1992 MAZDA PROTEGE Workshop Manual

ENGINE SPEED SENSING POWER STEERING N
P/S
23UONX-04!
PULLEY
P/S AND A/C
23UONX-04
DRIVE BELT
Inspection
1. Check the drive belts for wear, cracks, and fraying. Replace
as necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
3. Check the drive belt deflection by applying moderate pres-
sure (98 N,
10 kg, 22 lb) midway between the pulleys.
Note
l Measure the belt deflection between the specified
pulleys.
0 A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Set the deflection specification below accordingly.
* Check the belt deflection when the engine is cold,
or at least 30 minutes after the engine has stopped.
Deflection
mm (in)
New Used Limit
8-9.0 (0.31-0.35) 9.0-10.0 (0.35-0.39) 11.5 (0.45)
4. If the deflection is not within specification, adjust it.
23UONX-047
Drive belt tension check
WHEN SET
I
23UONX-048
Note
l Belt tension can be checked in place of belt
deflection.
aBelt tension can be measured between any two
pulleys.
Using the SST check the belt tension.
Tension
N (kg, lb)
New
491-589
(50-60, 11 O-l 32) Used
422-491
(43-50, 95-l 10) Limit
245
(25, 55)
N-41

N ENGINE SPEED SENSING POWER STEERING
13UONX-02
Adjustment
1. Loosen bolt @, nut @J, and locknut 0. Turn adjusting bolt
@? to adjust the belt to the specified tension.
2. Tighten locknut 0, bolt @, and nut @I to the specified
torques.
Tightening torque
Bolt @: 36-54 N-m (3.7-5.5 m-kg, 27-40 ft-lb)
Nut @J : 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Locknut 0:
31-46 Narn (3.2-4.7 m-kg, 23-34 f&lb)
Replacement
1. Loosen bolt @, nut 0, and locknut @.
2. Turn adjusting bolt @ to release the belt tension.
3. Remove the belt.
4. Install a new drive belt and adjust the tension and deflec-
tion. (Refer to above for adjustment.)
N-42

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

P INDEX
NDEX
LEVER STROKE (WHEN PULLED WITH A FORCE OF 98 N [lo kg, 22 lb])
FMVSS 116, DOT-3,
SAE J1703 OTCHES
1. Brake hydraulic line
Inspection / Removal /
Installation.. ............................... page P- 6
2. Brake pedal
Inspection (on-vehicle).
............... page P- 8
Removal / Inspection /
Installation ................................. page P-l 0
3. Master cylinder
Removal I installation.. ................ page P-10
Disassembly / Inspection /
Assembly .................................. page P-12
4. Power brake unit
Inspection (on-vehicle). ............... page P-l 3
Removal I Installation.. ................ page P-16
5. Dual proportioning valve
Inspection
................................... page P-l 6
Replacement.. ............................. page P-l 7
6. Front brake (disc)
Inspection (on-vehicle). ............... page P-l 8
Replacement.. .............................
page P-l 8
Removal / installation.. ................ page P-l 9
Inspection ...................................
page P-20
7. Caliper
Disassembly I Inspection /
Assembly.. ................................ page P-21
P-2
8. Rear brake (disc)
23UOPX-008
Inspection (on-vehicle) . . . . . . . , , ., . . . . page P-23
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-23
Removal / Installation . . . . . . . . . . . . . . . . . . page P-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-25
9. Caliper
Disassembly / Inspection /
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-26
10. Rear brake (drum)
Inspection (on-vehicle). . . . . . . . . . . . . . . . page P-28
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-28
11. Wheel cylinder
Disassembly / Inspection /
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-30
12. Parking brake (lever type)
Inspection (on-vehicle) . . . . . . . . . . . . . . . . page P-31
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-31
13. Parking brake cable
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-32
14. Parking brake lever
Removal / Inspection / --
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-33

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

CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE SYSTEM
PREPARATION
SST
49 0259 770B
For 49 F043 001
For
removal of
adjustment of
Wrench, flare nut
w brake pipe Adjust gauge
piston-to-push
rod clearance
49 0208 701A
For 49 0221 600C For
removal of
installation of
Air-out tool, boot 471 piston seal
Expand tool, disc brake pads
brake (Front disc brake)
._’
P-4

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