1992 MAZDA 323 ABS

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.

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.’

R OUTLINE
OUTLINE
OUTLtNE OF CONSTRUCTION
l The%onstruction and operation of the suspension system are basically the same as for previous models.
l The coil spring and shock absorber specifications are changed.
l The stabilizer specifications are changed.
SPECIFICATIONS
13EORX-302
Front suspension
Suspension type
Sprmg type
Shock absorber
Stabrlmr
Specifications
Strut
Coil spring
Oil filled Total toe-rn
Front
wheel
atignment
(‘Unladen)
Rear suspension
Suspensron type
Sprmg type
Shock absorber
Stabrlrzer
Rear wheei
alrgnment
(‘Unladen) Maximum steering 38* f 3*
309 f 30
-0045 f 45’
2035’ f 45’
KIngpin angle degree
12*to’
We Oil fifled
Damprng force N [ kgl Ibf 1 .‘? .@g,$g&;qJ&,$. ‘: ‘., . . ” ‘, : :,
at 0.3 m 112
]ls I Contraction ;. ~ .. . . . . .__. ..:, .. .. ,I. ._ :. . . f: ; _... .:
Type Torsion bar
Diameter mm. f in ]
19.t (0.751
Total toe-in mm fin!
2.h 3 (0.08 f 0.121
degree
O”12’ f 18’
Camber angle degree -0°20’ f 45’
13EORX-303
l Fuel tank full, radrator coolant and engine oil at speclfled levels; and spare tire, jack, and tools in designated positions. Front Coil Spring Specifications
1 Identification mark color Wire diameter Coif .center
M l l
I Free length A a2 mm lin)
diameter mm [in) . mm 1 in) Coil number Rear Coil Spring Speci?ications
ldentlfication mark color M” Wire diameter Coil center
Free length
mm {in) diameter mm 1 in J
mm {in) Coil number
*’ Maln Identlfcatlon mark on second cgil from bottom.
*’ Auxrllary &entificatton mark on thrrd coil from bottom.
Shaded areas tndcate
new specifrcat+ons 13EORXCS05
(I .f

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

SUSPENSION i
TECHNICAL DATA TD
I
Item
Specifications
Front suspension
Suspension type
strut
Sprrng type
Coil spring
Type Oil 1
Shock absorber
Damping force Extended
1,470 1150, 3N]
N [ kgf, Ibf ] at 0.3 mls
Compressed 1
686 (70, 154)
Stabilizer Type Torsion bar
Oiameter mm {in]
23.0 (0.91 )
Total toe-in mm (in>
2 f 3 (0.08 f 0.12)
degree
0*12’ f 18’
Front wheel Turning angle Inner
38* f 3*
alignment
degree Outer
300 f 30
(* Unladen)
Camber angle degree
-u045’ f 45’
Caster angle degree
2035 f 45’
Kingpin angle
degree 12010’
Rear suspension
Suspension type
I Strut
Spring type
Coil spring
Type Oil
Shock absorber
Damping force Extended
882 (90. 1981
N I kgf, Ibf t at 0.3 mis Compressed
392 140, 88 1
Stabilizer , Type Torsion bar
Diameter mm [in] ?9.? { 0.75 1
Rear wheel
Totat toe-in mm {ini
2 f 3 (0.08 f 0.12)
alignment degree
0°t2’ f 18’
(‘Unladen)
Camber angle degree
-0020’ f 45’
l Fuel tank Ml; radiator coolant and engrne oil at speciffed levels; and spare tire, jack, and tools in designated poations.
Coil Spring Specifications
Item Wire diameter Coil center diameter Free length Coil identification mark coler
mm [in] mm (in) mm (in] number
M” Ae2
Front With sunroof 14.5
IO.57 1 l32.5-158.5 15.22-6.24 ) 271.5 1 IO.69 ] 3.35 Pink
Green
.
WIthout sunroof 14.4 IO.561 1 132.6-158.6 (5.22-6.241 267.0 I IO.51 ] 3.24 Light blue Red
With sunroof 8.8-l 2.5
[ 1 0.34-0.49 128.5-131.2 15.0~5.17) 334 { 13.151 6.19 Cream -
Rear .
I 1 Without sunroof I ff;;y;4”81 I t28.6-13t.j [5.06--5.16) / 335 113.19) 1 6.23 1 Pink 1 - I
l I Main rdentrficatlon mark color: Indicated on second coil from bottom.’ l 2 Auxiliary identification mark color: Indicated on third coil from buttom.
TD-13

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