brake rotor MAZDA 626 1987 Workshop Manual

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

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)

ANTI-LOCK BRAKE SYSTEM (ABS) 1 1
ANTI-LOCK BRAKE SYSTEM (ABS)
STRUCTURAL VIEW
1. Hydraulic unit 4. Sensor rotor (front) 7. Wheel speed sensor (rear)
2. Relay box 5. Wheel speed sensor (front) 8. Sensor rotor (rear)
3. Control unit 6. Check connector
11—71

ANTI-LOCK BRAKE SYSTEM (ABS) 1 1
Diagnosis Table
Note
Flashing of the warning light shows past failure, and its illumination shows present failure.
Diagnosis indication Possible failure Flow chart
No. Warning light Voltmeter Possible failure Flow chart
No.
ON
n
i2vn
OV

Hydraulic unit Harness
Right front wheel speed
sensor ABS-1
ON
n nn
Hydraulic unit Harness Left front wheel speed sensor ABS-2

OFF

Hydraulic unit Harness Left front wheel speed sensor ABS-2

OFF
nnn

Hydraulic unit Harness
Rear wheel speed sensor ABS-3

n
nnnn
Right front sensor rotor ABS-4

n
nnnnn
Left front sensor rotor ABS-5

JLilTUITLTL
Right rear sensor rotor ABS-6

jirLruiJum
Left rear sensor rotor ABS-7

J n
Hydraulic unit Harness
Control unit connector (11-pin)
ABS-8

nnnn

Hydraulic unit Harness
Control unit connector (11-pin)
ABS-8

J nn

Relay box
Hydraulic unit
Harness
ABS-9

jumruiTL

Relay box
Hydraulic unit
Harness
ABS-10

j nnn
Relay box
Hydraulic unit
Harness
ABS-11

jinnjuuL

Relay box
Hydraulic unit
Harness ABS-12

j nnnn

Relay box
Hydraulic unit
Harness
ABS-13

jiruuirirL

Relay box
Hydraulic unit
Harness
ABS-14

j nnnnn
Hydraulic unit Harness Control unit
ABS-15

juuuiruL

Hydraulic unit Harness Control unit ABS-16

j JinjiruifL.
Control unit
ABS-17

jiruinjiri—
JinjiruifL.
Control unit
ABS-18

j
No signal; failure condi-tions not stored
in
memory
Control unit Control unit connector (17-pin) Battery capacity Alternator output voltage Wiring harness (warning light-control unit-check connector)
Inspect, and repair or replace as necessary
j
No signal; failure condi-tions not stored
in
memory
No problem When warning light does
not
illuminate with engine running and
no
jumper wire

76G11X092
11-75

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
Flow Chart (Refer to Wiring Diagram, Page 11—72.)
ABS-1
Possible failure
Right front wheel speed sensor, Harness, Hydraulic unit
Disconnect Q-01 (11-pin) connec-tor. Check continuity
at
harness side.
Q-01 (11-pin)
I
Continuity
Y (2C) Ground No

OK

Measure resistance
at
harness side.
Q-01 (11-pin) Resistance
Y (2C)
i 0
(2D) 800—1200
Q
OK
NG
Repair harness.

(Control unit — Right front sensor)
NG

Disconnect Q-03. Measure resistance
at
sensor.
Q-03 Resistance
Y
[ O
800—1200 Q

NG
Replace right front wheel speed sensor.

OK
Repair harness.

(Control unit — Right front sensor)

Check followings*
• Clearance between sensor and rotor standard: 0.3—1.1
mm
(0.012-0.043
in)
• Objects sticking
to
sensor
or
rotor
• Damaged sensor
or
rotor
• Sensor installation Tightening torque: 16-23 N-m (1.6-2.3 m-kg, 12—17 ft-lb)

OK

Connect Q-01 (11-pin) connector. Jump GB
to B at
Q-07 connector. Start engine. Check that warning light stays ON. Drive vehicle and check that warning light flashes (0.25 sec ON OFF)
at 15
km/h
(9
mph).

NG
Repair
or
replace
as
necessary
* All conditions can
be
verified
as
follows,
if an AC
voltmeter
is
available. 1. Jack
up
vehicle. 2. Measure sensor voltage while rotating right front wheel
one
revolution
per
second.
Q-01 (11-Din) Voltage (AC)
Y (2C) O (2D) More than 0.25V

NG
Check Q-01 connector,
or
Replace control unit.

OK

Replace hydraulic unit.

