brake MAZDA 323 1992 Suplement Owner's Guide

CONVENTfONAt BRAKE SYSTEM
13EOPX-33C
16EOPX-7 16
1
3
J
13EOPX 331
Disassembly note
Piston
Remove the piston with the SST.
Note
l The piston is removed by turning the SST counter-
clockwise.
Piston seal
Remove the piston seal with the SST.
Needle bearing
1. Secure the catiper in a vise.
Caution
l Do not remove the needle bearing if not necessary.
l Insert a soft, protective material (such as copper
ptates) in the jaws of the vise.
2. Remove the needle bearing from the caliper with the SST.
Bleeder screw
Loosen the bleeder screw by using the SST.
Assembly note
Bleeder screw
Tighten the bleed screw by using the SST.
Tightening torque:
5.9-8.8 Narn f 60-90 kgfcm, 53.-78 in4bf )
.
c
P-1 8

I- CONVENTIONAL BRAKE SYSTEM
P
I f3EOFX-33,
Needle bearing
1. Set the new needle bearing in the caliper with the needle
bearing hole facing the caliper cylinder.
2. Press the needle bearing into the caliper with the SST until
the SST bottoms against the caliper.
Piston
Assemble the piston with the SST.
Note
l The piston is assembled by turning the SST
clockwise.
16EOPX-718
P--t9 . .

TD TECHNICAL DATA
Hem Engine
SP DOHC turbo
Note ) I
1 st and 2nd
Synchronizer ring outer diameter
’ I 67.7 I2.665)
mm [in] 3rd and 4th 67.7 12.665 )
5th and reverse 55.7 t2.192)
Synchronizer key dimension 1st and 2nd @ 19.0 {0.748], 04.3 (0.171, 05.0 10.20)
mm [in] 3rd and 4th @ 17.0 10.669J, 04.3 (0.171, @ 5.0 lO.20)
5th and reverse 0 17.0 10.6691, m4.3
10.171, @I 5.0 fO.201
PROPELLER SHAFT
Item
length
Outer diameter Engineflransaxie Model BP DOHC turbo
G25MX-R (GSMX-R)
Front 834.3 { 32.85 ]
mm fin] Center 584 122.99)
Rear
I 437 { 17.20)
Front 75 (2.95)
mm { in] Center 57 12.24) f
Rear 57 12.241
FRONT AND REAR AXLES
Item Specifications
Front driveshaft

Jomt type Inside Double oftset joint
Outside Bell jotnt
Length of joint (between center of joint) mm { rn t - Right 392 (15.4)
left 306 (0.83 ]
Shaft diameter mm {in] 21.0 to.831
I
Rear driveshaft
Joint type Inside 1
Outside 1
Length of joint (between center of joint) mm [in ] ’ Right
Left
Shaft diameter mm (in)
J&t shatt
Length of joint
Shaft diameter
Front axle
Bearing play axial direction mm [in] 1
Rear axle
Bearing play axial direction mm lin] 1
Rear differential (viscous limited slip differential) Double offset joint
Bell joint
519.5 (20.5 ]
489.5 [f9.3]
21.0 IO.831
357.2 1 t4.11
21 .O (0.83 )
0.050 IO.002 ]
0.050 (0.002 ]
*
Reduction gear
Different ia gear
Oifferential ratro
Number of teeth
Flurd
L Ring gear
Drive .pinion gear
Grade
Viscosity Above -18*C fO*F ]
Below -18*C lOoF)
, Capacity
L fUS qt, Imp c$l Hypoid gear
Straight bevel gear
3.909
43
11
API Service GL-5
SAE 90
SAE 80W
0.65 lQ.69, 0.571 STEERING SI
1 Free olav 8RAKING SY
Brake type
Brake pedat
Height
Free play 1
Reserve travel
Clearance whet
Master cylinde
Master cylinder
Front disc brai
. Tyl?e
Thickness of p&
Thickness of pa

