brake fluid MAZDA PROTEGE 1992 Workshop Manual

HOW TO USE THIS MANUAL/FUNDAMENTAL PROCEDURES
SYMBOLS
There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such
materials during service.
Symbol Meaning Kind
Apply oil New engine oil or gear oil as appropriate
aI i . Apply brake fluid Only brake fluid
Apply automatic transaxle fluid Only ATF
Apply grease Appropriate grease
amal Apply sealant Appropriate sealant
0 Apply petroleum jelly Appropriate petroleum jelly
23UGIX-001
Note
l When special oil or grease is needed, this is shown in the illustration.
NOTES, CAUTIONS, AND WARNINGS
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each
one is there for a specific purpose.
NOTES give you added information that will help you to complete a
particular procedure.
CAUTIONS are given to prevent you from making an error that could damage the
vehicle. WARNINGS
remind you to be especially careful in those areas where carelessness can cause per-
sonal injury.
The following list contains some general WARNINGS you should follow when you work on
a vehicle.
9MUGIX-036
SMUGIX-037
a-4 FUNDAMENTAL PROCEDURES
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas be-
fore starting work.

PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Following items may be done at any time prior to delivery to your customer.
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Glass, exterior bright metal and paint for damage
Cl Wheel lug nuts, and locks (if equipped)
88-118 N.m (9-12 m-kg, 65-87 ft-lb)
q All weatherstrips for damage or detachment
0 Operation of hood release and lock
0 Operation of trunk lid, rear hatch, and fuel lid opener
Cl With trunk open, check for spare jack, tire, tools, and
fasteners securing these items in place.
Cl Door operation and alignment
Cl Headlight aim
INSTALL the following parts:
Cl Wheel caps or rings (if equipped)
q Outside rearview mirror(s)
1 UNDER HOOD-ENGINE OFF )
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Fuel, coolant and hydraulic lines, fittings, connections and
components for leaks
Cl Engine oil level
0 Power steering fluid level
0 Brake and clutch master cylinder fluid level
El Windshield washer reservoir fluid level
Cl Radiator coolant level
Cl Tightness of battery terminals
Cl Manual transaxle oil level
riizmiq
INSTALL the following parts:
Cl Rubber stopper for inside rearview mirror
CHECK operation of the following items:
0 Seat controls (sliding and reclining) and head restraint
Cl Folding rear seat
0 Door locks, including childproof door locks (if equipped)
Seat belts and warning system
Cl Ignition switch and steering lock
0 Inhibitor switch (ATX only)
U Starter interlock switch (clutch pedal, MTX only)
Cl All lights, including warning and indicator lamps
Cl Sound warning system
Cl Horn, wipers and washers (front and rear, if equipped)
0 Audio system (if equipped) 0 Cigarette lighter and clock
0 Sunroof (if equipped)
II Remote control outside rearview mirrors (if equipped)
Cl Power windows (if equipped)
q Heater, defroster and air conditioner at various mode
selections (if equipped)
CHECK the following items:
Cl Presence of spare fuse
0 Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
0 Pedal height and free play of brake and clutch pedal
Pedal height mm (in) Free play mm (in)
0 Parking brake
5-7 notches/98 N (10 kg, 22lb)
UNDER HOOD-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
q Automatic transaxle fluid level
[I
CHECK the following items:
Cl Underside fuel, coolant and hydraulic lines, fittings, con-
nections and components for leaks
0 Tires for cuts or bruises
0 Steering linkage, suspension, exhaust system and all un-
derside hardware for looseness or damage
[I
CHECK the following items:
0 Brake operation
0 Clutch operation
Cl Steering control
Cl Operation of gauges
q Squeaks, rattles or unusual noise
Cl Emergency locking retractors
0 Cruise control system (if equipped)
1 AFTER ROAD TEST (
CHECK for necessary owner information materials.
Following items must be done just before the delivery to your customer.
q Load test battery and charge if necessary
1 Volts 1 0 Install fuses for accessories
i.. _
0 Adjust tire pressure to the specification
Load test result cl Remove seat and floor mat protective covers
(Refer to door label) 0 Vacuum and clean interior of vehicle
0 Clean outside of vehicle q Inspect installation of option parts with invoice
23UOAX-002
A-2

