torque MAZDA PROTEGE 1992 Workshop Manual

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

P CONVENTIONALBRAKESYSTEM
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.
(1.9-2.6, 14-19)
1.3-2.2, 9.4-16)
(1 .O-1.6, 7.2-12)
13-22 (1.3-2.2, 9.4-16)
N.m (m-kg, ft-lb)
23UOPX-003
1. Connector 3. Master cylinder 6. Nut
2. Brake pipe
Installation Note 7. Power brake unit
Removal Note . . page P-l 1 . . . . . . . . . . . . . . . . . S ,,,.. page P-l 1 8. Gasket
Installation Note
4. Vacuum hose
. . . . . . . . . . . . . . . . . . . . . . . page P-l 1 5. Cotter pin and clevis pin
Cautlon
Take the following steps after installation:
l Add fluid and bleed the air. (Refer to page P-6.)
l Check all parts for fluid leakage. (Refer to page P-8.)
l Adjust and check the brake pedal. (Refer to page P-8.)
l Make an on-vehicle check of the unit. (Refer to page P-13.)
13uow007
03UOPX-043
t
0
A
.--- -------_- --
m--v
K/
6 B I)
P-l 6
DUAL PROPORTIONING VALVE
Inspection
1. Connect two pressure gauges (9,810 kPa [lo0 kg/cm’,
1,422 psi]) to the brake pipes with adapters as shown in
the figure.
Adapter and flare nut tightening torque:
13-22 N,m (1.3-2.2 m-kg, 9.4-18 f&lb)
Note
l Disconnect and connect the brake pipes with SST.
2. Bleed the air from the brake system.
(Refer to page P-6.)
3. Depress the brake pedal until the master cylinder pressure
equals A; then record rear brake pressure A’.
4. Depress the brake pedal again, apply additional pressure
until the pressure equals B; then record pressure 6’.
Fluid pressure kPa (kg/cm*, psi)
A A’ B B’
Rear drum 2,453 2,256-2,649 5,886 284%3,434
brake
(25, 356) (23-27, 327-384) (60, 853) (29-35, 412-498) --.-,
Rear disc 2,453 2,256-2,649 5,886 3,188-3,777
brake (25, 356) (23-27, 327-384) (60, 853) (32.5-38.5, 462-547)

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

CONVENTIONAL BRAKE SYSTEM P
23UOPX-025
03UOPX-071
13UOPX-01
Removal note
Brake pipe
Disconnect or connect the brake pipe from/to the wheel cyl-
inder with the
SST.
Tightening torque:
16-22 N.m (1.6-2.2 m-kg, 12-16 ft-lb)
Grease points
(1) Piston of wheel cylinder
(2) Anchor sliding parts
(3) Projection of backing plate
(4) Adjusting screw
(5) Adjusting sleeve contact surfaces
Inspection
Check for the following and repair or replace parts as
necessary.
Brake drum
1. Drum inner diameter
Standard ‘diameter: 200mm (7.90 in)
Diameter limit : 201mm (7.91 in)
Caution
l When repairing or replacing the drum, check the
contact with the shoe.
2. Scratches, uneven or abnormal wear inside drum
Note
l Repair if the problem is minor.
Installation note
Brake drum
Before installing the brake drum, depress the brake pedal to
verify operation of the automatic adjuster.
P-29

WHEELS AND TIRES
WEAR INDICATOR WEAR IbiDICATOR
13UOQX-00s
13UOQX-011 0
23UOQX-004
Tire Wear
1. Check the remaining tread.
Remaining tread
Standard tires: 1.6mm (0.063 in) min.
Snow tires: 50% of tread ’ _,I’
2. The tire should be replaced if the wear indicators are
exposed.
Inspection (Tire and Wheel)
The wheel or tire should be replaced if any crack, damage,
deformation or other problem is found.
Wheel and Tire Runout
1. Jack up the vehicle and place it on safety stands.
2. Set the probe of a dial indicator against the wheel, and meas-
ure the runout through one full revolution.
Runout:
_..’
Horizontal Aluminum wheel: 2.0 (0.079), Steel wheel: 2.5 (0.098)
Vertical 1.5 (0.059)
3. Replace the wheel if necessary.
Caution
l Adjust wheel balance after replacement of a wheel
or tire.
Lug Nut
1. Verify that the lug nuts are tightened to the specified torque.
Tightening torque:
66-l 16 N*m (9-12 m-kg, 65-67 ft-lb)
Q-4

WHEELS AND TIRES
L 13UOQX-005
FRONT
13UOQX-006
G=a I) OUTSIDE
BALANC
WEIGHT
REMOVAL / INSTALLATION
1. The wheel-to-hub contact surfaces must be clean.
2. Tighten the lug nuts to the specified torque.
Tightening torque:
88-l 18 N-m (9-12 m-kg, 85-87 ft-lb)
Caution
l When reinstalling a wheel, retighten the lug nuts to
the specified torque after about 1,000 km (820 miles)
driving.
TIRE ROTATION
To prolong tire life and assure uniform tire wear, rotate the tires
from every 3,000 km (1,860 miles) to every 6,000 km (3,720
miles).
Caution
l Do not include “TEMPORARY USE ONLY” spare tire
in rotation.
l Use the best tires on the front axle.
l After rotating the tires, adjust each tire to the speci-
fied air pressure. (Refer to page Q-3.)
WHEEL BALANCE ADJUSTMENT
If a wheel becomes unbalanced or if a tire is replaced or
repaired, the wheel must be rebalanced to within specification.
Maximum unbalance (at rim edge)
13 inch wheel: 11 g (0.39 oz)
14 inch wheel: 10 g (0.35 or)
Caution
l Do not use more than two balance weights on the
inner or outer side of the wheel.
l If the total weight exceeds 1OOg (3.5 oz) perslde,
rebalance after moving the tire around on the rim.
l Attach the balance weights tightly on the wheel.
l Select suitable balance weights for steel or alumi-
num alloy wheels.
l Do not use an on-car balancer on automatic trans-
axle models; it may cause transaxle damage.
.__’
Q-6

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)

WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT
Specifications
kern Specifications
Total mm (in) 2 f 3 (0.08 f 0.12)
Wheel alignment
(*‘Unladen) Rear toe-in
degree 0.2O f 0.3O
Camber angle -0020’ f 45’
*I Fuel tank full; radiator coolant and engine oil at specified level; and spare tire, jack, and tools in designated positions.
13UORX-012
Adjustment
Total toe-in
1. Loosen the lateral link locknuts.
2. Turn the lateral link adjustment link to adjust.
Note
l One turn of the link changes 11.3mm (0.44 in).
3. Tighten the lateral link locknuts to the specified torque.
Tightening torque:
55-64 N,m (5.6-6.5 m-kg, 41-47 ft-lb)
R-9

R
FRONTSHOCKABSORBERANDSPRING
Removal / Installation
1. Jack up the front of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal, referring to Installation Note.
5. After installation, measure the front wheel alignment, and adjust it if necessary.
Caution
l Retighten the shock absorber lower bolts to the specified torque after lowering the vehicle
(unladen condition).
1. Clip
2. Nut
3. Bolt
4. Nut 5. Shock absorber and spring
N.m (m-kg, R-lb
23UORX-0‘
- .^
Disassembly ............................... page H-l Z
Inspection ................................... page R-l 3
Assembly.. .................................. page R-14
Installation Note.. ........................ page R-12
R-l 1