length MAZDA 323 1992 Workshop Manual Suplement

GI IDENTIFICATION NUMBER tOCATlONS/UNlTS/ABBREVIATlONS
IDENTIFICATION NUMBER LOCATIONS
VEHICLE tDENTtRCATtUN NUM8ER (VIM) ENGINE MODEL AND NUMBER
I
UNITS
N.rn { kgf m or kgfcm,
f-t&f or tn.lbf 1 . . . . . . . . . . . . . . . . Torque
rpm ._ . . . Revolutions per minute
A.. ,_...___.... Ampere(s)
v I... Volt(s)
$2 . .._..__......_.....__... Ohm(s) (resls‘tance)
kPa { kgflcm*, psr] . . . . . . . Pressure
{usually positive)
mmHg I inl-lg ] . . . . . . . . . Pressure
(usually negatrve)
W . . . ._ .._.__ .._ . . . . . . ..,......... Watt
titers [US qt, Imp qt 1 . V&me
mm { rn 1 . . . . . . . . . . . . . . . . . . . . . . . Length
89UOGX-006
ABBREWATIONS
ABDC _. . . . . . . . . . . After bottom dead
center
A/C . . . . . . . ._.. _. . . . . . . . . Air conditioner
ACC .__ . . . . . . . Accessones
ATX .._ ._ . . . . . . . . . . . . . . Automate transaxle
ATDC _.. __ _. . . . . After top dead center
ATF ,... ._....__._.. Automatic transmission
fluid
BAC ._ . . . . . . . . . . . . . . ,. Bypass air control
BBDC _. . . . . . . . . . . . . .._. Before bottom dead
center
BTDC ., ._._... . . . Before top dead center
CPU . . . . . . . . . Central processrng unit EC-AT
........................... Electronrcally-controlled
automatic transmlsslon
ECU ._ ....................... Engine control unit
EG 1 ..................... Electronc gasoll ne
injectron
E/L. ............................ Electrrcal load
EX .............................. Exhaust
IC ................................ Integrated clrcult
IGN ........................... lgnrtlon
IN ..... ........................ Intake
INT
............................... Intermittent
ISC ............................ Idle speed control
U-l ................................
Left hand
M..
........................... Motor
MIL
........ ...................... MatfunctIon Indicator
iamp
MTX. ........................... Manual transaxle
00.. .............................. Overdnve
Of F .............................. Swrtch off
ON
............................... Switch
on
PCV .............................. Positive crankcase
ventilation
PRC .......................... Pressure regulator
control
P/S ............................. Power steerrng
P/W ............................
Power window
RH ............................... Rlght hand
SST
............................. Special service tool
ST.. ............................... Starl
SW.. ............................. Switch
TDC. ............................ Top dead center
4WD .............................
4-wheel drive
03UGIX-802
INS7
If a t’
and
Whe
1, II-!
2. II-!
3. E-
4. Dr
W-1 2

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

OUTLINE M
OUTttNE
OUTLiNE OF CONSTRUCTION
l TKe construction and operation of the front and rear axles are basically the same as previous models.
l Because of the use of a high power engine, the following parts are modified to improve rigidity.
(I) Larger front and rear bearings are used.
(2) Larger front and rear knuckles are used.
(3) A five-stud wheel hub is used.
l An ice scraper is newly installed on the rear knuckle to prevent ice from building up on the brake caliper.
(Refer to page M-14.)
13EOMX-303
SPECIWCATIONS
Hem Speclficatlons
Front driveshaft
Joint type inside
Double offset joint
Outsrde Bell joint
Length of joint (between center of joint) Right
392 I15.4)
mm lrn)
Left 306 IO.831
Shaft drameter mm fin)
21.0 (0.83)
Rear driveshaft
Inside
Joint type Double offset joint
Outside 5ell joint
Length of joint (between center of joint) Right
519.5 [ 20.5 1
mm [in]
Left.
489.5 ( 19.3 )
Shaft diameter mm (in) 21.0 [O&3]
Joint shaft
I
Length of joint
Shaft diameter
Front axle
mm jin] 357.2 114.11
mm {in] 21.0 {0.83]
4
Bearing play axial direction mm tin)
0.05 IO.002 ]
I
Rear axle
Bearing play axial direction mm (inj
Rear dtfferentlal (viscous limited slip differential) 0.05 (0.002 1
Reduction aear Hypoid gear
Differentral gear
Drfferential ratio Straight bevel gear
3.909
Number of teeth Ring gear .
Drive binion aear
43
If
Fluid I Grade API Service GL-5
Above -t8*C (O*F) SAE 90
Viscosity .
Below -18*C i O*Fl SAE 8OW
1 I Capacity L I US qt, imp stl 1 0.65 !O.SS, 0.571
1
13EOMX-304
M-3

