MAZDA PROTEGE 1992 Workshop Manual

ENGINE SPEED SENSING POWER STEERING
POWER STEERING OIL PUMP
N
Removal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of remnvnl
. ..-.-..
d 2 19-25 (1.9-2.6, 14-19)
- Nm (m-kg, f&lb)
23UONX-043
1. Bolt
2. Nut
3. Nut
4. Adjusting bolt
5. Drive belt
Replacement .,....,.,.,,,,.,.....,..,,.... page N-42
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page N-42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page N-41 6. Pressure hose
7. Return hose
8. Bolts
9. P/S oil pump assembly
N-37

N ENGINE SPEED SENSING POWER STEERING
Disassembly / Inspection / Assembly
1. The following procedures show replacement of the O-rings. If a problem is found in other parts, replace
the oil pump assembly.
2. Disassemble in the order shown in the figure, referring to
Disassembly Note.
3. Inspect all parts and replace as necessary.
4. Assemble in the reverse order of disassembly, referring to
Assembly Note,
1. Suction pipe
2. O-ring
3. Pressure-switch assembly
4. O-ring
5. Connector
6. O-ring
7. Control valve
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
8. Spring
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
9. Bracket
10. Pump body (rear)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Il. O-ring _,
12. Cam ring
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
13. Vane
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
14. Rotor
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
15. Side plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
16. O-ring
17. O-ring
18. Pin
19. Pump body (front)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
N-38

ENGINE SPEED SENSING POWER STEERING
93GONX-05:

93GONX-056

93GONX-O!
93GONX-05
Disassembly note
Oil pump
Note
l As shown in the figure, when securing the oil pump
in a vise, be sure to use the SST so that force is not
applied to the pulley or shaft.
Assembly note
Rotor
1. Install the rotor to the shaft with the rotor’s identification mark
facing upward.
Cam ring
1. Install the cam ring so that its identification mark is facing
downward.
Vane
1. Install the vanes (10 pieces) to the rotor, with the R part of
the vanes facing outward.
Inspection
Note
l Replace the pump assembly if necessary.
Pump body
1. Check the front and rear pump bodies for cracking or oth-
er damage and for abnormal wear of the moving surface
of the rotor.
N-39

N ENGINE SPEED SENSING POWER STEERING
93GONX-05
I 93GONX-05!
Cam ring, rotor, vanes, side plate
1. Check the moving surface of the cam ring’s vanes for ab-
normal wear.
2. Check the moving surface of the side plate and the pump
bodies for abnormal wear.
3. Check the moving surface of the vane cam ring for abnor-
mal wear.
4. Check the clearance of the rotor and vanes.
4
Control valve and spring
1. Check the control valve for cracking and other damage, for
clogging, and for abnormal wear of the moving part.
2. Check the spring for damage.

ENGINE SPEED SENSING POWER STEERING N
P/S
23UONX-04!
PULLEY
P/S AND A/C
23UONX-04
DRIVE BELT
Inspection
1. Check the drive belts for wear, cracks, and fraying. Replace
as necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
3. Check the drive belt deflection by applying moderate pres-
sure (98 N,
10 kg, 22 lb) midway between the pulleys.
Note
l Measure the belt deflection between the specified
pulleys.
0 A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Set the deflection specification below accordingly.
* Check the belt deflection when the engine is cold,
or at least 30 minutes after the engine has stopped.
Deflection
mm (in)
New Used Limit
8-9.0 (0.31-0.35) 9.0-10.0 (0.35-0.39) 11.5 (0.45)
4. If the deflection is not within specification, adjust it.
23UONX-047
Drive belt tension check
WHEN SET
I
23UONX-048
Note
l Belt tension can be checked in place of belt
deflection.
aBelt tension can be measured between any two
pulleys.
Using the SST check the belt tension.
Tension
N (kg, lb)
New
491-589
(50-60, 11 O-l 32) Used
422-491
(43-50, 95-l 10) Limit
245
(25, 55)
N-41

N ENGINE SPEED SENSING POWER STEERING
13UONX-02
Adjustment
1. Loosen bolt @, nut @J, and locknut 0. Turn adjusting bolt
@? to adjust the belt to the specified tension.
2. Tighten locknut 0, bolt @, and nut @I to the specified
torques.
Tightening torque
Bolt @: 36-54 N-m (3.7-5.5 m-kg, 27-40 ft-lb)
Nut @J : 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Locknut 0:
31-46 Narn (3.2-4.7 m-kg, 23-34 f&lb)
Replacement
1. Loosen bolt @, nut 0, and locknut @.
2. Turn adjusting bolt @ to release the belt tension.
3. Remove the belt.
4. Install a new drive belt and adjust the tension and deflec-
tion. (Refer to above for adjustment.)
N-42

