radiator MAZDA 323 1992 Workshop Manual Suplement

A PRE-DELIVERY INSPECTION TABLE
PRE-DELIVERY INSPECTION TABLE
[EXTERlORI
INSPECT and ADJUST, of necessary. the followlng Items to
specrfrcatron:
0 Glass, exterior bright metal and paint for damage
0 Wheel lug nuts
0 Tire pressures
0 All weatherstrips for damage or detachment
0 Operation of bonnet release and look
0 Operation of trunk Ild, hatch and fuel lbd opener
(of equipped)
0 Door operation and alignment
0 Headtrght aiming
INSTALL the foltowrng parts
0 Wheel caps or rrngs (if equipped)
0 Outsrde mirror(s)
1 UNDER BONNET-ENGINE OFF j
INSPECT and ADJUST. If necessary, the following items to
specrflcatlon.
0 Fuel, coolant and hydraulic tines, fittings, connectlons and
components for leaks
0 Engine 011 level
0 Power steering fluid level (of equipped)
0 Brake master cylinder fluky levels
0 Clutch master cylinder fturcl levels (If equipped)
0 Wtndshreld washer reservojr flurd level
0 Radiator coolant level and specrfic gravity
0 Tightness of water hose clamps
0 Tightness of battery terminals, electrolyte level and specific
gravity
0 Manual transaxle oil level
0 Drive belt(s) tension
Cl Carburetor lrnkage (choke control, wrde open throttle posi-
tion. etc ) (carburetor model only)
q Accelerator cable and linkage for free movement
0 Headlight cleaner and flurd level (if equipped)
BLEED air from fuel line (diesel engrne only)
CLEAN the spark plugs (except for diesel engine)
piEi6F]
INSTALL the following parts
0 Rubber stopper for rnsrde rear view mirror (if equjpped)
0 Fuse for accessories
CHECK the operation of the following items.
0 Seat controls (sliding and reclining) and head rest
0 Seat belts and warning system
Cl Ign&on switch and steering lock
0 Power window (if equipped)
D Door tacks including child proof door locks
Cl Inhibitor switch (ATX only)
Cl All Ikghts rncluding warning and Indicator lbghts
0 Ignition key reminder buzzer (If equipped)
A-Z
0 Horn, wbpers and washers (front and rear, If equipped)
0 Antenna (tf equipped)
0 Cigarette Ibghter and clock (if equipped)
0 Remote control outside mirror (if equrpped)
0 Heater, defogger and air conditioner at various mode selec-
tions (if equlppedj
0 Sunroof (If equipped)
CHECK the following items
0 Presence of spare fuse
0 Upholstery and Interior finish
CHECK and ADJUST, If necessary, the followjng items:
IJ Operation and fit of windows
0 Pedal height and free play of brake and clutch pedal
0 Parking brake UNDER BONNET-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
0 Operation of Idle-up system for air condbtroner or power steer-
ing (if equrpped)
0 Automatic transaxle flurd levet
0 tnltial ignrtlon timing (except disel engine)
0 Idle speed
0 Operation of throttle positron. sensor (EGI engrne)
0 Operation of cold start device and glow plug warning light
(diesel engine only)
0 Operation of dash pbt (EGI.engine)
fTiGGJ
CHECK the following items.
0 Underside fuel, coolant and hydraulic Irnes, ftttlngs, connec-
tions and components for leaks
0 Trres for cuts or brurses
0 Steering Itnkage, suspensron, exhaust system and all under-
side hardware for .looseness or damage 1 ROAD TEST j
CHECK the following items
0 8rake operation
0 Clutch operation
0 Steering control
!ZI Operation of meters and gauges
Cl Squeaks, rattles or unusual noises
Cl Engine general performance
0 Emergency locking retractors 1 AFTER ROAD TEST ]
REMOVE the seat and floor mat protective covers
CHECK for the necessary owner information materials, took
and spare tire
m vehicle
93EOAX-002
-- MAIN Char3 t: In
A: PC R: F!t T: Ti! Emis! The ed : to t!

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.

