・ft }

Legend

  1. Gasket

7. Wheel speed sensor installation

1. Preparations for wheel speed sensor installation

1) Clean the following sections.

  • Sensor mounting hole inside and mounting surface of the sensor bracket
  • Sensor bracket mounting surface of the knuckle

Note

  • Clean foreign material, such as rust and sensor fragments.
  • If any rust is found, remove it with a wire brush, etc.

Caution

  • If using rust penetrant when removing the wheel speed sensor, clean the part with a parts cleaner, etc.

2. Precautions for wheel speed sensor installation

Caution

  • When assembling the hub, do not contact and break the wheel speed sensor body and exciter ring.
  • The wheel speed sensor unit contains a magnet so that caution should be taken with metal objects.
  • When removing the hub and rotor, or when removing the hub and drum, the wheel speed sensor must be removed first before starting the procedure.
  • When the knuckle is removed by hammering etc., remove the wheel speed sensor before starting the work.
  • When installing the sensor, use your hand to push the sensor installation flange until it is firmly attached to the installation surface, and then tighten the bolt.
  • When inserting the sensor, do not pry or hammer it with a tool.
  • Do not tighten the sensor body fixing bolts with an air tool, but temporarily hand tighten and then fully tighten them.
  • After tightening the bolts, check that there is no clearance between the mounting flange and the mounting surface again.
  • Install the sensor harness using the twist prevention line as a reference to avoid twisting.
  • Take care not to pull the harness, which may result in it being cut.
  • Confirm that there is no harness interference.
  • Be careful not to damage the wheel speed sensor.

3. Installation (ABS-specification 2WD (Except high ride suspension specifications))

1) Install the wheel speed sensor to the knuckle.

Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in }

2) Install the harness bracket to the upper link and knuckle.

Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in } Harness bracket tightening bolt

Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in } Harness bracket tightening nut

Legend

  1. Connector position
  2. Wheel speed sensor
  3. Harness bracket tightening nut
  4. Harness bracket tightening bolt
  5. Wheel speed sensor tightening bolt

3) Connect the harness connector to the wheel speed sensor.

4) Make sure that the harness is not twisted.

4. Installation (ABS-specification 2WD (High ride suspension specifications), ABS-specification 4WD)

1) Install the wheel speed sensor to the knuckle.

Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in }

2) Install the harness bracket to the upper link and knuckle.

Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in } Harness bracket tightening bolt

Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in } Harness bracket tightening nut

3) Connect the harness clips to the harness as indicated by the arrows in the following diagram.

Legend

  1. Connector position
  2. Wheel speed sensor
  3. Harness bracket tightening nut
  4. Harness bracket tightening bolt
  5. Wheel speed sensor tightening bolt

4) Connect the harness connector to the wheel speed sensor.

5) Make sure that the harness is not twisted.

5. Inspection after vehicle restoration

1) Turn ON the ignition switch, and check whether the ABS warning light turns OFF after illuminating for approximately 3 seconds.

2) Start the engine and drive the vehicle straight forward from a stationary state. Slowly accelerate to 15 km/h {9.3 mph} and then slowly apply the brake until the vehicle stops. Check that there are no abnormal noises or problems with the braking force during this procedure.

3) Confirm whether the following symptom occurs during verification actions above.

  • The ABS warning light illuminates, or does not illuminate.
  • ABS operation noise or motor rotation noise is caused.
  • Brake pedal kickbacks are felt.
  • Desired braking force is not reached.

4) When the above symptom occurs, take the following action.

  • Check the installation status of the wheel speed sensor and connection status of the connector.
  • Check the DTCs, and perform inspection and take remedies for the ABS system in accordance with the diagnostic procedure for each DTC.

Caution

  • Since the ABS rotates the motor for a moment right immediately after the vehicle is started, sound of rotating motor may be heard. This operation for initial confirmation task and not at fault.

8. Disc wheel installation

1. Models with aluminum wheels

1) Temporarily tighten the disc wheel to the vehicle.

2) Lower vehicle.

3) Final tighten the wheel nut in the order shown in the diagram.

Tightening torque: 120 N⋅m {12 kgf⋅m / 87 lb⋅ft}

Caution

  • After completing installation, make sure to further tighten the wheel nuts to the specified torque after the vehicle has been driven a distance exceeding the standard value.

