1989 MAZDA 323 Factory Repair Manual

CAUTION GI
9MUGIX-032
9MUGIX-029
Fuse
Replacement
1. When replacing a fuse, be sure to replace it with one of
specified capacity.
If a fuse again fails after it has been replaced, the circuit
probably has a short circuit and the wiring should be
checked.
2. Be sure the negative battery terminal is disconnected be-
fore replacing a main fuse (80A).
3. When replacing a pullout fuse, use the fuse puller supplied
in the fuse box cover.
Wiring Harness
Wiring color codes
Two-color wires are indicated by a two-color code symbol.
The first letter indicates the base color of the wire and the sec-
ond the color of the stripe.
CODE COLOR
B Black
BR Brown
G Green
GY Gray
L Blue
LB Light Blue
LG Light Green CODE COLOR
0 Orange
P Pink
R Red
v Violet
w White
Y Yellow
- -
GI-15

A
PRE-DELIVERY INSPECTION
AND
SCHEDULED MAINTENANCE
SERVICES
PRE-DELIVERY
INSPECTION
. . . . . . . . . . . . . . . . . . . . . A- 2
PRE-DELIVERY INSPECTION TABLE . . . . . . . . . . A-
2
SCHEDULED MAINTENANCE SERVICES
(EXCEPT CANADA)
. . . . . . . . . . . . ..I..................
A- 3
SCHEDULE 1
(NORMAL DRIVING CONDITIONS) . . . . . . . . . ,. A-
3
SCHEDULE 2
(UNIQUE DRIVING CONDITIONS) . . . . . . . . . . . . A-
6
SCHEDULED MAINTENANCE SERVICES
(CANADA)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...‘....
A- 9
SCHEDULE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...*..
A- 9
23UOAX-001

PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Following items may be done at any time prior to delivery to your customer.
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Glass, exterior bright metal and paint for damage
Cl Wheel lug nuts, and locks (if equipped)
88-118 N.m (9-12 m-kg, 65-87 ft-lb)
q All weatherstrips for damage or detachment
0 Operation of hood release and lock
0 Operation of trunk lid, rear hatch, and fuel lid opener
Cl With trunk open, check for spare jack, tire, tools, and
fasteners securing these items in place.
Cl Door operation and alignment
Cl Headlight aim
INSTALL the following parts:
Cl Wheel caps or rings (if equipped)
q Outside rearview mirror(s)
1 UNDER HOOD-ENGINE OFF )
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Fuel, coolant and hydraulic lines, fittings, connections and
components for leaks
Cl Engine oil level
0 Power steering fluid level
0 Brake and clutch master cylinder fluid level
El Windshield washer reservoir fluid level
Cl Radiator coolant level
Cl Tightness of battery terminals
Cl Manual transaxle oil level
riizmiq
INSTALL the following parts:
Cl Rubber stopper for inside rearview mirror
CHECK operation of the following items:
0 Seat controls (sliding and reclining) and head restraint
Cl Folding rear seat
0 Door locks, including childproof door locks (if equipped)
Seat belts and warning system
Cl Ignition switch and steering lock
0 Inhibitor switch (ATX only)
U Starter interlock switch (clutch pedal, MTX only)
Cl All lights, including warning and indicator lamps
Cl Sound warning system
Cl Horn, wipers and washers (front and rear, if equipped)
0 Audio system (if equipped) 0 Cigarette lighter and clock
0 Sunroof (if equipped)
II Remote control outside rearview mirrors (if equipped)
Cl Power windows (if equipped)
q Heater, defroster and air conditioner at various mode
selections (if equipped)
CHECK the following items:
Cl Presence of spare fuse
0 Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
0 Pedal height and free play of brake and clutch pedal
Pedal height mm (in) Free play mm (in)
0 Parking brake
5-7 notches/98 N (10 kg, 22lb)
UNDER HOOD-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
q Automatic transaxle fluid level
[I
CHECK the following items:
Cl Underside fuel, coolant and hydraulic lines, fittings, con-
nections and components for leaks
0 Tires for cuts or bruises
0 Steering linkage, suspension, exhaust system and all un-
derside hardware for looseness or damage
[I
CHECK the following items:
0 Brake operation
0 Clutch operation
Cl Steering control
Cl Operation of gauges
q Squeaks, rattles or unusual noise
Cl Emergency locking retractors
0 Cruise control system (if equipped)
1 AFTER ROAD TEST (
CHECK for necessary owner information materials.
Following items must be done just before the delivery to your customer.
q Load test battery and charge if necessary
1 Volts 1 0 Install fuses for accessories
i.. _
0 Adjust tire pressure to the specification
Load test result cl Remove seat and floor mat protective covers
(Refer to door label) 0 Vacuum and clean interior of vehicle
0 Clean outside of vehicle q Inspect installation of option parts with invoice
23UOAX-002
A-2

