1992 MAZDA 323 wheel

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.

SUPPLEMENTAL SERVICE INFORMATION .
I
The following points in this section are changed in comparison to the Mazda 323 4-Wheel Drive Work-
shop Manual [I 229-l O-89t].
Turbocharger
l Removal / Installation
Wastegate solenoid valve
l Inspection
htercooter
l Removal I Installation
Fuel pump (main)
l Inspection
Fuel pump resistor/relay
l System operation
l Inspection
Injector
l Inspection
l Volume test
Injector resistor
l Inspection
Pressure regulator control system
l Solenoid valve (pressure regulator control}
Engine control unit (ECU)
l Inspection 13EOF3.320
F3-I 5

,,1
CONTROL SYSTEM F3 ‘1
Va: Battew voltage
Incorrect voltage Possible cause
Always OV
l ROOM IOA fuse burned l Open circuit In wiring from ROOM 10A fuse to ECU termina! 1A
Always OV
l Main relay malfunction l Open or short circuit in wiring from main relay to ECU terminal IB
Always OV (starter turns)
l Open or short circuit in wiring from ignition switch to ECU terminal IC
Always OV
Always VB
l Maln relay (FUEL INJ relay) malfunction l Open circuit in wiring from main relay to diagnosis connector terminal +B l Open or short circuit in wiring from diagnosis connector terminal MEN to
ECU terminal 1 D
l Poor connection at ECU connector l ECU malfunction
Always approx. 5V . ECU malfunction
Always below
2.5v
Always Ve -
-
No display on Self- * Main relay (FUEL INJ relay) malfunction
Diagnosis Checker
l Open circuit in wiring from main relay to diagnosis connector terminal + B
“88” displayed and
l Open or short clrcurt in wiring from diagnosis connector terminal FEN to
buzzer sounds con- ECU terminal tF
ti nuousl y
l Poor connection at ECU connector l ECU malfunction
Always QV
l Short circuit in wiring from igniter to ECU terminal 16
Always OV or VB
l Refer to Code No.42 Troubleshooting
(Refer to 323 4-Wheel Drtve Workshop Manual (12?9-IO-89L))
Always VB
Always OV
Always below
2.5V
Atways Ve I ’
l Fuel pump resistor/relay malfunction
l Open or short circurt in wiring from ECU terminal II to fuel pump resis-
tor/relay
A/C does not operate
l A/C reiay malfunction l Open circuit in wiring from ignition switch to A/C relay l Open circuit in wiring from A/C relay to ECU terminal 1J
A/C switch
OFF but l Short circuit in wiring from AIC relay to ECU terminal 1 J
A/C operates . ECU malfunction
l Poor connection at ECU connector l ECU malfunction
Always below 1 .OV a Short circuit in wiring from diagnosis connector terminal TEN to ECU termi-
nal 1K
Always Vs
l Open circuit In wiring from diagnosis connector terminal TEN to ECU terml-
nal IK
-
-
l Open circuit in winrig from diagnosis connector terminal GND to ground’
-
I -
.
. .
-. F3-47

