lock MAZDA 626 1987 Workshop Manual

ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
ELECTRONICALLY-CONTROLLED POWER STEERING
DISASSEMBLY
Disassemble in the sequence shown in the figure, referring to the disassembly note for specially marked
parts.
Caution
a) Because adjustment of the spool valve is not possible, do not disassemble the gear box
for spool valve repairs. If repairs are necessary, replace the gear box assembly.
b) In order to prevent the entrance of dirt, all disassembly and assembly should be done
in a clean area.
c) Before disassembly, plug the openings of all pipe installation fittings; then thoroughly
clean the steering gear and linkage.
86U10X-180
1. Pipe
2. Solenoid valve
3. Tie-rod end
4. Tie-rod end locknut
5. Spring clip
6. Boot wire
7. Boot
8. Tie-rod
9. Adjust cover locknut
10. Adjust cover
11. Spring
12. Pressure pad
13. Outer box assembly
14. Oil seal
15. Mounting bracket
16. Mounting rubber
10—75

ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
/
I I
86U10X-185
63U10X-127
86U10X-186
Tie-rods
1. Uncrimp the washer as shown in the figure.
2. Remove the tie-rod from the rack.
Locknut and adjust cover
Loosen the locknut and remove the adjust cover,
spring, and pressure pad.
Outer box
Protect the outer box with cloth and remove it with
a pipe wrench.
86U10X-187
10—77

ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
86U10X-197
86U10X-198
86U10X-199
6. Apply thread sealant to the threads of the adjust
cover.
7. Install the adjust cover to the gear housing and
tighten it as specified; then loosen it 35°.
Tightening torque:
4.5—5.5 Nm
(45—55 cm-kg, 39—48 in-lb)
8. Measure the pinion torque with the SST.
Pull scale: 1,000—1,400 g (35.3—49.4 oz)
9. If the pinion torque is not within specification, read-
just the adjust cover.
10. Lock the adjust cover with the locknut.
Tightening torque:
40—50
N
m
(4—5 m-kg, 29—36 ft-lb)
11. Set the rack in a vise and install the washer. Tight-
en the tie-rod.
Tightening torque:
60—80 N-m
(6—8 m-kg, 43—58 ft-lb)
Caution
Insert protective material (such as copper
plates) in the jaws of the vise.
76G10X-040
10—81

1 0 ELECTRICAL COMPONENTS OF ELECTRONICALLY-CONTROLLED POWER STEERING (ECPS)
76G10X-020
76G10X-021
Checking Condition
Condition A
1. Turn the ignition switch OFF.
2. Start the engine and let it idle.
3. Turn the steering wheel to the straight-ahead po-
sition, and check the output pattern.
Refer to page 10—89 for other patterns and indi-
cated failure points.
Condition B
1. Turn the ignition switch OFF.
2. Start the engine and let it idle.
3. Turn the steering wheel 45° left and right from the
center, and check the output pattern.
Refer to page 10—89 for other patterns and indi-
cated failure points.
Condition C
1. Turn the ignition switch OFF.
2. Place the vehicle on a chassis roller tester. Block
the rear wheels, and secure it with chains.
3. Start the engine. Put the transmission in gear and
operate the vehicle at more than 10 km/h (6.2
mph).
4.Check the output pattern.
76G10X-022
Normal pattern
4 4V
Normal pattern Normal pattern
uV
Refer to page 10—90 for other patterns and indi-
cated failure points.
Note
For vehicles equipped with ABS, the ABS
warning light may come on. This is not a fail-
ure. The light will go off when turning the ig-
nition switch OFF and back ON.
86U10X-213
10—88

1 0 ELECTRICAL COMPONENTS OF 4-WHEEL STEERING
Condition B
1. Place the vehicle on a chassis roller tester. Block
the rear wheels, and secure it with chains.
2. Turn the ignition switch OFF.
3. Start the engine after the ignition switch has been
OFF for at least 10 seconds. Put the transmission
in gear and operate the vehicle at more than 40
km/h (25 mph).
4. Check if the 4WS warning light flashes or il-
luminates within 60 seconds.
5.
If
flashing or illumination occurs, inspect the circuit
by referring to the table below.
76G10X045
Diagnosis Output Pattern
Warning light output pattern
0.5 sec —i 2.5 sec
Malfunction
Normal operation, control unit or wir-ing harness
Speed sensors or
wiring harness
Flow chart
No.
4WS—0
4WS—1
Rear steering gear
assembly
Solenoid valve or wiring harness
Stepper motor or wiring harness
Rear-to-front steer-ing ratio sensor or wiring harness
4WS—2
4WS—3
4WS—4
4WS—5
86U10X-225
10-96

