Mazda Protege 5. Manual — part 208

CONVENTIONAL BRAKE SYSTEM

04–11–1

04–11

04–11

CONVENTIONAL BRAKE SYSTEM

CONVENTIONAL BRAKE SYSTEM

LOCATION INDEX . . . . . . . . . . . . . . . . 04–11–2

AIR BLEEDING . . . . . . . . . . . . . . . . . . . . 04–11–3
VACUUM HOSE CHECK VALVE

INSPECTION (POWER BRAKE UNIT) . 04–11–3

BRAKE PEDAL INSPECTION . . . . . . . . 04–11–3

Brake Pedal Height Inspection. . . . . . . 04–11–3
Brake Pedal Height Adjustment . . . . . . 04–11–4
Brake Pedal Play Inspection . . . . . . . . 04–11–4
Brake Pedal Play Adjustment . . . . . . . 04–11–4
Pedal-to-floor Clearance Inspection. . . 04–11–5

BRAKE PEDAL

REMOVAL/INSTALLATION . . . . . . . . . 04–11–5

BRAKE SWITCH INSPECTION . . . . . . . 04–11–5
MASTER CYLINDER

REMOVAL/INSTALLATION . . . . . . . . . 04–11–6

Master Cylinder Installation Note . . . . . 04–11–6

FLUID LEVEL SENSOR INSPECTION. . 04–11–9
MASTER CYLINDER

DISASSEMBLY/ASSEMBLY . . . . . . . . 04–11–10

Stop Screw and O-ring (without ABS)

Assembly Note . . . . . . . . . . . . . . . . . . 04–11–11

Stop Pin and O-ring (with ABS)

Assembly Note . . . . . . . . . . . . . . . . . . 04–11–11

POWER BRAKE UNIT INSPECTION . . . 04–11–11

Power Brake Unit Function Check . . . . 04–11–11

POWER BRAKE UNIT

REMOVAL/INSTALLATION . . . . . . . . . 04–11–13

DUAL PROPORTIONING VALVE

(WITHOUT ABS) INSPECTION . . . . . . 04–11–13

DUAL PROPORTIONING VALVE

(WITHOUT ABS) AND BRAKE PIPE
JOINT (WITH ABS) REPLACEMENT . . 04–11–14

Dual Proportioning Valve

(Without ABS) or Brake Pipe Joint
(With ABS) Installation Note . . . . . . . 04–11–14

FRONT BRAKE (DISC) INSPECTION . . . 04–11–14

Brake Judder Repair Hint . . . . . . . . . . . 04–11–14
Disc Plate Thickness Inspection . . . . . . 04–11–16
Disc Pad Thickness Inspection . . . . . . . 04–11–16

FRONT BRAKE (DISC)

REMOVAL/INSTALLATION . . . . . . . . . . 04–11–17

Disc Plate Removal Note . . . . . . . . . . . 04–11–18
Disc Plate Installation Note . . . . . . . . . . 04–11–18
Disc Pad Installation Note . . . . . . . . . . . 04–11–18

DISC PAD (FRONT) REPLACEMENT . . . 04–11–19
CALIPER (FRONT)

DISASSEMBLY/ASSEMBLY . . . . . . . . . 04–11–20

Piston Disassembly Note . . . . . . . . . . . 04–11–20
Piston Seal Disassembly Note . . . . . . . 04–11–20
Bleeder Screw Assembly Note . . . . . . . 04–11–21

REAR BRAKE (DISC) INSPECTION . . . . 04–11–21

Brake Judder Repair Hint . . . . . . . . . . . 04–11–21
Disc Pad Thickness Inspection . . . . . . . 04–11–21
Disc Plate Thickness Inspection . . . . . . 04–11–21

REAR BRAKE (DISC)

REMOVAL/INSTALLATION . . . . . . . . . . 04–11–22

Disc Pad Installation Note . . . . . . . . . . . 04–11–22

DISC PAD (REAR) REPLACEMENT . . . . 04–11–23
CALIPER (REAR)

DISASSEMBLY/ASSEMBLY . . . . . . . . . 04–11–24

Piston Disassembly Note . . . . . . . . . . . 04–11–24
Piston Assembly Note . . . . . . . . . . . . . . 04–11–25

REAR BRAKE (DRUM) INSPECTION . . . 04–11–25

Brake Lining Thickness Inspection . . . . 04–11–25
Brake Drum Inspection . . . . . . . . . . . . . 04–11–25

REAR BRAKE (DRUM)

REMOVAL/INSTALLATION . . . . . . . . . . 04–11–26

Brake Drum Removal Note . . . . . . . . . . 04–11–27
Brake Drum Installation Note . . . . . . . . 04–11–27

WHEEL CYLINDER

DISASSEMBLY/ASSEMBLY . . . . . . . . . 04–11–27

End of Toc

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CONVENTIONAL BRAKE SYSTEM

04–11–2

CONVENTIONAL BRAKE SYSTEM LOCATION INDEX

A3U041101020W01

.

