1987 MAZDA 626 Workshop Manual

BRAKE HYDRAULIC LINE 1 1
REMOVAL AND INSTALLATION OF BRAKE
LINES
1. Loosen or tighten the flare nut with the SST.
Flare nut tightening torque: 13—22 N-m
(1.3—2.2 m-kg, 9—16 ft-lb)
2. When connecting the flexible hose, do not over-
tighten or twist it.
3. After installation:
(1) Check that the hose does not contact other
parts when the vehicle bounces or when the
steering wheel is turned all the way to the right
or left.
(2) Bleed the air from the brake system. (Refer to
page 11—9.)
REPLACEMENT OF BRAKE FLUID
1. Remove the brake fluid from the reservoir with a
suction pump.
2. Fill the reservoir with new, specified brake fluid.
3. Pump out the old brake fluid by loosening the
bleeder screws (one by one) and pumping the
brake pedal. (Refer to page 11—10 for details.)
AIR BLEEDING
Air Bleeding Locations
After the following parts are removed, air bleeding is necessary after installation.
Removed part
Air bleeding location
Removed part Front Rear Removed part
Right side Left side Right side Left side
Master cylinder * * * *
Wheel cylinder or caliper
Front Right side * — — —
Wheel cylinder or caliper
Front Left side — * — —
Wheel cylinder or caliper Rear disc Right side — — * — Wheel cylinder or caliper Rear disc Left side — — — * Wheel cylinder or caliper
Rear drum Right side — — * —
Wheel cylinder or caliper
Rear drum Left side — — — *
Dual proportioning valve * * * *
Hydraulic unit (ABS) * * * *
ABS: Anti-lock Brake System 76GHX-064 *: Indicates where air bleeding is necessary
11—9

1 1 BRAKE HYDRAULIC LINE
Procedure
1. Jack up the vehicle and support it with safety
stands.
2. Fill the reservoir with brake fluid. Be sure that it is
at least half full at all times during the air bleeding
process.
Caution
a) Be careful not to spill brake fluid onto a
painted surface.
b)Use only the specified brake fluid. Do not
mix it with any other type.
3. Remove the bleeder cap; then connect one end
of a transparent vinyl tube to the bleeder screw and
place the other end in a receptacle.
4. Have an assistant depress the brake pedal a few
times, and then hold it in the depressed position.
5. Loosen the bleeder screw, drain out the fluid, and
retighten the bleeder.
Note
a) The two people should stay in voice con-
tact with each other.
b) Be sure the pedal remains depressed until
the bleeder is tightened.
86U11X-014
6. Repeat steps 4 and 5 until no more air is dis-
charged.
7. Tighten the bleeder screw, and check that there
is no fluid leakage.
Bleeder screw tightening torque:
6—9 N-m (60—90 cm-kg, 52—78 in-lb)
Caution
Be sure to clean away any spilled fluid with
rags.
8. Add brake fluid to the reservoir up to the speci-
fied level.
11—10

BRAKE PEDAL 1 1
Pedal height
"tt^
Pedal-to-floor clearance
76G11X-008
BRAKE PEDAL
ON-VEHICLE INSPECTION
Pedal Height
Inspection
Check that the distance from the center of the upper
surface of the pedal pad to the firewall is as specified.
LHD and RHD
Pedal height: 222 mm (8.74 +0-200 in)
Adjustment
1. Disconnect the stop light switch connector.
2. Loosen locknut B and turn switch A until it does
not contact the pedal.
3. Loosen locknut D and turn rod C to adjust the
height.
4. Adjust the pedal free play and tighten locknut D.
5. Turn the stop light switch until it contacts the ped-
al; then turn an additional 1/2 turn. Tighten lock-
nut B.
Locknut B tightening torque:
14—18 N m (1.4—1.8 m-kg, 10—13 ft-lb)
Locknut D tightening torque:
24—34 Nm (2.4—3.5 m-kg, 17—25 ft-lb)
Pedal Play
Inspection
1. Depress the pedal a few times to eliminate the
vacuum in the system.
2. Gently depress the pedal again by hand, and
check the free play. (Until the valve plunger con-
tacts the stopper plate = until the power piston be-
gins to move.)
Pedal play: 4—7 mm (0.16—0.28 in)
76G11X-099
Adjustment
Loosen the locknut D of the operating rod C; then
turn the rod to adjust the free play.
Locknut D tightening torque:
24—34 Nm (2.4—3.5 m-kg, 17—25 ft-lb)
86U11X-018
11—11

