1989 MAZDA 323 engine oil

Jl TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem
Shift lever won’t shift
smoothly or is hard
to shift
Too much play in
shift lever
I------
Difficult to shift
Won’t stay in gear
Abnormal noise
I
Possible cause
Seized shift lever ball
Seized change control rod joint
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
Worn shift lever ball bushing
Bent change rod
No grease in transaxle control
Insufficient oil
Deterioration of oil quality
Wear or play of shift fork or shift rod
Worn synchronizer ring
Worn synchronizer cone of gear
Bad contact of synchronizer ring and cone of gear
Excessive longitudinal play of gears
Worn bearing
Worn synchronizer key spring
Excessive primary shaft gear bearing preload
improperly adjusted change guide plate
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
improperly installed extension bar
Worn shift fork
Worn clutch hub
Worn clutch hub sleeve
Worn gear sliding part of both shaft gears
Worn gear sliding part of each gear
Worn steel sliding groove of control end
Weak spring pressing against steel ball
Excessive thrust clearance
Worn bearing
Improperly installed engine mount
Insufficient oil
Deterioration of oil quality
Worn bearing
Worn sliding surfaces of gears or shafts
Excessive gear backlash
Damaged gear teeth
Foreign material in gears
Damaged differential gear or excessive backlash Remedy Replace
Replace
Replace
Replace
Replace
Replace
Replace
Lubricate with grease
Add oil
Replace with oil of
specified quality
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Replace
Replace
Replace
Tighten
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Tighten
Add oil
Replace
Adjust or replace
Replace
Replace
Replace with oil of
specified quality
Replace
Adjust or replace Page Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl- 7
Jl- 7
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-36
Jl-17
Jl-56
Jl-56
Jl-56
Jl-56
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-14
Jl-14
Jl-22, 24
Jl-22, 24
Jl-48
Jl- 7
Jl- 7
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-53
03UOJl-OC --
-../
51-6

/ cm-kg, -26-52 In-lb)
(3.8-5.3, 27-M)
Jl TRANSAXLE
INSTALLATION
1. Raise the vehicle and support it with safety stands.
2 Install in the order shown in the figure, referring to Installation Note.
3’ Add the specified amount of the specified transaxle oil. (Refer to page Jl-7.)
4: Warm up the engine and transaxle, and inspect for oil leakage and transaxle operation.
2.4-5.S N.m (30-60
9
1 8-11 N-m
o-110 cm-kg,
* h-95 In-lb)
.O,
cc.
ft-I
03UOJl-119
b)
51-48

03UOJi-12 3
03UOJl-124
L 03UOJl.126 I-
03UOJl-12
Jl TRANSAXLE
Driveshaft
Caution
l Verify that the oil seal is not damaged.
l Do not damage the oil seal
1. Insert the clip with the end-gap at the top of the groove.
2. Apply transaxle oil around the oil seal lip. Install the
driveshaft.
3. Verify that the driveshaft is correctly seated by pulling on
the shaft.
4. Connect the lower arm to the knuckle and tighten the clinch
bolt.
Tightening torque:
43-59 N-m (4.4-6.0 m-kg, 32-43 ft-lb)
Stabilizer (BP SOHC)
1. Tighten the nut until the specified amount of thread is ex-
posed at the end of the bolt.
Dimension A: 17-l 9mm (0.67-0.75 in)
Tie-rod end
1. Install the locknut.
Tightening torque:
42-57 N-m (4.3-5.6 m-kg, 31-42 ft-lb)
2. Secure the locknut with a new cotter pin.
Engine mounting member
1. Install the bolts and nuts as shown.
Tightening torque
@ : 37-52 N,m (3.6-5.3 m-kg, 27-36 ft-lb)
@I: 64-89 N-m (6.5-9.1 m-kg, 47-66 ft-lb)
51-50

TRANSAXLE Jl
03UOJl-12!
03UOJi-13
2. Tighten engine mount No.4 nuts.
Tightening torque:
67-93 N.m (6.6-9.5 m-kg, 49-69 ft-lb)
3. Remove the SST (Engine support).
Control rod and extension bar
1. Install the extension bar to the transaxle.
Tightening torque:
31-46 Nern (3.2-4.7 m-kg, 23-34 ft-lb)
2. Install the change control rod to the transaxle.
Tightening torque:
16-23 N*m (1.6-2.3 m-kg, 12-17 ft-lb)
Ground
1. Connect the ground to the clutch pipe bracket.
Tightening torque:
16-23 N-m (1.6-2.3 m-kg, 12-17 ft-lb)
Speedometer cable
1. Add the specified oil through the speedometer gear case
mounting. (Refer to page Jl-7.)
2. Install the speedometer driven gear.
Tightening torque:
7.6-l 2 N*m (60-120 cm-kg, 69-104 in-lb)
3. Connect the speedometer cable to the speedometer driv-
en gear.
J141

