Mazda5 Technical Guide 04 Brakes.pdf

BRAKES

OUTLINE . . . . . . . . . . . . . . . . . 04-00

ON-BOARD DIAGNOSTIC. . . . 04-02

CONVENTIONAL BRAKE

SYSTEM. . . . . . . . . . . . . . . . . . 04-11

PARKING BRAKE SYSTEM . . . 04-12

ANTILOCK BRAKE SYSTEM . . 04-13

DYNAMIC STABILITY

CONTROL . . . . . . . . . . . . . . . . . 04-15

04–00 OUTLINE

BRAKE ABBREVIATIONS . . . . . . . . . . . 04–00–1

BRAKE FEATURES . . . . . . . . . . . . . . . . 04–00–1

BRAKE SPECIFICATIONS. . . . . . . . . . . . 04–00–2

End of Toc

BRAKE ABBREVIATIONS

DPE040000000T01

ABS

Antilock Brake System

ATX

Automatic Transaxle

CAN

Controller Area Network

Control Module

CPU

Central Processing Unit

DSC

Dynamic Stability Control

EBD

Electronic Brakeforce Distribution

Hydraulic Unit

Ignition

Left Front

Left Rear

MTX

Manual Transaxle

OFF

Switch Off

Switch On

PID

Parameter Identification

Right Front

Right Rear

Switch

TCS

Traction Control System

WDS

Worldwide Diagnostic System

End Of Sie

BRAKE FEATURES

DPE040000000T02

Improved safety • Intrusion minimizing brake pedal adopted

• Large power brake unit (10 inch) with attached mechanical brake assist mechanism adopted

• Electronic brakeforce distribution (EBD) control adopted

• ABS adopted

• Dynamic stability control (DSC) adopted

Improved braking force • Large diameter front disc brakes adopted

• Large diameter rear disc brakes adopted

• Vacuum pump adopted (MZR-CD (RF Turbo))

Improved serviceability • Combined sensor integrating yaw rate and lateral-G sensors adopted

• Enhanced malfunction diagnosis system for use with WDS or equivalent

Improved operability • Center lever type parking brake, adjustable from vehicle interior, adopted

Size and weight reduction • Integrated construction of the hydraulic unit (HU) and control module (CM) adopted for the ABS

HU/CM and DSC HU/CM

• Semi-conductor element type ABS wheel-speed sensor adopted

• Magnetic encoder type ABS sensor rotor adopted

Improved brake pedal

operability

• A master cylinder with smaller diameter long-stroke type has been adopted

04–00–1

SECTION

To c o f S C T

OUTLINE

Improved reliability

• Specialized CAN communication adopted for communications between the combined sensor

and the DSC HU/CM

• DSC HU/CM with built-in brake fluid pressure sensor

End Of Sie

BRAKE SPECIFICATIONS

DPE040000000T03

Item

Specification

Type

Suspended design

Brake pedal

Pedal lever ratio

2.8

Max. stroke

(mm {in})

117 {4.61}

Master

cylinder

Type

Tandem

Cylinder bore

(mm {in})

22.2 {0.874}

Type

Ventilated disc

Cylinder bore

(mm {in})

57 {2.2}

Front brake

(disc)

Pad dimensions (area x thickness)

5,140 × 12.0 {7.967 × 0.47}

(mm 2 x mm {in 2 x in})

Disc plate dimensions

(mm {in})

With 15 inch brake: 278 × 25 {10.9 × 0.98}

With 16 inch brake: 300 × 25 {11.8 × 0.98}

Type

Solid disc

Cylinder bore

(mm {in})

38 {1.5}

Rear brake

(disc)

Pad dimensions (area x thickness)

2,700 × 10.8 {4.185 × 0.43}

(mm 2 x mm {in 2 x in})

Disc plate dimensions

(mm {in})

With 15 inch brake: 280 × 11 {11.0 × 0.43}

With 16 inch brake: 302 × 11 {11.9 × 0.43}

Power brake

unit

Type

Vacuum multiplier, single diaphragm

Outer diameter

(mm {in})

