technical data MAZDA 323 1992 Workshop Manual Suplement

Mazda 323
o Workshop
b Manual CONTENTS
r Title Section
IG eneral Information
Pre-Delivery inspection and
Scheduled Maintenance
Supplement
I Lubrication System
j Cooling System
FOREWORD
This is a supplement to the workshop manu-
a!(s) shown below. This supplement describes
service procedures of. new or modified me-
chanicat and/or ekctrical systems. For service
procedures and important safety notices not
contained in this supplement, please refer to
the previous workshop manual.
Workshop Manual:
Form No.1 203-l O-89F (vol. 1)
1206-1 O-89F (Vol.2)
1229-l O-89L
1275-l O-91 c
b
All information in this supplement was the
latest available at the time of printing, ail alter-
nations related to modifications will be notified
by Service Sulletin. Carburetor
m !I
Fuel and
Emission
Controt
System EGi unieaded Fuel BP (DOHC
and S
Diesel
-Electrica I System
I-- Clutch
Manual
Transaxie
1 Electronically Co Introlled
I
Automatic
Transaxle Hydraulicaf~y’Co~~~rull=;u
1 Transfer
Mazda Motor Corporation
HIROSHIMA, JAPAN [ Propefier Shaft
1 Front and Rear Axles
P ISteerIng System
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN)
shown on the following page. Braking System
IWheels and Tires
ISusiension
1 Bodv Electricat System
1 Heater and Air Conditioner System
1 Technical Data
Special Toots
Parts Index
/ Wiring Refer to the form No.
, Diagram 5232-l 0-92A
--
This manual explains onty the secticlns marked with shadows (-1
0 1992 Mazda Motor Corporation
PR1NTED tN JAPAN, JAN., ‘92 @I
1318010192A

TD
TECHNICAL DATA
ENGtNE ..................................................
TD- 2
LUBRICATlON SYSTEM ...........................
TD- 4
COOLING SYSTEM ..................................
TD- 5
FUEt AND EMISSION CONTROL
SYSTEMS
.............................................
TD- 6
ENGINE ELECTRICAL SYSTEM
................ TD- 7
CLUTCH .................................................
TD- 7
MANUAL TRANSAXLE AND TRANSFER
.... TD- 8
PROPELLER SHAFT
................................
TD-l 0
FRONT AND
REAR AXLES ....................... TD-lU
STEERING SYSTEM ................................
TD-11
BRAKING SYSTEM
..................................
TD-11
WHEELS AND TIRES
...............................
TD-12
SUSPENSION
......................................... TD-13
BODY ELECTRICAL SYSTEM
................... TD-14
STANDARD BOLT AND NUT TIGHTENING.
TORQUE ..............................................
TD-f 4
13ETOX-301
I
m I

TD TECHNICAL DATA
ENGINE (BP DOHC turbo)
Item m
Type BP DOHC turbo
Gasoline, 4-cycle
Cvlinder arranoement and number
1 In-line 4-cylinders
I
I Combustion chamber
I Pent&of
Valve system DOHC, belt-driven 16 valves
Bore x Stroke mm {in] 83.0 x 85.0 (3.27 x 3.35)
Total piston drsplacement cm3 Icu in] 1,839 {112.2)
Compression rat!0 8.2
1 Standard 1,127 111.5, t641-300
Compression pressure
kPa ( kgf/cm2, psi 1 -rpm
Valve timing Mintmum
Maximum drfference between
each cylinder
IN Open BTDC
Close ABDC
EX Open BBDC
Close ATDC ! 785 {8.CI, 114]-300
196 12.0, 28)
2*
51°
590
8*
Valve clearance
I I ---- f IN
mm linl EX I 0: Maintenance-free
0: Maintenance-free
Cylinder head
Height mm finI 133.8-l 34.0 { 5.268-5.276 1
DIstortion mm [in] 0.10 !0.004] max.
GrindIng mm [in) 0.10 {O.O04t max.
Cylrnder head-to-l-LA clearance rqm [ In] Standard 0.025-0.066 IO.001 O-0.0026 ]
Maximum 0.18 10.0071 1
Valve and valve guide
Valve head diameter
mm Ml IN 32.9-33.1 { 1.295-l -3031
27.85-28.15 ! 1.096-l .I08 I -
tN
0.025-0.060 ~0.0010-0.6024)
Valve stem-to-guide clearance mm {in] EX 0.030-0.065 (0.0012-0.0026)
Maximum
0.20 IO.008 1
Guide projection (Height “A”} mm IIn) Ex
Vslve seat 18.3-18.9 {O-720-0.744)
18.3-18.9 { 0:720-0.744 ] rem
Fanshaft -
;am height
Journal diamr
Camshaft be5
Camshaft run’
Camshaft enc
Cylinder b6
Height 1
Distortion
Grinding
Cylin’aer bore
Cylinder Borg
Piston -
Piston diams
Measured at
bore axis ant
(0.433 in) b
groove
Piston to cyi
Piston ring
ThickneSS
End gap (MJlt
Ring groove
Piston ring4
TD-2

