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Disc & Drum: Other Mazda Millenia I

Mechanical - Hydraulic 4 illustrations ~1598 words

BLEEDING BRAKE SYSTEM

Note. If vehicle is equipped with anti-lock brakes, see appropriate ANTI-LOCK article for brake bleeding procedure.

ApplicationSequence
All ModelsLongest Line First

BRAKE LINE BLEEDING SEQUENCE

MASTER CYLINDER PUSH ROD

Note. Push rod has an adjustment screw to maintain correct distance between booster push rod and master cylinder piston. If push rod is adjusted too long, it prevents master cylinder piston from completely releasing hydraulic pressure, causing brakes to drag. If push rod is adjusted too short, it causes excessive pedal travel and an undesirable clunk in booster area.

MPV & 626 M/T Without ABS

  1. Place Adjustment Gauge (49-F043-001) onto master cylinder. Turn screw on adjuster gauge until it contacts piston. Remove adjuster gauge. Apply 19.7 in. Hg to power brake unit.
  2. Invert adjuster gauge and place gauge on power brake unit. Adjust push rod on power brake unit until there is no clearance between push rod and adjuster gauge screw.

Protege & 626 With A/T Or ABS

  1. Turn adjusting nut on Adjustment Gauge (49-B043-001) clockwise to fully retract gauge rod. Place adjustment gauge onto power brake unit and tighten mounting nuts to 88-138 INCH lbs. (9.9-15.6 N.m). Apply 19.7 in. Hg to power brake unit. Turn adjustment gauge adjusting nut counterclockwise until it just contacts master cylinder push rod. Ensure gauge rod is seated by pressing lightly on end of gauge rod.
  2. Without disturbing adjusting nut, remove adjustment gauge from power brake booster and place on brake master cylinder. Press lightly on gauge rod to ensure rod is bottomed in master cylinder piston. DO NOT push so hard that piston moves.
  3. Note any clearance between adjustment gauge adjusting nut and adjusting gauge body. Note any clearance between adjustment gauge body and master cylinder body. Using Rod Holder (49-B043-003) and Socket (49-B043-004), adjust power brake push rod as necessary to obtain 0.004-0.016" (0.1-0.4 mm) between adjustment gauge adjusting nut and adjusting gauge body.

Millenia

  1. With master cylinder removed, remove seal and plate assembly from power brake unit. (Scheme 18) Install power brake unit gasket. Place Adjustment Gauge (49 E043 001A) onto power brake unit and tighten mounting nuts to 87-138 INCH lbs. (9.8-15.6 N.m).
  2. Apply 19.7 in. Hg to power brake unit. Measure depth of adjustment gauge rod. (Scheme 19) Rod depth should be 1.38" (35.1 mm). If rod depth is as specified, no adjustment is necessary. If gauge rod depth is not as specified, using Rod Holder (49-E043-003) and Socket (49-E043-004), adjust power brake push rod as necessary to obtain rod depth of 1.38" (35.1 mm).

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

REAR BRAKE SHOES

Note. Rear brakes are self-adjusting and require manual adjustment only if brake shoes have been replaced.

Protege & 626

Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake. Remove brake drum. Insert screwdriver between adjusting plate and quadrant. Twist screwdriver to disengage teeth. (Scheme 20) Push quadrant adjusting lever toward backing plate. Install brake drum. Operate parking brake a few times to reset adjuster. Adjust parking brake.

Scheme 20

Scheme 20: Protege & 626
Scheme 20: Protege & 626

Millenia & MPV

  1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove service plug from rotor. Insert a screwdriver into service plug hole and turn adjuster in direction of arrow marked on rotor until rotor will not turn.
  2. Rotate adjuster 3-5 notches in opposite direction. Ensure rotor rotates freely. Install service plug.
  1. On models with rear disc brakes, depress brake pedal several times. On models with rear drum brakes, start engine and depress brake pedal several times while vehicle is moving in reverse. Stop engine.
  2. Pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 6-8 notches on 626 or 5-7 notches on Protege, parking brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle. Release parking brake lever.
  3. Rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake lever is pulled one notch.
  1. Depress brake pedal several times. Pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 3-5 notches, parking brake is properly adjusted. If stroke is not 3-5 notches, raise and support rear of vehicle. Release parking brake lever.
  2. Remove parking brake lever cover. Rotate cable adjusting nut at lever end of cable until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

MPV

  1. Depress brake pedal several times. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 6-9 notches, parking brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle. Release parking brake lever.
  2. Remove adjusting nut clip and rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

BRAKE PEDAL FREE PLAY

With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS table. Adjust play by loosening push rod lock nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).