TECHNNlCAL DATA TD
STEERlNG SYSTEM
item
Steering wheel
Outer diameter
mm (in]
Free play
mm [in]
Operation force N [kgf, Ibf]
Lock-to-lock
Steering gear
TYF
Steerrng gear ratio
Backlash between rack and pinion
mm Iin] 1
N-m { kgfcm, inlbf ]
PInion Reload measured by torque wrench
preload
kgf ( ibf )
Preload measured by pull scale with attachment
Distance between left and right brackets
mm Iin]
Rack stroke mm {ini
Lubricant type
Oil capacity L (US qt, imp qt]
Dfive belt
I
Deflection with force of 98 N { 10 kgf, 22 Ibf 1 mm [in) Specifications
370 { 14.57)
O-30 [O-l .16)
29 13.0, 6.6) or less
2.51
Rack and pinjon
Infinite too)
0 101
l.O--.I.3 (10-14, 8.?-12.1)
1.0-1.4 (2.2-3.08)
258 (10.16)
121 (4.76)
ATF Dexron@II or M-III
0.8 (0.85, 0.70)
New
belt: 8-9 [0.31-0.351
Used belt: Q---t0 [ 0.35-0.39 1
BRAKlNG SYSTEM
Brake type Item ‘WIthout A8S With ABS
. Front . . . . . djsc, Rear . . . . . dtsc
Brake pedal
Heiaht mm linl i 203-206 f 7.99-8.7 1 I
Free play mm {in]
Reserve travel
Clearance when pedal depressed at 5& N 160 kgf, G? I’dl;’ 4-7 !0.16--0.281 12-15 [0.47-0.591
70 (2.76) min 60 (2.36) min
l t Master cylinder t
Master cylinder
Front disc brake . Type
Bore diameter mm {inj 25.4 11 .UO ] Tandem
t 23.8 (0.94 ]
- .-~
Type Ventilated
Thickness of pad mm [in) Standard 10 10.39)
Minimum 2 fO.08)
Thickness of disc plate
mm [in] Standard 24 10.94)
Minimum - 22 to.791
Runout of disc plate mm fin] 0.1 ~0.004]
Cylinder bore mm (ini 57.2 (2.25 ]
Rear brake (disc) b
r Type I
Solid
Thickness of pad mm (In] Standard 8.0 (0.311
Minimum 1 10.04)
Thickness of disc plate mm [in] r Standard 10 [0.39]
Minimum 8 {0.31)
Runout of drsc ‘plate mm (iti)
0.1 (0.004]
Cylrnder bore mm {in]
34.9 II.371
Parking brake
_ Type Mechanicaj twerear-wheel control
Parking brake lever notches
When lever is pulted at 98N [‘lo kgf, 22 tbf I 5-7

TD TECHNICAL DATA
Power brake unit
Diameter
km Without ABS With ABS
mm [in] 188.4 I7.42) +215.2 18.47) [ -
More than 1,080 Itl, 15611 1
I cn I tding force
1- II ,I
I
r-km pressure per lrei
KYa 1 Kgr/cm-, PSI 196 120, 441
at 0 kPa ImmHg, inHgJ
‘) -
j/N tkgf, Ibfl More than 8,730 189, I,2701
1196 (20, 44)
at 66.7 1500, 19.7)
kPa ImmHg, InHgj
Rear wheel hydraulic control system
Type Dual proportlonrng valve 1 ProportionIng valve
Switching point (Master cylinder pressure) kPa t kgflcm2, psi) 1,960 {20, 284)
WHEELS AND TIRES
Item Type Standard Temporary Spare
Size 5 l/2-JJxt5 4-Tx15
Offset mm
Wheel (in) 47.5 { 1.87 j 45 it.771
Pitch circle diameter mm (in] 114.3 {4.50)
Material
I Aluminum alloy
I Steel
Size 195150R15 82V T125/7OD15
Tire
Air kPa i kgflcm2.
pressure psi 1 Front ‘L200 12.4, 351
l 2245 12.5, 36)
Rear “216 (2.2, 321 ‘*245 12.5, 361 412 (4.2, 60)
t-lorizontai 2.0 { 0.079 1 2.5
Runout limit mm [in! L IO.098 ]
Wheel and
Vertical 1 1.5 [0.059] 2.0 (0.079 j
tire
1lnbafanr.e a lo21 t 9 to.31 1 -
*le.. Up to 3 persons
*2 . . . -Full load
SUSPENSI
Front susp
Suspensiorr
Spw tyw:
Shock abs>
Stabilizer
Front wheel
alignment
(
l Unladen;
Rear suspj
Suspension
Spring typi
Shock absc
Stabilizer
Rear whet
alignment
(‘Unladenj
l Fuet tank f
Coil Sp&
+I Main rder
l 2 Auxiliary I
TD-12

