oil capacity MAZDA 323 1992 Workshop Manual Suplement

The following chart shows interchangeability of the main parts of the previous BP DOHC Turbo engine
and the new BP DOHC Turbo engine for 4WD models.
S ymiols: 0 _. lnterc hangeable X . . . Not Interchangeable
Part name tnterchangeability
Remark
Cytlnder head 0
Camshaft 011 seal 0
Cvllnder head bolt 0
CB :
Cyh nder
blcck
related
Crankshaft
related
Timing belt
related
Valve
related
Lubrication
system
related Cylrnder head gasket 0
Wnder head cover 0
Cylinder head cover gasket
Cylinder block
MaEn bearina cao 0
0
0
Ma+n bearino suo~oFt elate I
0 I ” ,I I
Oil pan
Timrno belt cover I X
0 I
Turbocharger oil return pipe hole increased from
13mm IO.51 in) to 17mm IO.67 in)
Seal elate
Front orl seal I 0 I
I I 0
1
Rear 011 seal 0
Crankshaft 0
Marn bearina 0
Thrust bearing
Connectmg rod
Connecting rod beartng
Piston 0
;J
X
Shape different
Piston skirt shortened
I Piston pm cl
Tw
X Sectional shape different
Piston rrng Piston ring end gap increased from 0:?5--0.30mm
Second
X ~0.006-0.011 in ) to 0.35-0.50mm IO.01 4-0.019
in ] (Measured In cylinder)
Crankshaft pulley Shape different
Rear cover ;5
Flywheel
I 0
Flywheel bolt 0
Tbmlng belt 0
Timing belt crank pulley 0
Camshaft pulley 0
Timing belt tensioner and spring
0
Idler 0
Camshaft 0
AA
Valve Intake
Exhaust
cl
0
X Metallic sodium-filled valve
Valve spring Intake
I 0
and seat
Exhaust 0
Vatve wide I 0
Valve seal
Oil pump 0
Oil pump gasket 0
oil strainer 0
Oil strainer gasket 0
Oil cooler
X Heat dissi patlon capacity increased
Oil jet
Oil filter Shape different
1 Water pump 0
Coohng Thermostat 0
system
related Radiator 0
Cooling fan 0
I 3EO32.304
BZ-3.

G OUTLINE, SUPPLEMENTAL SERVICE INFORMATION
SPECIFfCATfUNS
Item
8attery
Dark current Voltage
Type and capacity Engine
v
(20-hour rate)
mA BP DOHC
12
55D23L (60Ah)
Max. 20
Type Output V-A f “‘i j.,: i .:.. ‘:.. ,, j j.: i.‘: ;:;:i :j;&?.:. .: .:.
__ : . . s.i-....‘:‘:. _.. j ;.’
Regulator type Transistorized (built-in IC regulator)
Regulated voltage v
14.1-14.7
I
C?*..*rlrrrl
Brush length mm [rn] }e 21.5 (0.846)
8.0 10.315)
I Drive belt deflection I 5.5-7.0 { 0.22-0.27 )
mm (intB8N (lOkgf,22Ibf) usea 6.0-7.5 (0.24-0.29 1
Limit 8.0 (0.311
, Type Direct
Starter Output v*$# : : ;..;. ‘:‘.. ._ .; : :‘: 7.:
.. .::“:.:j 1 ,5
. . . . .j$$g;g$y .“. :yy
Brush length mm {in] - Standard 17 [0.67]
Minimum
11.5 IO.4531
Dlstnbutor soark advance Electronic soark advance (ESA)
@EN termind of diagnosis connector grounded) II) f lo
I 1 Prtmary coil
**4 nn*
Ignltbon co11 Reststance 3
(at 20°C [68*F])
in IO-16 kQ lgnrtlon timing BTDC f ar
wrndfnb
I
Secondary 1
coil WindIn.. v.0 I
--v.yy 1
Spark plug NGK
NIPPONDENSU
Firing oraer
*Standard pfug
SUPPLEMENTAL SERVICE INFORMATION
The following points shown in this section are changed in comparison with 323 Workshop Manual
(1203-l O-89F) and 323 Workshop Manual Supplement (I 275-l O-91 C).
l Alternator . Starter
Specifications Specifications
l Spark plug
Specifications
13EGGX-303
G-2

TECHNICAL DATA TD
ENGINE ELECTRICAL SYSTEM
l ’ Dark current is the constant flow of current while the ignition switch is OFF. (i.e., engrne control unit, EC-AT control unit, audio, etc.)
l z Standard plug tteq Engine
BP OOHC turbo
Battery Voltage v 12
Type and capacity (2U-hour rate) 55D23t (60Ah)
Dark current
l r mA Max. 20.0
_ Type AC.
Output V-A 12-70
Regulator type Transistorized (bitt-in IC regulator)
Regutated voltage v 14.1--t4.7
Alternator
’ Standard
Brush length mm 1 in] r 21.5 { 0.846 ]
Minimum 8.0 (0.32 )
Drive belt deflection New 5.5-7.0 10.22-0.27 ]
98 N (10 kgf, 22 IM] Used 6-O-7.5 (0.24-0.29 1
mm Iin)
Limit 8.0 IO.31 1
, Type Direct
Starter Output v-kW
Standard
Brush length mm {in] Minimum
Distributor spark advance
Ignition timing BTDC
(TEN terminal of diagnosis connector grounded)
Primary coit
Ignition coil Resistance winding
(at 20°C 168OF)) Secondary coil
winding
NGK
TYW
Spark plug NIPPONDENSO
, ml WP mm (in)
Firing order 12-0.85
17 (0.671
11.5 IO.481
Etectronic spark advance (ESA)
10 f 10
0.81~-0.99Q
IO-16 kfI
BKRGEVXI I**/ BKRSEVXI 1
BKR7EVX-f f
K20PR-TPl l”‘/ KlGPR-TPI 1
K22PR-TP 11
1.0-l .f { 0.039-0.043)
l-3-4-2

