ABS MAZDA 323 1992 Workshop Manual Suplement

SCHEDULED MAINTENANCE SERVICES (Europe) A
Maintenance Number of months or km (miles), whichever comes first
Months’ ’
- 6 12 18 1 24 30 36 ] 42 48
Kllometers 1,000
10,000 20,000 30,000 1 40,000 50,000 60,000 1 70,000
80,000
(Miles) (600)
(6,000) j(12,000)~(18,000)~(24,000) (30,000) (36,000)~(42,000) (48,000)
Chassis and body (Cont’d)
Steering and front suspension
I ’ I
I 1 I
MTX oil A R
Rear axle oil
I R A A R
A A A R I
Trabsfercarrier oil R A 1 A
R A A A R
Bolts, nuts on chassis and body T T 1
T , T T
Body condltlon (Visual only) Inspect annually
Exhaust system heat shields I 1 I
Tires (Including spare tjresj with inflation
pressure adjustment I
I I I
Hinges and catches A A
A 1 A
Underside of vehicle I
I i 1 I I
Seat belt I
I f
I ’ I
Dnveshafl dust boots I I 1 I I
13EOAX.304
A-5

B2 OUTl1NE
COOUNG CHANNEL RtNG CARRtER
61.5mm i 2.42 in ] - 56.5mm (2.22 in
Piston diameter Piston diameter
Measured at 90* Measured at 90°
to pin bore axis I+ to pin bore axis
and t6.5mm and 11 .Omm
IO.650 in 1 below 10.433 in 1 below
oil rmg groove. oil ring groove.
COOLING CHANNEL
*IL YTLET
OIL t NiET
l The piston skirt is shortened for reduced weight and friction. l A cast iron ring carrier is installed in the piston to reduce piston-ring groove wear. l A cooling channel is incorporated in the body of the piston. The 011 jet squirts oil into this cootrng channel
and the or! absorbs
the heat from around the ring lands, reducing piston ring and cylinder wat! wear
Bz-4

EXHAUST ViitVE
EXHAUST SIDE
VALVE GUIDE
METALLIC SODIUM
(ABOUT 30% VOLUME)
VALVE STEM
.‘.‘*
:::I
:::I
VALVE HEAD
CYttNDER HEAD
IDENTlFtCATION OF METALLIC SODIUM-FILLED EXHAUST VALVE
l Superior he& dissipating .metallic sodium-filled exhaust valves are adopted. During engine operation, the
metalic sodium inside the valve stem melts. As the valve moves up and down, the sodium splashes around
inside the valve and helps to absorb heat from the cylinder head and to transfer it back to the engine
coolant through the valve guide. In this way, the combustion chamber temperature is reduced, reducing
knocking and improving fuel efficeincy.
l Special handling of sodium filled valves is required for personal safety. (See next page.)
B2-7

M FRONT AXLE
WHEEL HUB, STEERING KNUCKLE
RemovaI / Inspection I Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. InstaH in the reverse order of removal, referring to Installation Note.
Caution
l Loosely tighten the shock absorber bolts. Lower the vehicle and tighten the bolts to the specified
torque with the vehicle unladen.
4. Adjust the front wheel alianment.
16-22 ]1.6-2.3, 12-161 I
19.0-l 2.0, 65-86.7 I
1. Wheel hub nut
2. Wheel and tire
3. Locknut
Removal Note . . . . . . .._.. . . . . . . . . . . . . . . . . . . . page M-7
installation Note .I.........,..,............ page M-7
4. Brake caliper assembly
Service . _. . . . . . . . . ,__. . . , , . ._. _. , , . . . , . ._ ._. . . . . . Section P
5. Disc plate
lnspectioti .~~*.......*~...,......,,,.....*~...~. Section P
6. ABS wheel speed sensor (if equipped)
7. Tie rod end
Removal Note . . . . . . .._.......... I . .._.....= page M-7
lnstallatiofi Note . . .._... _.__......,....... page M-7
M-6
8. Lower ball joint
9. Steering knuckle, wheel hub, and dust cover
Inspect-wheel hub for cracks and damage
Inspect knuckle spindle for cracks and
damage
Inspect dust cuver for damage and dis-
tortion
Disassembly I Inspection I
Assembly . ..C1..............~...,.....,.....
page M-8

