1992 MAZDA 323 air bleeding

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

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
&
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I=-
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1 MASTER CYUh
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