R OUTLINE
OUTLINE
OUTLtNE OF CONSTRUCTION
l The%onstruction and operation of the suspension system are basically the same as for previous models.
l The coil spring and shock absorber specifications are changed.
l The stabilizer specifications are changed.
SPECIFICATIONS
13EORX-302
Front suspension
Suspension type
Sprmg type
Shock absorber
Stabrlmr
Specifications
Strut
Coil spring
Oil filled Total toe-rn
Front
wheel
atignment
(‘Unladen)
Rear suspension
Suspensron type
Sprmg type
Shock absorber
Stabrlrzer
Rear wheei
alrgnment
(‘Unladen) Maximum steering 38* f 3*
309 f 30
-0045 f 45’
2035’ f 45’
KIngpin angle degree
12*to’
We Oil fifled
Damprng force N [ kgl Ibf 1 .‘? .@g,$g&;qJ&,$. ‘: ‘., . . ” ‘, : :,
at 0.3 m 112
]ls I Contraction ;. ~ .. . . . . .__. ..:, .. .. ,I. ._ :. . . f: ; _... .:
Type Torsion bar
Diameter mm. f in ]
19.t (0.751
Total toe-in mm fin!
2.h 3 (0.08 f 0.121
degree
O”12’ f 18’
Camber angle degree -0°20’ f 45’
13EORX-303
l Fuel tank full, radrator coolant and engine oil at speclfled levels; and spare tire, jack, and tools in designated positions. Front Coil Spring Specifications
1 Identification mark color Wire diameter Coif .center
M l l
I Free length A a2 mm lin)
diameter mm [in) . mm 1 in) Coil number Rear Coil Spring Speci?ications
ldentlfication mark color M” Wire diameter Coil center
Free length
mm {in) diameter mm 1 in J
mm {in) Coil number
*’ Maln Identlfcatlon mark on second cgil from bottom.
*’ Auxrllary &entificatton mark on thrrd coil from bottom.
Shaded areas tndcate
new specifrcat+ons 13EORXCS05
(I .f

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.

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

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
Hem Engine
SP DOHC turbo
Note ) I
1 st and 2nd
Synchronizer ring outer diameter
’ I 67.7 I2.665)
mm [in] 3rd and 4th 67.7 12.665 )
5th and reverse 55.7 t2.192)
Synchronizer key dimension 1st and 2nd @ 19.0 {0.748], 04.3 (0.171, 05.0 10.20)
mm [in] 3rd and 4th @ 17.0 10.669J, 04.3 (0.171, @ 5.0 lO.20)
5th and reverse 0 17.0 10.6691, m4.3
10.171, @I 5.0 fO.201
PROPELLER SHAFT
Item
length
Outer diameter Engineflransaxie Model BP DOHC turbo
G25MX-R (GSMX-R)
Front 834.3 { 32.85 ]
mm fin] Center 584 122.99)
Rear
I 437 { 17.20)
Front 75 (2.95)
mm { in] Center 57 12.24) f
Rear 57 12.241
FRONT AND REAR AXLES
Item Specifications
Front driveshaft

