brake MAZDA 323 1992 Suplement Owner's Manual

P CONVENTIONAL BRAKE SYSTEM
1 t3EOPX.314
@ 66.7 kPa
Iso0 mmHg.
19.7 inHg)
16EOPX-05t
1
13EOPX.315
P-8
POWER BRAKE UNIT
Quick Inspection (On-vehicle)
Power brake unit function check
(Method-using tester)
Connect the SST, vacuum gauge A, and pedal depression
force gauge B as shown in the figure. After bleeding the
air from the SST, conduct the test as described in the 3steps
below.
Note l
Use commercMty available vacuum gauge and ped.
al depression force gauge.
a) Checking for vacuum loss
Unloaded condition
1. Start the engine.
2. Stop the engine when the vacuum gauge reading reaches
66.7 kPa (500 mmHg, 19.7 inHg ) .
3. Observe the vacuum gauge for 15 seconds. If the gauge
shows 63.3-66.7 kPa [475--500 mmHg, 18.7-19.7
inHg 1, the unit is operating.
Loaded condition
1. Start the engine.
2. Depress the brake pedal with a fdrrce of 196 N I20 kgf,
44 Ibfj.
3. With the brake pedal depressed, stop the engine when the
vacuum gauge reading reaches 66.7 kPa {SO0 mmlig,
19.7 inHg].
4. Observe the vacuum gauge for 15 seconds. If the gauge
shows 63.3-66.7 kPa I475--500 mmHg; 18.7-l 9.7
inHg 1, the unit is operating.
b) Checking for hydraulic pressure
1, If with the engine stopped (vacuum 0 kPa (0 mmHg, 0
hltlg 1) the fluid pressure is within specification, the unit is
operating.
Pedal force N fkgf. Ibf]
Fluid pressure kPa (kgf/cm2, psi)
196 LZO. 441 1080 111. 1561 min.
2, Start the engine. Depress the brake pedal when.the vacu-
urn reaches 66.7 kPa 1500 mmHg, 19.7 intlg 1. If the flu-
id pressure is within specification, the unit is operating.
Pedal force N 1 kgf, fbf I Fluid pressure .kPa { kgflcm’. ps 1
196 I20,441 6670 {68, 967
1 min.
-- WlTHOU
&
d
I=-
-
1 MASTER CYUh
.
i_

CONVENTIONAL BRAKE SYSTEM P
WlfH ABS
1 f3EOPX-3 I 7
I* 44 44’
/
13EOPX-318
MASTER CYLINDER PRESSURE kPa f kgffcm2, psi 1
16AOPX-m 0
PRUPORTIONING VALVE
Inspection
1. Connect the SST to the brake pipes with adapters as shown
in the figure.
Adapter and flare nut tightening torque:
12.8-21.5 Nsm f 130-220 kgfcm, I 134 90 inlbf 1
Note
l Disconnect and connect the brake pipes with SST.
2. Bleed the air from the brake system.
3. Depress the brake pedal until the master cylinder pressure
equals A; then record rear brake pressure A’.
4. Depress the brake pedal again, apply additional pressure
until the pressure equals B; then record pressure B’.
Fluid pressure
kPa { kgVcm2, psi]
A
A’ 8
8’
WITHOUT 1960
1960
ABS 120, 284 (20,284] 5880
1 al96 12, 28)
(60, 853) 2750 (28, 3881
*I96 12,281
WITH ABS $;;4 1960 f 20,284) 5880
1 *196 12,261 160, 853 3140 {32, 455)
1
*294 [3,42)
-,
--.
. p-g.’

P CONVENTIONAL BRAKE SYSTEM
FRONT BRAKE (DISC)
t nspection (on-ve hicte)
Disc pad
t. Jack up the front of the vehicle and support it with safety
stands.
2. Remove the wheels.
3. Sight through the caliper inspection hole and inspect the
remaining thickness of the pads.
1
Thickness: 2.Omm f 0.08 in ] min.
I LlL”r *-cl , a 4. Replace the pads as a set (right and left wheels) if either
is at br ‘less than the mintmum thickness.
Removal / inspection I installation
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to InstaHation Note.
4. After installation, perform the following.
(1) Add fluid and bleed the air.
(2) Check for fluid leakage.
(3) Depress the pedal a few times, then verify that the brakes do not drag while rotating the wheel by hand.