Standard: 50 to 100 km { 31 to 62 mile }

4) Install the wheel cap to the disc wheel.

Note

  • For models with 18-inch aluminum wheels, align the wheel cap groove with the air valve before installing.

5) Check that the surfaces of the wheel cap and wheel are flat.

Note

  • If the surfaces are not flat, the wheel cap may fall off.

Legend

  1. Valve
  2. Wheel cap groove

2. Models with steel wheels

1) Temporarily tighten the disc wheel and wheel cap to the vehicle.

2) Lower vehicle.

3) Final tighten the wheel nut in the order shown in the diagram.

Tightening torque: 120 N⋅m {12 kgf⋅m / 87 lb⋅ft}

Caution

  • After completing installation, make sure to further tighten the wheel nuts to the specified torque after the vehicle has been driven a distance exceeding the standard value.

Standard: 50 to 100 km { 31 to 62 mile }

9. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.

10. Brake fluid filling

The air bleeding procedure needs cooperation of 2 persons.

1. Precautions for brake fluid refill and air bleeding procedures

Caution

  • In the following cases, refill with brake fluid and bleed the air.
  • The brake pipe, brake hose, etc., have been disconnected.
  • Air is in the hydraulic system.
  • Brake fluid has been drained.
  • The brake is used when the fluid level in the brake fluid tank is extremely low.

Caution

  • Securely engage the parking brake during the air bleeding procedure.
  • When refilling with brake fluid and bleeding the air with the tires in contact with the ground, move the vehicle to a level area, and set chock blocks in place at the tires.
  • Always fill with new brake fluid.
  • Fill with brake fluid to prevent the mixing in of air bubbles.
  • To prevent intrusion of dirt, etc., clean the reservoir tank before removing the cap.
  • Add brake fluid up to the tank MAX level before the air bleeding procedure to prevent air from entering.
  • Do not fill the brake fluid tank with brake fluid over the MAX level.
  • Continue to adding brake fluid to at least half the brake fluid tank during the air bleeding procedure.

The brake fluid tank is shared with the clutch fluid tank. Because a partition inside the tank causes the fluid amounts of the brake chamber and clutch chamber to be different, check the brake fluid on the brake chamber side.

Legend

  1. MAX level
  2. MIN level
  3. Brake fluid chamber

Caution

  • Bleed air until air has been fully discharged from the hydraulic system.
  • Perform air bleeding procedures while maintaining sufficient brake fluid levels.
  • Use the following brake fluid brands.

Refer to "201.General Information 14B.Vehicle Information recommended fluids, lubricants and diesel fuels".

Caution

  • Do not use any brake fluid that contains petroleum components.

The rubber parts in the hydraulic brake system will expand or warp.

Caution

  • Do not use any brake fluid container that contains petroleum components or that is wet with water.

If water has entered, the boiling point of the brake fluid will be lowered.

Caution

  • Seal all containers to prevent them from getting dirty.
  • Because the painted surface will be damaged, do not spill brake fluid on a painted surface.
  • Bleed air from the brake fluid while the engine is running, and ventilate the room properly.

The vacuum brake booster may be broken if air bleeding is performed without starting the engine.

Caution

  • Be sure to check the brake fluid level on the brake fluid chamber side.

The brake fluid tank is shared with the clutch fluid tank, and a partition inside the tank causes the fluid amounts of the brake chamber and clutch chamber to be different.

Caution

  • For models with ABS specifications, remove the ABS slow blow fuse before performing the air bleeding procedure.

The ABS unit may be broken if air bleeding is performed without removing the ABS slow blow fuse.

2. Preparations for brake fluid refill and air bleeding procedures

Open the engine hood after pulling the parking brake lever.

1) Apply the parking brake.

2) Start the engine.

3) Remove the cap from the brake fluid tank.

4) Replenish the brake fluid tank with the brake fluid.

5) Perform the air bleeding procedure in the following order.

  • Brake master cylinder (When the brake master cylinder has been removed)
  • Left rear wheel cylinder
  • Right rear wheel cylinder
  • Left front brake caliper
  • Right front brake caliper

Note

  • If the brake fluid level is lowered or if air enters when the brake pipe is removed from the master cylinder, the air bleeding may be required at all 4 brakes.
  • When brake pipes have been removed from any of the brakes, air bleeding must be performed for that wheel cylinder or caliper.
  • If the piping is removed between the master cylinder and each brake, air bleeding of the operating brake system needs to be performed at the removed piping.