REAR AXLE
WHEEL HUB, KNUCKLE
Removal I Inspection / installation
1. Remove in the order shown in the figure, referring to
Removal Note. 2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to Installation Note.
Caution
l Loosely tighten the shock absorber bolts. Lower the vehicle and tighten the bolts to the specified
torque with the vehicle unladen.
4. Adiust the rear wheel alianment.
16-22 1?.6-2.3, 12-16 I
7
IO.o-13.0,
66-66.7 1 1. Wheel and tire
2. Locknut
Removal Note..; . . . . . . . . , . . . . ,.......- -.. page M-f 3
Installation Note .._...,.,...._.__........ page M-13
I$ Brake caliper assembly
Service . . . . . . . . . . . ..e......._......... ,.,...,....
Section P
4. Disc plate
‘Service ..I....................__....... . . . . . . . . . Section P 5. Af3S wheel speed sensor (if equipped)
6. Wheel hub, knuckle
Disassembly I Inspect& /
Assem bty . . . . . . . ..I..........*..*.*...-... page M-14
Inspect wheel hub and knuckle for damage
or cracks
Inspect dust cover for damage or defor-
mation
M-12

BRAKING SYSTEM
INDEX ..**.............=*..*..*....~.~............*.,.*...=.
P- 2
OUTLINE . . . . ..~....**.*...........*~...................***
1 P- 3
t il OUTLINE
OF CONSTRUCTION . . . . . . . s.e . . . .
l *..
P- 3
i SPECIFfCATIUNS
. . . . . . . . ..m...*.-..**......n.*.**...
P- 3
e , :
8 [ SERWCE /
SUPPLEMENTAL SERVICE INFORMATION s. P- 4
CONVENTIONAL BRAKE SYSTEM . . . .
l .m..m.s.m P-
5
PREPARATION
. ..* . . . . . . . . . . . . . . . . . . . l . . . . *.*..*.*..I P- 5
AIR BLEEDING (WITH ABS) . . . . . . l .* . . . . . . . . a . . . .
PA 6
POWER 8RAKE UNIT ..*.I..*....*..*....*...*..*..
P- 8
PROPORTJONING VALVE
l . . . . . . . . . . . . . . . . . l . . . . . .
P- 9
FRONT BRAKE (DISC)
. . . . ..**.*.........e.........
P-IO
DISC PAD
. . . . ..m*.m....*bL*m....*...............*......
P-l 1
DISC PLATE
..*..*..*.**..*..a.............*.-.*.....,.
P-12
CAMPER . . . ..m....I*.....*..m*..*......*......*....*...
P-l 2
REAR BRAKE (DISC)
. . . . . . . . . . . . . . . . . * . . . . . . . . l . . . . P-14
DISC PAD . . . . . . . . . . . . . . . . ..~.....................~.~...
P-l 5
DISC PLATE . . . . . . . . . . ..m.e..m....=...*...........*....
P-l 6
CALIPER . . . ..*..m.......I.......~m..~*..*.~......~...*.
P-97
13EOPX-301

INDEX
. WfTHOUT ABS
WITH ASS
‘MVSS 1 t6, DOT-3
.
1. Power brake unit
tnspection . . . . . . . . . . . . . . . . . . . . . . . .._......... 6. Catiper
page P- 8
Disassembly / tnspection I
2. Proportioning valve
tnspection . . . . . . .._..... . . . . . . . . . . . . . . . . . . . . . Assembly
P- . . . . . . . . . . . . ..I............I.....I page P-12
9
3. Front brake (disc) page
7. Rear brake (disc)
tnspection (on-vehicle). . . . . . . . . . . . . . . . page hspechn (on-vehicle) . . . . . . . . . . . . . . . . page P-l 4
P- IO
Removai / tnspection I 8. Disc pad t nstattation Replacement
page P-to 9. Disc plate ............I..r.... 1 . . . . . . . ~_. page P-15 .
. ..t..I...-.......-..l.._*.......
4. Disc pad
Replacem& Inspection . . . . . , . . . . . .
. . . . . ..a. ..I......,,,..
. . ..I.....-............-...,...
5. Disc piate page P-11
IO. Caliper page P-16
Inspection . . . . . . ._. ._. ._. __. . . ._. page P-l 2 Disassembly I t nspection I
Assembly . . . . . . ..I........................I page P-l 7
P-2 --
OUTL OlJTLlN
l The D
l HOWO
l Vehicl SPECIFI
Front dis:
Rear disc I
Braking for4
Brake. fluic:
Parking bra