OUTLINE J2
OUTLINE
SPECIFICATIONS
Item
Transaxle control
Synchromesh system EnginelTransaxle
BP DOHC
GSM-R Floor shift
Forward: Synchromesh
Reverse: Selective sliding and synchromesh
T- I-
Gear ratio
I
1 st 3.307
2nd 1.833
3rd 1.310
4th 1.030
5th 0.795
Reverse 3.166
Final gear ratio 4.105
q
Oil Viscosity All-season
Above -18OC (OOF) ATF DexronYI, M2C33F or SAE75W-80
API service GL-4 SAE80W-90
Capacity liters (US qt, Imp qt) 3.35 (3.55, 2.96)
23UOJ2-001
52-3

J2 TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Shift lever won’t shift
Seized shift lever ball Replace J2-46
smoothly or is hard Seized change control rod joint Replace JZ-46
to shift Bent change control rod Replace J2-46
Too much play in Worn change control rod bushing Replace J2-46
shift lever Weak shift lever ball spring Replace J2-46
Worn shift lever ball bushing Replace J2-46
Difficult to shift Bent change control rod Replace J2-46
No grease in transaxle control Lubricate with grease J2-46
Insufficient oil Add oil J2- 7
Deterioration of oil quality Replace with oil of J2- 7
specified quality
Wear or play of shift fork or shift rod Replace J2-13
Worn synchronizer ring Replace J2-18
Worn synchronizer cone of gear Replace J2-18
Bad contact of synchronizer ring and cone of gear Replace J2-18
Excessive longitudinal play of gears Replace J2-18
Worn bearing Replace J2-18
Worn synchronizer key spring
Replace J2-18
Excessive primary shaft gear bearing preload Adjust J2-32
Improperly adjusted change guide plate
Adjust J2-15
Won’t stay in gear Bent change control rod Replace J2-46
Worn change control rod bushing Replace J2-46
Weak shift lever ball spring Replace J2-46
Improperly installed extension bar Tighten J2-46
Worn shift fork Replace J2-18
Worn clutch hub Replace J2-18
Worn clutch hub sleeve Replace J2-18
Worn gear sliding part of both shaft gears Replace J2-18
Worn gear sliding part of each gear Replace J2-18
Worn steel sliding groove of control end Replace J2-13
Weak spring pressing against steel ball Replace J2-13
Excessive thrust clearance Replace J2-18
Worn bearing Replace J2-18
Improperly installed engine mount
Tighten J2-41
Abnormal noise Insufficient oil Add oil J2- 7
Deterioration of oil quality
Replace J2- 7
Worn bearing Adjust or replace J2-18
Worn sliding surfaces of gears or shafts Replace J2-18
Excessive gear backlash Replace J2-18
Damaged gear teeth Replace with oil of J2-18
specified quality
Foreign material in gears Replace J2-18
Damaged differential gear or excessive backlash Adjust or replace J2-44
J2-6

TRANSAXLE J2
INSTALLATION
1. Raise the vehicle and support it with safety stands.
2. Install in the order shown in the figure, referring to
Installation Note,
3. Fill the transaxle with the specified amount of the specified transaxle oil after installation.
4. Warm up the engine and transaxle, and inspect for oil leakaae and transaxle ooeration.
37-52 (3.8-5.3, 27-38) 37-52 (3.8-5.3, 27-38)
9.8-12 (1.0-1.2, 7.2-8.7)
7.8-l 2 (0.8-l .2, 5.8-8.7)
1. Transaxle
6. Tie-rod end
2. Engine mount No.4 7. Clutch release cylinder
3. Joint shaft
8. Engine mount No.2
4. Driveshaft
9. Exhaust pipe
Installation Note
10. Engine mount member
. . . . . . . . . . . . . . . . . . . . .
page J2-42 11. Control rod
5. Stabilizer
12. Extension bar
Installation Note 13. Starter
. . . . . . . . . . . . ..______. page J2-42 14. Ground
31-48 (3.2-4. ‘8
88-l 18 (g-12,65-87)
(6.5-9.1, 47-88)
37-52 (3.8-5.3, 27-38)
N.m (m-kg, Mb)
15. Neutral switch connector
16. Back-up light switch
connector
17. Speedometer
cable
18. Battery carrier
19. Battery
20. Air hose and resonance
chamber
21. Splash shield
22. Wheel and tire
52-41

N
STEERING SYSTEM
INDEX ......................................................
MANUAL STEERING ............................... ;I g
ENGINE SPEED SENSING POWER
STEERING (ESPS) ................................. N- 3
OUTLINE ..................................................
SPECIFICATIONS .................................... ;I ::
MANUAL STEERING ..................................
PREPARATION ....................................... ;I ;
TROUBLESHOOTING GUIDE.. .................. N- 5
BOOT ................................................... N- 6
STEERING WHEEL AND COLUMN.. .......... N- 6
STEERING GEAR AND LINKAGE .............. N-13
ENGINE SPEED SENSING POWER
STEERING .............................................. N-23
PREPARATION ....................................... N-23
TROUBLESHOOTING GUIDE.. .................. N-25
AIR BLEEDING ....................................... N-26
STEERING WHEEL AND COLUMN.. .......... N-26
POWER STEERING FLUID.. ...................... N-27
STEERING GEAR AND LINKAGE .............. N-30
POWER STEERING OIL PUMP.. ................ N-37
DRIVE BELT ........................................... N-41
23UONX-001