1992 MAZDA 323 lock

P CONVENTIONAL BRAKE SYSTEM
f 6EOPX-073
REAR BRAKE (DISC)
inspection (on-vehicle)
Disc pad
1, Jack up the rear of the vehicle and support it with safety
stands.
2, Remove the wheel and tires.
3. Verify the remaining thickness of the pads.
Thickness: f .Omm fU.04 in) min.
Removal I Inspection / 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 Installation Note.
4. After instaHation, check the following.
(1) Add fluid and bteed the air.
(2) Check for fluid leakage.
(3) Adjust the parking brake lever stioke.
(4) Depress the pedal a few times, then verify that the brakes do not drag while rotating the wheel bv hand,
1. Parking cable
7. Disc pad
13EOPX-32f page P-15 ,..
. . ..I...... above 2. Connecting bolt installation
3. Brake hose Note . ..*. 1 ,...... I.r. . . . . .
4. Lock bolt Inspection . ..-f...........III.I.......,,.
8. Outer shim
5. Caliper 9. Inner shim
Disassembly I Inspection I
Assem bty IO. Guide plate .
-. . . _. . . . . . . . . . . . . . . . . , . . . . . . . . . . . page P-l 7
Il. Bolt
6, V-spring 12. Mounting support
I 3. Disc plate
Inspection . . . . . . . . . . . . . . . . . . . .._...._.~
P-1 4 . . . page p-16 DISC PAD
Replacem
1 s Remove
2. Inspect
i 3. Install in
4. Adjust tF
1. Parking t
2. Ciip
3. Lock bolt
4. V-spring
5. Disc pad
Installa

CONVENTIONAL BF?AKE SYSTEM P
InstaHation note
Disc pad
Install the piston with the SST by turning it clockwise until
it stops.
13EOPX-327
DISC PAD Replacement
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 hstallation Note.
4. Adjust the parking brake lever stroke.
f . Parking
brake cable 2. Clip
3. Lock bolt
4. V-spring
5. Disc pad 6. Outer shim
7, lhner shim -
8. Guide plate
lnstaflation note . . . , . .._. . .I . . . . . . . . . . . . . . _. . . . . . . above . _’
.
P-1 5

CONVENTfONAt BRAKE SYSTEM
13EOPX-33C
16EOPX-7 16
1
3
J
13EOPX 331
Disassembly note
Piston
Remove the piston with the SST.
Note
l The piston is removed by turning the SST counter-
clockwise.
Piston seal
Remove the piston seal with the SST.
Needle bearing
1. Secure the catiper in a vise.
Caution
l Do not remove the needle bearing if not necessary.
l Insert a soft, protective material (such as copper
ptates) in the jaws of the vise.
2. Remove the needle bearing from the caliper with the SST.
Bleeder screw
Loosen the bleeder screw by using the SST.
Assembly note
Bleeder screw
Tighten the bleed screw by using the SST.
Tightening torque:
5.9-8.8 Narn f 60-90 kgfcm, 53.-78 in4bf )
.
c
P-1 8

I- CONVENTIONAL BRAKE SYSTEM
P
I f3EOFX-33,
Needle bearing
1. Set the new needle bearing in the caliper with the needle
bearing hole facing the caliper cylinder.
2. Press the needle bearing into the caliper with the SST until
the SST bottoms against the caliper.
Piston
Assemble the piston with the SST.
Note
l The piston is assembled by turning the SST
clockwise.
16EOPX-718
P--t9 . .