3. Air bleeding (Brake master cylinder)

1) Inspect the brake fluid level.

Note

  • Refill the brake fluid as necessary.
  • If the brake fluid has been filled, leave the system for at least 1 minute.

2) Disconnect the rear brake pipe from the brake master cylinder.

Legend

  1. Front brake pipe
  2. Rear brake pipe

3) Slowly depress the brake pedal once and hold it down.

4) Use a finger to completely plug the outlet of the master cylinder that is removed from the brake pipe, and slowly release the brake pedal.

5) Remove the finger from the outlet after the brake pedal has been completely returned.

Note

  • Repeat the process mentioned above until the brake fluid comes out overflowing from the outlet.

Caution

  • Be careful that the fluid level in the reservoir tank does not drop below the intermediate level indication.

6) Connect the brake pipe to the brake master cylinder.

7) Slowly depress the brake pedal once and hold it down.

8) Loosen the rear brake pipe.

9) Tighten the brake pipe again and slowly return the brake pedal.

Tightening torque: 13 to 19 N・m { 1.3 to 1.9 kgf・m / 10 to 14 lb・ft } Except ESC specifications

Tightening torque: 16 to 24 N・m { 1.6 to 2.4 kgf・m / 12 to 18 lb・ft } ESC specifications

10) Repeat the above procedure until no air is bled from the outlet when loosening the brake pipe.

11) Bleed the front brake pipe in the same way.

4. Air bleeding (Brake wheel cylinder or brake caliper)

Caution

  • Bleed air 10 times or more for the front wheel, and 15 times or more for the rear wheel.

1) Apply an appropriate wrench to the bleeder.

2) Connect a clear tube to the bleeder.

3) Dip one end of the tube into a clear container filled with brake fluid.

Note

  • The container should be approximately 1/3 full of brake fluid.

4) Slowly depress the brake pedal 3 times with a speed of once per second and hold it down.

Legend

  1. Brake pedal

5) Loosen the bleeder approximately 1/2 a turn and bleed the air from the brake fluid.

6) Tighten the bleeder.

Brake type
 Tightening torque
Front disc brake
 9 to 13 N・m { 0.9 to 1.3 kgf・m / 80 to 115 lb・in }
Rear drum brake
 6 to 8 N・m { 0.6 to 0.8 kgf・m / 53 to 71 lb・in }

7) Release the brake pedal.

Caution

  • Repeat the process mentioned above until no air bubbles are found in the discharged brake fluid.
  • If brake fluid does not come out, discharge air from the master cylinder.

Air has entered the master cylinder.

5. Inspection after bleeding air

1) After air bleeding is complete, depress the brake pedal and check for any abnormal conditions.

2) Check the brake fluid level in the brake fluid tank, and fill the brake fluid tank with brake fluid as necessary.

Caution

  • When filling, do not exceed the MAX level.

3) Depress the brake pedal and check for a sponge-like feeling.

Caution

  • If feeling like a sponge, repeat the air bleeding process.

4) Stop the engine.

Note

  • After completing the air bleeding procedure for the brake system, bleed the air from the clutch system as necessary.

5) Inspect all the brake pipes and brake hoses for the following.

  • Wear
  • Bending
  • Damage
  • Cracking
  • Dent

Note

  • Repair or replace if any abnormal conditions are found.

Caution

  • Joints of all pipes and hoses can be easily damaged.
  • Do not twist or bend the hose excessively when performing the procedure. Do not break the brake pipe when repairing or replacing the axle, suspension, etc.
  • When installing the brake pipe or the brake hose, make sure to perform inspection.
  • After removing the brake pipe or the brake hose, use a plug, tape, etc., to cover the opening and prevent the intrusion of foreign material.

6) Close the engine hood.

6. ABS slow blow fuse installation (ABS specifications)

1) Install the ABS slow blow fuse to the fuse box.

2) Turn ON the ignition switch and make sure the warning light turns OFF.

Caution

  • Clear the DTCs that were set to the EHCU by removing fuses.
Copyright Mazda Motor Corporation. All rights reserved.