height MAZDA 626 1987 Owner's Manual

ASSEMBLY 7B
(2) Install the clutch assembly by rotating it.
86U07B-414
Note
Measure the height difference between the re-
verse and forward drum and transaxle case.
Standard height: 0.8 mm (0.032 in)
76G07B-185
17. Install the snap ring into the bottom ring groove
of the turbine shaft.
86U07B-416
7B—207

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

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

MASTER CYLINDER 1 1
Adjustment
Adjust the piston to push rod clearance in the follow-
ing order.
1. For (a) of judgement table
(1) Measure the height of (D) and record after
removing the SST from the master cylinder.
76G11X-028
Adjust nut
(2) Install the SST again to the master cylinder,
and turn the adjust nut so that clearance (C)
between the SST and the master cylinder is
0 mm (Oin).
(3) Measure the height of (E) when clearance (C)
is 0 mm (Oin).
(E) — (D) = Projecting amount of the power
brake unit push rod
76G11X-029
(4) Remove the push rod from the power brake
unit.
63G11X-349
(5) Make the piston to push rod clearance 0 mm
(Oin) by turning the push rod and shortening
the push rod length by the amount of (E) — (D).
Note
The threads of the push rod are specially
designed so that the push rod bolt becomes
harder to turn past a certain point to prevent
loosening of the bolt. Turn the push rod bolt
only within this range when adjusting.
76G11X030
11—25

POWER BRAKE UNIT 1 1
86U11X-038
0
o
X
\ V^ Third
Second
^ First
86U11X-039
O X

fiSy

V
86U11X-040
Pedal-depression Pre!tur!9au9e
force gauge
^Intake manifold
86U11X-041
POWER BRAKE UNIT
FUNCTION CHECK
Simple Method
First step
1. With the engine stopped, depress the pedal a few
times.
2. With the pedal depressed, start the engine
3. If immediately after the engine starts the pedal
moves down slightly, the unit is operating.
Second step
1. Start the engine.
2. Stop the engine after it has run for
1
or 2 minutes.
3. Depress the pedal with the usual force.
4.
If
the first pedal stroke is long and becomes short-
er with subsequent strokes, the unit is operating.
5. If a problem is found, inspect for damage of the
check valve or vacuum hose, and examine the in-
stallation condition. Repair if necessary, and inspect
it once again.
Third step
1. Start the engine.
2. Depress the pedal with the usual force.
3. Stop the engine with the pedal still depressed.
4. Hold the pedal down for about 30 seconds.
5. If the pedal height does not change, the unit is
operating.
6. If there is a problem, check for damage to the
check valve or vacuum hose, and check the con-
nection. Repair if necessary, and check once
again.
If the nature of the problem is still not clear after fol-
lowing the 3 steps above, follow the more detailed
check described in "Method using tester".
Method Using Tester
Connect a pressure gauge, vacuum gauge, and ped-
al depression force gauge as shown in the figure. Af-
ter bleeding the air from the pressure gauge, conduct
the test as described in the 3 steps below.
Note
Use commercially available gauges and ped-
al depression force gauge.
11—27

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 3 FRONT WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT
86U13X-108
69G10X-031
Pre-inspection
1. Check the tire inflation and bring to the recom-
mended pressure.
2. Inspect the front wheel bearing play and correct,
it if necessary.
3. Inspect the wheel and tire runout.
4. Inspect the ball joints and steering linkage for any
excessive looseness.
5. The vehicle must be on level ground and have no
luggage or passenger load.
6. The difference in height between the left and right
sides from the center of the wheel to the fender
brim must be within 10 mm (0.39 in).
Caution
a) Front and rear wheel alignment should be
checked simultaneously. If adjustment is
made to either the front or rear wheels,
recheck the alignment, particularly toe-in,
on all other wheels.
b) Check and adjust the steering angle trans-
fer shaft after adjusting the front wheel
alignment. (Refer to Section 10)
TOE-IN
Inspection
1. Raise the front of the vehicle until the wheels clear
the ground.
2. Turn the wheels by hand, mark a line in the center
of each tire tread using a scribing block.
3. Place the front wheels in the straight-ahead posi-
tion and lower the vehicle.
4. Measure the distance between the lines at the front
and rear of the wheels.
Both measurements must be taken at equal
distances from the ground.
Toe-in (distance greater at rear than front):
3 ± 3 mm (0.12 ± 0.12 in)
Adjustment
To adjust the toe-in, loosen the left and right tie-rod
lock nuts, then turn the tie-rods by the same amount.
Caution
a) The left and right tie-rods are both right
threaded, so, to increase the toe-in, turn the
right tie-rod toward the front of the vehicle,
and turn the left tie-rod by the same amount
toward the rear.
b) One turn of the tie-rod (both sides) changes
the toe-in by about 7.2 mm (0.28 in).
c) Tighten the tie-rod locknuts to the specified
torque.
Tightening torque: 69—98 N-m
(7—10 m-kg, 51—72 ft-lb) 86U13X-110
13-50

