Mazda Protege 5. Manual — part 209

CONVENTIONAL BRAKE SYSTEM

04–11–5

04–11

Pedal-to-floor Clearance Inspection

1. Start the engine and depress the brake pedal with a force of 588 N {60 kgf, 132 lbf}
2. Verify that the distance from the floor panel to the pedal pad center is as specified when the pedal is

depressed.

•

If the distance is less than specified, check for the air in brake system.

Specification

ZM : 88 mm {3.5 in} min.
FS : 84 mm {3.3 in} min.

End Of Sie

BRAKE PEDAL REMOVAL/INSTALLATION

A3U041143300W02

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

End Of Sie

BRAKE SWITCH INSPECTION

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1. Disconnect the brake switch connector.
2. Inspect for continuity between the terminals of the

brake switch connector using the ohmmeter.

•

If not as specified, replace the brake switch.

End Of Sie

X3U411WA5

1

Brake switch connector

2

Spring pin

3

Clevis pin

4

Brake pedal

5

Brake switch

6

Pedal pad

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CONVENTIONAL BRAKE SYSTEM

04–11–6

MASTER CYLINDER REMOVAL/INSTALLATION

A3U041143400W01

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

Master Cylinder Installation Note
FS

1. Turn the nut of the SST clockwise to fully retract the SST gauge rod. Attach the SST to the power brake unit.

Tightening torque

9.9—15 N·m {1.0—1.6 kgf·m, 7.3—11 ft·lbf}

2. Apply a 66.7 kPa {500 mmHg, 19.7 inHg}

vacuum by using a vacuum pump.

3. Turn the adjusting nut of the SST

counterclockwise until the gauge rod just contacts
the push rod end of the power brake unit. Push
lightly on the end of the gauge rod to be sure it is
seated. Verify that there is no gap between the
adjusting nut and SST body.

4. Remove the SST from the power brake unit

without disturbing the adjusting nut. Set the SST
onto the master cylinder as shown in the figure.

Caution

••••

When pushing the SST gauge rod into
the master cylinder piston, only use
enough pressure to push the rod to the
bottom of the piston. If too much
pressure is applied, a false reading
will occur.

1

Brake fluid level sensor connector

2

Brake pipe

3

Hose (MTX)

4

Master cylinder
(See 04–11–6 Master Cylinder Installation Note

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CONVENTIONAL BRAKE SYSTEM

04–11–7

04–11

5. Push lightly on the end of the SST gauge rod to

be sure it has contacted the bottom of the master
cylinder piston, but do not push so hard that the
piston moves. Note any clearance between the
SST body and the adjusting nut (clearance B) or
between the body and the master cylinder
(clearance C).

Adjusting the push rod clearance at B

Note

•

The threads of the push rod are specially designed so that the bolt becomes harder to turn past a certain
point. This is to prevent the bolt from coming loose. Turn the bolt only within this range when adjusting.

1. Push lightly on the end of the SST gauge rod, and

measure the clearance between the adjusting nut
and the SST body.

2. Using the SST, turn the nut to lengthen the power

brake unit push rod an amount equal to the sum
substracting 0.1—0.4 mm {0.004—0.016 in} from
the clearance measured at B.

Measurement

Push rod

Clearance at (B)

Too short

Clearance at (C)

Too long

No clearance at (B) or (C)

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CONVENTIONAL BRAKE SYSTEM

04–11–8

Adjusting the push rod clearance at C or no clearance at B or C

Note

•

The threads of the push rod are specially designed so that the bolt becomes harder to turn past a certain
point. This is to prevent the bolt from coming loose. Turn the bolt only within this range when adjusting.

1. Measure and record height D1 of the gauge rod.
2. Turn the adjusting nut until the SST body sets

evenly on the master cylinder. (Turn only enough
for the body to touch.)

3. Measure and record height D2 of the gauge rod.

4. Subtract D1 from D2 and add 0.1—0.4 mm

{0.004—0.016 in}. Using the SST, turn the nut to
shorten the power booster push rod an amount
equal to the sum.

ZM

1. Place the SST atop the master cylinder. Turn the

adjusting bolt until it touches the bottom of the
push rod hole in the piston.

2. Apply 66.7 kPa {500 mmHg, 19.7 inHg} vacuum

to the power brake unit using a vacuum pump.

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