MAZDA PROTEGE 1992 Workshop Manual

CONVENTIONAL BRAKE SYSTEM P
23UOPX-02
Inspection
Check for the following and repair or replace parts as
necessary.
Disc pad assembly
1. Oil or grease on facing
2. Abnormal wear or cracks
3. Deterioration or damage by heat
4. Remaining lining thickness
Specified thickness: 8.0mm (0.31 in)
Minimum: l.Omm (0.04 in)
Disc plate
1. Runout
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 pad contact surface.
2. Wear or damage
Thickness
Standard: 9.0mm (0.35 in)
Minimum: 7.0mm (0.28 in)
P-25

P CONVENTIONAL BRAKE SYSTEM
CALIPER
Disassembly / Inspection / Assembly
Caution
l Replace the caliper assembly if a problem is found.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassemblv, referrina to
Assembly Note.
(3.7-5.5, 27-40)
5.9~Sh N-m
REPLACE (60-90 cm-kg, 52-78 in-lb)
@ REPLACE
N-m (m-kg, Mb)
23UOPX-01
1. Dust seal 8. Piston seal
Inspect for damage and poor sealing Disassembly Note . . . . . . . . . . . . . . . . . . . . . . .
page P-22
2. Piston 9. Spring
Disassembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Below 10. Operating lever
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-27 11. Boot
Inspect for wear and rust
3. Manual adjustment gear
4. Snap ring
5. Adjusting bolt
6. O-ring
7. Connecting link 12. Rubber cup and bleeder screw
13. Boot
14. Boot
15. Caliper body
Inspect for damage and cracks
Dlsassembly note
Piston
1. Turn the adjustment gear clockwise with an Allen wrench
to remove the piston from the adjustment gear. (Turn the
adjustment gear until it becomes easy to turn.)

CONVENTIONAL BRAKE SYSTEM
03UOPX-07
Assembly note
Piston
Insert the piston into the caliper and turn the adjustment gear
counterclockwise with an Allen wrench to pull the piston in-
ward. (Turn until it stops.)
P-27

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

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

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