MAZDA PROTEGE 1992 Workshop Manual

CONVENTIONAL BRAKE SYSTEM
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Poor braking
Leakage of brake fluid Repair P- 7
Air in system Bleed air P- 6
Worn pad or lining Replace P-l 8,23,28
Brake fluid, grease, oil, or water on pad or lining Clean or replace P-18,23,28
Hardening of pad or lining surface or poor contact Grind or replace P-l 8,23,28
Malfunction of disc brake piston Replace P-l 9,24
Malfunction of master cylinder or wheel cylinder Repair or replace P-l 0,21,26,
28,30
Malfunction of power brake unit Repair or replace P-16
Malfunction of check valve (vacuum hose) Replace P-15
Damaged vacuum hose Replace -
Deterioration of flexible hose Replace -
Malfunction of dual proportioning valve Replace P-17 Brakes pull to one
Worn pad or lining Replace P-l 8,23,28 side Brake fluid, grease, oil, or water on pad or lining Clean or replace -
Hardening of pad or lining surface or poor contact Grind or replace
Abnormal wear or distortion of disc, drum, pad, or lining Repair or replace P-l 8;3,28
Malfunction of automatic adjuster Repair or replace -
Looseness of backing plate I dust cover mounting bolts Tighten Section M
Malfunction of wheel cylinder Repair or replace P-21,26,30
Improperly adjusted wheel alignment Adjust Section R
Unequal tire air pressures
Adjust Section Q Brakes do not
No brake pedal play Adjust P- 9 release Improperly adjusted push rod clearance Adjust P-11
Clogged master cylinder return port Clean -
Weak brake pad or shoe return spring Replace -
Wheel cylinder not returning properly
Clean or replace
Malfunction of piston seal of disc brake Replace P-l;,24
Excessive runout of disc plate
Replace P-20,25 Pedal goes too far
Improperly adjusted pedal play Adjust P- 9 (too much pedal Worn pad or lining
Replace P-18,23,28 stroke) Air in system
Bleed air P- 6 Abnormal noise or
Worn pad or lining
Replace P-18,23,28 vibration during Deteriorated pad or lining Grind or replace - braking Brakes do not release Repair -
Foreign material or scratches on disc plate or drum con- Clean -
tact surface
Looseness of backing plate / dust cover or caliper Tighten
Section M,
mounting bolts P-l 9,24
Damaged disc or drum contact surface Replace -
Poor contact of pad or fining Repair or replace
P-18,23,28
Insufficient grease on sliding parts Grease - Steering wheel pulls
Dragging brake Repair - to one side Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Cl
Incorrect tire pressure -
Section Q
Malfunction of suspension -
Section R
mm> IAn\, ,.e
P-5

P CONVENTIONAL BRAKE SYSTEM
03UOPX-006
03UOPX-00
03UOPX-00
BRAKE HYDRAULIC LINE AIR BLEEDING
1. Jack up the vehicle and support it with safety stands.
Caution
l The brake fluid reservoir must be 314 full during air
bleeding.
2. Remove the bleeder cap and attach a vinyl hose to the
bleeder plug.
3. Place the other end of the vinyl tube in a clear container.
4. One person should depress the brake pedal a few times,
and then hold it in the depressed position.
5. A second person should loosen the bleeder screw, drain
out the fluid, and retighten the screw with the
SST.
Caution
l The two persons should stay in voice contact with
each other.
l Be sure the pedal remains depressed until the air
bleed screw is tightened.
6. Repeat steps 4 and 5 until no air bubbles are seen.
7. Check for correct brake operation.
8. Verify that there is no fluid leakage. Clean away any spilled
fluid with rags.
9. After bleeding the air, add brake fluid to the reservoir up
to the specified level.
Tightening torque:
5.9-8.8 N-m (0.8-0.9 m-kg, 4.3-8.5 ft-lb)
Note
l Air bleeding must be done from the bleeder screw
farthest from the disassembled parts to the nearest.
03UOPX-00
1. Brake pipe 2. Flexible hose
Inspection / Removal / Inspection / Removal /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-7
P-6

CONVENTIONAL BRAKE SYSTEM
G ‘lW /
03UOPX-01
03UOPX-01’
03UOPX-01,
23UOPX-00
Inspection, on-vehicle
Brake pipe
Check for cracks, damage, and corrosion of the brake pipe.
Replace the pipe or flare nut(s) if necessary.
Flexible hose
Check for scars, cracks, and swelling of flexible hose. Replace
the hose if necessary.
Removal
1. Remove the brake pipe with the SST.
2. Disconnect the clip and remove the flexible hose from the
bracket.
Installation
1. Fix the flexible hose in the bracket and connect the clip to it.
2. Connect the flexible hose to the brake pipe and tighten the
flare nut with the SST.
Caution
l Verify that the hose is not twisted.
l Verify that the hose does not contact other parts
when the vehicle bounces or when the steering
wheel is turned fully right or left.
Tightening torque:
13-22 N*m (1.3-2.2 m-kg, 9.4-16 ft-lb)
P-7