TD TECHNlCAt DATA -
BODY EtECTRtCAL SYSTEM
ttem
Headlight
Front fog light
Front turn signat light
Parking light
Front side turn light
StocYlailliaht Specifications (w)
ECE
I Swiss
60155
55
21
5
5
2115
Exterior tamps
Taillight &8) 5
Rear turn single tight 21
Back-up light
21
License plate light
5
Flash-to-pass light 55 (Austrra)
I -
Running Ilght
55 (Sweden, Norway, Iceland)
Rear fog light 21
Interior and spot lamp Interior 10
Spot 6
Interior Iamps
Interior lamp 10
Spot tamp (in overhead console) 8
Cargo compartment lamp
5
High beam
3.4
Turn light
3.4
Brake 3
Hold 3
Charge 3
011 pressure 3 -.
lndcator and n Washer 3
warning Iamps TUF~O 3
Fuel
1 3
Rear fog
I
! 3
1
ABS
Parktng brake
Illumination I 3
3 .
3.4
Rear
Cliff. lock f 3
3 I STANDARD BOLT AND NUT TIGHTENING TORQUE
! Diameter Pkh I 41
8T f&lb N-m I 81 mm {tn] mm fin] N-m 1 m-kg
dsf Wtb 1 Nm
mkg ft4b 6 IO.2361 1 {0.039] 4.2-6.2 /0.43-O-63 3.1-4.6
6.9-9.8 0.7-1.0 5.0-7.2 7.8-11.8 O-8-1.2 5.8-8.8
8 IO.3151 1.25 (0.049) 9.8-14.7 1 1.0-1.5 7.2-10.8 16-23 1 1.6-2.3 12-17 18-26 1.8-2.7 13-20
10 IO.3941
It.25 10.04911 20-28 1 2.0-2.9 1 14-21 31-46 1 3.2-4.7
23-34 36-54 3.7-5.5 27-40
I r
12 IO.4721
1.5 lO.OSSj 34-50 3.5-5-l 25-37 1 55-80
5.6-8.2 41-59 63-93 6.4-9.5 46-69
14 {0.551] 1.5 IO.059) - - - 75-103 7.7-10.5 56-76 102-137 lo-14 75-101
16 #0.630] 1.5 {O.OSSl - -
- f16-157 12-16 85-116 156-211 16-22 115-156
t8 (0.709) 1.5 [0.059] - - - 167-225 17-23
123-166 221-299 23-31 163-221
20 IO.7871 I,5 {0.059]
- - - 231-314 24-32 171-231 308-417 31-43
227-307
22 (0.866) 1.5 IO.0591
- 1 - - 334-423 32-43 231-312 417-564 43-58
' 307-416
24 10.945) 1.5 10.059) - 1
- - 1475-5461 41-56 298-403 1536-7261 55-74
396-536
c)
c) I
-.
c’
c .
4

SPECIAL TOOLS ST
ENGlNE
TOOL NUMBER
b DESCRIPTION PRlORlTY ILLUSTRATlON
49 0107 680A
Engine stand A
49 LO10 IA0
Hanger set,
engine stand
49 0636 IOOA
Arm, valve spring
lifter
49 8012 OA2
Prvot
A
49 5120 170
1 I
Remover, valve
seal
A ff==cB
49 E011 IA0
Brake, ring gear A Installer set, valve
seal & valve
Remover &
installer, valve
49 0221
061A
49 DO11
102
Lock tool,
crankshaft
- 49 GO14
001
Wrench, tit filter
49 9200 145
Adapter, radiator

ST SPECIAL TOOLS --
BRAKIN
STEERING (CONT’D)
--
TOOL fi
h DESC
--
19 1285
Wer,
Qeedle :
--
49 8065
Harness;
--
49 cw:
Setting
retainer
--
49 804
Socke: PRIORITY / ILLUSTRATJUN TOOL NUMBER
& DEScCRIPTION TOOL NUMBER
& DESCRIPTION PRlORITY
ILLUSTRATION
A
(IlIP
A
0
A
c!iz9 49 B032 310
49 8032 320
0
Wrench
A
(Power steermg)
jq
49 F032 303
Handle
(Power steering)
Protector, pmon seal
(Power steermg)
49 B032 311
Protector,
Jipper seat
(Power steering)
49 8032 325
Guide. rod seal
BRAKING
PRIORITY
ILLUSTRATION TOOL NUMBER
b DESCRlPTlON TOOL NUMSER
& DESCRIPTION PRIORITY
ILLUSTRATION
49 8043 001
Adjust gauge
I A 49 0259 770B
Wrench, flare nut
A
49 0221 60X
Expand tool,
disc brake 49 8043 002
Installer, bearing A
TOOL
& DES
--
49 BC:
Replac
rubber
InstallE
dust 3 49 0208 701A
Atr out tool, boot 49 8043 003
Turning, lock tool A
49 FAt8 602
49 U043 OAO
I
Gauge set,
I A
oil pressure Wrench ,disc
brake piston