272.1 {10.71}

Rear wheel

braking force

control device

Type

Electronic brakeforce distribution (EBD)

Brake piping Piping layout

X pattern

Type

Mechanical design, rear two-wheel braking

Parking brake

Operating method (application/release)

Manually operated lever design

Play adjustment method

Auto-adjusting

Brake fluid

Type

European (L.H.D. U.K.) specs.:

SAE J1703, FMVSS 116 DOT-3 or DOT-4

General (L.H.D. R.H.D.) specs.: SAE J1703, FMVSS 116 DOT-3

End Of Sie

04–00–2

ON-BOARD DIAGNOSTIC

04–02 ON-BOARD DIAGNOSTIC

ON-BOARD DIAGNOSTIC SYSTEM OUTLINE

[ABS, DYNAMIC STABILITY

CONTROL (DSC)] . . . . . . . . . . . . . . . . . 04–02–1

ON-BOARD DIAGNOSTIC SYSTEM FUNCTION

[ABS, DYNAMIC STABILITY CONTROL

(DSC)] . . . . . . . . . . . . . . . . . . . . . . . . . . 04–02–2

ON-BOARD DIAGNOSTIC SYSTEM PID/DATA

MONITOR FUNCTION [ABS, DYNAMIC STABILITY

CONTROL (DSC)] . . . . . . . . . . . . . . . . . 04–02–5

ON-BOARD DIAGNOSTIC SYSTEM ACTIVE

COMMAND MODES FUNCTION [ABS, DYNAMIC

STABILITY CONTROL (DSC)] . . . . . . . . 04–02–6

ON-BOARD DIAGNOSTIC SYSTEM EXTERNAL

TESTER COMMUNICATION FUNCTION

[ABS, DYNAMIC STABILITY CONTROL

(DSC)] . . . . . . . . . . . . . . . . . . . . . . . . . . . 04–02–7

DLC-2 CONSTRUCTION [ABS, DYNAMIC

STABILITY CONTROL (DSC)] . . . . . . . . 04–02–7

End of Toc

ON-BOARD DIAGNOSTIC SYSTEM OUTLINE [ABS, DYNAMIC STABILITY CONTROL (DSC)] DPE040243750T01

• The on-board diagnostic system consists of a malfunction detection system that detects abnormalities in input/

output signals when the ignition switch is at the ON position, a data monitor function that reads out specified

input/output signals and a active command modes function that allows for override operation of output parts

(such as solenoid valves).

• The data link connector 2 (DLC-2), which groups together all the connectors used for malfunction diagnosis

and detecting/repair into a single location, has been adopted, thereby improving serviceability. Diagnosis is

performed by connecting the WDS or equivalent to the DLC-2.

• In addition to DTC read-out, the WDS or equivalent is used to clear DTCs using the display screen of the

diagnostic tester, and to access the PID/data monitor and active command modes functions, providing

enhanced malfunction diagnosis and improved serviceability.

Block Diagram

DLC-2

B3E0402T004

1 DSC indicator light (with DSC)

2 DSC OFF light (with DSC)

04–02–1

ON-BOARD DIAGNOSTIC

3 ABS warning light

4 Brake system warning light

5 On-board diagnostic function

6 Memory function

7 Malfunction display function

8 Serial communication

9 Malfunction detection function

10 PID/DATA monitor function

11 Active command modes function

12 Fail-safe function

13 HU inspection function

14 Input device

15 Normal control area

16 Output device

17 WDS or equivalent

End Of Sie

ON-BOARD DIAGNOSTIC SYSTEM FUNCTION [ABS, DYNAMIC STABILITY CONTROL (DSC)]

DPE040243750T02

Malfunction detection function

• The malfunction detection function detects malfunctions in the input/output signal system of the ABS HU/CM

(vehicles with ABS) or DSC HU/CM (vehicles with DSC) when the ignition switch is at the ON position.

• When the ABS HU/CM and DSC HU/CM are started up, the following malfunction detections are performed.