11
BRAKING SYSTEM
OUTLINE 11—2
STRUCTURAL VIEW 11—2
SPECIFICATIONS 11— 4
TROUBLESHOOTING GUIDE 11— 5
ON-VEHICLE MAINTENANCE 11—6
BRAKE FLUID LEVEL IN MASTER
CYLINDER RESERVOIR 11— 6
BRAKE HYDRAULIC LINE 11—6
STRUCTURAL VIEW 11—6
ON-VEHICLE INSPECTION OF
BRAKE LINES 11— 8
REMOVAL AND INSTALLATION OF
BRAKE LINES 11— 9
REPLACEMENT OF BRAKE
FLUID 11— 9
AIR BLEEDING 11— 9
BRAKE PEDAL 11—11
ON-VEHICLE INSPECTION 11—11
REMOVAL 11—12
INSPECTION 11—13
INSTALLATION 11—13
MASTER CYLINDER 11—14
REMOVAL 11—15
DISASSEMBLY AND ASSEMBLY
(EXCEPT RHD DOHC TURBO).... 11—14
INSPECTION 11—17
DISASSEMBLY AND ASSEMBLY
(RHD DOHC TURBO) 11—18
INSPECTION 11—21
INSTALLATION 11—22
POWER BRAKE UNIT 11—27
FUNCTION CHECK 11—27
INSPECTION OF CHECK VALVE... 11—29
REMOVAL 11—29
DISASSEMBLY AND ASSEMBLY... 11—30
INSPECTION 11—32
INSTALLATION 11—33
VACUUM PUMP 11—35
ON-VEHICLE INSPECTION 11—35
REMOVAL AND INSTALLATION.... 11—35
DISASSEMBLY AND ASSEMBLY... 11—36
INSPECTION 11—37
DUAL PROPORTIONING VALVE 11—38
FUNCTION CHECK 11—38
REMOVAL AND INSTALLATION.... 11—39
FRONT DISC BRAKE 11—40
SIMPLE INSPECTION OF DISC
PAD WEAR 11—40
REPLACEMENT OF DISC PAD 11—40
REMOVAL 11—42
DISASSEMBLY AND ASSEMBLY... 11—43
INSPECTION 11—44
INSTALLATION 11—45
REAR DISC BRAKE 11—46
SIMPLE INSPECTION OF DISC
PAD WEAR 11—46
REPLACEMENT OF DISC PAD 11—46
REMOVAL 11—49
DISASSEMBLY AND ASSEMBLY... 11—50
INSPECTION 11—54
INSTALLATION 11—55
REAR DRUM BRAKE 11—56
REMOVAL 11—56
DISASSEMBLY AND ASSEMBLY
OF WHEEL CYLINDER 11—59
INSPECTION 11—60
INSTALLATION 11—61
PARKING BRAKE 11—65
ON-VEHICLE MAINTENANCE 11—65
REMOVAL AND INSTALLATION
OF PARKING BRAKE LEVER 11—66
REMOVAL OF PARKING BRAKE
CABLE 11—68
INSTALLATION OF PARKING
BRAKE CABLE 11—69
ANTI-LOCK BRAKE SYSTEM
(ABS) 11—71
STRUCTURAL VIEW 11—71
WIRING DIAGRAM 11—72
TROUBLESHOOTING 11—73
DIAGNOSIS INDICATION MODE ... 11—86
MEMORY CANCEL 11—86
ABS WARNING LIGHT 11—87
RELAY BOX 11—87
WHEEL SPEED SENSOR 11—87
SENSOR ROTOR 11—90
HYDRAULIC UNIT FLUID 11—94
HYDRAULIC UNIT 11—94
CONTROL UNIT CIRCUIT 11—99
76G11X-001

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