76G11X-055
11—76

ANTI-LOCK BRAKE SYSTEM (ABS) 1 1
ABS-2
Possible failure
Left front wheel speed sensor, Harness, Hydraulic unit
Disconnect
Q-01
(11-pin)
con-
nector.
Check continuity
at
harness side.
Q-01 (11-pin) Continuity
W (2A) Ground No

OK

Measure side.
Q-01 (11-pin) Resistance
W (2A) R (2B) 800-1200
fl
OK

Connect Q-01 (11-pin) connector. Jump GB
to B
at (Q-07) connector. Start engine.
Check that warning light stays ON. Drive vehicle and check that warn-ing light flashes (0.25 sec ON OFF) at
15
km/h
(9
mph).

NG
Repair harness (Control unit
—
Left front sensor)
resistance
at
harness

NG

Disconnect Q-02 Measure resistance
at
sensor.
Q-02 Resistance
W
| R
800-1200
0
OK

Check followings*
• Clearance between sensor and rotor standard: 0.3—1.1
mm
(0.012-0.043
in)

• Objects sticking
to
sensor
or
rotor • Damaged sensor
or
rotor
• Sensor installation Tightening torque: 16-23 N m
(1.6—2.3 m-kg, 12-17 ft-lb)

NG
OK
NG
Repair
or
replace
as
necessary

NG
Check Q-01 connector,
or
Replace control unit.

OK

Replace hydraulic unit.
Replace left front wheel speed
sensor.
Repair harness.
(Control unit
—
Left front sensor)
"All conditions can
be
verified
as
follows,
if an AC
voltmeter
is
available. 1. Jack
up
vehicle. 2. Measure sensor voltage while rotating left front wheel
one
revolution
per
second.
Q-01 (11-pin) Voltage (AC)
W (2 A)
|
R (2B) More than
0
25V

86U11X-146
11-77

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
ABS-3
Possible failure
Rear wheel speed sensor, Harness, Hydraulic unit
Disconnect
Q-01
(11-pin)
con-

nector.
Check continuity
at
harness side.
Q-01 (11-pin) Continuity
G (2H) Ground No YG (2E) Ground No
Measure side.
Q-01 (11-pin) Resistance
YG (2E) YL (2F) 800—1200
fi
G (2H)
] L
(2J) 800—1200
fi
OK

Connect Q-01 (11-pin) connector. Jump GB
to B at
Q-07 connector. Start engine.
Check that warning light stays ON. Drive vehicle and check that warn-ing light flashes (0.25 sec ON OFF) at
15
km/h
(9
mph).

NG
Repair harness (Control unit
—
Rear speed sensor)

OK

resistance
at
harness

NG

Disconnect Q-09 and Q-05 Measure resistance
at
sensor.
Q-09, Q-05 Resistance
YG YL 800-1200
0
G L 800-1200
0
OK

Check followings* • Clearance between sensor and rotor standard: 0.3—1.1
mm
(0.012-0.043
in)
• Objects sticking
to
sensor
or
rotor
• Damaged sensor
or
rotor
• Sensor installation Tightening torque: 16-23 N-m
(1.6—2.3 m-kg, 12—17 ft-lb)

NG
Repair
or
replace
as
necessary

NG
Check Q-01 connector. Replace control unit.
or

OK

Replace hydraulic unit,
Replace rear wheel speed
sensor.

OK
Repair harness.
(Control unit
—
Rear speed sensor)
* All conditions can
be
verified
as
follows,
if an AC
voltmeter
is
available. 1. Jack
up
vehicle. 2. Measure sensor voltage while rotating rear wheel
one
revolution
per
second.

fi
wheel Q-01 (11-pin) Voltaqe (AC)
Left |YG (2E) YL (2F) More than 0.25V Right G (2H) L(2J)
More than 0.25V

86U11X-147
11-78

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
SENSOR ROTOR
Inspection
Check the sensor rotor for missing or damaged teeth.
86U11X-177
Removal of Front Sensor Rotor
1. Loosen the front wheel lug nuts.
2. Block the rear wheels.
3. Jack up the front of the vehicle and support it with safety stands.
4. Remove the wheels.
5. Remove in the sequence shown in the figure, referring to removal note for the specially marked parts.
86U11X-178
1. Hub cap
2. Locknut
3. Driveshaft (Refer to section 9)
4. Sensor rotor
11-90

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)
Removal of Rear Sensor Rotor
1. Loosen the rear wheel lug nuts.
2. Block the front wheels.
3. Jack up the rear of the vehicle and support it with safety stands.
4. Remove the wheels.
5. Remove in the sequence shown in the figure, referring to removal note for the specially marked parts.
86U11X-182
1. Hub cap
2. Locknut
3. Caliper assembly and
mounting support
4. Disc plate
5. Sensor rotor
Removal note
Sensor rotor
Remove the sensor rotor from the hub assembly with
the SST.
86U11X-183
11—92