7 Schedule 1 (Normal Driving Conditions) (Cont’d)
MAINTENANCE
INTERVALS 1 ::::“’ rths ’ 7.5
DPERATION x 1,000 miles
x 1,000 km 3r mi
15
15
24
1
Page
l- . whichever comes first s (kilometer!
37.5
37.5
60 52.5
52.5
64 60
60
96
I
l-7
Service data and inspection points
l Hoses for cracks or wear l Coolant level E-5
Zooling system
Engine coolant
Fuel filter
‘die speed
Fuel lines
Brake lines, hoses and connections
l Coolant capacity:
5.0 liters (5.3 US qt, 4.4 Imp qt) . . . . . . . . . . MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) . . . . . . . . . . ATX
I E-6 -
F-l 24
l ATX: P range, MTX: Neutral
700-800 rpm (with parking brake applied)
l Fittings, connections, and components for F-80
F-120
-
H-6
P-28
P-29
P-20
P-25
P-18
P-25
---
N-27
N-8
-
M-21
-
F-136
u-35
u-39 leaks
0 Proper attachment and connections
l Operation l Pedal height (with carpet):
196-204mm (7.72-8.03 in)
l Free play:
5--13mm 10.197-0.512 in) Clutch pedal
l Wheel cylinder operation and leakage
l Lining for wear or damage l Lining thickness:
Minimum . . . . . 1 .Omm (0.04 in)
l Drum inner diameter
Maximum..... 201mm (7.91 in) Drum brake
l Caliper operation l Disc plate thickness:
Minimum.... Front 20mm (0.79 in)
Rear 7.0mm (0.28 in)
l Pad thickness:
Minimum.... Front 2.0mm (0.08 in)
Rear l.Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozing l Free play.... O-30mm (O-l .18 in)
l Damage, looseness, and grease leakage
l Cracking and damage
l Retighten all loose nuts and bolts I
1
Disc brake
I
---l-T
Steering operation and linkage
Front suspension ball joints
Drive shaft dust boots
Bolts and nuts on chassis and body
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor am01 anni I
l Insulation clearance
- ,.
Inspect rerrlgerar
Inspect operation annually -

I
Schedule 2 (Unique Driving Conditions) (Cont’d)
(kil
I :
I :
’ 1 iii ichever comes first lometers), Y
25 30 35
25 30 35
40 48 58
I
45
45
72 50
50
80
-
-
I
I
I
I
I
T
I
,
40
iii
i5i
-
-
-
-
-
-
-
-
-
I
-
-
T -
-
-
- -
1 nspec L :t rerngeranr amount annually
Inspect operation annually m
rs
E
24
-
-
-
I
-
-
-
T
-
T fn
iiF
is
w
-
-
-
-
-
-
-
-
- iii
iii
,s
-
I
-
I
-
I
-
I
T
I-
r
T
-
T7
Service data and inspection points Page l
Operation l Pedal height (with carpet):
196-204mm (7.72-8.03 in) l
Free play
5-13mm (0.197-0.512 in) l
Wheel cylinder operation and leakage l Lining for wear or damage l Lining thickness:
Minimum l.Omm (0.04 in) l
Drum inner diameter: H-6
Clutch pedal
P-28
P-29 Drum brake
Maximum 201mm (7.91 in) l
Caliper operation l Disc plate thickness:
Minimum Front.... 20mm (0.79 in)
Rear . . . . . 7.0mm (0.28 in) l
Pad thickness:
Minimum Front.... 2.0mm (0.08 in)
Rear . . . . . 1 .Omm (0.04 in) l
Operation and looseness l Fluid leakage or oozing l Free play.... O-30mm (O-l.18 in) l
Damage looseness and grease leakage l
Cracking and damage l
Retighten all loose nuts and bolts l
Insulator clearance
-
- P-20
P-25
P-18
P-25
N-27
N-8 Disc brake
Steering operation and linkage
Front suspension ball joint
Drive shaft dust boots
Bolts and nuts on chassis and body
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor -
M-21
-
F-136
u-35
u-39