102-137 (10.4-14.0,
22-29 (2.2-3.0, 16-21)
75.3-1011
1. Flexible hose 7. Outer shim
2. Bolt 8. Inner shim
3. Callper 9. Guide plate
Disassembly I t nspection / IO. Mounting support
Assembly . _. . . . . _. ._. . . . . . . . . . . . , i.. . . ,:, . page P-l 2 t 1. Disc plate
4. Boot Inspection . . . . . . . . . . . . . . . . . . . . . . . . .,......_.. page P-1 2
5. V-spring
6. Disc pad
Inspection . . . . . . . . . . . . . . . . . . . . .._.__....._........... above InstaUation Note . . . . . . . . . . . . . . . . . .._...... page P-l 1 DlSC PAC
Reptacem
I. Remove
2. tnstatl in
1; Em
2. V-spring
3. Disc paa
fnstatle

CONVENTIONAL BRAKE SYSTEM
- P
Installation note
I
I Disc pad
Before installing the disc pads, push the piston
fully inward by using the
SST.
13EOPX DISC PAD
Replacement
I_ Remove in the order shown in the
figure. 2. Instalt in the reverse order of removal, referring to Installation Note.
N-m fltgfm, ft4bf 1 1. Bolt t 3EOPX-33: 2. V-spring
4. ‘Outer shim
3. Disc pad 5. tnner shim
Installation Note . 6. Guide plate
. . . . . . . . . . . . . . . . . . . . ..l._.........
above -
P-1 I

P CONVENTIONAL BRAKE SYSTEM
16EOPX-066
I
CALIPER DISC PLATE
Jnspection
Disc plate thickness
1. Measure the thickness of the disc plate.
Standard: 24mm (0.94 in)
Minimum: 22mm (0.87 in]
2- If the
thickness is not within specification, replace the disc
plate.
Disc plate runout
Caution
l There must be no wheet bearing looseness.
4. Measure the runout at the outer edge of the contact sur-
face of the disc pad.
Runout: 0.1 mm [ 0.004 in ) max.
2. If the runout is not within specification, repair or replace the
disc plate.
Uisassembly I Inspection I Assembly
I, Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect ail parts and repair of replace as necessary.
3$ Assemble in the reverse order of disassemblv. referring to Assembly Note.
REPLACE
1, Dust seal
tnspect for damage and poor seating
2. Piston
Disassembly Note.:. .,._..... . . . . . . . . . . . page P-13
Inspect for wear
and rust
3. Piston seat
N-m 1 kgfcm, In-lbf I
13EOqX-32: 4. Bleeder cap, bleeder screw
Disassembly Note.. . . . . . . . . . . . . , . . . ._. . . page P-l 3
.. Assembly Note ..*.*......-*...*.........;
5. Caliper
body page P-13
Inspect for damage, wear and rust
Disassembly Note.. . . . . _. . . . . . . . . . . . . . page P-l 3
P-12 - G

CONVENTIONAL BRAKE SYSTEM P
13EOPX-324
I %EOPX-071
Disassembly note
Piston
Caution
l Blow the compressed air slowly to prevent the pis-
ton from popping out.
I. Place a piece of wood in the caliper.
2. Blow compressed air through the pipe hole to force the pis-
ton out of the caLper.
Piston seal
Remove the piston seal from the caliper by using the SST.
I
Bleeder screw
Loosen the bleeder screw by using the SST.
Assembly note
Bleeder screw
Tightening the bteeder screw by using the SST.
Tightening torque:
5.9-8.8 Nom (60-90 kgfcm, 53-78 in&f ]