SYSTEM INDEX
ENGINE-RELATED SYSTEMS STARTING SYSTEM...............2 4
CHARGING SYSTEM...............2 6
ENGINE CONTROL SYSTEM.........2 8
COOLING FAN SYSTEM............3 6
CHASSIS-RELATED SYSTEMS ANTI-LOCK BRAKE SYSTEM........82
INSTFUJMENT CLUSTER-RELATED SYSIEMS IrS$;MENT CLUSTER 6 WARNING
........................ 38
BODY-F&LATEX) SYSTEMS
WINDSHIELD WIPER 6 WASHER.....4 0
HEADLIGHT CLEANER.............4 0
REAR WIPER & WASHER...........4 2
HORNS...................,......6 0
REAR WINDOW DEFROSTER.........6 4
SOUND WARNING SYSTEM..........6 6
POWER WINDOWS.................7 4
POWER DOOR LOCK...............7 6
POWER OUTSIDE MIRRORS.........7 8
SLIDING SUNROOF...............8 0
SEAT WARMERS..................8 4
INTERIOR LIGHTING SYSTEMS IG KEY CYLINDER LAMP..........6 6
INTERIOR 6 SPOT LAMPS.........6 6
COURTESY LAMPS................6 8
TRUNK COMPARTMENT LAMP........6 8
ILLUMINATION LAMPS............7 0
EXTERIOR LIGHTING SYSTEMS
HEADLIGHTS
EXCEPT F.R.GERMANY...........44
F.R.GERMANY..................46
HEADLIGHT LEVELING SYSTEM.....46
TAILLIGHTS
EXCEPT F.R.GERMANY...........48
F.R.GERMANY..................5 0
LICENSE PLATE LIGHTS
EXCEPT F.R.GERMANY...........4 8
F.R.GERMANY..................5 0
POSITION LIGHTS
EXCEPT F.R.GERMANY...........4 4
F.R.GERMANY..................!i? 0
FRONT 6 REAR FOG LIGHTS.......52
TURN 6 HAZARD FLASHER
LIGHTS.......................54
STOPLIGHTS
F.R.GERMANY.a................5 6
EXCEPT F.R.GERMANY...........5 8
BACK-UP LIGHTS................6 0
AIR CONDITIONING-RELATED SYSTEMS HEATER........................6 2
ACCESSORIES CIGARETTE LIGHTER.........<....64
DIGITAL CLOCK.................64
AUDIO SYSTEM..................72
OTHER DIAGNOSIS CONNECTOR...........86

GI Reading Wiring Diagrams
System circuit diagram/connector diagram
l These diagrams show the circuits for each system, from the power supply to the ground. The power
supply side is on the upper part of the page, the ground side on the lower part. The diagrams describe
circuits with the ignition switch off. Below is an explanation of the various points in the diagram.
I Indicates operating conditions for switches.
I
The prefix letter indicates the system in which the
:onnector is used.
JB: Joint box connections
X : Common connectors
A : Charging system/starting system
connectors
B : Engine control system connectors
C : Gauge control system connectors
D : Wiper system connectors
E : Lighting system connectors
F : Signal system connectors
G : Air-conditioning system connectors
l-l : Transmission Control sysetm connectors
I : Interior lamp system connectors
J : Audio/radio connectors
K : Power window/power door lock system
connectors
L : Remote control mirror system connectors
M : Sliding sunroof system connectors
N : Power steering/4-wheel steering system
connectors
0 : Anti-lock brake system connectors.
P : Power seat/seat heater system connectors
Q : Auto cruise control system connectors
R : Auto adjusting suspension system
connectors
S : Passive shoulder belt control/Airbag system
connectors
T : Others
Y : Ground connector
4
IGNITION SYSTEM mENGINE CONTROL
A harness ground is represented differently than
a unit ground.
Types of grounds
Harness
Unit Symbol