SCHEDULED MAINTENANCE SERVICES (CANADA)
Schedule
2 1,000 km
x 1,000 mile! Number of months or kilometers (miles), whichever comes first
Months 5 10 15 20 25 30 35 40 45 50 55 60
8 16 24
32 40 40 56 64 72 80 88 96
s 5 10 15 20 25 30 35 40 45 50 55 60
I I I Service data and inspection points Page
MAINTENANCE
OPERATION
l Cracks or damage Bl-5 l Tension 82-5
l Oil pan capacity
B6 SOHC: 3.0 liters (3.2 US qt, 2.6 Imp qt)
All BP : 3.6 liters (3.8 US qt, 3.2 Imp qt)
l Oil filter capacity: D-5
0.17 liter (0.18 US qt, 0.15 Imp qt) Drive belts I I I I I I I I I I I I
Engine oil RRRRRRR R R R R R
Oil filter R R R R R R R R R R R R D-5
81-12
82-12
F-79 Replace every 96,000 km (60,000 miles)
Engine timing belt*’
Air cleaner element
T
-
-
I
-
-i
-
I
-
-
-
-
-
-i-
- -
R -
-
-
-
T
-
-
-
-
-
-
-7
- -
-
-
-
T
-
-
-
-
-
-
T
- -r
-
-
I
-
T
-
I
-
-
-
-
-
-i
-
-
-
-
-
T
-
-
-
-
-
-
T
- -
-
-
-
T
-
-
-
-
-
-
T
- i?-
-
R
-
I
-
R
-i
-
I
F
T
T
-
I
-i
-i
-
-
-
-
-
T
-
-
-
-
-
-
-i
- -
l Plug gap: 1.0-l .l mm (0.039-0.043 in)
l Recommended spark plugs .-
Engine NGK NIPPONDENSO
86 SOHC BKR5E-11 KlGPR-Ull
BKRGE-11 K20PR-U 11
BP SOHC BKR5E-11 KlGPR-Ull
BKRGE-11 K20PR-U
11
BKRSE-11 KlGPR-Ull
BP DOHC BKRGE-11 K20PR-U 11
BKR7E-11 K22PRU 11 G-18
R
-
I
-
R
-i- Spark plugs -
-
-
-
I
-
-
E-5
Cooling system l Hoses for cracks or wear
l Coolant level
0 Coolant capacity: 5.0
liters (5.3 US qt, 4.4 imp qt) ..,.,..,,. MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) . . . . . . . . . . ATX
l Level and condition
l ATX: P range, MTX: Neutral
700-800 rpm (with parking brake applied) E-6
Engine coolant
E-5
F-80
F-124 I
- I
Idle speed
Fuel filter
PCV valve *’
Emission hoses and tubes
Fuel lines
Brake lines, hoses and connections
Automatic transaxle fluid (ATF) -
-
-
I *2
l Operation - F-138
F-6 -
-
- -
-
-
l Fittings and connections
l Fittings, connections, and components for
leaks
l Proper attachment and connections
l Level and conditinn F-l 20 - K-l 35
I I
- I
- I