P CONVENTIONAL BRAKE SYSTEM
f 6EOPX-073
REAR BRAKE (DISC)
inspection (on-vehicle)
Disc pad
1, Jack up the rear of the vehicle and support it with safety
stands.
2, Remove the wheel and tires.
3. Verify the remaining thickness of the pads.
Thickness: f .Omm fU.04 in) min.
Removal I Inspection / Installation
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to Installation Note.
4. After instaHation, check the following.
(1) Add fluid and bteed the air.
(2) Check for fluid leakage.
(3) Adjust the parking brake lever stioke.
(4) Depress the pedal a few times, then verify that the brakes do not drag while rotating the wheel bv hand,
1. Parking cable
7. Disc pad
13EOPX-32f page P-15 ,..
. . ..I...... above 2. Connecting bolt installation
3. Brake hose Note . ..*. 1 ,...... I.r. . . . . .
4. Lock bolt Inspection . ..-f...........III.I.......,,.
8. Outer shim
5. Caliper 9. Inner shim
Disassembly I Inspection I
Assem bty IO. Guide plate .
-. . . _. . . . . . . . . . . . . . . . . , . . . . . . . . . . . page P-l 7
Il. Bolt
6, V-spring 12. Mounting support
I 3. Disc plate
Inspection . . . . . . . . . . . . . . . . . . . .._...._.~
P-1 4 . . . page p-16 DISC PAD
Replacem
1 s Remove
2. Inspect
i 3. Install in
4. Adjust tF
1. Parking t
2. Ciip
3. Lock bolt
4. V-spring
5. Disc pad
Installa

CONVENTIONAL BF?AKE SYSTEM P
InstaHation note
Disc pad
Install the piston with the SST by turning it clockwise until
it stops.
13EOPX-327
DISC PAD Replacement
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3, Install in the reverse order of removal, referring to hstallation Note.
4. Adjust the parking brake lever stroke.
f . Parking
brake cable 2. Clip
3. Lock bolt
4. V-spring
5. Disc pad 6. Outer shim
7, lhner shim -
8. Guide plate
lnstaflation note . . . , . .._. . .I . . . . . . . . . . . . . . _. . . . . . . above . _’
.
P-1 5

P CONVENTIONAL BRAKE SYSTEM
DtSC PLATE
Inspection
Disc plate thickness
I. Measure the thickness of the disc plate.
Standard: IOmm [ 0.39 in)
MInimum: 8mm (0.31 in 1
2, if the thickness is not within specification, replace the disc
plate.
Disc plate runout
Caution
l There must be not wheel bearing looseness.
I. Measure the runout at the outer edge of the contact sur-
face of the disc pad.
Runout: U.lmm [ 0.004 in) max.
2. If the runout is not within specification, repair or replace the
disc plate. CALIPE,
Disasstt
1. Disass
2. lnspec
3. Assem
i
1. Sleeve
2. Boot
I
1 3. Boot
4. RetainhI
5. Dust se2
i 6. Piston
Disaa
1 ASSen
i i InsP% InsP% 7. Piston st St
Disass E
8. Snap rin rl
9, stopper r
IO. Adjuster !r
. ’
tnspec
P-l 6

CONVENTIONAL BRAKE SYSTEM P
CALIPER
Disassembly / fnspection / Assembly
Csation
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.
REPL A
3 Hm 1 kgtm, ?btbl I
lC#EOPX-32
’ 1,
Sleeve 1 I. O-ring
2. Boot 12. Connecting link
i 3. Boot Inspect for damage and wear
4. Retaining ring 13. Return spring
5, Dust seal 34. Operating Iever
6. Piston 15. Boot
a* *
Disassembly Note . . . . . . .- . . . . . . . I*.- ,... page P-16
Assembly Note . . . . . . . . . . . . . . . . . . . . . . ..I.. page P-19
Inspect for wear and
rust 7. Piston seat
Disassembly Note *........ s . . . . . . . . . . -.. page P-1 8
8. Snap ring
9. stopper
IO. Adjuster spindle Inspect for damage and wear 16. Neeare oearrng
Disassembly Note ..........*...I..... ..* page P-l 8
Assembly Note .*.............*........e.* page P-19
17. Bleeder screw and rubber cap
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . . page P-18
Assembly Note . . ..*.................*....
page P-18
.I& Cable bracket
19. Caliper body inspect for damage, wear and rust