ABS HU/CM

— The ABS and brake system warning lights illuminate for approx. 3.0 s when the ignition switch is turned to

the ON position to inspect for open circuits in the lights. At the same time, the fail-safe relay is operated,

and the input/output signals of each part is monitored for malfunction diagnosis. After starting to drive, the

first time the vehicle speed is approx. 10 km/h {6.2 mph} or more the pump motor is operated and

malfunction diagnosis is performed again. Input/output signals are monitored for malfunction determination

when the ignition switch is at the ON position.

DSC HU/CM

— The ABS and brake system warning lights, and DSC indicator lights illuminate for approx. 3.0 s and the

DSC OFF light illuminates for approx. 1.8 s when the ignition switch is turned to the ON position to inspect

for open circuits in the lights. At the same time, the fail-safe relay is operated, and the input/output signals

of each part is monitored for malfunction diagnosis. After starting to drive, the first time the vehicle speed is

approx. 10 km/h {6.2 mph} or more the pump motor is operated and malfunction diagnosis is performed

again. Input/output signals are monitored for malfunction determination when the ignition switch is at the

ON position.

• When malfunctions are detected, the corresponding lights are illuminated to alert the driver. Using the external

tester communication function, DTCs can be output through the CAN_H and CAN_L of the DLC-2. At the same

time, malfunction detection results are sent to the memory and fail-safe functions.

Memory function

• The memory function stores DTCs of malfunctions in input/output signal systems. With this function, once a

DTC is stored it is not cleared after the ignition switch has been turned off (LOCK position), even if the

malfunctioning signal system has returned to normal.

• Since the ABS and DSC control modules have built-in non-volatile memory, DTCs are not cleared even if the

battery is removed. Therefore, it is necessary to clear the memory after performing repairs. Refer to the

Workshop Manual for the DTC clearing procedure.

Fail-safe function

• When the malfunction detection function determines a malfunction, each light illuminates to advise the driver.

At this time, the fail-safe function controls the ABS, EBD, TCS * and DSC * as shown in the fail-safe function

malfunction contents table.

* : Only vehicles with DSC

Warning

• If EBD control is suspended the rear wheels could lock-up before the front wheels. If this occurs,

the vehicle could swerve and become unstable. Therefore always inspect the system immediately

if EBD control is suspended.

Fail-safe Function Malfunction Contents (Vehicles With ABS)

04–02–2

ON-BOARD DIAGNOSTIC

DTC

Fail-safe function

Warning light illumination status

Control status

Malfunction

location

WDS or

equivalent

display

ABS warning light

Brake system

warning light

(when parking brake

is released)

ABS control

EBD control

B1317

Illuminated

Control disabled

Power supply system

B1318 *1

Illuminated

Illuminated *2

Control disabled

Control

disabled *2

Not illuminated *3

Control enabled *3

ABS HU/CM

(internal

malfunction)

B1342

C1267

Illuminated

Control disabled Control disabled

Pump motor, motor

relay

C1095

Illuminated

Not illuminated

Control disabled Control enabled

C1141

ABS sensor rotor

C1142

C1143

C1144

Illuminated

Not illuminated *4

Control disabled Control enabled *5

C1145

ABS wheel-speed

sensor

C1146

C1147

C1148

Illuminated

Not illuminated *4

Control disabled Control enabled *5

C1233

ABS wheel-speed

sensor/ABS sensor

rotor

C1234

C1235

C1236

Illuminated

Not illuminated *4

Control disabled Control enabled *5

Brake switch

C1446

Not illuminated

Control enabled Control enabled

CAN line

U1900

Not illuminated *6

Control enabled Control enabled

U2012

: Detected if vehicle speed is 20 km/h {12.4 mph} or more .

: Detected regardless of time if at approx. 8 V .

: Detected if condition of approx. 9.7 V or less continues for 210 ms or more .

: Illuminates when two wheels or more have a malfunction.

: Control disabled when two wheels or more have a malfunction.

: Illuminates depending on malfunction contents.

04–02–3

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