1987 MAZDA 626 Workshop Manual

POWER BRAKE UNIT 1 1
INSTALLATION
1. Install in the reverse order of removal, referring to installation note for specially marked parts.
2. Tighten all nuts and bolts to the specified torque, referring to torque specifications.
3. After installation:
(1) Add fluid and bleed the air. (Refer to page 11—9.)
(2) Check all parts for fluid leakage.
(3) Make an on-vehicle check of the unit (Refer to page 11—27.)
(4) Verify that the vacuum hose does not contact other parts.
Torque specifications
76G11X-035
1. Vacuum hose and check valve
11—33

1 1 POWER BRAKE UNIT
Installation Note
Application of grease and sealant
1. Apply grease to the clevis pin contact surface.
2. Apply sealant to the gasket contact surface.
86U11X-057
Vacuum hose and check valve
Install the vacuum hose and check valve, noting the
installation direction.
Note (MTX)
The check valve is pressed into the vacuum
hose. There is an arrow on the hose surface
to indicate direction of installation.
76G11X-036
11—34

VACUUM PUMP 1 1
VACUUM PUMP
1. Disconnect the vacuum hose and release the re-
maining vacuum.
2. Connect a vacuum gauge as shown in the figure.
3. Run the engine at idle speed.
Idle speed: 720 1 20 rpm
4. Check that the vacuum reaches 500 mmHg (19.7
inHg) in 8 seconds or less.
5. Check that the maximum vacuum is within approx.
700—720 mmHg (27.6—28.3 inHg) in 80 sec-
onds or less.
REMOVAL AND INSTALLATION
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal, referring to installation note for specially marked parts.
Note
The engine oil will leak out when disconnecting the oil hose. Prepare a suitable container
for it to drain into.
76G11X-038
76G11X-037
1. Vacuum hose
2. Oil return hose
3. Oil inlet hose
4. Drive velt cover
5. Vacuum pump

1 1 VACUUM PUMP
Vacuum pump
Checking
point
B -
VacuumA^^^^ pump [
(o) y
©
Rear
\ camshaft
jpulley
AHP"
76G11X-039
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the sequence shown in the figure.
2. Assemble in the reverse order of disassembly.
Installation Note
Belt deflection
Inspection
Check the belt deflection within specification apply-
ing moderate pressure.
Specification
New belt: 7.5—8.5mm (0.30—0.33)
Used belt: 8.5—9.5 mm (0.33—0.37)
Adjustment
1. Loosen the mounting bolt ©and adjust bolt (§).
2. Lever the vacuum pump outward and apply ten-
sion to the belt.
3. Tighten the mounting bolt ®and adjust bolt (§)to
the specified torque. (See page 11 —35.)
18—49 N-m (2.0—5.0 m-kg, 14—36 ft-lb) ' 39—77 N-m (4.0—7.0 m-kg, 29—51 ft-lb)
29—59 N-m (3.0—6.0 m-kg, 22—43 ft-lb)
,_B.B Nm--90 cm-kg, 5.9 (60 52—78 In-lb)
2.0—4.9 N-m (20—50 cm-kg, 17—43 In-lb)
49—88 Nm (5.0-9.0 m-kg, 51—65 It-lb)
Left hand threads
1. Vacuum pump housing
2. Rotor
3. Vane
76G11X-040
4. Center plate
5. Vacuum pump bracket
assembly
6. O-ring
7. Pulley
11-36

VACUUM PUMP 1 1
INSPECTION
1. Check the rotor, housing and cover for wear or
damage.
2. Check the O-ring for deterioration or damage.
3. Check the vane for wear or damage. Replace if
necessary.
Height:
13.0—13.5 mm (0.512—0.530 in)
76G11X-041
4. Check the housing inner diameter.
Diameter:
57.0—57.1 mm (2.244—2.248 in)
76G11X-042
11-37

