lock MAZDA 323 1992 Suplement Owner's Manual

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

SPECIAL TOOLS ST
CLUTCH AND MANUAL TRANSAXLE (CONT’D)
PRIORITY ILLUSTRATION TOOL NUMBER
& DESCRIPTION TOOL NUMBER
& DESCRIPTION PRIORITY IttUSTRATlON
49 8027 001
Holder, diff. side A
gear 49 FTO? 361
Remover, bearing
49 B027 002A
P reload adaptor A 49 0710 520
Puller, bearing
49 8531 555
Gauge block A 49 8531 565
Drwe pinton
model A
49 0727 570 49 8017 102
Preload adapter A
Gauge body,
plnron herght
49 0259 720
Adjustment
wrench, side
bearing
-
FRONT AND REAR AXLES
C
i TOOL NUMBER
8, DESCRIPTION PRIORITY / ILLUSTRATION TOOL NUMBER
& DESCRIPTION
49 F027 004 49 NO27 001
Attachment
tf~?O Gauge Mock
49 GO33 102
Attachment A

SPECIAL TOOLS ST
STEERING (CONT’D)
PRIORITY TOOL NUMBER
et QESCRlPTlUN ILLUSTRATION
19 HO02 671
4dapter
Power steering) A
(Power steering)
(Power steering)
49 6032 3t2
(Power steering)
49 6032 323
Remover body,
rod seal
49 8032 316
Support block,
PM
(Power steering)
49 B032..327
Wrench,
outer box
49 9032 315
Installer, oil seal A
(Power steering)
0
19 8032 317
qemover ,
Dearing & oil seal
:Power steermg) B
49 8032 324
Protector body,
rod seal A
49 8032 305
Holder, power
steering pump
(Power steermg) A
49 8032 326
Protector,
outer box A
49 8032 306
Wrench, plug
(Power steermg) A
49 8032 321
Adapter
(Power steering) A
A
n
49 GO32 317
House (Power steering)
ST-7

ST SPECIAL TOOLS --
BRAKIN
STEERING (CONT’D)
--
TOOL fi
h DESC
--
19 1285
Wer,
Qeedle :
--
49 8065
Harness;
--
49 cw:
Setting
retainer
--
49 804
Socke: PRIORITY / ILLUSTRATJUN TOOL NUMBER
& DEScCRIPTION TOOL NUMBER
& DESCRIPTION PRlORITY
ILLUSTRATION
A
(IlIP
A
0
A
c!iz9 49 B032 310
49 8032 320
0
Wrench
A
(Power steermg)
jq
49 F032 303
Handle
(Power steering)
Protector, pmon seal
(Power steermg)
49 B032 311
Protector,
Jipper seat
(Power steering)
49 8032 325
Guide. rod seal
BRAKING
PRIORITY
ILLUSTRATION TOOL NUMBER
b DESCRlPTlON TOOL NUMSER
& DESCRIPTION PRIORITY
ILLUSTRATION
49 8043 001
Adjust gauge
I A 49 0259 770B
Wrench, flare nut
A
49 0221 60X
Expand tool,
disc brake 49 8043 002
Installer, bearing A
TOOL
& DES
--
49 BC:
Replac
rubber
InstallE
dust 3 49 0208 701A
Atr out tool, boot 49 8043 003
Turning, lock tool A
49 FAt8 602
49 U043 OAO
I
Gauge set,
I A
oil pressure Wrench ,disc
brake piston

SYSTEM INDEX
ENGINE-RELATED SYSTEMS STARTING SYSTEM...............2 4
CHARGING SYSTEM...............2 6
ENGINE CONTROL SYSTEM.........2 8
COOLING FAN SYSTEM............3 6
CHASSIS-RELATED SYSTEMS ANTI-LOCK BRAKE SYSTEM........82
INSTFUJMENT CLUSTER-RELATED SYSIEMS IrS$;MENT CLUSTER 6 WARNING
........................ 38
BODY-F&LATEX) SYSTEMS
WINDSHIELD WIPER 6 WASHER.....4 0
HEADLIGHT CLEANER.............4 0
REAR WIPER & WASHER...........4 2
HORNS...................,......6 0
REAR WINDOW DEFROSTER.........6 4
SOUND WARNING SYSTEM..........6 6
POWER WINDOWS.................7 4
POWER DOOR LOCK...............7 6
POWER OUTSIDE MIRRORS.........7 8
SLIDING SUNROOF...............8 0
SEAT WARMERS..................8 4
INTERIOR LIGHTING SYSTEMS IG KEY CYLINDER LAMP..........6 6
INTERIOR 6 SPOT LAMPS.........6 6
COURTESY LAMPS................6 8
TRUNK COMPARTMENT LAMP........6 8
ILLUMINATION LAMPS............7 0
EXTERIOR LIGHTING SYSTEMS
HEADLIGHTS
EXCEPT F.R.GERMANY...........44
F.R.GERMANY..................46
HEADLIGHT LEVELING SYSTEM.....46
TAILLIGHTS
EXCEPT F.R.GERMANY...........48
F.R.GERMANY..................5 0
LICENSE PLATE LIGHTS
EXCEPT F.R.GERMANY...........4 8
F.R.GERMANY..................5 0
POSITION LIGHTS
EXCEPT F.R.GERMANY...........4 4
F.R.GERMANY..................!i? 0
FRONT 6 REAR FOG LIGHTS.......52
TURN 6 HAZARD FLASHER
LIGHTS.......................54
STOPLIGHTS
F.R.GERMANY.a................5 6
EXCEPT F.R.GERMANY...........5 8
BACK-UP LIGHTS................6 0
AIR CONDITIONING-RELATED SYSTEMS HEATER........................6 2
ACCESSORIES CIGARETTE LIGHTER.........<....64
DIGITAL CLOCK.................64
AUDIO SYSTEM..................72
OTHER DIAGNOSIS CONNECTOR...........86