13 REAR WHEEL ALIGNMENT
76G13X-033
86U13X-116
86U13X-117
86U13X-116
13-52
REAR WHEEL ALIGNMENT
PRE-INSPECTION
1. Check the tire inflation and bring to the recom-
mended pressure.
2. Inspect the wheel and tire runout.
3. The vehicle must be on level ground and have no
luggage or passenger load.
4. Check that the suspension is correctly adjusted.
5. The difference in height between the left and right
sides from the center of the wheel to the fender
rim should be within 10 mm (0.39 in).
Caution
a) Front and rear wheel alignments should be
checked simultaneously. If adjustment is
made to either the front or rear wheels,
recheck the alignment, particularly toe-in,
on all other wheels.
b) Check and adjust the steering angle trans-
fer shaft after adjusting the rear wheel align-
ment. (Refer to Section 10.)
TOE-IN
Inspection
1. Raise the rear of the vehicle until the wheels clear
the ground.
2. Turn the wheels by hand, mark a line in the center
of each tire tread using a scribing block.
3. Lower the vehicle.
4. Measure the distance between the marked lines
at the front and rear of the wheels.
Toe-in
0 ± 3 mm (0 ±0.12 in) 2WS
3 ± 3 mm (0.12 ±0.12 in) 4WS
Adjustment (2WS)
1. Loosen the adjusting rod lock nuts, then adjust the
toe-in.
2. To increase the toe-in, turn the adjusting rods as
follows:
Right rod — Turn counterclockwise
Left rod — Turn clockwise
To decrease the toe-in, turn the adjusting rods as
follows:
Right rod — Turn clockwise
Left rod — Turn counterclockwise
Caution
a) Both the left and right rods must be adjust-
ed by the same amount.
b) One turn of the adjusting rod (both sides)
changes the toe-in by about 11.6 mm (0.46
in).
3. Tighten the adjusting rod lock nuts to the speci-
fied torque.
Tightening torque:
55—80 N-m (5.6—8.2 m-kg, 41—59 ft-lb)

QUARTER WINDOW GLASS 1 4
4. Apply a thin coat of primer to the bonding area of
the body and glass, and allow 30 minutes for it
to dry.
Caution
Keep the area free of dirt. Do not touch the
surface. If primer gets on the hands, remove
it immediately.
86U14X-154
Repair
seal
lOver 10mm
\> " fl(Q.4iri)
J -Quarter
window glass
5. After the primer dries, apply a bead of repair seal
to a height of 10 mm (0.4 in) min. around the
edge of the glass.
86U14X-155
6. Attach the glass to the body.
86U14X-157
14-65

1 4 SLIDING SUNROOF
76U14X-067
Set plate
76U14X-068
1.5mm (0.016 in)
: ? ©—
A-A Cross section
76U14X-069
B-B Cross section
Adjust screw Fitting screw jj
Fitting screw®
14. Fully close the lower panel.
15. Install the slide panel to the lower panel, and tight-
en securely.
16. Insert the sun shade from the notch in the set plate,
and push it all the way back.
17. Insert the set plate cap.
18. Adjust the height of the slide panel.
(Cross-section A-A)
Adjust so that the height difference between the
outer panel and roof panel is 1.5 mm (0.06 in)
max.
(Cross-section B-B adjustment)
(1) Loosen installation screws (1) and (2).
If the adjustment is only about 2 mm (0.08 in)
don't loosen screw (1).
(2) Turn the screws to adjust.
Turning to the right raises, and to the left lowers.
(3) Tighten installation screws (1) and (2).
76U14X-070
14-88