brake MAZDA 323 1992 Workshop Manual Suplement

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GENERAL INFORMATION
1MPORTANT INFORMATION
..................... GI- 2
BASIC ASSUMPTIONS ............................ a- 2 I
SAFETY RISK
........................................ Gl- 2
POSSIBLE LOSS OF WARRANTY
............. Gl- 2
WARNING ON LUBRICANTS
AND GREASES
.................................... GI- 2
HOW TO USE THIS MANUAL..
.................. GI- 3
PREPARATION
...................................... GI- 3
REPAtR PROCEDURE .............................
GI- 3
SYMBOLS .............................................
GI- 4
NOTES, CAUTIONS, AND WARNINGS.. .....
Gl- 4
FUNDAMENTAL PROCEDURES
................. GI- 4
PROTECTION OF THE VEHICLE .............. G1- 4
A WORD ABOUT SAFE-T-Y
....................... Gl- 5
PREPARATION OF TOOLS
AND MEASURING EQUIPMENT ............. Gi- 5
SPECIAL TOOLS ....................................
GI- 5
REMOVAL OF PARTS .............................
GI- 5
DISASSEMBLY ......................................
GI- 5
REASSEMBLY
....................................... GI- 6
ADJUSTMENTS .....................................
Gl- 7
RUBBER PARTS AND TUBtNG ................ GI- 7
JACK AND SAFETY STAND POStTlONS .... GI- 8
VEHICLE LIFT (20SUPPORT TYPE)
POSITIONS ............................................
GI- 6
MAINTENANCE NOTE ..............................
GI- 9
SPEEDOMETER TESTER CHECK
............. GI- 9
BRAKE TESTER CHECK
......................... GI- 9
CHASSIS DYNAMOMETER CHECK.. ......... Gl-I 0
WHEEL BALANCE.R ...............................
GI-I 0
TOWtNG ...............................................
GI-I 0
IDENTlFiCATlON NUMBER LOCATIONS
..... GI-I
2 .UNlTS .....................................................
GI-I 2
ABBREVIATIONS
.....................................
GI-12
CAUTION
................................................ GI-13
INSTALLATlON OF MOBILE TWO-WAY
RADIO SYSTEM ...................................
Gl-13
PRECAUTIONS TO TAKE WHEN
SERVICING AN ELECTRICAL SYSTEM ..i GI-f4
HANDLING CONNECTORS ..................... GI-f 5
USING ELECTRICAL
MEASURlNG EQUIPMENT ........................................
GI-16
13EGIX-30 1

GI HOW TO USE THIS MANUAL/FUNDAMENTAL PROCEDURES
SYM00LS
There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such
matertals during service
*
Symbol
w-
l Apply otl Meaning Kind
New engtne 011 or gear 011 as approprkate
Apply brake fluid Only brake fluId
I
Apply automatic transmtsslon fluid Only ATF
Apply grease Appropriate grease
Apply sealant Approprrate sealant
0
Apply petroleum Jelly
Appropriate petroleum jetty
05UGIX-005 Note
l When special oil or grease is needed, this is shown in the illustration.
NOTES, CAUTIONS, AND WARNINGS
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each
one IS there fur a specific purpose.
NOTES give you added information that wilt help you to complete
a particular procedure. CAUTlONS are given to prevent you from making an error that could damage
the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause
personal injury. The following list contains some general WARNINGS you should follow when you work
on a vehrcle
. 9MUGlX.036
FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE
Always .be sure to cover fenders, seats, and
fore starting work. floor areas be-
1
T.
i
8
s
Q
8
e

MAlNTENANCE NOTE GI
.
FREE ROLLER
I t 3EGlX-304
MAlNTENANCE NOTE
SPEEDOMETER TESTER CHECK
Caution
l Do not clutch abruptly.
l Do not attempt rabbit starts or accelerate quickly. 13EGIX-302
[Front wheel free-roller method]
1. Set the free roller securely on the floor under the front wheels
by matching it to the wheel base and front tread.
2. Place the vehicle softly on the tester and free roller.
3. Start the engine, and engage the clutch softly at a low speed
in 2nd gear; then gradually increase the speed.
4. Upon completion of the test, stop the engine by gradually
decelerating with soft braking.
[Front wheel jack-up method1
1’. Place the rear wheels on the roller.
2. Jack up the front wheels and mount on a safety stand.
3. Start the engine, and engage the clutch softly at a low speed
in 2nd gear; then gradually increase the speed.
Caution
l When using either the front wheel free-roller meth-
od or front wheel jack-up method, secure the vehi-
cle to prevent forward and lateral movement by
attaching towing hardware (chain or wire) to the
front and rear tow hook or tie-down hook.
BRAKE TESTER CHECK
Caution
. To stabilize the drag force of the viscous coupling,
conduct the brake test after the speedometer test.
1. Place the wheels to be tested (front or rear) on the roller.
2. Shift itit0 NEUTRAL.
3. Drive the tester roller and check.
a-9

