1992 MAZDA 323 brake

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

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
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.

CONVENTlONAL BRAKE SYSTEM P
13EOPX-309
f3EOPX-310
13EOPX-311
Rear Brakes
1. Fill the fluid reservoir to the MAX mark with the specified
brake fluid.
2. With the ignition switch ON, fully depress the brake pedal
several times.
3. When the hydraulic-unit pump stops add the specified brake
fluid to the reservoir MAX mark if necessary,
If the hydraulic-unit pump coniinJes tti run for more than
one minute, do the following:
(1) Jack up the vehicle and support it on safety stands.
(2) Remove the bleeder cap and attach a vinyl hose to the
bleeder screw.
(3) Insert the other end of the vinyl hose into a clear con-
tainer.
(4) Loosen the bleeder screw by using the SST.
(5) With the ignition switch ON, fully depress the brake pedal
several times.
(6) Tighten the bleeder screw and continue with Step 2 of
the main procedure.
Cautfon
l Do not run the hydraulic-unit pump for more than
two minutes.
l The brake fluid reservoir must be kept 3/4 fult dur-
ing air bleeding.
l 8e careful not tb spill brake fluid onto a painted
surface.
l Use only the specified brake fluid. Do not mix differ-
ent brands of fluid.
4. Jack up the vehicle and support it on safety stands.
5. Remove the bleeder cap and -attach a vinyl hose to the
bleeder screw I
6, Place the other end of the vinyl hose into a clear fluid-filled
container.
7. With the ignition switch ON, have an assistant depress the
brake pedal serveral times, and then hold the pedal down.
Caution .
l The two people should sta)i within voice contact of u
each other.
l Be sure the pedal remains depressed until the bleed-
er screw is tightened.
l Release the brake pedal intermittently to stdp the
pump motor.
l Care must be used when opening the rear caliper
bleeder screw, because of the.high pressure buift
up from a fully-charged accumulator..
9. Use the SST to loosen the bleedes screw to let fluid and
air e-ape. Retighten the bleeder screw by using the SST.
9. Repeat Steps 7 and 8 until no ai! bubbles are seen.
IO. Check for correct brake operation. .
11 l Verify thai there is no fluid feakage. Clean aw& any spilled
flu@ with rags.’ .
f 2. After bleeding the air from the brqke system, add brake fluid _
to the reservoir MAX mark. . -
13EOPX-3 12
,: .
P-7

P CONVENTIONAL BRAKE SYSTEM
1 t3EOPX.314
@ 66.7 kPa
Iso0 mmHg.
19.7 inHg)
16EOPX-05t
1
13EOPX.315
P-8
POWER BRAKE UNIT
Quick Inspection (On-vehicle)
Power brake unit function check
(Method-using tester)
Connect the SST, vacuum gauge A, and pedal depression
force gauge B as shown in the figure. After bleeding the
air from the SST, conduct the test as described in the 3steps
below.
Note l
Use commercMty available vacuum gauge and ped.
al depression force gauge.
a) Checking for vacuum loss
Unloaded condition
1. Start the engine.
2. Stop the engine when the vacuum gauge reading reaches
66.7 kPa (500 mmHg, 19.7 inHg ) .
3. Observe the vacuum gauge for 15 seconds. If the gauge
shows 63.3-66.7 kPa [475--500 mmHg, 18.7-19.7
inHg 1, the unit is operating.
Loaded condition
1. Start the engine.
2. Depress the brake pedal with a fdrrce of 196 N I20 kgf,
44 Ibfj.
3. With the brake pedal depressed, stop the engine when the
vacuum gauge reading reaches 66.7 kPa {SO0 mmlig,
19.7 inHg].
4. Observe the vacuum gauge for 15 seconds. If the gauge
shows 63.3-66.7 kPa I475--500 mmHg; 18.7-l 9.7
inHg 1, the unit is operating.
b) Checking for hydraulic pressure
1, If with the engine stopped (vacuum 0 kPa (0 mmHg, 0
hltlg 1) the fluid pressure is within specification, the unit is
operating.
Pedal force N fkgf. Ibf]
Fluid pressure kPa (kgf/cm2, psi)
196 LZO. 441 1080 111. 1561 min.
2, Start the engine. Depress the brake pedal when.the vacu-
urn reaches 66.7 kPa 1500 mmHg, 19.7 intlg 1. If the flu-
id pressure is within specification, the unit is operating.
Pedal force N 1 kgf, fbf I Fluid pressure .kPa { kgflcm’. ps 1
196 I20,441 6670 {68, 967
1 min.
-- WlTHOU
&
d
I=-
-
1 MASTER CYUh
.
i_

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.’

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

CONVENTIONAL BRAKE SYSTEM
- P
Installation note
I
I Disc pad
Before installing the disc pads, push the piston
fully inward by using the
SST.
13EOPX DISC PAD
Replacement
I_ Remove in the order shown in the
figure. 2. Instalt in the reverse order of removal, referring to Installation Note.
N-m fltgfm, ft4bf 1 1. Bolt t 3EOPX-33: 2. V-spring
4. ‘Outer shim
3. Disc pad 5. tnner shim
Installation Note . 6. Guide plate
. . . . . . . . . . . . . . . . . . . . ..l._.........
above -
P-1 I