parking brake MAZDA PROTEGE 1992 Owner's Manual

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

P CONVENTIONAL BRAKE SYSTEM
23UOPX-02
WHEEL CYLINDER
Disassembly / inspection / Assembly Caution
Take the following steps after installation:
l Add fluid and bleed the air. (Refer to page P-6.)
l Check for fluid leakage. (Refer to page P-6.)
l Depress the brake pedal a few times and check that
the rear brakes do not drag while rotating the wheel.
l Check the parking brake lever stroke.
(Refer to page P-31.)
Caution
l if a problem is found in the wheel cylinder or the piston, replace the wheel cylinder as an as-
sembly.
1. Disassemble the wheel cylinder in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly.
5.9-8.8 N-m
1. Dust boot
2. Piston
Inspect for corrosion and damage
3. Piston cup
4. Spring and caps
23UOPX-02
5. Rubber cup and bleeder screw
6. Steel ball
7. Wheel cylinder body
Inspect for corrosion and damage
P-30

PARKING BRAKE SYSTEM
PARKING BRAKE SYSTEM
TROUBLESHOOTING GUIDE
Problem
Brakes do not
release
Parking brake does
not hold well Possible cause
Improper return of parking brake cable or improper ad-
justment
Excessive lever stroke
Brake cable stuck or damaged
Brake fluid or oil on pad or lining
Hardening of pad / lining surface or poor contact Remedy Repair or adjust
Adjust
Repair or replace
Clean or replace
Grind or replace Page P-32
P-31
P-32
P-i,28
ONOPX-080
PARKING BRAKE SHOE
Removal / Inspection / Installation
Disc brake
Removal and Installation (Refer to page P-23)
Inspection (Refer to page P-25)
Drum brake
Removal and Installation (Refer to page P-28)
Inspection (Refer to page P-29)
03u0Px-081
13UOPX-021
03UOPX-08
PARKING BRAKE (LEVER TYPE)
Inspection
Check that the stroke is within specification when the parking
brake lever is pulled with a force of 98 N (IO
kg, 22 lb).
Stroke: 5-7 notches
Adjustment
1. Before adjustment, start the engine and depress the brake
pedal several times while the vehicle is moving in reverse.
2. Stop the engine.
3. Remove the screw and the parking brake lever cover.
4. Remove the adjusting nut clip and turn the adjusting nut
at the front of the parking cable.
5. After adjustment, check the following points:
(1) Turn the ignition switch ON, pull the parking brake le
ver one notch, and check that the parking brake warn-
ing lamp illuminates.
(2) Verify that the rear brakes do not drag.
P-31

P PARKING BRAKE SYSTEM
PARKING BRAKE CABLE
Removal / Inspection / Installation
Caution
l Adjust the parking brake lever stroke.
l Depress the brake pedal a few times and check that the rear brakes do not drag while rotating
the wheels.
1. Remove the cable in the order shown in the figure.
2. Visually check each part, and replace it if necessary.
3. Install in the reverse order of removal.
16-23 (1.6-2.3, 12-17)
19-26 (1.9-2.6, 14-19)
N-m (m-kg, ft-lb)
03UOPX-08,
1. Rear console
3. Return spring 7. Clip
Removal / Installation
4. Front parking cable 8. Rear parking cable
. . . . . . . . . . . . . . . . . . . . . ..I. Section S 5. Nut (Disc brake type)
Inspect for damage and
2. Adjusting nut
6. Bolt (Drum brake type)
wear
P-32

