1992 MAZDA PROTEGE brake

Removal / Installation
Caliper
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
CONVENTIONAL BRAKE SYSTEM P
1
39-49 (4.0-5.0, 2! 3-36)
@ .-- . . -3
16-
‘(

N.m (m-kg, Mb)
23UOPX-023
1. Flexible hose 5. Caliper
2. Pad pin Disassembly / Inspection I
3. Disc pad assembly Assembly , . , , . , . . . . . . . . . . , . . . . . . . . . . . . . . . . . page P-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-20 6. Guide plate
7. Disc plate
Inspection . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-20 4. Bolt
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-8.)
l Depress the brake pedal a few tlmes and check that
the rear brakes do not drag While rotating the wheel.
03UOPX-052 P-19

P CONVENTIONAL BRAKE SYSTEM
23UOPX-01. 5
84
03UOPX-055
Inspection
Check for the following and repair or replace parts as
necessary.
Disc pad assembly
1. Check for oil or grease on the facing, abnormal wear or
cracks, and deterioration or damage from heat.
2. Measure the thickness of the lining.
Specified thickness: 1Omm (0.39 in)
Minimum : 2.0mm (0.08 in)
3. Check visually for damage or wear of the guide plate.
Disc plate
1. Measure the thickness of the disc plate.
Standard: 22mm (0.87 in)
Minimum: 20mm (0.79 in)
2. Measure the runout at the outer edge of the contact sur-
face of the disc pad.
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 plate surface.
P-20

CONVENTIONAL BRAKE SYSTEM P
CALIPER
Disassembly / Inspection / Assembly
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and depair or replace as necessary.
3. Assemble in the reverse order of disassembly.
1. Sleeve pin
2. Boot
3. Rubber cap and bleeder screw ..,.......... Below
4. Retaining ring
5. Dust seal
6. Piston
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . . page P-22
Inspect for damage, wear and rust 7. Piston seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . . page P-22
8. Caliper body
Inspect for damage, wear and rust
Disassembly note
Rubber cap and bleeder screw
Remove the rubber cap and remove the bleeder screw from
the brake caliper with the
SST.
P-21

P CONVENTIONAL BRAKE SYSTEM
I
13UOPX-023
Piston
Place a piece of wood in the caliper; then blow compressed
air through the hole to force the piston out of the caliper.
Caution
l Blow the compressed air slowly to prevent the pis-
ton from suddenly popping out.
1
03UOPX.058
Piston seal
Remove the piston seal from the brake caliper with the SST.
P-22

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.)