P
BRAKING SYSTEM
INDEX ......................................................
OUTLINE .................................................. ;I g
SPECIFICATIONS .................................... P- 3
CONVENTIONAL BRAKING SYSTEM.. ......... P- 4
PREPARATION ....................................... P- 4
TROUBLESHOOTING GUIDE .................... P- 5
AIR BLEEDING .......................................
BRAKE HYDRAULIC LINE.. -
...................... F- t
BRAKE FLUID ........................................
BRAKE PEDAL ....................................... ;I ;
MASTER CYLINDER ................................ P-l 0
POWER BRAKE UNIT .............................. P-13
DUAL PROPORTIONING VALVE.. .............. P-l 6
FRONT BRAKE (DISC) ............................. P-16
CALIPER ............................................... P-21
REAR BRAKE (DISC) ............................... P-23
CALIPER ............................................... P-26
REAR BRAKE (DRUM) ............................. P-28
WHEEL CYLINDER .................................. P-30
PARKING BRAKE SYSTEM ........................ P-31
TROUBLESHOOTING GUIDE .................... P-31
PARKING BRAKE SHOE .......................... P-31
PARKING BRAKE (LEVER TYPE) ............... P-31
PARKING BRAKE CABLE.. ....................... P-32
PARKING BRAKE LEVER ......................... P-33
13UOPX-001

P INDEX
NDEX
LEVER STROKE (WHEN PULLED WITH A FORCE OF 98 N [lo kg, 22 lb])
FMVSS 116, DOT-3,
SAE J1703 OTCHES
1. Brake hydraulic line
Inspection / Removal /
Installation.. ............................... page P- 6
2. Brake pedal
Inspection (on-vehicle).
............... page P- 8
Removal / Inspection /
Installation ................................. page P-l 0
3. Master cylinder
Removal I installation.. ................ page P-10
Disassembly / Inspection /
Assembly .................................. page P-12
4. Power brake unit
Inspection (on-vehicle). ............... page P-l 3
Removal I Installation.. ................ page P-16
5. Dual proportioning valve
Inspection
................................... page P-l 6
Replacement.. ............................. page P-l 7
6. Front brake (disc)
Inspection (on-vehicle). ............... page P-l 8
Replacement.. .............................
page P-l 8
Removal / installation.. ................ page P-l 9
Inspection ...................................
page P-20
7. Caliper
Disassembly I Inspection /
Assembly.. ................................ page P-21
P-2
8. Rear brake (disc)
23UOPX-008
Inspection (on-vehicle) . . . . . . . , , ., . . . . page P-23
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-23
Removal / Installation . . . . . . . . . . . . . . . . . . page P-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-25
9. Caliper
Disassembly / Inspection /
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-26
10. Rear brake (drum)
Inspection (on-vehicle). . . . . . . . . . . . . . . . page P-28
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-28
11. Wheel cylinder
Disassembly / Inspection /
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-30
12. Parking brake (lever type)
Inspection (on-vehicle) . . . . . . . . . . . . . . . . page P-31
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-31
13. Parking brake cable
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-32
14. Parking brake lever
Removal / Inspection / --
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-33

OUTLINE
OUTLINE
SPECIFICATIONS
item Specifications
Brake pedal
Master cylinder
Front disc brake
Rear disc brake
Rear drum brake
Power brake unit
Braking force control device
Brake fluid Type Suspended
Pedal lever ratio
I 4.1
I
Max. stroke mm (in) 140 (5.51)
I
Type
Cylinder inner diameter mm (in)
Type
Cylinder bore mm (in)
Pad dimensions (area x thickness)
mm’ (in2) x mm (in)
Disc plate dimensions mm (in)
(outer diameter x thickness) Tandem (with level sensor)
22.22 (0.875)
Ventilated disc (integral)
53.97 (2.12)
13-in wheel: 3,800 (5.89)x 10 (0.39)
14-in wheel: 4,300 (6.66) x 10 (0.39)
13-in wheel: 235 x 22 (9.25 x 0.87)
14-in wheel: 257 x 22 (10.12 x 0.87)
We
I Solid disc (mounting support)
I
Cylinder bore mm (in)
I 30.2 (1.19)
I
Pad dimensions (area x thickness)
mm2 (in’) x mm (in)
Disc plate dimensions mm (in)
(outer diameter x thickness)
Type 2,600 x 8.0 (4.03 x 0.31)
251 x 9 (9.88 x 0.35)
Leading-trailing
Wheel cylinder inner diameter mm (in) 17.46 (0.687)
I
Lining dimensions mm (in)
(width x length x thickness) 35x192.0x4.5 (1.38x7.56x0.18)
I
Drum inner diameter mm (in) 200 (7.9)
I
Shoe clearance adjustment Automatic adjuster
Vacuum multiplier
@ : 214 (8.43) @ : 239 (9.41)
Dual proportioning valve
FMVSS 116: DOT-3, SAE: J1703
Type
Diameter
Type mm (in)
Parking brake
Type
Operation system Mechanical two rear wheel control
Center lever I
3 With BP SMTX, B6, @With BP 4EATX
I I
23UOPX-001
P-3

CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE SYSTEM
PREPARATION
SST
49 0259 770B
For 49 F043 001
For
removal of
adjustment of
Wrench, flare nut
w brake pipe Adjust gauge
piston-to-push
rod clearance
49 0208 701A
For 49 0221 600C For
removal of
installation of
Air-out tool, boot 471 piston seal
Expand tool, disc brake pads
brake (Front disc brake)
._’
P-4