MAZDA 626 1987 Workshop Manual

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

FRONT DISC BRAKE 11
13. Lower the caliper assembly onto the mounting
support.
14. Tighten the mounting bolt to the specified torque.
Tightening torque:
31—41 N-m (3.2—4.2 m-kg, 23—30 ft-lb)
76G11X-076
15. Mount the wheels.
16. Apply the brakes a few times; then turn the wheels
and check that the brakes do not drag excessively.
17. Lower the vehicle.
18. Tighten the wheel lug nuts.
Tightening torque:
88—118 N-m (9.0—12.0 m-kg, 65—87 ft-lb)
76G11X-077
11—41

1 1 FRONT DISC BRAKE
REMOVAL
1. Loosen the wheel lug nuts.
2. Jack up the front of the vehicle and support it with safety stands.
3. Remove the wheels.
4. Remove in the sequence shown in the figure.
Warning Asbestos dust is a health hazard. Do not blow away brake dust with compressed air.
Caution
Brake fluid will damage painted surfaces. If it does get on a painted surface, wipe it off
immediately.
76G11X-078
1. Flexible hose
2. Caliper assembly
3. V-spring
4. Outer pad and shim
5. Inner pad and shim
6. Guide plate
7. Mounting support
8. Disc plate (Refer to section 9)
11—42

FRONT DISC BRAKE 1 1
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the sequence shown in the figure, referring to disassembly note for specially marked
parts.
2. Inspect all parts, referring to inspection note.
3. Assemble in the reverse order of disassembly, referring to assembly note for specially marked parts.
76G11X-079
1. Snap ring
2. Dust seal
3. Piston
4. Piston seal
5. Guide pin
6. Pin boot
7. Bushing
8. Cap
9. Bleeder screw
Disassembly Note
Piston
Place a piece of wood in the caliper; then blow com-
pressed air through the hose connection hole to force
out the piston.
Caution
Blow the compressed air a little at a time to
prevent the piston from popping out.
76G11X-080
Piston seal
Remove the piston seal from the caliper with the SST.
86U11X-074
11-43

1 1 FRONT DISC BRAKE
86U11X-075
76G11X-081
86U11X-077
Inspection Note
Check the following and replace any faulty parts.
1. Cylinder and piston for wear or rust
2. Caliper body for damage or cracks
3. Boot for damage or poor sealing
Assembly Note
Application of grease
Coat the following parts with the grease supplied in
the seal kit.
1. Piston seal
2. Dust seal
3. Guide pin
4. Guide pin boot
5. Bushing
Piston
Coat the piston and the cylinder with brake fluid; then
insert the piston straight into the cylinder.
86U11X-078
11—44

FRONT DISC BRAKE 1 1
INSPECTION
Check the following and replace any faulty parts.
Disc Pad
1. Oil or grease on facing
2. Abnormal wear or cracks
3. Deterioration or heat damage 4. Remaining lining thickness
Thickness: 2.0 mm (0.08 in) min.
86U11X079
Disc Plate
1. Runout
Runout: 0.1 mm (0.004 in) max.
Caution
a) There must be no wheel bearing looseness.
b) Measure at the outer edge of the disc plate
surface.
86U11X-080
2. Wear or damage
Thickness specifications:
mm (in)
Standard Minimum
13 inch-wheel 20 (0.79) 18 (0.71)
14 or 15 inch-wheel 24 (0.94) 22 (0.86)
76G11X-046
11-45

1 1 FRONT DISC BRAKE
INSTALLATION
1. Install in the reverse order of removal.
2. Tighten all nuts and bolts to the specified torque, referring to torque specifications.
3. After installation:
(1) Add brake fluid and bleed air. (Refer to page 11—9.)
(2) Depress the brake pedal a few times and check that the front brakes do not drag excessively
while the wheels are being rotated.
Note
Refer to page 11—40 for pad installation.
Torque specifications
76G11X-047
11—46

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

1 1 REAR DISC BRAKE
86U11X-087
86U11X-088
13. Lift the caliper assembly onto the mounting
support.
14. Tighten the mounting bolt to the specified torque.
Tightening torque:
16—24 Nm (1.6—2.4 m-kg, 12—17 ft-lb)
15. Connect the parking cable end to the operating
lever; then tighten the locknut.
Tightening torque:
20—28 N-m (2.0—2.9 m-kg, 14—21 ft-lb)
Caution
There must be no clearance between the ca-
ble end and the operating lever.
16. Mount the wheels.
17. Apply the brakes a few times; then check that the
brakes do not drag excessively while the wheels
are being rotated.
18. Lower the vehicles.
19. Tighten the wheel lug nuts.
Tightening torque:
88—118
N
m (9—12 m-kg, 65—87 ft-lb)
76G11X-083
11-48