lock MAZDA PROTEGE 1992 Workshop Manual

P CONVENTIONAL BRAKE SYSTEM
Removal / Inspection / Installation
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. install in the reverse order of removal.
4. After installation, check and adjust the pedal height and free play if necessary.
r
20-34 (2.0-3.5, 14-25)
N-m (m-kg, ft-lb)
23UOPX-01
1. Cotter pin
2. Clevis pin
3. Nut
4. Lock washer
5. Bolt 6. Return spring 9. Bushing
Inspect for wear and damage Inspect for wear
7. Pedal 10. Bushing
Inspect for bending and Inspect for wear
damage 11. Pad
8, Pedal pipe Inspect for wear
MASTER CYLINDER
Removal / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
3. After installation. add brake fluid. bleed air, and check for fluid leakage.
1.3-2.2, 9.4-16)
9.6-16 (1.0-1.6, 7.2-12)
13-22 (1.3-2.2, 9.4-l
N.m (m-kg, ft-lb)
23UOPX-01
1. Connector 4. Nut and washer
2. Brake pipe 5. Master cylinder
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-i 1 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page P-l 1
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page P-l 1 Disassembly / Assembly /
3. Hose (MTX) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-l 2
P-l 0

CONVENTIONAL BRAKE SYSTEM P
03UOPX-02,
4
ADJUSTING BOLT
‘ ’
I ’ “-
03UOPX-025
r
03UOPX-02
6
ir
23UOPX.OC
OWOPX-028
Removal note
Brake pipe
Disconnect the brake pipe from the master cylinder with the
SST.
Caution
l Do not allow the brake fluid to get on painted sur-
faces. If it does, wlpe it off immediately.
Installation note
Master cylinder
Piston to push rod clearance
Before installing the master cylinder, check the clearance be-
tween the piston of the master cylinder and the push rod of
the power brake unit as follows.
1. Place the
SST atop top of the master cylinder. Turn the ad-
justing bolt until it bottoms in the push rod hole in the piston.
2. Apply 500
mmHg (19.7 in-Hg) vacuum to the power brake
unit with a vacuum pump.
3. Invert the adjustment gauge used in Step 1 and place it on
the power brake unit.
4. Measure the clearance between the end of the gauge and
the push rod of the power brake unit. If it is not
Omm (0
in),
loosen the push rod locknut and turn the push rod to
make the adjustment.
Note
l By making the above adjustment, the clearance be-
tween the push rod and piston (after Installation of
the brake master cylinder and the power brake unit)
will be as shown in the table below.
Push rod-to-piston clearance
When vacuum applied to unit is
0 mmHg (0 inHg) 0.4-0.6mm (0.016-0.024 in)
I
When vacuum applied to unit is
approx. 500 mmHg (19.7 inHg)
I O.l-0.4mm (0.004-0.016 in)
Brake pipe
1. Tighten the brake pipe flare nut with the SST.
Tightening torque:
13-22 N,m (1.3-2.2 m-kg, 9.4-16 ft-lb)
P-l 1

CONVENTIONAL BRAKE SYSTEM
REAR BRAKE (DISC)
Quick Inspection, On-vehicle
Disc pad
1. Jack up the rear of the vehicle and support it with safety
stands.
2. Remove the wheels.
3. Verify that the remaining thickness of the pads.
Thickness: l.Omm (0.04 in) min.
1 SUOPX-011
Replacement
Disc pad
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
12-16 (1.2-l .6, 6.7-l 2
N.m (m-kg, &lb)
,,?I lftPY.rl17
1. Screw plug
2. Manual adjustment gear
Removal Note, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page P-24 _.,--. ,. ., . .
4. M-spring
5. Disc pad assembly
Inspection . , . , , . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . page P-25
6. Shim
3. Lock bolt 7. Guide plate
Removal note
Manual adjustment gear
Turn the manual adjustment gear counterclockwise with an
Allen wrench to pull the brake caliper piston inward. (Turn until
it stops)
03UOPX-062
P-23