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1

Vacuum line
(See 04–11–3 VACUUM HOSE CHECK VALVE
INSPECTION (POWER BRAKE UNIT))

2

Brake pedal
(See 04–11–3 BRAKE PEDAL INSPECTION)
(See 04–11–5 BRAKE PEDAL REMOVAL/
INSTALLATION)

3

Brake switch
(See 04–11–5 BRAKE SWITCH INSPECTION)

4

Master cylinder
(See 04–11–6 MASTER CYLINDER REMOVAL/
INSTALLATION)
(See 04–11–10 MASTER CYLINDER
DISASSEMBLY/ASSEMBLY)

5

Brake fluid level sensor
(See 04–11–9 FLUID LEVEL SENSOR
INSPECTION)

6

Power brake unit
(See 04–11–11 POWER BRAKE UNIT
INSPECTION)
(See 04–11–13 POWER BRAKE UNIT REMOVAL/
INSTALLATION)

7

Dual proportioning valve (without ABS) or brake
pipe joint (with ABS)
(See 04–11–13 DUAL PROPORTIONING VALVE
(WITHOUT ABS) INSPECTION )
(See 04–11–14 DUAL PROPORTIONING VALVE
(WITHOUT ABS) AND BRAKE PIPE JOINT (WITH
ABS) REPLACEMENT )

8

Front brake (disc)
(See 04–11–14 FRONT BRAKE (DISC)
INSPECTION)
(See 04–11–17 FRONT BRAKE (DISC) REMOVAL/
INSTALLATION)

9

Front disc pad
(See 04–11–19 DISC PAD (FRONT)
REPLACEMENT)

10

Front caliper
(See 04–11–20 CALIPER (FRONT)
DISASSEMBLY/ASSEMBLY)

11

Rear brake (disc)
(See 04–11–21 REAR BRAKE (DISC)
INSPECTION)
(See 04–11–22 REAR BRAKE (DISC) REMOVAL/
INSTALLATION)

12

Rear disc pad
(See 04–11–23 DISC PAD (REAR)
REPLACEMENT)

13

Rear caliper
(See 04–11–24 CALIPER (REAR) DISASSEMBLY/
ASSEMBLY)

14

Rear brake (drum)
(See 04–11–25 REAR BRAKE (DRUM)
INSPECTION)
(See 04–11–26 REAR BRAKE (DRUM) REMOVAL/
INSTALLATION)

15

Wheel cylinder
(See 04–11–27 WHEEL CYLINDER
DISASSEMBLY/ASSEMBLY)

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CONVENTIONAL BRAKE SYSTEM

04–11–3

04–11

AIR BLEEDING

A3U041143001W01

Note

•

The brakes should be bled whenever a brake line is disconnected. If a hydraulic line is disconnected at
the master cylinder, start at the slave cylinder farthest from the brake master cylinder, and move to the
next farthest slave cylinder until all 4 cylinders have been bled. If the disconnection point is anywhere
except the master cylinder, start at the point closest to the disconnection, and move to the next closest
slave cylinder until all 4 cylinders have been bled.

Specified fluid

SAEJ1703 or FMVSS 116 DOT-3

1. On level ground, jack up the vehicle and support it evenly on safety stands.
2. Remove the bleeder cap and attach a vinyl tube to the bleeder screw.
3. Place the other end of the vinyl tube in a clear, fluid filled container.
4. The first person depresses the brake pedal a few times, and then holds it in the depressed position.
5. The second person loosens the bleeder screw,

drains out the fluid and closes the screw using the
SST.

6. Repeat Steps 4 and 5 until no air bubbles are

seen. The reservoir should be kept about 3/4 full
during bleeding to prevent air from reentering the
lines.

Tightening torque

5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}

7. Inspect for correct brake operation.
8. Verify that there is no fluid leakage. Wipe off any

spilled fluid immediately.

9. After bleeding the brakes, add brake fluid to the maximum level.

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VACUUM HOSE CHECK VALVE INSPECTION (POWER BRAKE UNIT)

A3U041143980W01

1. Remove the clamps and vacuum hose.
2. Apply both suction and pressure to the engine-side hose, and verify that air blows only toward that side.

•

If air flows in both directions or not at all, replace the vacuum hose.

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BRAKE PEDAL INSPECTION

A3U041143300W01

Brake Pedal Height Inspection

1. Verify that the distance from the carpet to the center of the upper surface of the pedal pad is as specified.

Pedal height (reference value)

185 mm {7.28 in}

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CONVENTIONAL BRAKE SYSTEM

04–11–4

Brake Pedal Height Adjustment

1. Disconnect the brake switch connector.
2. Loosen locknut B and turn switch A until it does

not contact the pedal.

3. Loosen locknut D and turn rod C to adjust the

height.

4. Tighten the bolt with locknut B so that clearance

between the bolt for brake light switch A and
pedal stopper is within the specification.

Specification

0.1—1.0 mm {0.004—0.039 in}

Tightening torque

13.8—17.6 N·m {140—180 kgf·cm, 122—156

in·lbf}

5. Connect the brake switch connector.
6. After adjustment, inspect the pedal play and the

brake light operation.

Brake Pedal Play Inspection

1. Depress the pedal a few times to eliminate the vacuum in the system.
2. Remove the spring pin, verify that the holes in the fork and in the pedal are aligned, and reinstall the pin. (See

04–11–5 BRAKE PEDAL REMOVAL/INSTALLATION.)

3. Gently depress the pedal by hand until resistance

is felt, and check the pedal play.

Pedal play

4—12 mm {0.16—0.47 in}

Brake Pedal Play Adjustment

1. Remove the spring pin and clevis pin. (See 04–11–5 BRAKE PEDAL REMOVAL/INSTALLATION.)
2. Loosen locknut D and turn rod C to align the

holes in the fork and in the pedal.

3. Install the clevis pin and the spring pin.
4. Tighten locknut D.

Tightening torque

24—34 N·m {2.4—3.5 kgf·m, 18—25 ft·lbf}

5. Check the pedal height and the brake light

operation.

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