TECHNICAL DATA TD
Hem
Camshafi
Engine
BP DOHC turbo
IN Standard
Cam height mm 1 in) Wear limrt
EX Standard
Wear llmrt
Standard
Journal diameter mm 1 In] (M.1 --NW
Out-of-round
Standard
Camshaft bearing oil clearance mm { in ] (No. f-440.5)
Maximum
Camshaft runout mm {in)
Camshaft end play mm Iin] - Standard
Maximum
Winder block
Height mm {in)
Distortion mm {in]
Grinding mm (in)
Cylinder bore diameter Standard size
mm Iin) 0.25 [ 0.010) oversize .
0.50 [ 0.020 ] oversize
Cylinder bure taper and out-of-round mm [in]
Piston
44.094 { 1.7360 ]
43.894 f 1.7281 ]
44.603 [ 1.7560)
44.403 [ t .748t ;
X940-25.965 I 1.0213-l .0222 j
0.05 (0.002] max.
0.035-0.081 [ 0.0014-0.0032 )
0.15 (0.006)
0.03 (0.0012 1 max.
0.07-O. 19 [ 0.0028-0.0075 1
0.2 IO.008 1
221.5 (8.720)
0.15 [0.006) max.
0.20 [0.008] max.
83.006-83.013 13.2679-3.2682 ]
83.256-83.263
13.2778-3.2781 ]
83.506-83.513
( 3.2876-3.2879 )
0.019 [0.0007) max.
Piston diameter Standard size 82:954-82.974 13.2659-3.2667 1
Measured at 90° to pin
bore axis and 11 .Omm
oversize 83.21 I-83.217
10.433 in] below oil ring 0.25 j 0.010 ]
13.2760-3.2763 ]
groove mm {In)
0.50 { 0.020) oversize 83.461-83,467
{ 3.2859-3.2861 )
Piston to cybnder clearance
Piston ring
mm (in) Standard 0.039-0.052 [ 0.0015-0.0020 ]
Maximum
0.15 [0.006]
Thickness mm {in] Top
Second
, Top
End gap (Measured in the cylinder) Second
mm I in 1 Oil (rail)
Maximum
TOP
Ring groove width in piston
mm (in) Second
r
Oil
Piston ring-to-ring groove clearance TOP
mm (in] Second
Maximum
Piston pin
Diameter mm {in)
Piston-to-piston pin clearance mm iin]
Connecting rod bush-to-piston pin clearance mm Iin)
Connecting rod and connecting rod bearing
Length (Center to center) mm {in] 1
Bending mm [in]
Small end bore (Bush inner diameter) mm [in)
Big end bore mm {in)
Bfg end width mm [in) 1
Standard
Connecting rod side clearance mm I in 1 Maximum I
Crankshaft
Crankshaft iunout mm {ln) 1.470-l ,495 { 0.0579-0.0589 ]
1.47-l -49 [0.0579-0.0587 )
0.15-0.30 [ 0.006-0.012 1
0.35-0.50 { 0.014-0.019 1
0.20-0.70 (0.008-0.028 )
1.0 [0.039)
1.520-I .535 f0.0598~9.0604 f
1.52-l .54 ~0.0598-0.0606)
3.02-3.04 (0.1189-0.1197 1
0.025-0.065 { 0.001 O-0.0026 ]
0.03-OXI7 (O.O012--0.0028)
._
0.15 (0.006]
19.987-l 9.993 (.0.7869-0.7871 )
-0.005-0.013 { -0.0002-0.0005 1
O.Ql O-0.027 ~0.0004-0.0011 )
m D 132.85-132.95 (5.230-5.234 1
0.075 ( 0.0030 ] max./50 I1:97 ]
20.003-20.014 ( 0.7875-0.7880 1
48.000-48.016 [ 1.8898-l 48904 ]
21.838-21.890 (0.8598-0.86t81
0.11 O-O.262 f 0.0043-0.0103 1
0.30 [0.012)
0.04 (0.0016)
mdx.
TCI rl

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 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

SPECIAL TOOLS ST
ENGlNE
TOOL NUMBER
b DESCRIPTION PRlORlTY ILLUSTRATlON
49 0107 680A
Engine stand A
49 LO10 IA0
Hanger set,
engine stand
49 0636 IOOA
Arm, valve spring
lifter
49 8012 OA2
Prvot
A
49 5120 170
1 I
Remover, valve
seal
A ff==cB
49 E011 IA0
Brake, ring gear A Installer set, valve
seal & valve
Remover &
installer, valve
49 0221
061A
49 DO11
102
Lock tool,
crankshaft
- 49 GO14
001
Wrench, tit filter
49 9200 145
Adapter, radiator