CONVENTIONAL BRAKE SYSTEM
Installation note
Manual adjustment gear
1. Turn the manual adjustment gear clockwise until the brake
pads just touch the disc pIaTe.
2. Return the manual adjustment gear l/3-turn
Removal / Installation
Caliper
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal, referring to Installation Note.
5. Tighten all nuts and bolts to the specified torques, referring to the figure.
@ 22-29 (2.2-3.0, 16-22)

23-30 (2.2-3.1, 16-
N.m (m-kg, R-lb)
23UOPX-00
1. Parking cable 7. Caliper
Removal I Inspection / Disassembly / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . ,.,........ page P-32 Assembly ,.....*........................... page P-26
2. Connecting bolt 8. Disc pad assembly
3. Brake hose Replacement ,...,.,.,.,........*........... page P-23
4. Screw plug Inspection . . . . . . . ..*......................... page P-25
5. Manual adjustment gear 9. Bolt
Removal Note . . . . . . . . . . . . . . . ,,..,.,....... page P-23 10. Mounting support
Installation Note ,....,.,..,.,...,., ,...,., page P-24 11, Disc plate
6. Lock bolt Inspection .,...........*..................... page P-25
After installation:
(1) Add brake fluid and bleed air. (Refer to page P-6.)
(2) Adjust the parking brake lever stroke. (Refer to page P-31 .)
(3) Depress the brake pedal a few times and check that the rear brakes do not drag excessively while
rotating the wheel by hand.
P-24

P CONVENTIONAL BRAKE SYSTEM
CALIPER
Disassembly / Inspection / Assembly
Caution
l Replace the caliper assembly if a problem is found.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassemblv, referrina to
Assembly Note.
(3.7-5.5, 27-40)
5.9~Sh N-m
REPLACE (60-90 cm-kg, 52-78 in-lb)
@ REPLACE
N-m (m-kg, Mb)
23UOPX-01
1. Dust seal 8. Piston seal
Inspect for damage and poor sealing Disassembly Note . . . . . . . . . . . . . . . . . . . . . . .
page P-22
2. Piston 9. Spring
Disassembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Below 10. Operating lever
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-27 11. Boot
Inspect for wear and rust
3. Manual adjustment gear
4. Snap ring
5. Adjusting bolt
6. O-ring
7. Connecting link 12. Rubber cup and bleeder screw
13. Boot
14. Boot
15. Caliper body
Inspect for damage and cracks
Dlsassembly note
Piston
1. Turn the adjustment gear clockwise with an Allen wrench
to remove the piston from the adjustment gear. (Turn the
adjustment gear until it becomes easy to turn.)

CONVENTIONAL BRAKE SYSTEM
03UOPX-07
Assembly note
Piston
Insert the piston into the caliper and turn the adjustment gear
counterclockwise with an Allen wrench to pull the piston in-
ward. (Turn until it stops.)
P-27

P CONVENTIONAL BRAKE SYSTEM
REAR BRAKE (DRUM)
Quick Inspection, On-vehicle
1. Jack up the rear of the vehicle and support it with safety
stands.
2. Remove the wheels.
3. Remove the brake drum. (See below)
4. Verify the remaining thickness of the lining.
Thickness: l.Omm (0.04 in) min.
I
1 BUOPX-017
Removal / Inspection / Installation
1. Remove the lining in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
(18.0-24.0, 130-l 74)
N-m (m-kg, R-lb)
371 InPx-fll’
--_-. ,. -. 9
1. Screw
2. Brake drum
Inspection.. . . . . . . . page P-29
Installation Note
. . . . . . . . . . . . . . . . . . . . . . . page P-29
3. Return spring
4. Hold pin and spring
5. Anti-rattle spring
6. Brake shoe (leading side)
Inspection . . . . . . . . . . . . . . Above 7. Brake shoe (trailing side)
Inspection . . . . . . . . . . . . . . . . Above
8. Stopper spring and clip
9. Return spring
10. Parking brake cable
11. Operating lever assembly
12. Brake pipe
Removal Note . . page P-29 13. Bolt
14. Wheel cylinder
Disassembly I Inspection /
Assembly . . . . . . . page P-30
15. Wheel cylinder gasket
16. Hub cap
17. Locknut
18. Wheel hub
19. Backing plate
P-28