GI MAINTENANCE NOTE
VIEWED
.OM BELOW
‘REE
13EGfX-307
I
I t3EGIX-308 CHASSIS DYNAMOMETER CHECK
Caution
l Do not clutch abruptly. l Do not attempt rabbit starts or accelerate quickly.
1. Remove the propeller shaft.
2. Lock the center differential (2WD).
3. Place the front wheets on the roller.
4. Lock the rear wheels and apply the parking brake.
5. Drive the tester roller and check.
6. Upon completion of the test, gradually decelerate with soft
braking and stop the engine.
7. When the test is done, return the differential lclck rod to the
free condition (4WD) and reinstall the propeller shaft.
WHEEL BALANCER (On-the-car Balance)
1.
Jack up all four wheels. Support the wheels to be checked
(front or rear) with the wheel balancer sensor stand and the
remainrng wheels with safety stands.
2. Set the on-the-car balancer. With the center differential in
free condition, drove the tires with the engine; then check.

MAINTENANCE NOTE
TOWlNG
Caution
g Use method @I to tow vehicles having problems in the steering system or drivetrain.
Towing method
0 Rope towing items to confirm
Parking brake Transaxle shtft posttton Remarks
Released Neutral
@ Towlng with front wheels off
ground
Released Neutral Remove propeller shaft
@ Towtng by wrecker truck
Released Neutral
Rempve propetler shaft
@Towing or hauling with all wheels
off ground
Engaged Any posItIon
13EGIX.30
TIE-DOWN HOOKS - FRONT TIE-DOWN HOOKS
- REAR (HATCHBACK)
!

A PRE-DELIVERY INSPECTION TABLE
PRE-DELIVERY INSPECTION TABLE
[EXTERlORI
INSPECT and ADJUST, of necessary. the followlng Items to
specrfrcatron:
0 Glass, exterior bright metal and paint for damage
0 Wheel lug nuts
0 Tire pressures
0 All weatherstrips for damage or detachment
0 Operation of bonnet release and look
0 Operation of trunk Ild, hatch and fuel lbd opener
(of equipped)
0 Door operation and alignment
0 Headtrght aiming
INSTALL the foltowrng parts
0 Wheel caps or rrngs (if equipped)
0 Outsrde mirror(s)
1 UNDER BONNET-ENGINE OFF j
INSPECT and ADJUST. If necessary, the following items to
specrflcatlon.
0 Fuel, coolant and hydraulic tines, fittings, connectlons and
components for leaks
0 Engine 011 level
0 Power steering fluid level (of equipped)
0 Brake master cylinder fluky levels
0 Clutch master cylinder fturcl levels (If equipped)
0 Wtndshreld washer reservojr flurd level
0 Radiator coolant level and specrfic gravity
0 Tightness of water hose clamps
0 Tightness of battery terminals, electrolyte level and specific
gravity
0 Manual transaxle oil level
0 Drive belt(s) tension
Cl Carburetor lrnkage (choke control, wrde open throttle posi-
tion. etc ) (carburetor model only)
q Accelerator cable and linkage for free movement
0 Headlight cleaner and flurd level (if equipped)
BLEED air from fuel line (diesel engrne only)
CLEAN the spark plugs (except for diesel engine)
piEi6F]
INSTALL the following parts
0 Rubber stopper for rnsrde rear view mirror (if equjpped)
0 Fuse for accessories
CHECK the operation of the following items.
0 Seat controls (sliding and reclining) and head rest
0 Seat belts and warning system
Cl Ign&on switch and steering lock
0 Power window (if equipped)
D Door tacks including child proof door locks
Cl Inhibitor switch (ATX only)
Cl All Ikghts rncluding warning and Indicator lbghts
0 Ignition key reminder buzzer (If equipped)
A-Z
0 Horn, wbpers and washers (front and rear, If equipped)
0 Antenna (tf equipped)
0 Cigarette Ibghter and clock (if equipped)
0 Remote control outside mirror (if equrpped)
0 Heater, defogger and air conditioner at various mode selec-
tions (if equlppedj
0 Sunroof (If equipped)
CHECK the following items
0 Presence of spare fuse
0 Upholstery and Interior finish
CHECK and ADJUST, If necessary, the followjng items:
IJ Operation and fit of windows
0 Pedal height and free play of brake and clutch pedal
0 Parking brake UNDER BONNET-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
0 Operation of Idle-up system for air condbtroner or power steer-
ing (if equrpped)
0 Automatic transaxle flurd levet
0 tnltial ignrtlon timing (except disel engine)
0 Idle speed
0 Operation of throttle positron. sensor (EGI engrne)
0 Operation of cold start device and glow plug warning light
(diesel engine only)
0 Operation of dash pbt (EGI.engine)
fTiGGJ
CHECK the following items.
0 Underside fuel, coolant and hydraulic Irnes, ftttlngs, connec-
tions and components for leaks
0 Trres for cuts or brurses
0 Steering Itnkage, suspensron, exhaust system and all under-
side hardware for .looseness or damage 1 ROAD TEST j
CHECK the following items
0 8rake operation
0 Clutch operation
0 Steering control
!ZI Operation of meters and gauges
Cl Squeaks, rattles or unusual noises
Cl Engine general performance
0 Emergency locking retractors 1 AFTER ROAD TEST ]
REMOVE the seat and floor mat protective covers
CHECK for the necessary owner information materials, took
and spare tire
m vehicle
93EOAX-002
-- MAIN Char3 t: In
A: PC R: F!t T: Ti! Emis! The ed : to t!