TECHNICAL DATA TD
Item
t-2 slmfl fork and reverse gear Standard 0.1 O-O.45 [ 0.004-0.018 1
mm {in] Wear limit
I 0.95 (0.037 ]
3-4 shift fork and ctutch hub sleeve Standard 0.10-0.40 [0.004-O.OlS]
mm [In]
Wear limit
I 0.90 (0.035 ]
5th shift fork and clutch hub sleeve Standard 0.10-0.36 {0.004-0.014]
mm [in]
Wear limit
I 0.86 [ 0.034 1
Reverse idle gear and reverse lever Standard 0.10-0.35 ~0.004-0.014 )
mm fin)
Wear limit
I 0.85 tO.033)
Standard o-0.05 [ 0-0.002 ]
Primary shaft gear mm [in ] 0.20 lO.OOS], 0.25 [O.OlO), 0.30 (0.012], 0.35 (0.014),
Adjustment shims 0.40 lO.OlS], 0.45 [O.OlS), 0.50 (0.020], 0.55 [0.022],
0.60 fO.0241. 0.65 f0.0261. 0.70 fO.0281
Standard t 0.03-0.08 { 0.001-0.003 1
Secondary shaft gear mm [in] 0.20 tO.O08], 0.25 {O.OlO], 0.30 (0.012], 0.35 [0.014),
Adjustment shims 0.40 (O.Ot6], 0.45 (0.018], 0.50 [0.020], 0.55 10.022),
0.60 IO.0241, 0.65 {0.026], 0.70 [0.028]
Center differential
Me Planetary carrier
Number of ring gear teeth
Number of pinion gear teeth Outer
Inner
Outer
Inner 59
75
14
! 14
Number of sun gear teeth
Number of idle-gear teeth
Bearing preload Pinion gear side
I 43
Idle gear side 43
37
N.m { kgfcm. inlbf 1 3.0-3.9 f30-40, 27-34 )
0.25 {O.OtOl, 0.30 {0.012],
CI---.-- ---I--A --I: _d---* -L!- aeanng pretoaa aqusrmenr snrm mm [in] 0.10
0.35
0.55
0.75
0.95
1.15 0.004 ], 0.20
0.014), 0.40
0.022 ) , 0.60
0.030 ) , 0.80
0.0371, 1.00
0.0451. 1.20 0.008
0.016
0.024
0.031
0.039
0.047 -
: 0.45 lO.O18], 0.50 !0.020],
: 0.65 0.85 (0.026] [0.033], p 0.70 0.90 [ { 0.028 0.035], 1,
I 1.05 (0.041], 1.10 [P.O43], r
End play of ring gear mm {in) 0.1510.36 i 0.006-0.012 ]
Ring gear end play adjustment washer mm {in) 1.20 40.047], 1.35 t0.053], 1.50 [0.059),
1.65 {0.065], 1.80 iO.071 1
End play of sun gear mm (in]
0.100-0.300 [ 0.0039-0.0118 ]
-
Sun gear adjustment washer mm {in] 3.5 lO.lSS], 3.7 (0.146). 3.9 (0.154].
4.1 IO.161 1, 4.3 [O.lSS]
Transfer Cattier
Final gear reduction ratio 4.214
Number of teeth
Oil Ring gear -
Pinion gear
Type
Capacity
L I US qt, Imp q?] . 37
11
API: GL-5
Above -18% lOoF]: SAE 90
Below -18OC {OOF]: SAE 8OW
0.5 [0.53. 0.44)

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

GI Reading Wiring Diagrams
Symbols
Symbol Meaning Symbol Meaning
Battery
l Generates electricity through
Resistance 0 A resistor with a constant value.
chemical reaction. l Mainly used to protect electrical
l Supplies direct current to circuits. components in circuits by maintaining
rated voltage.
l Reading resistance values.
<Colored >
Ground (1)
l Connecting point to vehicle body or No.1 color band other ground wire where current flows No.2 color band
-A-
from positive to negative terminal of No.3 mbr band
battery. No.4 color band
1 l Ground (1) indicates a ground point to
body through wire harness.
Ground (2)
l Gound (2) indicates point where
component is grounded directly to
body.
Remarks
l Current will not flow through a circuit if
ground is faulty.
Fuse (1)
0 Melts when current flow exceeds that
specified for circuit, interrupts current
I__q/y)__ now.
Precautions
(box)
l Do not replace with fuses exceeding
Fuse (2) specified capacity.
(Cartridge)
Main fuse/Fusible <Cartridge type> <Fusible link>
Transistor (1)
l Electrical switching component. l Turns on when voltage is applied to Motor
0 Converts electrical energy into
mechanical energy.
Transistor (2)
0 Reading code. a Pulls in and discharges gases and
liquids.
Number of temtinak
Lamp l Emits light and generates heat when Current flows through filament. Cigarette lighter l Electrical coil that generates heat.