CONTROL SYSTEM F3
VS: Battery voltage
Incorrect voltage Possible cause
Ab&e OV
l Poor contact at ground terminal l Open circuit in wiring from ECU to ground
Always approx. OV or approx. 2V
l Refer to Code No. 02 Troubleshooting
(Refer to 323 Workshop Manual (l203-lo-89F))
Always approx. OV or approx. 1.5V
l Refer to Code No, 03 Troubleshooting
(Refer to 323 Workshop Manual (1203-lo-89F))
Always OV
Always OV
- -
l Refer to Code No. 05 Troubleshooting
(Refer to 323 4-Wheel drive Workshop Manual (1229-10-891))
l Short circuit in wiring from ECU terminal 2K to throttle sensor, or airflow
meter
l Poor connection at ECU connector l ECU matfunctlon
Below 4.5V or above 5.5V
-
l ECU matfunction
l Refer to section 1
Always OV
l Throttle sensor malfunction l Short circuit in wlnng from ECU termrnal 2M to throttle sensot l Poor connection at ECU connector
. ECU malfunction
Always approx. 5V . Throttle sensor misadjustment
l Open circuit in wiring from ECU terminal 2D to throttle sensor
Always constant
l Open circuit in wiring from ECU terminal 2M to throttle sensor
. Open circurt in wiring from ECU terminal 2K to throttle sensor
l Open circuit in wiring from ECU terminal 2D to throttle sensor
Always above 1V 1 . Throttle sensor mtsadjustment
Always OV (after warm-up)
Always approx. IV (after warm-up)
l Refer to Code No. 15 Troubleshooting
(Refer to 323 Workshop Manual (1203-I O-89F))
l Refer to Code No.17 Troubleshooting
(Refer to 323 Workshop Manual (1203-lo-89F))
Always OV or approx. 5V
l Refer to Code No. 08 Troubleshooting
(Refer to 323 Workshop Manual (t203-lo-89F))
Always OV or approx. 5V
Always OV or approx. 5V
l Refer to Code No. 10 Troubleshooting
(Refer to 323 Workshop Manual (l203-lo-89F))
l Refer to Code No. 09 Troubleshooting
(Refer to 323 Workshop Manual (1203-10.89F))
Always OV
I
l Indicator broken l Open or short circuit In wiring from ECU 2R to ignition switch
13EOF3-36;
F3

OUTLINE
OUTLINE OF CONSTRUCTlON
l A hydraulic clutch control mechanism IS used.
l The basic construction is the same as the previous 323 BP DOl-fC turbo models, except that the thickness
of clutch disc.
t3EOHX-302
SPECIFICATIONS
I Clutch control
1 Hydraulic
I
Clutch cover
Type
Set load N [kgf, lbf] Diaphragm spring
5,494 (560, 1,232)
Outer dlarneter mm {in)
230 19.05)
1
1 Inner diameter mm {in) 1
155 [6.10]
Clutch disc Pressure plate side
mm {ini 3.5 (0.14) 3.2 [0.13]
1 Thickness 1 I
I
_ Flywheel Btde
mm {in1 . 3.5 (0 14)
3.2 (0.13j
Type Suspended
Pedal ratio 6.55
Clutch pedal
Full stroke mm ijn]
I 135 t5.311
1
I Hetght (With carpet)
mm tin{ 196-204 { 7.72-6.03 1
1 Clutch master cylinder 1 tnner dtameter mm [in] 15.87 10.625)
I
1 Ctutch release cylinder
1 Inner diameter mm {in)
I 19.05 [0.7501
I
Clutch fluid SAE 31703 or FMVSSI 16 DOT-3
1
13EOHX-303
H-2

FRONT AND REAR AXLES
INDEX ..*** . . . . . l . . . ...* . . . . . . . ..**...I* . . . . . .*..*.* . . . . . . . M- 2
1 FEATURES 1
OUTIJNE .................................................
M- 3
OUTLINE Of CONSTRUCTION
................. M- 3
SPECIFICATIONS ....................................
M- 3 t
SUPPLEMENTAL SERVICE INFORMATION.. M- 4
FRONT AXLE
l ,..,..,..............,.....*.............. M- 5
PREPARATION . . . . . . . . ..*.*...........m..........*... M- 5
WHEEL HUB, STEERING KNUCKLE . . . ..I.... M- 6
REAR AXLE *...............*............................ M-l 1
PREPARATION
l . . . . ..*..*...................*..*..... M-l 1
WHEEL HUB, KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . .
M-12
)I
13EOMX.301
q

INDEX
13EOMX-302
1, Front axle
2. Rear axle
Wheel hub, steering knuckle
Wheel hub, knuckle
Removal I Inspection I
Removal I Inspection I
Installation
..1*.,..*............*......*... page M- 6
Installation . . . . . . . . . . . . . . , . . . . . . . . . . , , . ..-.
Disassembly ! Inspection I
Disassembly / lrispection I p&ge M-l 2
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I.. page M- 8
Assembly ,..........................,..... page M-l 4
M-2
.
SPEC
Joint
--
Lengt
SE”
--
Rear
--
Joint
--
Lengt
-e
Shak
--
Johi
-m
tengt
--
Shat:
Front
I3eari
&z
--
Bear jr --
Rear
Redrll -- Difl et-t
Di#ert
Numt

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