1992 MAZDA 323 service

BRAKING SYSTEM
INDEX ..**.............=*..*..*....~.~............*.,.*...=.
P- 2
OUTLINE . . . . ..~....**.*...........*~...................***
1 P- 3
t il OUTLINE
OF CONSTRUCTION . . . . . . . s.e . . . .
l *..
P- 3
i SPECIFfCATIUNS
. . . . . . . . ..m...*.-..**......n.*.**...
P- 3
e , :
8 [ SERWCE /
SUPPLEMENTAL SERVICE INFORMATION s. P- 4
CONVENTIONAL BRAKE SYSTEM . . . .
l .m..m.s.m P-
5
PREPARATION
. ..* . . . . . . . . . . . . . . . . . . . l . . . . *.*..*.*..I P- 5
AIR BLEEDING (WITH ABS) . . . . . . l .* . . . . . . . . a . . . .
PA 6
POWER 8RAKE UNIT ..*.I..*....*..*....*...*..*..
P- 8
PROPORTJONING VALVE
l . . . . . . . . . . . . . . . . . l . . . . . .
P- 9
FRONT BRAKE (DISC)
. . . . ..**.*.........e.........
P-IO
DISC PAD
. . . . ..m*.m....*bL*m....*...............*......
P-l 1
DISC PLATE
..*..*..*.**..*..a.............*.-.*.....,.
P-12
CAMPER . . . ..m....I*.....*..m*..*......*......*....*...
P-l 2
REAR BRAKE (DISC)
. . . . . . . . . . . . . . . . . * . . . . . . . . l . . . . P-14
DISC PAD . . . . . . . . . . . . . . . . ..~.....................~.~...
P-l 5
DISC PLATE . . . . . . . . . . ..m.e..m....=...*...........*....
P-l 6
CALIPER . . . ..*..m.......I.......~m..~*..*.~......~...*.
P-97
13EOPX-301

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

%
:
1 SUPPLEMENTAL SERVICE INFORMATION, WHEELS AND TIRES Q .
SUPPLEMENTAL SERVICE INFORMATKM
The following point in this section is changed in comparison with the Mazda 323 Workshop Manual Voi-
ume 2 (1206~IO-89F).
l Wheels and tires
I Wheel balance adjustment
13EOQX-30 13EOUX-305
j
WHEELS AND TIRES
I
WHEEL BALANCE ADJUSTMENT
If a wheel becomes unbalanced or if a tire is replaced or
repaired, the wheel must be rebalanced to within specifi-
cation.
Maximum unbalance (at rim edge): 9 g IO.32 oz j
Caution
l Do not use more than two balance weights on the
inner or outer side of the wheel,
l One batance weight; max. 60 g (2-f oz 1.
l if the total weight exceeds IOU g (3.5 or] on one
side, rebalance after moving the tire around on the
rim.
l Attach the balance weights tightly to the wheel.
. Select suitable balance weights for aluminum alloy
wheels.

S
BODY
INDEX . . . . . ..*.I........**........*.~*.~............*.......
s- 2
OUTLINE ..................................................
s- 3
UUJLINE OF CONSTRUCTION ..................
S- 3
BONNET BULGE
....................................
s- 3
RADIATOR GRILLE ................................. s- 4
FRONT BUMPER .................................... s- 4
REAR SKIRT ...........................................
s- 6
WHEEL ARCl-i MOLDING .........................
s- 5
( SERVICE j
SUPPLEMENTAL SERVICE fNFURMATION.. S- 6
BONNET BULGE
.......................................
s- 7
COMPONENTS ....................................... s- ‘7
FRONT BUMPER
.......................................
s- 8
COMPONENTS .......................................
s- 8
REAR SKIRT .............................................
S-10
COhiIPONENTS .......................................
S-10
Wt=fEEL ARCH MOLDING ............................
S-l 1
COMPONENTS .......................................
S-l 1
13EOSX301

S SUPPLEMENTAL SERVICE INFORMATION
SUPPLEMENTAL SERVICE lNFORMATlON
The following points in this section are changed in comparison with 323 Workshop Manual (1229-~()439~).
*
BONNET BULGE
l Removal / installation
FRONT BUMPER
l Removal / Installation
REAR SKIRT
l Removal / Installation
WHEEL ARCf-f MOLDfNG
l Removal / Installation
13EOSX-310
S-6
BONNE
COMPOh
Rembvaf
1. Removi
2. lnstatl if

