1992 MAZDA 323 technical data

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

TECHNICAL DATA TD
Item
t-2 slmfl fork and reverse gear Standard 0.1 O-O.45 [ 0.004-0.018 1
mm {in] Wear limit
I 0.95 (0.037 ]
3-4 shift fork and ctutch hub sleeve Standard 0.10-0.40 [0.004-O.OlS]
mm [In]
Wear limit
I 0.90 (0.035 ]
5th shift fork and clutch hub sleeve Standard 0.10-0.36 {0.004-0.014]
mm [in]
Wear limit
I 0.86 [ 0.034 1
Reverse idle gear and reverse lever Standard 0.10-0.35 ~0.004-0.014 )
mm fin)
Wear limit
I 0.85 tO.033)
Standard o-0.05 [ 0-0.002 ]
Primary shaft gear mm [in ] 0.20 lO.OOS], 0.25 [O.OlO), 0.30 (0.012], 0.35 (0.014),
Adjustment shims 0.40 lO.OlS], 0.45 [O.OlS), 0.50 (0.020], 0.55 [0.022],
0.60 fO.0241. 0.65 f0.0261. 0.70 fO.0281
Standard t 0.03-0.08 { 0.001-0.003 1
Secondary shaft gear mm [in] 0.20 tO.O08], 0.25 {O.OlO], 0.30 (0.012], 0.35 [0.014),
Adjustment shims 0.40 (O.Ot6], 0.45 (0.018], 0.50 [0.020], 0.55 10.022),
0.60 IO.0241, 0.65 {0.026], 0.70 [0.028]
Center differential
Me Planetary carrier
Number of ring gear teeth
Number of pinion gear teeth Outer
Inner
Outer
Inner 59
75
14
! 14
Number of sun gear teeth
Number of idle-gear teeth
Bearing preload Pinion gear side
I 43
Idle gear side 43
37
N.m { kgfcm. inlbf 1 3.0-3.9 f30-40, 27-34 )
0.25 {O.OtOl, 0.30 {0.012],
CI---.-- ---I--A --I: _d---* -L!- aeanng pretoaa aqusrmenr snrm mm [in] 0.10
0.35
0.55
0.75
0.95
1.15 0.004 ], 0.20
0.014), 0.40
0.022 ) , 0.60
0.030 ) , 0.80
0.0371, 1.00
0.0451. 1.20 0.008
0.016
0.024
0.031
0.039
0.047 -
: 0.45 lO.O18], 0.50 !0.020],
: 0.65 0.85 (0.026] [0.033], p 0.70 0.90 [ { 0.028 0.035], 1,
I 1.05 (0.041], 1.10 [P.O43], r
End play of ring gear mm {in) 0.1510.36 i 0.006-0.012 ]
Ring gear end play adjustment washer mm {in) 1.20 40.047], 1.35 t0.053], 1.50 [0.059),
1.65 {0.065], 1.80 iO.071 1
End play of sun gear mm (in]
0.100-0.300 [ 0.0039-0.0118 ]
-
Sun gear adjustment washer mm {in] 3.5 lO.lSS], 3.7 (0.146). 3.9 (0.154].
4.1 IO.161 1, 4.3 [O.lSS]
Transfer Cattier
Final gear reduction ratio 4.214
Number of teeth
Oil Ring gear -
Pinion gear
Type
Capacity
L I US qt, Imp q?] . 37
11
API: GL-5
Above -18% lOoF]: SAE 90
Below -18OC {OOF]: SAE 8OW
0.5 [0.53. 0.44)

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

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

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