Jomt type Inside Double oftset joint
Outside Bell jotnt
Length of joint (between center of joint) mm { rn t - Right 392 (15.4)
left 306 (0.83 ]
Shaft diameter mm {in] 21.0 to.831
I
Rear driveshaft
Joint type Inside 1
Outside 1
Length of joint (between center of joint) mm [in ] ’ Right
Left
Shaft diameter mm (in)
J&t shatt
Length of joint
Shaft diameter
Front axle
Bearing play axial direction mm [in] 1
Rear axle
Bearing play axial direction mm lin] 1
Rear differential (viscous limited slip differential) Double offset joint
Bell joint
519.5 (20.5 ]
489.5 [f9.3]
21.0 IO.831
357.2 1 t4.11
21 .O (0.83 )
0.050 IO.002 ]
0.050 (0.002 ]
*
Reduction gear
Different ia gear
Oifferential ratro
Number of teeth
Flurd
L Ring gear
Drive .pinion gear
Grade
Viscosity Above -18*C fO*F ]
Below -18*C lOoF)
, Capacity
L fUS qt, Imp c$l Hypoid gear
Straight bevel gear
3.909
43
11
API Service GL-5
SAE 90
SAE 80W
0.65 lQ.69, 0.571 STEERING SI
1 Free olav 8RAKING SY
Brake type
Brake pedat
Height
Free play 1
Reserve travel
Clearance whet
Master cylinde
Master cylinder
Front disc brai
. Tyl?e
Thickness of p&
Thickness of pa

SUSPENSION i
TECHNICAL DATA TD
I
Item
Specifications
Front suspension
Suspension type
strut
Sprrng type
Coil spring
Type Oil 1
Shock absorber
Damping force Extended
1,470 1150, 3N]
N [ kgf, Ibf ] at 0.3 mls
Compressed 1
686 (70, 154)
Stabilizer Type Torsion bar
Oiameter mm {in]
23.0 (0.91 )
Total toe-in mm (in>
2 f 3 (0.08 f 0.12)
degree
0*12’ f 18’
Front wheel Turning angle Inner
38* f 3*
alignment
degree Outer
300 f 30
(* Unladen)
Camber angle degree
-u045’ f 45’
Caster angle degree
2035 f 45’
Kingpin angle
degree 12010’
Rear suspension
Suspension type
I Strut
Spring type
Coil spring
Type Oil
Shock absorber
Damping force Extended
882 (90. 1981
N I kgf, Ibf t at 0.3 mis Compressed
392 140, 88 1
Stabilizer , Type Torsion bar
Diameter mm [in] ?9.? { 0.75 1
Rear wheel
Totat toe-in mm {ini
2 f 3 (0.08 f 0.12)
alignment degree
0°t2’ f 18’
(‘Unladen)
Camber angle degree
-0020’ f 45’
l Fuel tank Ml; radiator coolant and engrne oil at speciffed levels; and spare tire, jack, and tools in designated poations.
Coil Spring Specifications
Item Wire diameter Coil center diameter Free length Coil identification mark coler
mm [in] mm (in) mm (in] number
M” Ae2
Front With sunroof 14.5
IO.57 1 l32.5-158.5 15.22-6.24 ) 271.5 1 IO.69 ] 3.35 Pink
Green
.
WIthout sunroof 14.4 IO.561 1 132.6-158.6 (5.22-6.241 267.0 I IO.51 ] 3.24 Light blue Red
With sunroof 8.8-l 2.5
[ 1 0.34-0.49 128.5-131.2 15.0~5.17) 334 { 13.151 6.19 Cream -
Rear .
I 1 Without sunroof I ff;;y;4”81 I t28.6-13t.j [5.06--5.16) / 335 113.19) 1 6.23 1 Pink 1 - I
l I Main rdentrficatlon mark color: Indicated on second coil from bottom.’ l 2 Auxiliary identification mark color: Indicated on third coil from buttom.
TD-13