boot 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

FRONT AXLE M
13EOMX308
13EOMX-310
1
13EOMX-311
Removal note
Locknut
Caution
l Do not damage the drive shaft.
l Do not reuse the locknut.
1.
Raise the staked portion of the locknut using a chisel.
2. Lock the
hub by applying the brakes.
3. Remove the locknut.
Tie rod end
Caution i
l Do not damage the dust boot.
t
Losen the nut and disconnect the tie rod end bv using the
I
SST.
P
Installation note
Tie rod end
Caution
l Do not damage the dust boot.
tnstall the nut and secure it with the new cotter
Tightening torque:
43-56 N-m (4.3-5.8 kgf,m, 31-41 ft-lbf
Locknut
lnstail a new
locknut and stake it, as shown. pin.
Tightening torque: 236-318 N-m
f 24.0-32.5 kgfm, 174-235 ftelbf ]
M-7.

I :
;!
i
I
I
CONVENTIONAL BRAKE SYSTEM P
CONVENTIONAL BRAKE SYSTEM
PREPARATION
SST
49 0259 770B
Wrench, fiare nut For
removal and 49 U043 OAO
Gauge set, oil
pressure For
Inspectron of
brake fluId
pressure
49 uo43 004
Gauge, oil
pressure
{Part 04
49 U043 OAO) For
inspection of
brake fluid
pressure 49 UO43 005
Joint
(Part of
49 UO43 OAO) For
inspection of
brake fluid
o pressure
49 0208 70tA
Air-out tool, boot For
removal of
piston seal 49 FAf8 602
Wrench, disc
brake piston For
removal and
installat!on of disc
call per piston
49 1258 071
Puller, bearing For 49 0221 600C
removal of caliper
a-- E;.;d tool, disc needle bearing For
installation of
brake pads

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

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

‘T 1 SPECIAL TOOLS
STEERING
rONT AND REAR AXLES (CUNT’D)
3 FO27 005
ttachment @62
9 F027 009
ttachment
68 and $77
9 Vool 795
staller. ort seal
9 BOO1 795
xtafter, oil seal 3 HO02 671
dapter
bwer steer1
9 8032 3ti
lemover ,
rearing & oI
Power steer
19 B032 3’
‘m3ctor trc
d seal
--
3 B032 3t
older, pot
leering pu
‘ower stt:c
--
9 8032 3
Votector ,
her bw
--
$9 8032 :
Mench, r
[Power stl
-- TOOL NUMBER
& DESCRIPTION PRiORlTY
ILLUSTRATION
49 HO34 201
Support blczk
49 HO27 002
Remover, bearing
49 F026 103
Puller, wheel hub
49 F026 102
Installer, bearing A
fEERING
I’OdL NUMBER
L DESCRIPTION PRIORITY ILLUSTRATION
PRIORITY ) ILLUSTRATION TOOL NUMBER
& DESCRlPTtON
49 GO33 108 19 0180 510B
Utachment
Ireload B
Adapter, caster
camber gauge A
19 8032
adapter
,Power 31
--
49 GO32
House
power 5 49 HO32 301 $9 0118 850C
Uler, ball joint
I A Wrench
(Power steering)
49 1232 670A
Gauge set,
power steering 49 1243 785
installer.
dust boot A

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

SPECIAL TOOLS ST
BRAKING (CONT’D)
TOOL NUMBER
81 DESCRIPTION PRIORITY tLLUSTRATION
49 1285 071
Puller, A
needle bearing
49 B066 001
Harness (ABS) A
49 BO66 OAO
retainer
49 B043 004
Socket wrench A
FRONT AN5 REAR SUSPENSION
c TOOL NUMBER
& DESCRIPTION PRIORITY ILLUSTRATION
1
49 8034 2AOA
Replacer set,
rubber bush A
49 8038 785
:
Installer, A
dust boot TOOL NUMBER
& DESCRIPTION PRIORITY
ILLUSTRATION
49 GO25 001
Installer, P ’
sensor rotor
49 LO43 002
retainer
49 LO43 003
Setting tool,
retainer A
49 LO43 004
Protector
q@
:
- - -
TOOL NUMBER
& DESCRIPTION
49 GO34 1AO
Compressor,
coil spring
support Mock
PRIORITY
A ILLUSTRATION