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

TD TECHNICAL DATA
LU8RlCATtON SYSTEM
Item
Lubricating method
011 pump Engine
BP DOHC turbo
Force-fed
6 . Trochoid gear
Relief pressure
kPa I kgf/cm’. psi] 343-441 [ 3.5-4.5, 50-64 1
Regulated pressure kPa { kgf/cm’ , psi ] -rpm
294-392 { 3.0-4.0, 43--57.1.3,000
Inner rotor tooth tip to outer. rotor Standard
0.02-0.16 (OJOOS-O.O063]
clearance
mm {in]
Maximum I
0.20 [ 0.0078 )
Outer rotor to body clearance
Side clearance
Oil fIl!er
, TYpe
Relief pressure differential . mm [in) Standard
Maximum
mm {in) Standard
Maximum 1
kPa’ f kgf/cm’, psi 1 0.09-0.18 ~0.00354.Ofl71]
0.22 { 0.0087 1
0.03-0.11 ~0.0012-0.0043~
0.14 {0.0055)
Full-flow, paper element
. 78-118 (0.8-1.2. 11-17) Srade
----l-in
Viscosity
num her
Item
Cooling metha
Water pump
, We
Impeller diame
Number of imf
Speed ratio -
Water seal !$
Thermostat
Jype. _
Opening terq
/Full-open
1 F&open lift
I
Antifreeze E
TD-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

TO TECHNICAL DATA
FUEL AND EMISSION CONTROL SYSTEMS
Item.
Idle speed
tgf-don trrmng-
Fuel pump
MaxImum output pressure
Transfer pump
Maximum output pressure
Fuel filter Engine
rPm
BTDC
kPa [ kgf/cm2, psi 1 1
kPa { kgflcm2, PSI ) 1 BP OUHC turbo
800 f 50
10 l 10
490-736 (5.0-7.5, 71-1 IO]
39 10.4, 5.7 ) or higher
I Type
Low-pressure side Nylon element (in fuel pump)
Hiah-Dressure side PaDer element
Pressure regulator
Regulating low kPa ( kgflcm2, psr 1 265-314 (2.7-3.2, 38-46 1
pressure High kPa { kgflcm2, psr 1 304-392 (3.1-4.0, 44-57 1
lniector
_ Type Low-ohmic
Type of drive
Electromechanical
Resistance q
Approx. 2.11 Q (at 20% ( 68*f )]
lniector reslstor
L - Resistance/injector
Idle-speed control (tSC) valve
TvDe n 1 6 [at 20°C 168OFjj
I Rotarv
Resistance
Solenoid valve (purge control)
Resbstance
Solenoid valve {wastegate)
Resistance n(
R I
i-l I 1 t-13 [at ZO*C {68OF j]
23-27 tat 20°C l68OFll
. r.
33-39 lat 20°C I68OF 11
Solenoid valve (PRC)
Resistance Low temp. q
33-39 [at 2O*C {SS*F]]
High temp. 0 1 33-39 [at 20°C (68OF]]
Water thermosensor
-20°C ( -4OFJ 1 14.6-17.8
Resistance kQ 2o”c I 68OF) 2.21-2.69
40°C ( tO4OF) 1.0-l 3
80°C I176OFJ 0.29-0.35
Airflow meter
Resistance R E244Vs
E2*Vc Fuity closed
Fully open I 20-600
20- 1,000
200-400
EP++THAA
(intake air
thermosensor) -2O*C ( -4OFj 1 13,600-l 8,400
20% 1 68OF) 1 2,210-2,690
6O*C 114OOFl i 493-667
EI ~Fc
I Fully closed 00
0 1
Oxygen sensor (ceramic beater coil)
Resistance
Fuel tank Approx. 6 [at 20°C f68OF)]
I CaDacW L I US oal. ImD aal I I 60 I 15.9, 13.2 I
I
Air cleaner
Element type
Fuel
Specrficatioir Oil permeated
Unteaded premium (RON 95 or higher)
l TEN terminal of diagnosis connector grounded. .
-
ENGINE ELI
3attery
I
Dark current’
Alternator
Starter
Distributor qr
Ignition timin?
ffEN terminal
Ignition coil
Spark plug
l ’ Dark current
r2 Standard pl

