Brake MAZDA 626 1987 Workshop Manual

1 1 OUTLINE
OUTLINE
STRUCTURAL VIEW
i
Front disc/rear drum brake
4-wheel disc brake
1. Brake pedal
2. Power brake unit
3. Brake master cylinder
4. Parking brake lever
5. Dual proportioning valve
6. Front disc brake
86U11X-002
7. Rear drum brake
8. Parking brake cable
9. Rear disc brake
11—2

OUTLINE 11
86U11X-003
1. Front disc brake
2. Hydraulic unit
3. Pipe joint
4. Master cylinder
5. Power brake unit
6. Relay box
7. Control unit
8. Wheel speed sensor
9. Sensor rotor
10. Rear disc brake
11. Parking brake lever
12. Parking brake cable
Front disc brake
(Ventilated disc)
Rear disc brake
(Solid disc)
Rear drum brake
(Leading-trailing)

1 1 OUTLINE
SPECIFICATIONS
Item Specification
Brake pedal
Type Suspended
Brake pedal Pedal lever ratio 4.2 Brake pedal
Max. stroke mm (in) LHD: 136.5 (5.37) RHD: 135 (5.31)
Master cylinder Type Tandem (with level sensor) Master cylinder
Cylinder inner diameter mm (in) 22.22 (0.87)
Front disc brake
Type Mounting support, Ventilated disc
Front disc brake
Cylinder bore mm (in) 53.97 (2.12)
Front disc brake Pad dimensions (area x thickness) mm2 x mm (in2 x in) 4,800 x 10 (7.44 x 0.39) Front disc brake
Disc plate dimensions mm (in) (outer diameter x thickness) 13 inch-wheel: 242 x 20 (9.53 x 0.79) 14 or 15 inch-wheel: 264 x 24 (10.39 x 0.94)
Rear disc brake
(Turbo model)
Type Mounting support, Solid disc
Rear disc brake
(Turbo model)
Cylinder bore mm (in) 30.2 (1.19)
Rear disc brake
(Turbo model) Pad dimensions (area x thickness) mm2 x mm (in2 x in) 2,900 x 8 (4.5 x 0.31)
Rear disc brake
(Turbo model)
Disc plate dimensions mm (in) (outer diameter x thickness) 259 x 10 (10.2 x 0.39)
Rear drum brake
(Non-Turbo model)
Type Leading-trailing
Rear drum brake
(Non-Turbo model)
Wheel cylinder inner diameter mm (in) 17.46 (0.69)
Rear drum brake
(Non-Turbo model) Lining dimensions mm (in)
(width x length x thickness) (a): 25 x 191.9 x 5 (0.98 x 7.56 x 0.20)
(b): 30 x 219.3 x 5 (1.18 x 8.63 x 0.20)
Rear drum brake
(Non-Turbo model)
Drum inner diameter mm (in) (a): 200.0 (7.87) (b): 228.6 (9.0)
Rear drum brake
(Non-Turbo model)
Shoe clearance adjustment Automatic adjuster
Power brake unit Type Vacuum multiplier Power brake unit
Diameter mm (in) 238 (9.37)
Braking force control device Type Dual proportioning valve or ABS (if equipped)
Brake fluid DOT-3 or DOT-4, or SAE J1703
Parking brake Type Center lever (Mechanical two rear brakes)
(a)...13-inch wheel in General LHD and RHD models
(b)...Except 13-inch wheel in General LHD and RHD models
11-4