OUTLlNE P
OUTLfNE
OUTLINE OF CONSTRUCTION
l The brake system remains similar to that of the previous model. l However, because all new models use a higher-horsepower engine, the brake system is enlarged as a whole.
l Vehicles without ABS use a portless-type master cylinder
13EOPX-303
SPECIFICATIONS
Brake pedal
Master cylinder
Front drsc brake
Rear disc brake
Power brake unit
Braking force control device
Brake fluid
Parking brake Item Specification
Type Suspended
I
PedaJ lever ratio 4.1
Max. stroke mm [in] 140 j5.511
I,
Type Tandem
Cylinder inner diameter mm {in] Without ABS: 25.4 j 1 .UO ]
With ABS: 23.8 to.941 3-
Type Ventilated disc ?
Cylinder bore mm [in)
57.2 12.253
Pad dimensions (area x thickness)
mm2 {rn2) xmm [In) 5,200 (8.OSl x 10 (0.39)
Disc plate dimensions mm (in]
(outer diameter x thickness) 274x24 (10.79x0.94)
Type Solid disc
Cylinder bore mm Jon]
34.9 j 1.37 ]
Pad dimensions (area x thrckness)
mm’ (in21 xmm [in) 3,200 I4.961 x8 (0.31)
DISC plate dimensions mm t,n]
(outer diameter x thickness) 280x10 (tl.02xu.39]
il
Type Without ABS: Vacuum multIplier
With ABS: Hydraulrc muttiplier
Diameter mm Iln]
(without ABS) 188.4 17.42) +215.2 t8.47)
We Without ABS: Dual proportioning valve
With ASS: Proportioning valve
FMVSS 116, DOT-3, SAE J1703
Mechanical twGrear-wheel control
Type
Operation system Center lever
13EOPX.304 t

P SUPPLEMENTAL SERVICE INFORMATION I
. .
SUPPLEMENTAL SERVICE
INFORMATION
The following points in this section are changed and added in comparison with Workshop Manuals
(1206-I 0-89F), (I 229-I 0-89L) and (12751 O-91 c).
Air bleeding (with ABS)
Power brake unit (SST newly established)
l Inspection (on-vehicte)
Proportioning valve (SST newly established)
l Inspection
Front brake
l Inspection (on-vehicle)
Removai I Inspection / Installation
Disc pad
l Replacement
Disc plate
l Inspection
Caliper
l Disassembly I Inspection I Assembly
Rear brake
l Inspection (on-vehicle)
l Removal i Inspection I Installation
Disc pad
l Replacement 4
Disc plate
l Inspection
Caliper
l Disassembly I Inspection I Assembly 13EOPX-305
4
P-4
CON
PREP,
SST
Pm
49
ue4
Gauge, pressL r
(Part d
49 um
Pa
49 uw
HOti (Part 0;
49 uu4;
49 1258
Duiler, LH

P CONVENTIONAL BRAKE SYSTEM
93GOW74:
13EOPX-307
AIR BLEEDlNG (WITH ABS)
Front Brakes
1. Fill the fluid reservoir to the MAX line with the specified brake
fluid.
Caution
l The brake fluid reservoir must remain 3/4 full dur-
ing air bleeding.
l Be careful not to spill brake fluid onto a painted
surface.
l Use only the specified brake fluid. Do not mix it with
any other type.
2. Jack up the vehicle and support it on safety stands.
3. Remove the bleeder cap and attach a vinyl hose to the
bleeder screw.
4. PIace the other end of the vinyl hose into a clear fluid-filled
container.
5. Have an assistant depress the brake pedal a few times, and
then hold it depressed.
6. Using the SST, loosen the bleeder screw and drain out the
fluid and air. Retighten the bleeder screw.
Caution
l The two persons should stay in voice contact with
each other.
l Be sure the pedal remains depressed until the air
bleed screw is tightened.
7. Repeat Steps 5 and 6 until no air bubbles are seen.
8. Check for ‘correct brake operation.
9. Verify that there is no fluid leakage. Clean away any spilled
fluid with rags.
IO. After bleeding the air, add brake fluid to the reservoir up
to the MAX level.