SCHEDULED MAINTENANCE SERVICES A
SCHEDULED MAINTENANCE SERVICES
MAINTENANCE TABLE
Chafi symbols:
1 : Inspect: Visual examination and/or functional measurement of system’s operation or
performance , A: Adjust: Examination resulting in adjustment or replacement
n
R: Replace or change
T: Tighten
REMARKS
After 80,000 km or 48 months, continue to follow the described maintenance at the recommended intervals.
As for * marked items in this maintenance chart, note the following points.
+ 1 Major service interval at 12 months/20,000 km (12,000 miles).
Lubrication service based on distance only 10,000 km (6,000 miles) not time.
l 2 Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt
if equipped.
‘3 Replacement of the timing belt is required at every 100,000 km (60,000 mile). Failure to replace the tim-
ing bett may result in damage to the engine.
‘4 tf the vehicle is operated under any of the following conditions, it is suggested that the engine oil and
oil filter be changed more often than the recommended intervals.
a) Driving in dusty conditions. I
:
b) Extended periods of idling or low speed operation. i
i!
c) Driving for a prolonged periods in cold temperatures or regularly driving onty short distances.
*5 If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often
than at usual recommended intervals.
l 6 This IS a full function check of all electrical systems, i.e, atl
ltghts. washers (including condition of blades)
electric windows, sunroof, horn etc.
‘7 Replace every two years. $1
‘I
If there has been continuous hard driving, mountain
drivtng, or if the brakes are used extensively or the
vehicle is operated in extremely humid climates, the brake fluid should be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the-emission control and relat-
ed system, as well as for efficient engine operation. It is strongly recommended that all servicing related
to these systems be done by your Authorised Mazda Dealer.
13EOAX-302 -4
I!
A-3

SELF-DIAGNOSIS FUNCTION F3 I
Open or short crcuit
13EOFS322
Caution l If there is more than one failure present, the code numbers will be indicated in numerical or-
der, lowest number first.
l After repairing a failure, turn off the ignition switch, disconnect the negative battery cable,
and depress the brake pedal for at least twenty seconds to erase the service code from the
ECU memory. II
F3-17

OUTLINE M
OUTttNE
OUTLiNE OF CONSTRUCTION
l TKe construction and operation of the front and rear axles are basically the same as previous models.
l Because of the use of a high power engine, the following parts are modified to improve rigidity.
(I) Larger front and rear bearings are used.
(2) Larger front and rear knuckles are used.
(3) A five-stud wheel hub is used.
l An ice scraper is newly installed on the rear knuckle to prevent ice from building up on the brake caliper.
(Refer to page M-14.)
13EOMX-303
SPECIWCATIONS
Hem Speclficatlons
Front driveshaft
Joint type inside
Double offset joint
Outsrde Bell joint
Length of joint (between center of joint) Right
392 I15.4)
mm lrn)
Left 306 IO.831
Shaft drameter mm fin)
21.0 (0.83)
Rear driveshaft
Inside
Joint type Double offset joint
Outside 5ell joint
Length of joint (between center of joint) Right
519.5 [ 20.5 1
mm [in]
Left.
489.5 ( 19.3 )
Shaft diameter mm (in) 21.0 [O&3]
Joint shaft
I
Length of joint
Shaft diameter
Front axle
mm jin] 357.2 114.11
mm {in] 21.0 {0.83]
4
Bearing play axial direction mm tin)
0.05 IO.002 ]
I
Rear axle
Bearing play axial direction mm (inj
Rear dtfferentlal (viscous limited slip differential) 0.05 (0.002 1
Reduction aear Hypoid gear
Differentral gear
Drfferential ratio Straight bevel gear
3.909
Number of teeth Ring gear .
Drive binion aear
43
If
Fluid I Grade API Service GL-5
Above -t8*C (O*F) SAE 90
Viscosity .
Below -18*C i O*Fl SAE 8OW
1 I Capacity L I US qt, imp stl 1 0.65 !O.SS, 0.571
1
13EOMX-304
M-3

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