1987 MAZDA 626 lock

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

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

MASTER CYLINDER 1 1
Installation Note
Piston to push rod clearance adjustment
(Except RHD DOHC TURBO)
Before installing the master cylinder, check the clear-
ance between the piston of the master cylinder and
the push rod of the power brake unit as follows.
1. Place the SST on the top of the master cylinder;
then turn the adjust bolt until it contacts the bot-
tom of the push rod hole in the piston.
76G11X-024
2. Apply 500 mmHg (19.7 inHg) vacuum to the pow-
er brake unit with a vacuum pump.
76G11X-100
——x y V \ ''/v'/
\
i By Adjust bolt
86U11X-036



Locknut IV"

\ i i '
3. Invert the SST used in step 1, and place it on the
power brake unit.
4. Check the clearance between the adjust bolt and
the push rod of the power brake unit. If it is not
0 mm, loosen the push rod locknut and turn the
push rod to adjust.
76G11X-101
11-23

POWER BRAKE UNIT 1 1
76G11X-034
INSPECTION OF CHECK VALVE
Note (MTX)
The check valve is pressed into the vacuum
hose. There is an arrow on the hose surface
to indicate direction of installation.
Inspection
1. Disconnect the vacuum hose from the engine.
2. Apply suction and pressure to the hose from the
engine side. Check that air flows only toward the
engine.
If the air passes in both directions or not at all, re-
place the check valve (along with the hose).
REMOVAL
Remove in the sequence shown in the figure, referring to removal note for specially marked parts.
1. Fluid level sensor connector
2. Vacuum switch coupler
(RF, RF-CX)
3. Brake pipe
4. Master cylinder
5. Clutch pipe holder
6. Vacuum hose and check
valve
7. Clevis pin
8. Steering shaft
76G11X-069
9. Power brake unit
10. Gasket
11. Locknut
12. Operating lever
11-29

POWER BRAKE UNIT 1 1
76G11X-071
Disassembly Note
Front and rear shells
1. Secure the front shell studs in a vise after attach-
ing suitable nuts to them to prevent damage to the
studs.
2. Before separating the front and rear shell assem-
blies, make matching marks to be used in reas-
sembly.
3. Fit a wrench onto the rear shell studs; then fasten
two of them with suitable nuts.
4. Rotate the rear shell counterclockwise to unlock.
Caution
The rear shell is spring loaded; loosen it
carefully.
Retainer key
Depress the plunger rod fully; then remove the re-
tainer key.
86U11X-049
86U11X-050
Assembly Note
Application of Grease
Before assembly, coat the parts shown in the figure
with silicon grease.
(1) Entire surface of reaction disc
(2) Dust seal lip
(3) Push rod
(4) Diaphragm-to-shell contacting surfaces
(5) Power piston
(6) Valve plunger oil seal
Retainer key
1. Push down the plunger rod.
2. Align the groove of the valve plunger with the slot
of the power piston.
3. Insert the retainer key.
86U11X-051
11—31

1 1 POWER BRAKE UNIT
Diaphragm
Install the diaphragm to the power piston and plate.
Caution
Check that the diaphragm is well seated in the
groove.
86U11X-052
Rear shell assembly
Assemble the rear shell assembly; carefully guiding
the tube end of the power piston through the dust
seal of the rear shell.
86U11X-053
Front shell and rear shells
Press down the rear shell assembly, and rotate it
clockwise until the matching marks are aligned.
Caution
Fit suitable nuts to two studs of the rear shell
and tighten them to mount the wrench.
76G11X-072
INSPECTION
1. Inspect all rubber parts. Wipe free of fluid and care-
fully inspect all rubber parts for cuts, nicks, and
other damage.
2. Check the power piston for cracks,distortion, chip-
ping, and damaged seats.
3. Inspect the reaction disc rubber for deterioration.
4. Check that the seats of the valve rod and plunger
are smooth and free of nicks and dents.
5. Inspect the front and rear shells for scratches,
scores, pits, dents, and other damage.
6. Check the diaphragm for cuts and other damage.
11—32

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

REAR DISC BRAKE 1 1
REAR DISC BRAKE
SIMPLE INSPECTION OF DISC PAD WEAR
1. Loosen the rear wheel lug nuts.
2. Jack up the rear 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 1 mm
(0.04 in) min.
76G11X-082
86U11X-084
REPLACEMENT OF DISC PAD
Caution
Replace the left and right pads at the same
time.
1. Loosen the wheel lug nuts.
2. Release the parking brakes.
3. Jack up the rear of the vehicle and support it with
safety stands.
4. Remove the wheels.
5. Remove the parking brake cable from the cable
bracket and the operating lever.
6. Remove the upper mounting bolt; then pivot the
caliper.
7. Remove the V-springs.
8. Remove the pads and shims.
Warning
Asbestos dust is a health hazard. Do not blow
away brake dust with compressed air.
86U11X-085
86U11X-086
9. Apply the grease supplied in the pad attachment
set to the new shims; then attach them to the new
pads.
10. Turn the piston fully inward by rotating the SST
clockwise. Align the piston groove as shown in the
illustration.
Note
The piston groove and inner pad alignment pin
must be aligned when the inner pad is in-
stalled.
11. Install the pads and shims to the mounting support.
12. Install the pad clip.
11—47