P CONVENTIONAL BRAKE SYSTEM
03UOPX.01
03UOPX-01
03UOPX-01
23UOPX-0
BRAKE FLUID
Inspection
Leakage inspection
Depress the brake pedal several times, and inspect for leak-
age of the brake line system. __,
Brake Fluid Level
Leakage check
Verify that the fluid level in the reservoir is between the MAX
and MIN lines on the reservoir.
Add fluid if it is below MAX.
Replacement
1. Follow the procedure outlined in Air Bleeding.
(Refer to page P-6).
2. Continue bleeding and replacing the brake fluid until only
clean fluid is expelled.
3. Fill the reservoir to the MAX level.
BRAKEPEDAL
Inspection, On-vehicle
Brake pedal height
Inspection
Verify that the distance from the center on the pedal pad to
the floor mat is as specified.
Specification: 193-196mm (7.60-7.72 in)
Adjustment
1. Disconnect the stoplight switch connector.
2. Loosen locknuts @J and turn switch @ until it does not con-
tact the pedal.
3. Loosen locknuts (I?J and turn rod @ to adjust the height
of the brake pedal.
4. Tighten the stoplight switch until it contacts the pedal; then
turn it an additional 112 turn. Tighten locknuts @ and @I.
5. Connect the stoplight switch connector.
6. Verify operation of the stoplights.
P-8

CONVENTIONAL BRAKE SYSTEM
03UOPX-021
PEDAL-TO-FLOOR
CLEARANCE

03UOPX-02
Pedal Play
Inspection
1. Depress the pedal a few times to eliminate the vacuum in
the system.
2. Gently depress the pedal by hand and check the free play
(until resistance is felt).
Pedal play: 4-7mm (0.16-0.26 in)
Adjustment
1. Loosen locknut @and turn rod @to adjust the free play.
2. Verify the pedal height and the stoplight operation.
Pedal-To-Floor Clearance
Inspection
Verifv that the distance from the floor panel to the center of
the pedal pad is as specified when the pedal is depressed
with a force of 569 N (60
kg, 132 lb).
Pedal-to-floor clearance: 70mm (2.76 in) min.
If the distance is less than specified, check for the following
problems:
1. Air in brake system
2. Malfunction of automatic adjuster (Rear drum brakes)
3. Worn shoes or pads
P-9

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

P CONVENTIONAL BRAKE SYSTEM
Disassembly / Assembly / Inspection
1. After removing the brake fluid, disassemble 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.
Caution
l Secure the master cylinder flange in a vise when necessary.
l Replace the piston assembly, if necessary.
l Do not let foreign material enter the cylinder, and do not scratch the inside of the cylinder
or the outer surface of the piston.
REP1 .ACE
0.98-1.47 (10-15, 8.7-13.0)
o R,NG ,,,dcE @.96-2.45 (20-25, 17.4-21.7)
- 3
N.m (cm-kg, in-lb)
1. Reservoir cap assembly 5. Bushing 9. Primary piston assembly
2. Float 6. Stopper screw 10. Secondary piston assembly
3. Screw 7. Fluid level sensor 11. Master cylinder body
4. Reservoir 8. Snap ring
P-12

CONVENTIONALBRAKESYSTEM P
1 SUOPX-001
03UOPX-03
0
o3uoPx-os
0
POWER BRAKE UNIT
Quick Inspection, On-vehicle
Power brake unit function check
k:;;p{e method)
1. With the engine stopped, depress the pedal a few times.
2. With the pedal depressed, start the engine.
3. If immediately after the engine starts the pedal moves down
slightly, the unit is operating.
Step 2
1. Start the engine.
2. Stop the engine after it has run for
1 or 2 minutes.
3. Depress the pedal with the usual force.
4. If the first pedal stroke is long and becomes shorter with
subsequent strokes, the unit is operating.
5. If a problem is found, inspect for damage of the check valve
or vacuum hose and examine the installation. Repair if
necessary, and inspect it once again.
Step 3
1. Start the engine.
2. Depress the pedal with the usual force.
3. Stop the engine with the pedal held depressed.
4. Hold the pedal down for
about 30 seconds.
5. If the pedal height does not change, the unit is operating.
6. If there is a problem, check for damage to the check valve
or vacuum hose, and check the connection. Repair if neces-
sary and check once again.
If the nature of the problem is still not clear after the 3 steps
above, follow the more detailed check described in “Method-
using tester,” below.
(Method-using tester)
Connect a pressure gauge, vacuum gauge, and pedal depres-
sion force gauge as shown in the figure. After bleeding the
air from the pressure gauge, conduct the test as described
in the 3 steps below.
Note
l Use commercially available gauges and pedal
depression force gauge.
a) Checking for vacuum loss
Unloaded condition
1. Start the engine.
2. Stop the engine when the vacuum gauge reading reaches
500 mmHg (19.7 inHg).
3. Observe the vacuum gauge for 15 seconds. If the gauge
shows 475-500
mmHg (18.7-19.7 inHg), the unit is
operating.
P-13

P CONVENTIONAL BRAKE SYSTEM
0 8
500 mmHg
(19.7 inHg)
96 N (20 kg, 44 lb)
03UOPX-03
03UOPX-03
03UOPX-031
Loaded condition
1. Start the engine.
2. Depress the brake pedal with a force of 196 N (20 kg, 44
lb).
3. With the brake pedal depressed, stop the engine when the
vacuum gauge reading reaches 500 mmHg (19.7 inHg).
4. Observe the vacuum gauge for 15 seconds. If the gauge
shows 475-500 mmHg (18.7-19.7 inHg), the unit is
operating.
b) Checking for hydraulic pressure
1. If with the engine stopped (vacuum 0 mmHg) the fluid pres-
sure is within specification, the unit is operating.
Pedal force Fluid pressure
196 N (20 kg, 44 lb) 1 1,177 kPa (12 kg/cm2, 171 psi) min
2. Start the engine. Depress the brake pedal when the vacu-
um reaches 500 mmHg (19.7 inHg). If the fluid pressure
is within specification, the unit is operating.
Pedal force Fluid pressure
196 N (20 kg, 44 lb) 7,063 kPa (72 kg/cm’, 1,024 psi)
P-14