TROUBLESHOOTING GUIDE 1 1
TROUBLESHOOTING GUIDE
The table below covers the normal braking system. Refer to page 11—73 for ABS system.
Problem Possible cause Remedy Page
Poor braking Leakage of brake fluid Air in system Worn pad or lining
Brake fluid, grease, oil, or water on pad or lining Hardening of pad or lining surface or poor contact Malfunction of disc brake piston Malfunction of master cylinder or wheel cylinder Malfunction of power brake unit
Malfunction of check valve (vacuum hose)
Damaged vacuum hose Deterioration of flexible hose Malfunction of dual proportioning valve
Repair Air bleed Replace
Clean or replace Grind or replace Replace Repair or replace Repair or replace Repair or replace Replace Replace Replace
11-9 11-40,47,56 11-40,47,56 11-40,47,56 11—43,50 11-14,57 11-29 11-29 11-29
11-39
Brakes pull to one
side
Worn pad or lining
Brake fluid, grease, oil, or water on pad or lining Hardening of pad or lining surface or poor contact Abnormal wear or distortion of disc, drum, pad, or lining Malfunction of automatic adjuster Looseness of backing plate mounting bolts Malfunction of wheel cylinder
Improper adjustment of wheel bearing preload, or wear Improper adjustment of wheel alignment Unequal tire air pressures
Replace Clean or replace Grind or replace Repair or replace Repair or replace Tighten
Repair or replace Refer to Section 9 Refer to Section 10 Refer to Section 12
11-40,47,56 11-40,47,56 11-40,47,56 11-40,47,56 11-56 11-61 11-57
Brakes do not
release
No brake pedal play
Improper adjustment of push rod clearance
Clogged master cylinder return port Shoe does not return properly Wheel cylinder does not return properly Improper return due to malfunction of piston seal of disc brake Excessive runout of disc plate Improper return of parking brake cable or improper ad-justment
Improper adjustment of wheel bearing preload
Adjust
Adjust
Clean
Adjust Clean or replace Replace
Replace Repair or adjust
Refer to Section 9
11-11
11—23,24
11-57 11—43,50
11-65
Pedal goes too far (too much pedal stroke)
Air in system due to insufficient brake fluid
Improper adjustment of pedal play Worn pad or lining Air in system
Add fluid and bleed air
Adjust Replace Air bleed
11—9
11—11 11-40,47,56 11-9
Abnormal noise or
vibration during
braking
Worn pad or lining Deterioration of pad or lining Brakes do not release
Foreign material or scratches on disc plate or drum con-tact surface
Looseness of backing plate or caliper mounting bolts Damage or deviation of disc or drum contact surface Poor contact of pad or lining Insufficient grease on sliding parts
Replace
Grind or replace
Repair
Clean
Tighten Replace Repair or replace Apply grease
11-40,47,56 11-40,47,56
11-61 11-56 11-40,47,56
Parking brake
does not hold well
Excessive lever stroke
Brake cable stuck or damaged
Brake fluid or oil on pad or lining Hardening of pad or lining surface or poor contact
Adjust
Repair or replace Clean or replace Grind or replace
11-65
11-68
11-40,47,56
11-40,47,56
76G11X-003
11—5

1 1 ON-VEHICLE
MAINTENANCE,
BRAKE HYDRAULIC
LINE

ON-VEHICLE MAINTENANCE
BRAKE FLUID LEVEL IN MASTER CYLINDER
RESERVOIR
Check the fluid level in the reservoir. It should be be-
tween the Max and Min lines on the reservoir.

If
the fluid level is extremely low, check the brake sys-
tem for leaks.
Fluid specification:
DOT-3 or DOT-4 or SAE J1703
76G11X-004
BRAKE HYDRAULIC LINE
STRUCTURAL VIEW
Standard
Front
86U11X-007
11—6

BRAKE HYDRAULIC LINE 1 1
ABS
86U11X-OOB
11-7

1 1 BRAKE HYDRAULIC LINE
RF-CX
76G11X-005
ON-VEHICLE INSPECTION OF BRAKE LINES
Check the following and replace or repair any faulty
parts.
1. Cracks, damage, corrosion of brake hose
2. Damage to brake hose threads
3. Scars, cracks, and swelling of flexible hose
4. Fluid leakage of all lines
86U11X-009
11—8
expert22 fl/ia http://rutracker.org

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

1 1 BRAKE HYDRAULIC LINE
Procedure
1. Jack up the vehicle and support it with safety
stands.
2. Fill the reservoir with brake fluid. Be sure that it is
at least half full at all times during the air bleeding
process.
Caution
a) Be careful not to spill brake fluid onto a
painted surface.
b)Use only the specified brake fluid. Do not
mix it with any other type.
3. Remove the bleeder cap; then connect one end
of a transparent vinyl tube to the bleeder screw and
place the other end in a receptacle.
4. Have an assistant depress the brake pedal a few
times, and then hold it in the depressed position.
5. Loosen the bleeder screw, drain out the fluid, and
retighten the bleeder.
Note
a) The two people should stay in voice con-
tact with each other.
b) Be sure the pedal remains depressed until
the bleeder is tightened.
86U11X-014
6. Repeat steps 4 and 5 until no more air is dis-
charged.
7. Tighten the bleeder screw, and check that there
is no fluid leakage.
Bleeder screw tightening torque:
6—9 N-m (60—90 cm-kg, 52—78 in-lb)
Caution
Be sure to clean away any spilled fluid with
rags.
8. Add brake fluid to the reservoir up to the speci-
fied level.
11—10

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