F3 TURBOCHARGERCONTROLSYSTEM
1. Radiator
2. Insulator 3. Air hose, and air pipe
4. Oxygen sensor connector
5. Front exhaust pipe
13EOF534
F3-38 6. Water hose
7. Oil pipe
8. Exhaust manifold and turbocharger
Removal Note ,.........I.....f.~.~l....... II.I.... below
Installation Note . . . . , , l.. . . . . . . , ,.. ,..*, , . . . . . . . . . below
13EOF3-339
Removal Note Exhaust
manifold and turbocharger 1. Remove the exhaust manifold and the turbocharger as an
assembly.
2. Separate the turbocharger assembly from the exhaust
manifold.
Installation Note
Exhaust manifold and turbocharger’ I I Remove .all old gaskets and
sealant. 2. Install new gaskets.
3. Supply 25 cc ( 1.5 cu in ] of oil through the oil passage
of the turbocharger.
4. Mount the turbocharger assembly to the exhaust manifold.
5. Install the turbocharger and the exhaust manifold assem-
bly to the engine and loosely tighten the nuts.
6. Install the bracket and the front exhaust pipe, and tighten
the turbocharger mounting nut%
WASTEGATE SOLENOD VALVE
Caution
l The wastegate solenoid valve must be replaced with
the turbocharger, it cannot be replaced by itself.
Inspection 1. Disconnect the connector.
2. Measure the resistance of the solenoid valve.
Resistance: 35-45 !‘l (at 20°C f68OFj) 3. M not as specified, replace the wastegate solenoid valve and
turbocharger as an assembly, if necessary.
(Refer to page F3-37.)
3. Instc

S
BODY
INDEX . . . . . ..*.I........**........*.~*.~............*.......
s- 2
OUTLINE ..................................................
s- 3
UUJLINE OF CONSTRUCTION ..................
S- 3
BONNET BULGE
....................................
s- 3
RADIATOR GRILLE ................................. s- 4
FRONT BUMPER .................................... s- 4
REAR SKIRT ...........................................
s- 6
WHEEL ARCl-i MOLDING .........................
s- 5
( SERVICE j
SUPPLEMENTAL SERVICE fNFURMATION.. S- 6
BONNET BULGE
.......................................
s- 7
COMPONENTS ....................................... s- ‘7
FRONT BUMPER
.......................................
s- 8
COMPONENTS .......................................
s- 8
REAR SKIRT .............................................
S-10
COhiIPONENTS .......................................
S-10
Wt=fEEL ARCH MOLDING ............................
S-l 1
COMPONENTS .......................................
S-l 1
13EOSX301

l The exterior parts are designed to emphasize the function and appearance of the superbly proportioned
body.
: OUTtlNE OF CONSTRUCTION
1 xosx.303
.c
Bonnet bulges are provided in bonnet
. . . . . . . . . . . . ..I................~.....
s-3
A large, body-colored front bumper fascia is adopted., , ..,..,.... S-4
Wheel arch moldings are fitted to fenders . . . . . . . ,..*. l.. . . . . . . . . . . . . . . . . . S-5
- Air inlet area of radiator grille is enlarged
................................. S-4
- Bumper mesh is provided in front bumper
..............................
s-4 Rear skirt is attached under rear bumper.. ............................... S-5
13EOSX-304 BONNET BULGE
l Bonnet bulges are fittGd to the bonnet to match the dynamic appearance of the vehicle and to give it
a high-quality look.

UUTLINE
RADfATOR GRfLtE
l The air inlet area of the radiator grille is enlarged for improved cooling efficiency.
FRONT BUMPER
l The large front bu,mper includes fog lights and bumper mesh to give the vehicle a dynamic appearance.
l tight and rigid polyurethane is used for the bumper fascia.
l The air inlet area is adopted for improved cooling efficiency.
s-4
REAR SKI
l The rear 5
l Light and
WHEEL AR4
l Wheel arc

S
FRONT BUMPER FRONT BUMPER
COMPONENTS
Rem’ovat ! Installation
1. Removal in the order shown
2. Install in the reverse order of
1 in the figure.
removal.
-9-9.8 Nm 170-100 kgfem,
U-87 h.lbfJ
f4-m Ikgf-m, ft-lbf J
13EOSX-312
4. Front bumper
Disassembly / Assembly
. . . . . . . . . ..m... page S-9 1. Radiator grille
2. Front conbination light
3. Headlight
5-8
Disassembh
I . Disassemi
2. Assemble
t
1. Fog lights
-
a
-I. 2. Bumper rear
3. Bumper me

T ~WPe~MENTAL SERVICE INFORMATION, EXTERIOR LIGHTING SYSTEM
SUPPLEMENTAL SERVICE INFORMATION
The following points shown in this section are changed in comparison with 323 Workshop manual supple-
menP(1229-1 O-89t) and 323 Workshop manual supplement (1275-l O-91 C>.
Front fog light
l Removal I Installation
13EOTX-305
EXTERIOR LIGHTING SYSTEM
FRONT FOG LIGHT
Removat / tnstaitation
I. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
I. Radiator grille
2. Front combination light
3. Headlight 4. Front bumper
5. Front fog light
T-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

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