T
BODY ELECTRICAL SYSTEM
INDEX .*,........,..............*....*...*.........*....*.*.
T- 2
jFEATURESl
OUTLINE . . . . . . ..*.....*..*...~.=.........*.*........*~...~
T- 3
FEATURES .e . . . . . *..* . . . . . . * . . . . . . * . . . . . . . *..I . . . . . . . . .
T- 3
LIGHTING SYSTEM .,....*.*..m...*..,...,a*..*.*..,..
T- 3
SPECIFICATDNS .I..*.*...*....*....*.............,.
T- 3
SUPPLEMENTAL SERVICE
INFORMATlON I . . . . . . . . . . . . . . . . . *.*.a=..* . . . . . . . *..*.s
T- ,4
EXTERlOR LlGHTlNG SYSTEM . . . . .
l . . ..e.am..a.. T-
4
FRONT FOG LIGHT
. . . . . . n .* . . . . . l ...* . . . . . s* .,..I..
T- 4
f3EOTX-301
H .

T ~WPe~MENTAL SERVICE INFORMATION, EXTERIOR LIGHTING SYSTEM
SUPPLEMENTAL SERVICE INFORMATION
The following points shown in this section are changed in comparison with 323 Workshop manual supple-
menP(1229-1 O-89t) and 323 Workshop manual supplement (1275-l O-91 C>.
Front fog light
l Removal I Installation
13EOTX-305
EXTERIOR LIGHTING SYSTEM
FRONT FOG LIGHT
Removat / tnstaitation
I. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
I. Radiator grille
2. Front combination light
3. Headlight 4. Front bumper
5. Front fog light
T-4

TECHNICAL DATA TD
Engine
Item BP DOHC turbo
Engine oii
Total (dry engine} 4.0 14.2, 3.5)
Capacity
L IUS qt, Imp qtl Ott pan 3.6 (3.8, 3.2)
011 filter 0.17 (0.18, 0.15)
Grade API Service SD, SE, SF or SG
Above 30°C (86*F) SAE 40
O*C-40*C ~32°F-1040F 1 SAE 30
-1 OOC--2O*C [ 14OF-68OF ] SAE 2OW-20
Viscosity Above -10% [14*Fj SAE ZOW-40 or 2OW-50
number -25*C--3O*C I-1 3OF-86OF ] SAE 1 OW-30
Above -25OC (-13*F1 SAE low-40 or low-50
Below O*C (32*F] SAE 5W-30
Below -2O*C I-4*F] SAE 5W-20
COOLING SYSTEM
L
item
Zooling method - 1 Engine
BP DUHC turbo
I Water-cooled, forced crrcutation
water pump
Type
mpeller diameter
Number of impeller blades
Speed ratio
tiater seal type
rhermostat
bfpe
Opening temperature
Full-open temperature
Full-open lift mm [in)
OC (OF)
*C j*FJ
mm (in] Centrifugal, V-belt driven
75 12.95)
6
1 : 1.05
Unified mechanical seal
Wax, two-stage
Marn: 86.5-89.5 [ 788-I 93 1
Sub: 83.5-86.5 [182-i 88)
loo (212)
Main: 8.0 (0.31 1 min.
Sub: 1.5 IO.061 min.
Radbtor
Type
Cap valve opening pressure kPa { kgflcm2, psi)
Cooling circuit checkrng pressure kPa ( kgflcm2, psi 1
Cooling fan
Type
Number of blades
Outer diameter mm {in 1
Capacity w-v
Current A
Water thermoswitch
OFF-+ON “C 1°F) 1
Radiator thermoswitch
OFFdON OC (OF]
Coolant
Capacity LWS qt,
Imp qt) Coolant protection
Above -16*C (3OF]
Antifreeze solutron
.Above -26*C t-1 5*F ) -
Above -4UOC I-40°F) Corrugated fin
74-103 {0.75--1.05, 11-15)
103 11.05, 15)
Electric
5
340 (13.41
160-12
Hi: 13.3+ 10% max., Lo: 8.8+ 10% max.
97 f207)
105 [221)
6.0 16.3, 5.3)
Specific gravity at 20*C (68*f)
1.054
1.066
1.078 -.ep
1