SCHEDULED MAINTENANCE SERVICES (EXCEPT CANADA)
Follow Schedule 1 (Normal Driving Conditions) if the vehicle is mainly operated where none of the following conditions apply.
Follow Schedule 2 (Unique Driving Conditions) if any of the conditions below apply:
l Repeated short-distance driving.
l Driving in dusty conditions.
* Driving with extended use of brakes.
* Driving in areas where road salt or other corrosive materials are used.
l Driving on rough and/or muddy roads.
l Extended periods of idling and/or low-speed operation.
l Driving for prolonged periods in cold temperatures and/or extremely humid climates.
Schedule 1 (Normal Driving Conditions)
Number of months or miles (kilometers), whichever comes first
Months 7.5 15 22.5 30 37.5 45 52.5 60
7.5 15 22.5 30 37.5 45 52.5 60
12 24 36 46 60 72 64 96 Service data and inspection points Page
Bl-5
B2-5
D-5
D-5
Bl-12
B2-12
F-79
G-18 MAINTENANCE
OPERATION
m Cracks or damage
B Tension
m Oil pan capacity
B6 SOHC: 3.0 liters (3.2 US qt, 2.6 Imp qt)
All BP : 3.6 liters (3.8 US qt, 3.2 Imp qt)
l Oil filter capacity:
0.17 liter (0.18 US qt, 0.15 Imp qt)
-
l Plug gap: 1.0-l .l mm (0.039-0.043 in)
l Recommended spark plugs
Engine NGK NIPPONDENSO
B6 SOHC BKR5E-11 KIGPR-Ull
BKRGE-11 K20PR-U 11
BP SOHC BKR5E-11 KlGPR-Ull
BKRGE-11 K20PR-U 11
BKR5E-11 KlGPR-Ull
BP DOHC BKRGE-11 K20PR-U 11
BKR7E-11 K22PR-Ull I I
R R R R R R R R
R R R R R R R R Drive belts
Engine oil
Oil filter
Engine timing belt*’
Air cleaner element Replace every 60,000 miles (96,000 km)
I
Spark plugs

7 Schedule 1 (Normal Driving Conditions) (Cont’d)
MAINTENANCE
INTERVALS 1 ::::“’ rths ’ 7.5
DPERATION x 1,000 miles
x 1,000 km 3r mi
15
15
24
1
Page
l- . whichever comes first s (kilometer!
37.5
37.5
60 52.5
52.5
64 60
60
96
I
l-7
Service data and inspection points
l Hoses for cracks or wear l Coolant level E-5
Zooling system
Engine coolant
Fuel filter
‘die speed
Fuel lines
Brake lines, hoses and connections
l Coolant capacity:
5.0 liters (5.3 US qt, 4.4 Imp qt) . . . . . . . . . . MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) . . . . . . . . . . ATX
I E-6 -
F-l 24
l ATX: P range, MTX: Neutral
700-800 rpm (with parking brake applied)
l Fittings, connections, and components for F-80
F-120
-
H-6
P-28
P-29
P-20
P-25
P-18
P-25
---
N-27
N-8
-
M-21
-
F-136
u-35
u-39 leaks
0 Proper attachment and connections
l Operation l Pedal height (with carpet):
196-204mm (7.72-8.03 in)
l Free play:
5--13mm 10.197-0.512 in) Clutch pedal
l Wheel cylinder operation and leakage
l Lining for wear or damage l Lining thickness:
Minimum . . . . . 1 .Omm (0.04 in)
l Drum inner diameter
Maximum..... 201mm (7.91 in) Drum brake
l Caliper operation l Disc plate thickness:
Minimum.... Front 20mm (0.79 in)
Rear 7.0mm (0.28 in)
l Pad thickness:
Minimum.... Front 2.0mm (0.08 in)
Rear l.Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozing l Free play.... O-30mm (O-l .18 in)
l Damage, looseness, and grease leakage
l Cracking and damage
l Retighten all loose nuts and bolts I
1
Disc brake
I
---l-T
Steering operation and linkage
Front suspension ball joints
Drive shaft dust boots
Bolts and nuts on chassis and body
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor am01 anni I
l Insulation clearance
- ,.
Inspect rerrlgerar
Inspect operation annually -

