1989 MAZDA 323 horn

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

MANUAL STEERING N
Removal / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal.
39-49 (4-5, 29-36)
Q
3-2.7, 13-20)
2.0-5.9 N.m (20-60 cm-kg, 17-52 In
N.m (m-kg. Mb)
1. Horn cap 6. Undercover
2. Locknut 7. Dust cover
3. Steering wheel 8. Fixing bolt (Intermediate shaft/Pinion shaft)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-10 9. Interlock cable (ATX only)
4. Column cover 10. Steering shaft assembly
5. Combination switch Disassembly / Assembly . . . . . . . . . . . . . page N-l 0
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section T Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
N-9

BODY ELECTRICAL SYSTEM
INDEX .......................................... T- 2
RELAY ....................................... T- 2
INSTRUMENT CLUSTER AND
SWITCHES ................................ T- 3
EXTERIOR LIGHTS.. ..................... T- 4
INTERIOR LAMPS.. ...................... T- 5
CRUISE CONTROL SYSTEM.. ........ T- 6
AUDIO ....................................... T- 7
OTHER ...................................... T- 8
OUTLINE ...................................... T- 9
HOW TO USE THIS SECTION.. ...... T- 9
ELECTRICAL TROUBLESHOOTING
TOOLS .....................................
ELECTRICAL SYMBOLS - ............... T- 1x
TROUBLESHOOTING GUIDE.. .........
T- 11
FUSE AND JOINT BOX ..................
T- 12
STRUCTURAL VIEW.. ...................
T- 12
FUSES ....................................... T- 13
CIRCUIT BREAKER.. ....................
T- 14
JOINT BOX ................................. T- 15
RELAY .......................................... T- 16
STRUCTURAL VIEW.. ...................
T- 16
.-
FLASHER UNIT ........................... T- 17
DOOR LOCK TIMER UNIT ............
T- 17
HORN RELAY ............................. T- 18
HEADLIGHT RELAY.. ................... T- 18
TNS RELAY ................................ T- 18
DRL RELAY (CANADA). ................ T- 18
SWITCHES .................................... T- 19
STRUCTURAL VIEW.. ................... T- 19
SWITCH ..................................... T- 20
COMBINATION SWITCH ...............
T- 23
EXTERIOR LIGHTING SYSTEM ....... T- 29
STRUCTURAL VIEW.. ...................
T- 29
AIMING ...................................... T- 30
TROUBLESHOOTING.. .................
T- 30
HEADLIGHT AND FRONT
COMBINATION LIGHT.. ..............
T- 41
REAR COMBINATION LIGHT.. ....... T- 43
HIGH-MOUNT STOPLIGHT.. .......... T- 45
DRL RESISTOR ........................... T- 46
STOPLIGHT SWITCH.. .................. T- 47
BACK-UP LIGHT SWITCH ............. T- 47
LICENSE PLATE LIGHT.. ..............
T- 47
REAR SIDE MARKER LIGHT ......... T- 48
INTERIOR LAMP SYSTEM ..............
T- 49
STRUCTURAL VIEW.. ...................
T- 49
TROUBLESHOOTING ...................
T- 50 SPOT LAMP
(IN OVERHEAD CONSOLE) ......... T- 52
INTERIOR LAMP
(WITHOUT SUNROOF). ............... T- 52
INTERIOR LAMP (WITH SUNROOF) T- 53
INTERIOR AND SPOT LAMP
(WITHOUT SUNROOF). ............... T- 53
CARGO COMPARTMENT LAMP.. .. T- 54
TRUNK COMPARTMENT LAMP.. ... T- 54
COURTESY LAMP ....................... T- 54
CENTRAL PROCESSING UNIT (CPU) T- 55
SYSTEM DIAGRAM ...................... T- 55
CPU .......................................... T- 56
WARNING SYSTEM.. ...................... T- 58
WARNING BUZZER AND TIMER .... T- 58
WARNING AND INDICATOR LAMP T- 60
INSTRUMENT CLUSTER.. ............... T- 63
PREPARATION ............................ T- 63
STRUCTURAL VIEW ..................... T- 63
TROUBLESHOOTING ................... T- 64
INSTRUMENT CLUSTER
AND SPEEDOMETER CABLE.. .... T- 89
WATER THERMOSENSOR ............ T- 72
FUEL GAUGE SENDER UNIT.. ...... T- 73
REAR WINDOW DEFROSTER.. ........ T- 74
STRUCTURAL VIEW.. ................... T- 74
TROUBLESHOOTING ................... T- 75
FILAMENT .................................. T- 77
REAR WINDOW DEFROSTER
SWITCH .................................... T- 77
CRUISE CONTROL SYSTEM.. ......... T- 78
STRUCTURAL VIEW.. ................... T- 78
TROUBLESHOOTING GUIDE.. ....... T- 79
SELF-DIAGNOSTIC INSPECTION .... T- 80
TROUBLESHOOTING ................... T- 83
CRUISE CONTROL UNIT .............. T- 85
HORN ........................................... T- 88
HORN AND HORN RELAY.. .......... T- 88
AUDIO .......................................... T- 89
STRUCTURAL VIEW.. ................... T- 89
OUTLINE OF AUDIO.. .................. T- 90
SYSTEM ..................................... T- 91
TROUBLESHOOTING ................... T- 92
CAUSES OF NOISE ..................... T- 96
AUDIO COMPONENT.. ................. T- 98
DOOR SPEAKER .........................
REARSPEAKER .......................... ;-
- !3;
ANTENNA FEEDER ..................... T- 99
23UOTX-001