ApplicationIn. (mm)
MPV0.16-0.28 (4-7)
Millenia & Protege0.16-0.47 (4-12)
626
19970.16-0.47 (4-12)
19980.31-0.47 (8-12)

BRAKE PEDAL FREE PLAY SPECIFICATIONS

MPV & 626

  1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center. Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Rotate switch away from pedal. Loosen push rod lock nut. Rotate push rod until correct pedal height is obtained. See «BRAKE PEDAL HEIGHT SPECIFICATIONS»(ref-121748-S27937180612001090500000) table.
  2. Adjust pedal free play. See «BRAKE PEDAL FREE PLAY»(ref-121748-S41067751242001090500000) under ADJUSTMENTS. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).
  3. Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight switch lock nut 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.
  4. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center. Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure.
  5. Measure applied pedal height. See «BRAKE PEDAL HEIGHT SPECIFICATIONS»(ref-121748-S27937180612001090500000) table. If distance is not as specified, check for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.

Millenia & Protege

  1. Released pedal height is measured between brake pedal and stoplight switch mounting bracket. (Scheme 21) Disconnect stoplight switch electrical connector and remove switch. Measure length "L" between stoplight switch mounting bracket and brake pedal. (Scheme 21) On Millenia, length should be 0.79-0.90" (20-23 mm). On 1997 Protege, length should be 0.71-0.86" (18-22 mm).
  2. If clearance is as specified, install stoplight switch. No adjustment is necessary. If clearance is not as specified, loosen lock nut "B" and rotate self-locking nut "A" counterclockwise until it does not contact brake pedal.
  3. Loosen push rod lock nut and rotate push rod until correct clearance between brake pedal and stoplight switch mounting bracket is obtained. Tighten push rod lock nut. Rotate self-locking nut "A" clockwise until clearance between brake pedal and end of self-locking nut "A" is 0.004-0.039 (0.1-1.0 mm). (Scheme 21) Tighten lock nut "B". NOTE: When adjusting brake pedal height, a NEW stoplight switch must be used. Stoplight switch can only be adjusted one time.
  4. Install NEW stoplight switch. Stoplight switch is automatically adjusted by pulling back on brake pedal until stoplight switch click noise is heard. Reconnect stoplight switch electrical connector. Check stoplight operation. Adjust pedal free play. See «BRAKE PEDAL FREE PLAY»(ref-121748-S41067751242001090500000) under ADJUSTMENTS. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).
  5. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center. Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure.
  6. Measure applied pedal height. See «BRAKE PEDAL HEIGHT SPECIFICATIONS»(ref-121748-S27937180612001090500000) table. If distance is not as specified, check for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.
ApplicationIn. (mm)
Pedal Released
MPV7.5-7.9 (191-201)
Protege8.6-8.8 (217.8-228.8)
626
19977.5-7.7 (191-196)
19987.6 (193)
Pedal Applied (1)
MPV3.3 (85)
Millenia3.8 (95)
Protege2.8 (70)
626
19973.3 (85)
19982.4 (60)
(1) Minimum height.
(1)Minimum height.

BRAKE PEDAL HEIGHT SPECIFICATIONS

Scheme 21

Scheme 21
Scheme 21

PROPORTIONING VALVE

  1. Connect 2 pressure gauges and adapters to proportioning valve. One to input port and other to output port. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-121748-S10661176762001090500000) . Depress brake pedal until pressure gauge reads as specified and check output pressure. See «PROPORTIONING VALVE PRESSURE SPECIFICATIONS»(ref-121748-S21803847522001090500000) table.
  2. Depress brake pedal again, applying additional pressure. Recheck output pressure. See «PROPORTIONING VALVE PRESSURE SPECIFICATIONS»(ref-121748-S21803847522001090500000) table. If output pressure is not as specified, replace proportioning valve.
Application/ModelInlet Pressure psi (kg/cm 2 )Outlet Pressure psi (kg/cm 2 )
Millenia430 (31)400-460 (28-32)
850 (60)520-600 (37-42)
MPV427 (30)370-484 (26-34)
853 (61)583-697 (41-49)
626
With ABS500 (35)470-530 (33-37)
850 (60)597-683 (42-48)
Without ABS500 (35)470-530 (33-37)
850 (60)557-643 (39-45)
Protege
With ABS356 (25)328-384 (23-27)
Without ABS853 (61)568-654 (40-46)
1.5L356 (25)328-384 (23-27)
853 (61)483-569 (34-40)
1.8L356 (25)328-384 (23-27)
853 (61)654-740 (46-52)

PROPORTIONING VALVE PRESSURE SPECIFICATIONS

POWER BRAKE UNIT

  1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal does not move as specified, go to next step.
  2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is operating. If length of strokes is equal, check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary, and go to next step.
  3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal height remains at same height, power brake unit is operating. If pedal height recedes, check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary.

REAR AXLE BEARING & OIL SEAL

Note. For information on models with sealed wheel bearings, see appropriate article in SUSPENSION.

More articles — Disc & Drum