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Servicing Mercedes-Benz AIRMATIC Suspensions

The Mercedes-Benz AIRMATIC suspension system was introduced in 1999 on the S-Class and has subsequently been used on the E-Class and most of the automaker’s SUVs. The system employs electronically controlled air springs that provide an ideal balance...

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Mazda: Performing Regular Undercar Maintenance

In this article, we’ll take a look at brake and undercar service on the Mazda vehicle lineup, with the footnote that even though this type of work ­becomes routine when you have a preventive maintenance mindset, good work habits from beginning to end...

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ZF 8-Speed Transmission Replacement

The ZF 8HP transmission made its debut in 2009, and since its introduction, has been one of the top choices for international car manufacturers. BMW, one of ZF’s largest customers, uses the 8HP across its entire product portfolio. BMWs featuring...

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The Ins And Outs Of Sanders

Sanders are required tools in today’s collision repair shop. Body techs and painters rely upon them every day to achieve that perfect finish on your customers’ vehicles. Whether you’re prepping a panel for paint or removing imperfections before...

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Are You Regularly Maintaining Your Equipment?

Technicians who are idling because the welder won’t feed wire, the hydraulic ram won’t pull chains, the booth heater won’t heat or the air compressor won’t compress enough air is a costly mistake, as labor time is the most expensive thing in any...

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Celebrate 'Back To The Future' Day By Watching The Time Machine Get A 2015 Detail

    For many today is just another Wednesday, but for a lot of people it is more than just your average Wednesday, it is "Back to the Future" Day. It is a day that everyone who watched the cult classic trilogy Back to the Future recognizes...

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Using Your Oscilloscope: Current Ramp Test Ignition Coils

Regardless of design configuration, the role of the ignition coil is to multiply battery voltage into high voltage. Following Ohm’s law for the conversion of volts to amperes, oil-filled coils generally require 3 to 5 amperes of primary current...

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Serial Data Bus Diagnostics

Understanding The Function of Serial Data Buses If serial data buses did not exist, a wiring harness would have to be five times its normal size and use twice as many sensors to deliver the same level of functionality and safety we see in the modern...

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Throttle-By-Wire Codes: P1512 On 2002 GMC Envoy

The PCM continuously monitors the commanded and actual throttle positions. The commanded throttle position is compared to the actual throttle position based on ­accelerator pedal position and possibly other limiting factors, and both values should...

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Home Brake Job BRAKE JOB: 2004-2009 Mazda3

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The 2004-2009 Mazda3 is based on the Ford global C1 platform, shared with the European Ford Focus and Volvo S40.  Nothing is really groundbreaking about the brake system. But, not paying attention to the details can end in a post brake job comeback.

Front Brakes
Pads should be replaced when there is 2mm or less of friction material. The rotors have enough material on them to last at least one turning on the lathe. The runout specification for these vehicles is .002” and disc thickness variation should be far below .0005”.

Mazda claims repeated panic braking may raise the temperature in some portions of the disc plate by approx. 1,000°C (l,832°F). This temperature is almost near impossible to achieve this side of a high-speed police chase.

The calipers mount to the brackets using caliper guide pins with Allen heads. The sleeves  and boots should be disassembled, cleaned and lubricated every time the brakes are replaced. The torque for the guide pins is 21 ft/lbs and the caliper bracket bolts should be tightened to 75 ft/lbs.

Rear Brakes
All Mazda3 models have rear disc brakes. The calipers mount to the brackets using caliper guide pins with Allen heads. The sleeves and boots should be disassembled, cleaned and lubricated every time the brakes are replaced. The torque for the guide pins is 21 ft/lbs and the caliper bracket bolts should be tightened to 55 ft/lbs.

Mazda uses a hand-brake that is incorporated into the rear caliper. They use a couple of systems to retract rear pistons. The later-model cars require the familiar method of turning the piston clockwise while applying pressure, where others will have a plug on the back side of the caliper that provides access for an Allen wrench to facilitate retracting the piston, but be careful as you retract the piston.

After the pads are replaced, pump the pedal and adjust the parking brake mechanism in the rear calipers. If the level has too much travel, perform the following steps:
1. Pump the brake pedal a few times.
2. Remove the service hole cover of the rear console.
3. Turn the adjusting nut and adjust the parking brake lever.
4. After adjustment, pull the parking brake lever one notch and verify that the parking brake warning light illuminates.
5. Verify that the rear brakes do not drag.

ABS/DSC Diagnostics and Repair
The Mazda3 comes in two flavors, ABS and ABS with Dynamic Stability Control. Both systems connect to other vehicle components via a high-speed serial data bus. The DSC system ties more components together like a yaw/pitch sensor and steering position sensor onto the bus.

If you are seeing communication-related DTCs, it is essential that you fully diagnose problems with the system before you start replacing sensors and modules. Some of these vehicles have been on the roads for more than six years and the connections are starting to corrode and fret.

One of the main culprits of ABS/DCS problems are the connectors, especially under the hood where the control/modulator unit connects. Being able to measure values at the connectors and observe data on a scan tool is essential for diagnosing problems.

If a modulator/control unit is replaced, the pressure sensors must be re-calibrated with a scan tool that is able to communicate with the chassis/ABS module. If this is not performed, it can result in brake failure and lock up.

If you have DTCs C1141, C1142, C1143, C1144, C1233, C1234, C1235 or C1236 (ABS wheel-speed sensor/ABS sensor rotor), chances are something is wrong with the wheel bearings. Another cause for these codes could be an accumulation of metal debris on the sensor. The front bearings are press-in cartridge-style units. Rear wheel bearings are hub units. In the front, the tone ring, or encoder, is on the inner seal of the bearing and the sensor is mounted in the knuckle. The parameters for these codes to be set are abnormalities in the signal like a weak signal or large differences in the value when compared to the other sensors.

If you have DTCs C1145, C1155, C1165 or C1175 (open sensor), it could be damaged wiring or a failed sensor. If you have more than one, chances are there is a problem with the connection at the control unit or in the front or rear harnesses for the sensors.

These DTCs will usually clear themselves after repairs are made and the vehicle is driven above 6.2 mph when the self-diagnostic check is performed.

Some customers may report a slight clunk, bang or jolt from the front of the vehicle. This concern will most likely occur during the vehicle’s first forward movement, and after the vehicle sits for a few hours and/or a cold soak. This is a normal operating noise of the ABS system.

If you encounter a customer complaint for this concern, explain that the noise comes from the ABS/TCS/DSC “Malfunction Detection Function” initial check. The initial check is a necessary function to ensure the normal operation of the ABS/TCS/DSC system.

This initial test function occurs during the vehicle’s first forward movement and when the vehicle reaches approximately 6.2 mph.

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Andrew Markel

Andrew Markel

Andrew Markel is the editor of Brake & Front End magazine. He has been with Babcox Media for 15 years. He is a technician and former service writer and holds several automotive certifications from ASE and ­aftermarket manufacturers. He can be reached at [email protected]
Andrew Markel

Latest posts by Andrew Markel (see all)

  • Adan o

    Front passenger brake sticks. I replaced the brake caliper and brake hose and the front passenger brake still sticks. Any recomedations

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