1992 MAZDA PROTEGE Workshop Manual

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

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