Note
I .*.* Inspect, and if necessary correct, clean, or replace
A.... Adjust
R.... Replace or change
T.... Tighten
After 60 months or 60,000 miles (96,000 km), continue to follow the described maintenance at the recommended intervals.
As for * marked items in this maintenance chart, note the following points:
* 1 Replacement of the timing belt is required every 60,000 miles (96,000 km). Failure to replace the timing belt may result in damage to the engine.
*2 This maintenance is required for all states except California. However, we recommend that it also be performed on California vehicles.
*3 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability.

y Schedule 2 (Unique Driving Conditions)
OPERATION
Drive belts MAINTENANCE / Number of months or miles (kilometers), whichever comes first
INTERVALS Months
5 IO 15 20 25 30 35 40 45 50 55 60
x 1,000 milea i 5 10 15 20 25 30 35 40 45 50 55 60
x 1,000 km 8 16 24 32 40 48 56 64 72
80 88 96
I I Service data and inspection points Page
l Cracks or damage Bl-5 l Tension B2-5
l Oil pan capacity
B6 SOHC: 3.0 liters (3.2 US qt, 2.6 Imp qt)
All BP : 3.6 liters (3.8 US qt, 3.2 Imp qt)
l Oil filter capacity: D-5
I I I I I I I I I I I
RRRRRRR R R R R R
Replace every 3,000 miles (4,800 km) or every 3 months
R R R R R RRRRRRR
0.17 liter (0.18 US qt, 0.15 Imp qt) Engine oil
Engine oil (For Puer-to-Rico)
Oil filter D-5
81-12
82-12
F-79
G-18 Replace every 60,000 miles (96,000 km)
Engine timing belt*’
Air cleaner element -
-
-
-
-
-
-
-
- -
-
-
-
-
-
-
-
-
FL
-
R
-
I
-
R
-
4 *;
-
-
*3
T
- -
-
-
-
-
-
-
-
- -
-
-
-
-
-
-
-
-
*2 -
-
-
-
-
-
-
-
- - R -
l Plug gap: l.O--l.lmm (0.039-0.043 in)
l Recommended spark plugs
Engine NGK NIPPONDENSO
B6 SOHC BKR5E-11
KlGPR-Ull
BKRGE-I 1 K20PR-U 11
BP SOHC BKR5E-I 1 KlGPR-Ull
BKRGE-11 K20PR-U 11
BKRSE-I 1 Kl GPR-Ul 1
BP DOHC BKRGE-11 K20PRUll
BKR7E-11 K22PR-U 11 R
Spark plugs
I
l Hoses for cracks or wear l Coolant level E-5
Cooling system
R
l Coolant capacity:
5.0 liters (5.3 US qt, 4.4 Imp qt) MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) ...,,,,,. ATX
l ATX: P range, MTX: Neutral E-6
Engine coolant
A
-
R
-
I
-
I Idle speed , F-80
F-124 / 700-800 rbrn (with parkina brake applied) -
- -
- , , I .I
-
Fuel filter
l Fittings, connections, and components for
leaks
l Prooer attachment and connections F-120
- Fuel lines
Brake lines. hoses and connections