1992 MAZDA PROTEGE height

H CLUTCH MASTER CYLINDER
23UOHX-Ot ,a
\ I 03UOHX-016
7
I
03UOHX-014
Removal Note
Clutch pipe
1, Disconnect the clutch pipe with the SST.
2. Disconnect the clutch hose from the reservoir.
3. Plug the outlet of the reservoir.
Installation Note
Clutch pipe
1. Tighten the clutch pipe with the SST.
Tightening torque:
13-22 N.m (1.3-2.2 m-kg, 9-16 ft-lb)
Air Bleeding
I. After installation, bleed the clutch system.
(Refer to page below.)
Inspection and Adjustment
Clutch pedal height and free play
(Refer to page H-5.)
AIR BLEEDING
The clutch hydraulic system must be bled to remove air in-
troduced whenever a hydraulic line is disconnected.
Note
l The fluid in the reservoir must be maintained at the
3/4 level or higher during air bleeding.
Caution
l Clutch fluid will damage a painted surface. If fluid
does get on a painted surface, wipe it off im-
mediately.
l Do not mix different brands of clutch fluid.
l Do not reuse the clutch fluid that was drained. __,

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

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

WHEEL ALIGNMENT
WHEEL ALIGNMENT
PRE-INSPECTION
1. Check the tire inflations and set to the recommended pressure, if necessary.
2. Inspect the front wheel bearing play; replace the bearing if necessary.
3. inspect the wheel and tire runout.
4. Inspect the ball joints and steering linkage for any excessive looseness.
5. The vehicle must be on level ground and have no luggage or passenger load.
6. The difference in height between the left and right sides from the center of the wheel to the fender brim
must not exceed
10mm (0.39 in).
7. Shake the vehicle to check operation of the shock absorbers.
03UORX.007
FRONT WHEEL ALIGNMENT
Specifications
item
Specifications
Maximum Inner 4o” f: 2O
steering angle Outer
33O f 2O
Total mm (in) 2 f 3 (0.08 f 0.12)
toe-in dearee 0.20 f 0.30 Wheel alignment
(*‘Unladen) Front
*I Fuel tank full; radiator coolant and Camber angle -0005 * 45’
Caster angle 1°55’ f 55’
Kingpin angle 12O25’
engine oil at specified level; and spare tire, jack, and tools in designated positions.
23UORX-008
I
I 23UORX-023
Adjustments
Maximum steering angle
1. Loosen the left and right tie rod locknuts, then turn the tie
rods equally.
Maximum left/right difference: 3mm (0.12 in)
2. Tighten the tie rod locknuts.
Tightening torque:
34-50 N-m (3.5-5.1 m-kg, 25-37 ft-lb)
3. Adjust the toe-in after adjusting the steering angle.
4. Inspect and adjust the toe-in after adjusting the turning angle.
I 23UORX-024
R-7

S TRUNK LID
03uosx-04’
HINGE (L.H.)
RIGHT SPRING -1
I
,i I
II
1
k
TRUNK LID
TRUNK LID
SEC.B--8
6 * 1.5 (0.31 * 0.06)
SECA-A mm (in)
03uosx-01
Removal Note
Balance springs
Remove the balance springs from the brackets (LH/RH) with
pliers.
Warning
l Use care when moving the balance spring.
Installation Note
Balance springs
1. Install the hook of each balance spring to the lid hinge as-
sembly.
2. Install the balance spring at the @or @position as shown.
Warning
l Use care when moving the balance spring.
Adjustment Note
Balance spring
Adjust the balance spring tension as described below.
(a) Increase: Set the right spring from standard position @
to @.
(b) Decrease: Set the left spring from standard position @to
03.
Trunk lid
Centering
1. Loosen the hinge bolts and adjust as shown.
2. Tighten the bolts to the specified torque.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 89-95 in-lb)
Height
1. Loosen the lid striker installation bolts as shown.
2. Tighten the bolts to the specified torque.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 89-95 in-lb)
s-34

WINDSHIELD WIPER AND WASHER S
ALIGNMEhT MARK
23UOSX.023
MOLDING END FACE
!6-
1.10-1.26)
/ COWL GRILLE END FACE
mm (in
o3uosx-l2!
tATCHBACK
-L I COWL dRlLLE
mm (in:
03uosx-131
Removal Note / Installation Note
Wiper motor and bracket
1. Make an alignment mark on the bracket before removing
the motor arm from the motor.
2. Align the motor arm with the mark on the bracket when in-
stalling the arm.
Tightening torque:
1 l-18 N,m (1 lo-180 cm-kg, 95-158 in-lb)
Adjustment Note
Arm helght
1. Turn the wiper switch ON to operate the motor.
2. Turn the wiper switch OFF to set the automatic park position.
3. Set the arm height as shown in the figure.
Tightening torque:
9.8-14 N-m (100-140 cm-kg, 87-122 in-lb)
Washer nozzle
Insert a needle or similar object into the nozzle hole and move
the nozzle to adjust the spray direction.
s-73