PARKING BRAKE SYSTEM
PARKING BRAKE LEVER
Removal / Inspection / Installation
Caution
l Install the parking brake switch so that it contacts the parking brake lever when the lever is
fully released.
l Turn the ignition switch ON, and check that the parking brake warning lamp illuminates with
the lever pulled one notch.
1. Block the wheels firmly.
2. Release the parking brake.
3. Remove in the order shown in the figure.
4. Inspect all components and parts, Replace parts if necessary.
5. Install in the reverse order of removal.
6. After installation: Adiust the parking lever stroke. (Refer to paae P-31 .)
N.m (m-kg, R-lb)
23UOPX.022
1. Rear console 5. Parking brake switch
Removal / Installation . . . . . . . . . . . . . . . . . . . . . Section
S 6. Parking brake cap
2. Adjusting nut 7. Release button
3. Bolt 8. Parking lever spring
4. Parking brake lever assembly 9. Parking brake lever
Inspect for damage and wear
P-33

WHEEL ALIGNMENT
WHEEL ALIGNMENT
PRE-INSPECTION
1. Check the tire inflations and set to the recommended pressure, if necessary.
2. Inspect the front wheel bearing play; replace the bearing 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 not exceed
10mm (0.39 in).
7. Shake the vehicle to check operation of the shock absorbers.
03UORX.007
FRONT WHEEL ALIGNMENT
Specifications
item
Specifications
Maximum Inner 4o” f: 2O
steering angle Outer
33O f 2O
Total mm (in) 2 f 3 (0.08 f 0.12)
toe-in dearee 0.20 f 0.30 Wheel alignment
(*‘Unladen) Front
*I Fuel tank full; radiator coolant and Camber angle -0005 * 45’
Caster angle 1°55’ f 55’
Kingpin angle 12O25’
engine oil at specified level; and spare tire, jack, and tools in designated positions.
23UORX-008
I
I 23UORX-023
Adjustments
Maximum steering angle
1. Loosen the left and right tie rod locknuts, then turn the tie
rods equally.
Maximum left/right difference: 3mm (0.12 in)
2. Tighten the tie rod locknuts.
Tightening torque:
34-50 N-m (3.5-5.1 m-kg, 25-37 ft-lb)
3. Adjust the toe-in after adjusting the steering angle.
4. Inspect and adjust the toe-in after adjusting the turning angle.
I 23UORX-024
R-7

WHEEL ALIGNMENT
Camber and Caster
1, Jack up the front of the vehicle and support it with safety
stands.
2. Remove the mounting block nuts.
-
1 BUORX-01
23UORX-0;
3. Push the mounting block downward, and turn it to the
desired position.
Direction indicator
position
A
: Difference from standard position
Camber angle Caster angle
+14’ +14’
+29’ O0
+14’ -14’
4. Install and tighten the mounting nuts to the specified torque.
Tightening torque:
29-40 Nnrn (3.0-4.1 m-kg, 22-30 ft-lb)
Total toe-in
1. Loosen the left and right tie rod locknuts, then turn the tie
rods equally.
Caution
l The left and right tie rods are both right threaded,
so, to increase the toe-in, turn the right tie rod to-
ward the front of the vehicle and the left tie rod
equally toward the rear.
l One turn of the tie rod (both sides) changes the toe-
in by about 6mm (0.24 in).
2. Tighten the tie rod locknuts.
Tightening torque:
34-50 N-m (3.5-5.1 m-kg, 25-37 ft-lb)