7 Schedule (Cont’d)
rile
iii
48
30
-
R
I
R !rs
25
40
25
-
-i- , whichever comes first
OPERATION MAINTENANCE Number of m
INTERVALS Months
x 1,000 km
x 1,000 miles
ii
is
G
-
i-
-
-
I
5-
T
-
-
-
-
-
-
- ii
z
ro
-
I-
-
-
I
- 45
72
45
-
-i-
-
-
I
-
ry 15 month:
I I I
A
t
A
j
milt Service data and inspection points Page
l Capacity
MTX B6, BP SOHC:
2.68 liters (2.83 US qt, 2.36 Imp qt)
BP DOHC
3.35 liters (3.55 US qt, 2.96 Imp qt)
ATX: 6.3 liters (6.7 US qt, 5.5 Imp qt)
l Level and condition
- Jl-7
J2-7
- Transaxle oil
l Wear and damaae -i- -i- -i- -
Brake fluid, clutch fluid
Brake fluid*3 -
Q-3, 5
Q-6
N-27
P-28
P-29 I I
- I
1,oo
-i
-
-
-
-
-
-
- I
G
T
-
-
-
-
-
-
- I
15,(
I Tire inflation pressure and wear l Proper pressure-
-
l Level and condition
l Wheel cylinder operation and leakage l Lining for wear or damage l Lining thickness:
Minimum 1 .Omm (0.04 in)
l Drum inner diameter. 3s) or f
I I
I
:t r
- Rotate tires
Power steering fluid
Drum brake ? every
I I
Disc brake I I
Maximum 201mm (7.91 in)
l Caliper operation l Disd plate thickness:
Minimum Front.... 20mm (0.79 in)
Rear . . . . . 7.0mm (0.28 in)
l Pad thickness:
Minimum Front.... 2.0mm (0.08 in) P-20
P-25
P-l 8
P-25
N-27
N-8 Rear . . . . . 1 .Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozina
l Free play.... O--3OmmjO-1.18 in)
l Damage looseness and grease leakage
l Cracking and damage
l Insulator clearawp .-v
-
Steering operation and linkage
I
-i-
-I-
-i- Front suspension ball joint
Drive shaft dust boots
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor
Suspension components (front and rear)
All chassis and body nuts and bolts
All locks and hinaes
Washer fluid -
M-21
F-136
u-35
u-39
-
- IY efrigerant amount ann
*. I# mspec
Inspect operation annualry -
l Damaae
l Retighten all loose nuts and bolts
l Lubricate all locks and hinges
l Level
l ODeration - Function of all lights l !%t and damage -

H CLUTCH FLUID
CLUTCH FLUID
PREPARATION
SST
49 0259 7708 For
Wrench, flare nut ~ air bleeding
03UOHX-007
REPLACEMENT
Note
l A common reservoir is used for the clutch and brake
system fluids.
l The fluid in the reservoir must be maintained at the
3/4 level or higher during replacement.
Caution
l Be careful not to spill the fluid on a painted surface.
If this should happen, wash it off Immediately.
l Do not mix different brands of fluid.
l Do not reuse the clutch fluid that was drained.
1. Drain the brake fluid from the master cylinder through a
wheel cylinder.
2. Remove the bleeder cap from the clutch release cylinder
and attach a vinyl hose to the bleeder plug.
03UOHX-006 -
3. Place the other end of the vinyl hose in a clear container.
4. Slowly pump the clutch pedal several times.
5. With the clutch pedal depressed, loosen the bleeder screw
with the
SST to let the fluid escape. Close the bleeder screw
with the
SST.
6. Repeat Steps 4 and 5 until only clean fluid is seen.
7. Tighten the bleeder screw.
Tightening torque:
5.9-8.8 N.m (80-90 cm-kg, 52-78 in-lb)
8. Add fluid to the MAX mark.
9. Slowly pump the clutch pedal several times.
Verify that there is no fluid leakage.
10. Check operation of the clutch system.
11. Check operation of the brake system.
H-4

M REAR AXLE
!O
03UOMX-01 0
0.5mm
19
Removal note
Brake pipe
Caution
l After disconnecting the brake pipe, plug it to avoid
fluid leakage.
1. Disconnect the brake pipe with the SST.
lnstallatlon note
Brake pipe
1. Tighten the brake pipe with the SST.
Tightening torque:
13-22 N*m (1.3-2.2 m-kg, 9.4-16 ft-lb)
Locknut
1. Install a new locknut and stake it, as shown.
Tightening torque:
177-236 Narn (16-24 m-kg, 130-l 74 ft-lb)
M-12

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

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