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

TD TECHNICAL DATA
CLUTCH
Jmn -
Clutch control
Clutch oedat Engine/Transaxle BP DOW turbo
G25MX-R {G5MX-R)
Hydraulic Type I
Suspended
Pedal ratio mm [in) 6.55
Full stroke mm {in] 135 t5.311
Height (With carpet) mm [in] 196-204 (7.72-8.03 1
Free play mm (in] 5.5-l 7.4 {0.22-0.69 ]
Distance to carpet when clutch fully
disengaged mm [in) Minimum 41.0 (1.61 ]
Flywheel
Runout limit mm {in] 0.200 [ 0.0079)
Clutch disc
1
, Type I Single dry plate
Runout limit mm (in) 0.700 [ 0.0276 )
Wear limit mm {in] 0.3 [ 0.012 ] from rivet head
Outer diameter mm {in] 230 {9.05)
Inner diameter mm {in) 155 i6.10)
Facing thickness mm [in] Flywheel side
I 3.5 (0.14)
Pressure elate side 3.5 10.141
Clutch cover
Type
Set load
Ctutch fluid
Type I
N [kgf, Ibf) 1
I Diaphragm spring
5,494 1560, 1,232)
SAE J1793 or FMVSS116 DOT-3 MANUAL TRANSAXLE AND TRANSFER
SpecMcation
Transaxle type
Transaxle control
Transaxle shift control
Syncromesh system G25MX-R (G5MX-R)
Floor shift
Cable
Forward: Synchromesh
Reverse: Seiective sfidina and svnchromesh
I 1 st 3.454 a
2nd 1.833
3rd 1.310
Gear ratio
4th 0.970
5th 0.717
Reverse 3.166
Final gear ratio I . 4.214
Speedometer gear ratio (Driven gear/drive gear) 1.045 (23122)
Grade API service GL-4
011 Viscocity AkeaSQn: ATF Dexron@II or M-ID
Above -l8*C (OOF): SAE 75W-90
Capacity L {USqt, Imp itI 2.6 12.7, 2;2]
Runout
Primary shaft gear runout
Secondary shaft gear runout mm {in) 0.050. [ 0.0020 ]
mm [in] 0.015 { 0.0006 ]
Clearance
1st’ (Gear inner dia. -shaft puter dia)
2nd (Gear inner dia. -shaft outer dia)
3rd {Gear inner dia. -shaft outer dia)
4th (Gear inner dia. -shaft outer dia)
5th (Gear rnner dia. -shaft outer diaj mm {in] 1 0.030-0.080 { 0.0012-0.0~3 11
mm {in) 0.030~0.08C (-0.0012-0.0031 1
mm (in) 0.030-0.080 I 0:0012-0.003i 1
mm [in] 0.030-0.080 [ 0.0012-0.0031 ]
mm [lnl 0.030--0.080 ~0.0012-0.0031 1
1. TD-8
Lern
l-2 sift for
3-4 shift fri
5th shift f;t
Reverse iti
Thrust cli
1st gear
2nd gear
3rd gear
4th gear
5th gear
. .
Primary St
Seconda:
Center ci
Type :
Number
c
Number (
Number r
Number ;
Bearing ;
Bearing
1
End plai
Ring get
End pi&i
Sun gea
frltnsfe~
Final g&f
Number

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)