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

EXTERIOR LIGHTING SYSTEM T
Headlights either do not operate or are dim Low-High beam or passing flasher does not
J operate
Burnt out bulb or poor grounding J
03UOTX-049 Defective combination switch
03UOTX-050
(Canada) Daytime running lights (DRL) do not operate
Confirm that headlights operate with the light switch ON
(second position) OK
Turn OFF the light switch and turn ON the ignition
switch when parking level pulling
I
Check head 30A main fuse OK
Check DRL resistor OK Repair DRL resistor 10A fuse
Confirm battery voltage on R and L/G wire of the DRL NG
relay Repair harness (Fuse - DRL relay)
I
I
Check the DRL relay
Repair DRL relay
1 OK
Confirm battery voltage on (BRNV) wire of the DRL con-
trol unit NG
Repair harness (DRL relay - DRL control unit) OK
Confirm battery voltage on (L/G) wire of the DRL control NG
unit Repair harness (Rear wiper fuse - DRL control unit) OK
Confirm continuity of (G/R) wire of the DRL control unit x Repair harness (DRL control unit - Parking brake
to ground switch) or check the parking brake switch 1 OK
Confirm continuity on (B) wire of the DRL control unit to
NG
ground Repair harness (DRL control unit ground) OK
-1 NG
Confirm approx. 8V on the DRL resistor Repair harness (DRL control unit - DRL headlight)
I
Confirm battery voltage on (
Confirm approx. 8V on (R/W) wire of the DRL resistor Repair harness (DRL resistor - DRL relay)
Repair harness (DRL control unit - DRL resistor)
23UOTX-019
T-33

WARNING SYSTEM T
13UOTX-07
63U15X-05
, I//
‘nF -
-
-
FUEL
13UOTX.08C
- CHARGE
13UOTX-08
13UOTX-08
Inspection
Brake system warning lamp
1. Disconnect the connector from the brake fluid level sensor.
2. Connect a jumper wire between “G/Y” and “6” terminal
(body ground).
3. Start the engine and check that the BRAKE warning lamp
illuminates.
Caution
l Be sure that the parking brake is fully released be-
fore checking.
4. If there is no illumination, check the fuse, bulb, and wiring
harness.
Brake fluid level sensor
Connect an ohmmeter to each terminal of the brake fluid lev-
el sensor connector.
Check for continuity when the float is moved up and down.
The sensor is good if there is continuity when the float is be-
low the “MIN” mark, and if there is no continuity when the
float is above the “MAX” mark. If the sensor does not pass
this test, replace it.
Fuel-level warning lamp
1. Disconnect the connector from the fuel tank unit.
2. Connect the connector terminal “W/R” to the body ground.
3. Start the engine and check that the FUEL warning lamp il-
luminates.
4. If there is no illumination, check the fuse, warning lamp, and
wiring harness.
Alternator warning lamp
1. Start the engine, connect the connector terminal “W/B” to
a body ground.
2. Check that the alternator warning lamp illuminates.
3. If there is no illumination, check the warning lamps, wiring
harness and alternator. Replace or repair as necessary.
Engine oil pressure warning lamp
1. Disconnect the connector from the oil pressure switch.
2. Start the engine and connect the connector terminal “Y/R”
to a body ground.
3. Check that the “OIL” warning lamp illuminates. If it does
not, replace the sender switch or repair the wiring harness
if bulb is not burnt out.
T-61

2L BUZZER 2A 28 2C 2D 1A 3K l--r nnmn
I I‘ I
1C 3L 2E 2G IL iG 1F 1D tB
3F 38 3G 1E 3D
l-l rt
II l-l
l-l It II l-l 1J 11 1H
1G IF 1E 1D 1C 1B 1A 2L 2K 2J 21 2H 2G 2F 2E 2D 2C 28 2A
r-l It ,I 3L 3K 3J 31 3H 3G 3F 3E 3D 3C 3B 3A
Ter- I I minal Connected to 1 1A Combination switch
1B Ground
IC Fuel tank unit
1 ID 1 EGI control unit
I
II L 1J 1
L Ter-
minal Connected to
2A Speed sensor output
28 Light switch (high beam)
2C Turn switch (L)
20 Turn switch (R)
2E Ground
2F Ground
2L 1 IGI battery Ter-
minal Connected to
3A
38 Alternator
3c
30 Oil pressure switch
3E
3F Parking brake switch, Brake fluid switch
3G Passive shoulder belt control unit
3H h
I 31
3J
3K
IG2 battery
3L Water temperature gauge unit

