tow MAZDA 626 1987 Owner's Manual

ASSEMBLY 7C
4. Use the following procedure to adjust the front
clutch drum end play and select the adjust shim.
(1) Set the oil pump gasket onto the transaxle
case.
(2) Place the adjust shim onto the front clutch
drum.
(3) Install the oil pump and bearing race into the
transaxle; then tighten the oil pump mounting
bolts to the specified torque.
Tightening torque:
15—22 N m (1.5—2.2 m-kg, 11—16 ft-lb)
76G07C-300
76G07C-301
63U07B-220
(4) Position the transaxle with the oil pump facing
down ward position.
(5) While turning the connecting shell 2 complete
turns, push the front clutch drum toward the
oil pump with a screwdriver to seat the front
clutch drum.
(6) Measure the clearance between the front clutch
drum and the connecting shell. This clearance
is the front clutch drum end play.
End play: 0.5—0.8 mm (0.020—0.031 in)
(7) If the end play is not within specification, ad-
just it by selecting the proper adjust shim.
Shim sizes mm (in)

1.3 (0.051) 1.5 (0.059) 1.7 (0.067)
2.3 (0.091) 1.9 (0.075) 2.1 (0.083)
1.7 (0.067)
2.3 (0.091)
2.5 (0.098) 2.7 (0.106)

76G07C-302
7C-113

TROUBLESHOOTING GUIDE 9
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Faulty operation of
driveshaft
Broken ball joint
Broken tri-pod joint
Worn or seized joint
Replace
Replace
Replace
9—31
9—35
9—31, 35
Abnormal noise from driveshaft Insufficient grease in joint or spline Excessive backlash on spline Worn joint
Add or replace
Replace
Replace
9—33, 36 9—31, 35 9-31, 35
Steering wheel pulls. (Steering wheel pulls toward either right or left side)
Bent steering linkage
Fatigued coil spring
Lower arm bushing worn or damaged Bent knuckle Bent lower arm or loose mounting Incorrect toe-in adjustment Improper tire air pressure Unevenly worn tires (left and right tires) Brake dragging
Refer to Section 10 Refer to Section 13 Refer to Section 13 Replace Refer to Section 13 Refer to Section 13 Refer to Section 12 Refer to Section 12 Refer to Section 11
9-11
Unstable handling Bent steering linkage
Joint in steering system worn or damaged
Incorrect steering pinion preload adjustment Fatigued coil spring
Faulty shock absorber(s) Lower arm bushing worn or damaged Incorrect toe-in adjustment (front or rear) Improper tire air pressure Wheel(s) bent or unbalanced
Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 13 Refer to Section 13 Refer to Section 13 Refer to Section 13 Refer to Section 12 Refer to Section 12
—
Excessive steering wheel play Faulty front wheel bearing Incorrect steering pinion preload adjustment Rack and pinion worn Joint in steering system worn or damaged Lower arm bushing worn or damaged
Adjust Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 13
9-11
Tires excessively worn or worn un-evenly
Incorrect toe-in adjustment Improper tire air pressure Unbalanced wheel(s)
Refer to Section 13 Refer to Section 12 Refer to Section 12 —
Abnormal noise
from axle
Faulty wheel bearing Replace 9-11,18,23
86U09X-006
9—7

ENGINE SPEED SENSING POWER STEERING 1 0
3. Tap in a new roll pin.
86U10X-175
i V
vlM^lPl'' \f ) j//
/f
Boot
1. Apply grease to the inner surface of the small end
of the boot.
2. Install the boot. Wrap a new wire around the large
end of the boot two times and then twist it 4 to 4.5
times. Bend the twisted part toward the mounting
bracket.
Note
Be careful not to break the boot wire.
3. Install the spring clip on the small end of the boot.
86U10X-176
Tie-rod end
Align with the mark made before disassembly, and
then tighten the nut.
86U10X-177
Oil pipe
Secure the mounting bracket in a vise so that the oil
pipe connections face upward.
86U10X-178
10-73

