MAZDA PROTEGE 1992 Workshop Manual

CONVENTIONAL BRAKE SYSTEM P
03UOPX-039
ARROW MARK
23UOPX-Old
Check valve
Inspection
1. Disconnect the vacuum hose (with intenal check valve) from
the engine side.
2. Apply suction and pressure to the hose from the engine side.
Verify that air flows only toward the engine.
Caution
l If the check valve is bad, replace the hose with the
valve.
3. Install the vacuum hose with the arrow facing the engine.
P-15

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 P
Caution
l Do not attempt to adjust the dual proportioning
valve.
l After the inspection, bleed the air from the brake
system and check for fluid leakage.
l If the measurements are not within specification,
replace the valve assembly.
03UOPX-045
13-22 (1.3-2.2, 9.4-16) TJ
R P @ 19-23 (1.9-2.3, 14-17)
Replacement
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.
13-22 (1.3-2.2, 9.4-16)
_-. .--.. ^. uwurx-047 N-m (m-kg, R-lb)
23UOPX-oc
1. Brake pipe 2. Bolt
Removal I Installation Note . . . . . . . . . . . . . . . . . Below 3. Dual proportioning valve
Removal / Installation note
Brake pipe
Loosen and tighten the brake pipes with the SST.
P-17

CONVENTIONAL BRAKE SYSTEM
FRONT BRAKE (DISC)
Quick Inspection, On-vehicle
Disc pad
1. Jack up the front of the vehicle and support it with safety
stands.
2. Remove the wheels.
3. Verify the remaining thickness of the pads.
Thickness: 2.0mm (0.08 in) min.
Replacement
Disc pad
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal, referring to
Installation Note.
23UOPX-oc
1. M-spring 4. Disc pad 5. Anti-squeak shim
2. W-pin Installation Note . . . . . . . . Below 6. Outer shim
3. Pad pin Inspection ,.,..,... page P-20 7. Inner shim
P-18
IBUOPX-01
Installation note
Disc pad
When installing the disc pads, push the piston fully inward with
the
SST and an old pad.

Removal / Installation
Caliper
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
CONVENTIONAL BRAKE SYSTEM P
1
39-49 (4.0-5.0, 2! 3-36)
@ .-- . . -3
16-
‘(

N.m (m-kg, Mb)
23UOPX-023
1. Flexible hose 5. Caliper
2. Pad pin Disassembly / Inspection I
3. Disc pad assembly Assembly , . , , . , . . . . . . . . . . , . . . . . . . . . . . . . . . . . page P-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-20 6. Guide plate
7. Disc plate
Inspection . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-20 4. Bolt
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-8.)
l Depress the brake pedal a few tlmes and check that
the rear brakes do not drag While rotating the wheel.
03UOPX-052 P-19

P CONVENTIONAL BRAKE SYSTEM
23UOPX-01. 5
84
03UOPX-055
Inspection
Check for the following and repair or replace parts as
necessary.
Disc pad assembly
1. Check for oil or grease on the facing, abnormal wear or
cracks, and deterioration or damage from heat.
2. Measure the thickness of the lining.
Specified thickness: 1Omm (0.39 in)
Minimum : 2.0mm (0.08 in)
3. Check visually for damage or wear of the guide plate.
Disc plate
1. Measure the thickness of the disc plate.
Standard: 22mm (0.87 in)
Minimum: 20mm (0.79 in)
2. Measure the runout at the outer edge of the contact sur-
face of the disc pad.
Runout: O.lmm (0.004 in) max.
Caution
l There must be no wheel bearing looseness.
l The measurement location is the outer edge of the
disc plate surface.
P-20

CONVENTIONAL BRAKE SYSTEM P
CALIPER
Disassembly / Inspection / Assembly
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and depair or replace as necessary.
3. Assemble in the reverse order of disassembly.
1. Sleeve pin
2. Boot
3. Rubber cap and bleeder screw ..,.......... Below
4. Retaining ring
5. Dust seal
6. Piston
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . . page P-22
Inspect for damage, wear and rust 7. Piston seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . . page P-22
8. Caliper body
Inspect for damage, wear and rust
Disassembly note
Rubber cap and bleeder screw
Remove the rubber cap and remove the bleeder screw from
the brake caliper with the
SST.
P-21

P CONVENTIONAL BRAKE SYSTEM
I
13UOPX-023
Piston
Place a piece of wood in the caliper; then blow compressed
air through the hole to force the piston out of the caliper.
Caution
l Blow the compressed air slowly to prevent the pis-
ton from suddenly popping out.
1
03UOPX.058
Piston seal
Remove the piston seal from the brake caliper with the SST.
P-22

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