TECHNICAL DATA TD
Item
Coolant Engine/Transaxle B6 SOHC BP SOHC BP DOHC
MTX 1 ATX 1 MTX 1 ATX 1 MTX 1 ATX
Capacity
liters tus qt, Imp qt) (5Z.4) (8.E.3) (5&4) (SE.3) (5.?i.4) (S.E.3)
Coolant protection Volume percentage %
Specific gravity at
Water Coolant 20% (68OF)
Antifreeze solution Above -16OC (3OF)
65 35 1.054
Above -26OC (-15OF) 55 45 1.066
I Above -4OOC (-40°F) 45 55
1.078
F. FUEL AND EMISSION CONTROL SYSTEMS Item
idle speed*‘**
Ignition timing** Fuel pump
Maximum output pressure Fuel filter Engine
B6 SOHC BP SOHC BP DOHC
vm 700-800
BTDC 6O--8O 4O---6O 90-l 10
kPa (kg/cm*, psi) 1 441-637 (4.5-6.5, 64-92) ‘Type
Low-pressure side Nylon element (in fuel pump)
High-pressure side Paper element Pressure regulator
Regulating pressure kPa (kg/cm*, psi) 1 265-314 (2.7-3.2, 38-46) Injector
Type
High-ohmic
Type of drive Electromechanical
Resistance n 12-16 Idle speed control (ISC) valve
Type
Rotary
Resistance n ] 11-13 Purge control solenoid valve
Resistance n 1 23-27 Water thermosensor
-20°C( -4OF) 14.6-17.8
Resistance k6 20°C( 68QF) 2.21-2.69
40% (104OF) 1.0-l .3
80°C(1760F) 0.29-0.35 Airflow meter
E2++Vs Fully closed 20-600 q D Fully open 20-l ,000
E~HVC 200-400
Resistance g Ez++THAA -2O%(-4OF) 13,600-18,400
(Intake air 20%( 68OF) 2,210-2,690
thermosensor)
60°C(1400F) 493-667
Eic*Fc Fully closed 00
Fully open 0 Fuel tank
Capacity liters (US gal, Imp gal) I
Hatchback 50 (13.2, 11.0) PROTEGE . . . . 55 (14.5, 12.1) Air cleaner
Element type Oil permeated Fuel
Specification Unleaded regular (RON 91 or higher)
*’ With parking brake applied (Canada)
*’ TEN terminal of diagnosis connector grounded
TD-9

TD TECHNICAL DATA
P. BRAKING SYSTEM
Item
3rake type
Brake pedal
Height mm (in)
Free play mm (in)
Reserve travel mm (in)
Clearance when pedal depressed at 589 N (60 kg, 132 lb)
Master cylinder
Type
Master cylinder
Bore diameter mm (in) 1
Front disc brake
We
Thickness of pad
mm (in) Standard
Minimum
Thickness of disc plate
mm (in) Standard
Minimum
Runout of disc plate mm (in)
Cylinder bore
mm (in) Specifications
Front . . . . . disc, Rear . . . . . disc or drum
193-196 (7.60-7.72)
4-7 (0.16-0.28)
70 (2.76) min
Tandem
22.22 (0.875)
Ventilated
10 (0.39)
2 (0.08)
22 (0.87)
20 (0.79)
0.1 (0.004)
53.97 (2.12)
Rear brake (drum)
We
Thickness of lining
I Drum inside diameter
1
tiheel cylinder bore
I Parking brake
Type
Parking brake lever notches Leading & trailing
mm (in) Standard 4.5 (0.18)
Minimum 1 (0.04)
mm (in) Standard 200 (7.90)
Maximum 201 (7.91)
mm (in) 17.46 (0.687)
Mechanical two-rear-wheel control
When lever is pulled at 98N (10 kg, 22 lb)
Power brake unit
Diameter mm (in) 5-7
(a): 214 (8.43) (b): 239 (9.41)
More than 1,177 (12, 171)/196 (20, 44)
Fluid pressure per treading force
kPa (kg/cm’, psi)/N (kg, lb) (4
@I at 0 mmHg (0 inHg)
More than 7,063 (72, 1,024)/l 96 (20, 44)
at 500 mmHg (19.7 inHg)
More than 1,517 (15, 213)/196 (20, 44)
at 0 mmHg (0 inHg)
More than 8,593 (88, 1,261)/196 (20, 44)
at 500 mmHg (19.7 inHg)
Rear wheel hydraulic control rystem
Type Dual proportioning valve
_-_.
. .- ,. . . . !
P.IF
Switching point (Master cylinder pressure)
KPa (kg/cm-, PSI) ) z,4~j3 (25, 356)
(a): BP engine with SMTX, B6 engine
(b): BP engine with 4EATX ..-
-’
TD-18