GI Reading Wiring Diagrams
System circuit diagram/connector diagram
l These diagrams show the circuits for each system, from the power supply to the ground. The power
supply side is on the upper part of the page, the ground side on the lower part. The diagrams describe
circuits with the ignition switch off. Below is an explanation of the various points in the diagram.
I Indicates operating conditions for switches.
I
The prefix letter indicates the system in which the
:onnector is used.
JB: Joint box connections
X : Common connectors
A : Charging system/starting system
connectors
B : Engine control system connectors
C : Gauge control system connectors
D : Wiper system connectors
E : Lighting system connectors
F : Signal system connectors
G : Air-conditioning system connectors
l-l : Transmission Control sysetm connectors
I : Interior lamp system connectors
J : Audio/radio connectors
K : Power window/power door lock system
connectors
L : Remote control mirror system connectors
M : Sliding sunroof system connectors
N : Power steering/4-wheel steering system
connectors
0 : Anti-lock brake system connectors.
P : Power seat/seat heater system connectors
Q : Auto cruise control system connectors
R : Auto adjusting suspension system
connectors
S : Passive shoulder belt control/Airbag system
connectors
T : Others
Y : Ground connector
4
IGNITION SYSTEM mENGINE CONTROL
A harness ground is represented differently than
a unit ground.
Types of grounds
Harness
Unit Symbol

Reading Wiring Diagrams
Loaic symbols I
ypes of logic symbols Operation Expressing output Simple relay circuits
OR
Input to A or 8 will Low electricai potential (L) at A and B +
produce output at C. no output (L) at C
A
6
D- High electrical potential (H) at A or B +
C output (H) at C
AND Input to A and B will High electrical potential (H) at A and B +
produce output at C. output(H) at C
q---J-c
Low electrical potential (L) at A or B + A
no output (L) at C
B a-00-a C
6
INV No input to A will produce Low electrical potential (L) at A -+
an output at B. no ground (H) B
An input to A will not High electrical potential (H) at A +
A- 6 produce an output at B. grounds (L) B A- 6
PROCESS Simplified representation of complex functions within circuit describes
main function. (Examples)
---
--I- 1 1. Igniters
I
-L-l Signal detector for engine control unit, cooling unit, and tachometer.
Ii- 2. r”~“-‘-‘-““‘~~‘.“’
Sbnsl conwflw :
i...-..--.---......-.~~
Signal converter for turn and hazard flasher unit and igniter unit.
Abbreviations used in this booklet
A
AAS
ABS
ACC
ACCEL
ACV
ADD
AE
AIS
ALL
ALT
EP
ANT
EV
EP
ATX
A/C
AIF
AIR
:AC
B/L
CARB
CCT
CIGAR
COMBI
CON
CONT
CPU
CSD
DEF
DOHC
ECPS Ampere
Autoadjusting Suspension
Antilock Brake System
Accessory
Accelerator
Air Control Valve
Additional
Acoustic Equilibration
Air Injection System
Automatic Load Leveling
Alternator
Amplitude Modulation
Amplifier
Antenna
Autostop
Alr Supply Valve
Automatic transmission
Atmospheric Pressure
Automatic Transaxle
Air Conditioner
Air Fuel
Auto Reverse
Battery
Bypass Air Control Valve
Bilevel
$rr$:,tor
Cigarette
Combination
Conditioner
Control
Central Procassino Unit
&Id-Start Device -
Defroster
Double-Overhead Camshaft
Electronically Controlled Power
Steering ECU
EGI
EGR
ELEC
ELR
ETR
EXH
E
FICB
FM
F/S
F/I
GEN
ET
HI
H/D
I;LUMl
INT
ISC
JB
LCD
LF
k!
z Engine Control Unit
Electronic Gasoline Injection
Exhaust Gas Recirculation
Electrio
Emergency Locking Retractor
Electronic Tuner
Exhaust
Front
Fast-Idle Cam Breaker
Frequency Modulation
Feedback
Fuel lniector
Generator
Heater
High-Energy Ignition
High
Heater/Defroster
Ignition
lllumlnation
Idle-Speed Control
Joint Box
Liquid Crystal Display
Left Front
Left Hand
Low
Left Rear
Low Wave
:I, Motor
Middle
MIL
MIN Malfunction Indicator Lamp
Minute
MIX
Mixture
MPX Multiplex
ZR Manual Transmission
MTX Mechanical Tuning Radio
Manual .Transaxie PRG
PTC
P/S ass
kc
FIF
. . .
RH
RPM
!2EL
SQ
ST
SW
TCV
TEMP
TICS
TR
TWS
V
VENT
VOL
VRIS
W Middle Wave
Normally Closed
Normally Open
Overdrive
Switch Off
Switch On
Power
Pressure Regulator Control
Solenoid Valve
Purge Solenoid Valve
Positive Temperature Coefficient
Heater
Power Steering
;im&k-Start System
Recirculation
Right Front
Right Hand
Revolutions Per Minute
Right Rear
Solenoid
Squares Per Milimeter
Start
Switch
Twin Scroll Turbocharger
Solenoid Valve
Temperature
Triple Induction Control System
Transistor
Total Wiring System
Volt
Ventilation
Volume
Variable Resonance Induction
System
Watt(s)
IO