1
1
DUAL PROPORTIONING VALVE
B6U11X-060
DUAL PROPORTIONING VALVE
FUNCTION CHECK
1. Connect
two
pressure gauges [9,810
kPa (100

kg/cm2,1,422 psi)
]
to the brake pipes and adap-
tors
as
shown
in
the
figure.
Adaptor and flare
nut
tightening torque:
13—22 N m (1.3—2.2 m-kg, 9—16 ft-lb)
Note
Disconnect and connect the brake pipes with
the
SST
(49
0259 770B).
2. Bleed
air
from
the
brake system.
(Refer
to
page 11—9.)
76G11X-043
t 0}
^
£
»

Rear

brake
pressu
kPa
(kg/cm2,
p
>
DO

Rear

brake
pressu
kPa
(kg/cm2,
p
>
DO
TTi
A
B

Master cylinder pressure
kPa
(kg/cm2,
psi)

76G11X-044
Depress the brake pedal until the master cylinder
pressure equals A; then measure rear brake pres-
sure
A'.

Depress the brake pedal again; apply additional
pressure until
A
equals
B;
then measure pressure
B'.
If the measurements
are
not
within specification,
replace
the
valve assembly.
Install the brake pipes to the valve,
and
bleed
air

from
the
brake system.
Specification
Fluid pressure
kPa
(kg/cm2,
psi)

A A' B B'
Except General
LHD
and
RHD

1,962 (20,284)
1,962 ±
196
(20
± 2,
284
± 28)
6,867 (70,995)
3,434 ±
196
(35
± 2,
498
± 28)

General
LHD
and
RHD
2,943 (30,427)
2,943 ±
196
(30
± 2,
427
± 28)

6,867 (70,995) 4,120 ±
196
(42
± 2,
597
± 28)

11-38

DUAL PROPORTIONING VALVE 1 1
REMOVAL AND INSTALLATION
1. Remove in the sequence shown in the figure, referring to removal and installation note for specially
marked parts.
2. Install in the reverse order of removal.
3. After installation:
(1) Add brake fluid and bleed the air. (Refer to page 11—9.)
(2) Check the brake lines for fluid leakage.
Caution
Brake fluid will damage painted surfaces. If it does get on a painted surface, wipe it off
immediately.
Except RF-CX
O
76G11X-045
1. Brake pipe 2. Dual proportioning valve
Removal and Installation Note
Brake pipe
Disconnect or connect the brake pipes with the SST.
76G11X-103
11-39

1 1 FRONT DISC BRAKE
76G11X-073
86U11X066
76G11X-074
FRONT DISC BRAKE
SIMPLE INSPECTION OF DISC PAD WEAR
1. Loosen the front wheel lug nuts.
2. Jack up the front of the vehicle and support it with
safety stands.
3. Remove the wheels.
4. Look through the caliper inspection hole and check
that the remaining thickness of the pad is 2 mm
(0.08 in) min.
Note
When the remaining thickness becomes 2 mm
(0.08 in), the wear indicator informs that the
pad should be replaced by creating a squeal-
ing noise before any disc plate damage
occurs.
REPLACEMENT OF DISC PAD
Caution
Replace the left and right pads at the same
time.
1. Loosen the front wheel lug nuts.
2. Block the rear wheels firmly.
3. Jack up the front of the vehicle and support it with
safety stands.
4. Remove the wheels.
5. Remove the lower mounting bolt.
6. Pivot the caliper on the top bolt and support it.
7. Remove the V-springs.
Note
V-springs are equipped for non-asbesto pad
type.
8. Remove the pads and shims.
Warning (Asbesto pad type)
Asbestos dust is a health hazard. Do not blow
away brake dust with compressed air.
9. Apply the grease supplied in the pad attachment
set to the new shims, and attach them to the new
pads.
10. Push the piston inward with the SST and the old
pad.
11. Install the new pads and shims into the mounting
support.
12. Install the V-springs (non-asbesto pad type).
76G11X-075
11-40