wheel MAZDA 323 1992 Suplement Service Manual

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

S REAR SKIRT
REAR SKIRT -
COMPONENTS
Rembal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
Note
l Remove the rear bumper to remove and install the rear skirt.
1. Rear skit-! 2. Rear bumper
S-10 WHEEL,
COMPONE
Removal I
1. Remove i
2. Install in t
I, Front why
Removi
I nstallat

WHEEL ARCH MOLDING S
WHEEL ARCH MOLDING
COMPONENTS
Removal I installation
1 Remove in the order shown in the figure referring to Removal Note
2.
Install in the reverse order nf rernmtal
rA*rrinh h Inr+dld:nm
&l-r- ’
lXOSX-31
1, Front wheel arch molding
- - 2. Rear wheel arch molding
Hemoval Note .............................. page S-l 2
Removal Note ............. .
Installation Note.. ................
page S-13 installation Noe page S-I 2
I I / ;
........................
........................... page S-14
S-t 1

S
Removal Note
Front wheel arch molding
WHEEL ARCH MOLDING
The front wheel arch moldings are attached to the body with adhesive and clips as shown in the figure
To?emove the molding, puti it forward to unhook the pin and clips, taking care not
to damage them,’
Note
. If the molding is difficult to remove, soften the adhesive by using a hot air blower.
->7
ADHESIVE
SEC. A-A
SEC. B-B
SEC. C-C
Rear wheel arch molding 13EosX-316
‘The rear wheel arch moldings are attached to the body with adhesive, double-coated adhesive tape and
fasteners. To remove the motding, first remove the fastners, then pull the molding forward to unhook the
pin, taking care not to damage it.
Note
l If the molding is difficuft to remove, soften the adhesive and adhesive tape by using a hot
air blower.
ADHESIVE
DOUBLE-COATED
ADHESIVE TAPE
SEC. D-D
SEC. E-E SEC. F-F

WHEEL ARCH MOLDING
Installation
Note
S
Front wheel arch molding
1. Remove the original adhesive from the molding mounting
surface of the body.
Caution
l Do not damage the surrounding painted area.
Note
l If the adhesive is difficult to remove, soften it by
using a hot air blower.
I URETHAtiE ADHESIVE
I
13EOSX-320
13EOSX-321
2. Clean and degrease the molding mounting surface of the
body and the bonding area of the molding.
3. Apply primer to the bonding area of the molding and allow
it to dry for approximately 30 minutes.
Caution
l Keep the area free of dirt, moisture, and grease.
l Do not touch the primed surfaces.
4. Apply urethane adhesive to the bonding area of the molding.
Caution
l The application range of urethane adhesive at each
point should be approximately 5 mm [ 0.2 in 1 wide
and 60 mm [ 2.4 in 1 long. Do not apply excessive
adhesive.
5. Align the molding to the body with the pin and clips, and
then install it.
6. Lightly press on the molding to obtain good adherence.
1
i
1
S-f 3 I

S WHEEL ARCH MOLDING
13EOSX-323
r
ADHESIVE TAPE
mm fin]
f 3EOSX-324
13EOSX.325
s-14.
Rear wheel arch molding
1. Remove the original adhesive from the molding mounting
surface of the body.
Caution
l Do not damage the surrounding painted area.
Note
l tf the adhesive is difficult to remove, soften it by
using a hot air blower.
2. Clean and degrease the molding mounting surface of the
body and the bonding area of the molding.
3. Apply primer to the bonding area of the molding and allow
it to dry for approximately 30 minutes.
Caution
l Keep the area free of dirt, moisture, and grease.
l Do not touch the primed surfaces.
4. Apply strips of double-coated adhesive tape to the bond-
ing area of the molding.
Note
l Use 40 mm I-1.6 in) lengths of tape.
5. Apply urethane adhesive to the bonding area of the molding.
Caution
l The application range of urethane adhesive should
be approximately 5 mm f 0.2 iii ) wide and 60 mm
(2.4 in) long. Do not apply excessive adhesive.
6. Peel the protection paper from the double-coated adhesive
tape.
7. Align the molding to the body with the pin, and then install it,
8. Lightly press on the molding to obtain good adherence.
9. tnstall the fasteners.

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
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

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 TECHNICAL DATA
Power brake unit
Diameter
km Without ABS With ABS
mm [in] 188.4 I7.42) +215.2 18.47) [ -
More than 1,080 Itl, 15611 1
I cn I tding force
1- II ,I
I
r-km pressure per lrei
KYa 1 Kgr/cm-, PSI 196 120, 441
at 0 kPa ImmHg, inHgJ
‘) -
j/N tkgf, Ibfl More than 8,730 189, I,2701
1196 (20, 44)
at 66.7 1500, 19.7)
kPa ImmHg, InHgj
Rear wheel hydraulic control system
Type Dual proportlonrng valve 1 ProportionIng valve
Switching point (Master cylinder pressure) kPa t kgflcm2, psi) 1,960 {20, 284)
WHEELS AND TIRES
Item Type Standard Temporary Spare
Size 5 l/2-JJxt5 4-Tx15
Offset mm
Wheel (in) 47.5 { 1.87 j 45 it.771
Pitch circle diameter mm (in] 114.3 {4.50)
Material
I Aluminum alloy
I Steel
Size 195150R15 82V T125/7OD15
Tire
Air kPa i kgflcm2.
pressure psi 1 Front ‘L200 12.4, 351
l 2245 12.5, 36)
Rear “216 (2.2, 321 ‘*245 12.5, 361 412 (4.2, 60)
t-lorizontai 2.0 { 0.079 1 2.5
Runout limit mm [in! L IO.098 ]
Wheel and
Vertical 1 1.5 [0.059] 2.0 (0.079 j
tire
1lnbafanr.e a lo21 t 9 to.31 1 -
*le.. Up to 3 persons
*2 . . . -Full load
SUSPENSI
Front susp
Suspensiorr
Spw tyw:
Shock abs>
Stabilizer
Front wheel
alignment
(
l Unladen;
Rear suspj
Suspension
Spring typi
Shock absc
Stabilizer
Rear whet
alignment
(‘Unladenj
l Fuet tank f
Coil Sp&
+I Main rder
l 2 Auxiliary I
TD-12