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

ANTI-LOCK BRAKE SYSTEM (ABS) 1 1
Installation of Front Sensor Rotor
Install in the reverse order of removal, referring
Torque specifications
Removal note
Sensor rotor
Tap the sensor rotor off the drive shaft with a chisel.
to installation note for the specially marked parts.
Installation note
Sensor rotor
Press the sensor rotor onto the driveshaft with the
SST.
Caution
Install the sensor rotor with chamfered edge
toward the driveshaft.
11—91

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
t
2. Bleed air from the system.
3. Depress the brake pedal, and compare the fluid
pressure of the front brake with that of the rear
brake.
Fluid pressure kPa (kg/cm2, psi)

Front brake side Rear brake side
A 2,943 (30,427)
A'
2,747-3,139
(28-32, 398-455)

A B
B 6,867 (70,995)
B'
3,924-4,316 (40-44, 569-626)

Front brake pressure kPa (kg/cm2, psi) 4. If the measurement is not within specification re-
place the hydraulic unit assembly. 86U11X-194
REMOVAL
Caution
a) Brake fluid will damage painted surfaces. If it does get on the painted surfaces, wipe
it off immediately.
b) Oo not tip the hydraulic unit to prevent the brake fluid in the reservoir from draining.
1. Remove the nuts mounting the fuel filter and ignitor to the bracket and move them toward the engine.
2. Remove the air cleaner assembly.
3. Remove the master cylinder. (Refer to page 11—14.)
4. Remove the hydraulic unit in the sequence shown in the figure.
76G11X-062
11—96

1 3 FRONT SHOCK ABSORBER AND SPRING
AAS actuator
1. Disconnect the AAS actuator connector.
2. Remove the AAS actuator.
86U13X-011
Shock absorber clinch bolts and nuts
1. Remove the shock absorber clinch bolts and nuts.
2. Remove the shock absorber upper mounting nuts.
76G13X-013
Installation Note
Mounting block
Install the mounting block to the suspension tower
with the white mark facing the front-inside direction.
Tightening torque: 46—63 N-m
(4.7—6.4 m-kg, 34—46 ft-lb)
86U13X-013
Shock absorber clinch bolts and nuts
Install the clinch bolts and nuts.
Tightening torque: 93—117
N
m
(9.5—11.9 m-kg, 69—86 ft-lb)
86U13X-014
13—14

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

REAR WHEEL ALIGNMENT 13
86U13X-119
Adjustment (4WS)
To adjust the toe-in, loosen the left and right tie-rod
locknuts, and 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 7.8 mm (0.31 in).
c) Adjust the toe-in after adjusting the steer-
ing angle.
Tighten the tie-rod locknuts to the specified torque.
Tightening torque: 69—98 N-m
(7—10 m-kg, 51—72 ft-lb)
86U13X-120
CAMBER
Preparation
1. Remove the center caps from the wheels.
2. Uncrimp the locknut and remove it.
86U13X-121
Inspection
1. Install the SST to the driveshaft.
86U13X-122
13—53

14 WINDSHIELD GLASS
Repair seal
Dam
_5 mm
.(0.19
11 mm
(0.43 in)
6. Prepare the nozzle of the sealant gun so that it has
a flange that can run along the edge of the glass,
and a V from which the sealant can flow. Once the
primer is dry, apply the sealant around the entire
circumference to fill the gap between the dam and
the edge of the glass with a ridge of sealant 11
mm (0.43 in) high.
Keep the bead of sealant smooth and even,
reshaping it where necessary with a spatula.
86U14X-11E
7BU14X-026
76G14X-044
Replenished section
with sealing agent
— Glass
7. Lift the glass into place. Push it in lightly toward
the vehicle to compress the sealant.
Caution
Open the windows to prevent the glass from
being pushed out by air pressure if a door is
closed.
Hardening time of repair seal
Temperature Surface hardening
time
Time required until car
can be put in service
5°C (41 °F) Approx. 1.5 hrs 12 hrs
20°C (68°F) Approx. 1 hr 4 hrs
35°C (95°F) Approx. 10 min. 2 hrs
8. Use a scraper to smooth away any sealant that
oozes out. Add more sealant to any points of poor
contact.
9. Check for water leaks. If a leak is found, wipe the
water off well and add repair seal (B001 77 739)
where needed.
Spacer
86U14X-120
14-50