1992 MAZDA 323 engine oil

F3 II TURBOCHARGER CONTROL SYSTEM ‘1
1’
:j
TURBOCHARGER CONTROL
SYSTEM
TURBOCHARGER
Re’inovaf / Installation
Caution
l Be careful of the following points after turbocharger removal.
l Do not carry the turbocharger by the actuator rod or actuator hose.
l Do not drop the turbocharger.
l Set the turbocharger down with the turbine shaft horizontat.
l Cover the intake, exhaust, and oil passages to prevent dirt or other material from entering
the turbocharger.
l Use the specified new studs when installing the turbocharger.
1, Disconnect the negative battery cable.
2. Raise the vehicle and support it on safety stands.
3. Remove the undercover.
4. Orain the engine coolant.
5. Remove in the order shown in the figure, referring to Removal Note.
6. Install in the reverse order of removal, referring to Installation Note.
I-- 7.8-1 1 N-m ~80-110 kgfcm. 69-96 idbf j
3946 13.94.7, 2% 3842 13.94.3, 28-
31--46 13.2-4.7, 23-341
T, REPLACE .
12-18 1 f-2-1.8, 8.7-13 I
GASKET, REPLACE
19-26 1 t .9-2.6, 14-19 1
7.6-11 Mm t80-?lO kgfcm, 69-95 hlbfl
~-t-n 1 kgf-m, Wlbt]
13EOF3 3.31
F3-3i

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

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

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

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

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