1 1 BRAKE PEDAL
Pedal-to-floor clearance
76G11X-009
REMOVAL
Remove in the sequence shown in the figure.
Pedal-to-Floor Clearance
Inspection
Check that the distance from the floor panel to the
center of the upper surface of the pedal pad is as
specified when the pedal is depressed with a force
of 589 N (60 kg, 132.3 lb).
Pedal-to-floor clearance:
LHD and RHD
95 mm (3.7 in) min.
If the distance is less than specified, check for the
following problems.
1. Air in brake system
2. Malfunction of automatic adjuster (rear drum
brakes)
3. Worn shoes or pads
86U11X-020
1. Clevis pin
2. Brake pedal
3. Return spring
4. Guide pipe
5. Bushing
6. Brake pad
11—12

BRAKE PEDAL 1 1
INSPECTION
Check the following and replace or repair any faulty
parts.
1. Pedal pad for wear or damage
2. Bushing for wear
3. Bolt for bending
4. Pedal for bending
5. Return spring for weakness or damage
86U11X-021
INSTALLATION
1. Install in the reverse order of removal.
2. Tighten all nuts and bolts, referring to torque specifications.
3. After installation:
Check and adjust the pedal height and play. (Refer to page 11—11.)
Torque specifications
76G11X-010
Installation Note
Application of grease
Apply grease to the following parts:
(1) Inner and outer surfaces of bushing
(2) Outer surface of guide pipe
(3) Contact surface of clevis pin and spring
86U11X-023
11—13

1 1 MASTER CYLINDER
MASTER CYLINDER
REMOVAL
Remove in the sequence shown in the figure, referring to removal note for specially marked parts.
Caution
Brake fluid will damage painted surfaces. If it does get on a painted surface, wipe it off
immediately.
1. Fluid level sensor connector
2. Brake pipe
76G11X-011
3. Master cylinder
4. Clutch pipe holder (LHD MTX ABS)
Removal Note
Brake pipe (Flare nut type)
1. Place rags under the master cylinder to prevent
brake fluid from dripping on painted surfaces.
2. Disconnect the brake pipe from the master cylin-
der with the SST.
76G11X-012
11—14

MASTER CYLINDER 1 1
DISASSEMBLY AND ASSEMBLY (EXCEPT RHD DOHC TURBO)
1. Pour out the brake fluid.
2. Disassemble in the sequence shown in the figure, referring to disassembly note for specially marked
parts.
3. Assemble in the reverse order of disassembly, referring to assembly note for specially marked parts.
Caution a) Do not to allow any foreign material into the master cylinder during repairs. b)Do not scratch the inside of the cylinder or the outer surface of the piston.
Note
The primary piston assembly is not repairable. Replace it as an assembly.
76G11X-013
1. Fluid level sensor 5. Secondary piston assembly
2. Stopper screw and O-ring 6. Reservoir assembly
3. Snap ring 7. Bushing
4. Primary piston assembly
11—15

1 1 MASTER CYLINDER
86U11X-029
Disassembly Note
Stopper screw
Remove the stopper screw with a Phillips screwdriver.
Note
Prepare a suitable container for the brake fluid
to drain into.
Snap ring
Push the primary piston with a Phillips screwdriver
and remove or install the snap ring with snap-ring
pliers.
Secondary Piston Assembly
Remove the secondary piston assembly by gradual-
ly blowing compressed air into the cylinder.
Caution
Use a rag to catch the secondary piston as-
sembly when applying compressed air.
Assembly Note
Application of brake fluid
Before assembly, apply brake fluid to the following
parts:
1. Cylinder inner surface
2. Piston
3. Piston cups
4. Bushings
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86U11X030
11—16