T INDEX
INDEX
RELAY
ION 8
1. Flasher unit
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-i 7
2. Door lock timer unit
Inspection . . . . . . . . . . . . . . . . . ..l.........I..... page T-l 7
3. Horn relay
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-l 8
4. DRL control unit (Canada)
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-33
T-2
13UOTX-00:
5. DRL relay (Canada)
inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-l 8
6. TNS relay
Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-l 8
7. Headlight relay
Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-l 8

T INDEX
OTHER
1, Joint box (including CPU)
Removal / Installation . . . . . . . . . . . . . . . . . . page T-l 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-58
2. Circuit breaker
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-14
3. Horn
Removal I Installation . . . . . . . . . . . . . . . . . . page T-88
23UOTX-OOf
4. Main fuse
Removal I Installation . . . . . . . . . . . . . . . . . . page T-14
5. Rear window defroster (Filament)
Troubleshooting ,..........,,...,........,
page T-75
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-77
Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-77
T-8

T FUSE AND JOINT BOX
Specifications (Cont’d)
Fuse Color
METER 15A Blue
WIPER 20A Yellow
STOP 20A Yellow
TAIL 15A
Blue
SUNROOF 15A Blue
DEFOG 20A Yellow
HEATER 30A Light green Protected circuit Instrument panel (gauges and warning lamps), Back-up light, Turn signal,
Cruise control system
Windshield wiper and washer
Stoplight, Horn
Taillight, Side marker light, Parking light, Illumination light, License plate light
Sunroof
Rear window defroster
Blower motor
13UOTX-067
L
r 03UOTX-01
1 BL
PULLER
t
L 03UOTX-01
CIRCUIT
BREAKER
RESET BUTTON
03UOTX.01
Removal / Installation
Main fuse
1. Remove the main fuse box mounting bolts.
2. Open the main fuse box lid and remove the bolt.
3. Remove MAIN 80A fuse.
4. Install in the reverse order of removal.
Fuse
When replacing a fuse, use the fuse puller supplied in the fuse
box cover.
CIRCUIT BREAKER
Note
l Push button to reset circuit breaker after operating
dlagnosls of malfunction.
5
T-14

T RELAY
RELAY
STRUCTURAL VIEW
:TION S
1 SUOTX-01:
1. Flasher unit
5. DRL relay (Canada)
Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page
T-l 7 2. Door lock timer unit
inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . .
T-l 7
3. Horn relay page
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T-l 8 4.
DRL control unit (Canada) page
Troubleshooting .,..........,..,.......... page T-33 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. TNS relay page
T-l 8
Inspection .I..............,.................. page T-l 8
7. Headlight relay
Inspection ,,,,....,.,.,......,~~,...~.....,.~ page T-i 8
T-l 6

T RELAY
23UOTX-01
d b
23UOTX-01 I
d b
23UOTX-0’
d b
ZNOTX-01
HORN RELAY
Inspection
1. Connect the battery voltage to the “d” terminal and the
ground to the “b” terminal. Check for continuity between
the “a” and “c” terminals.
HEADLIGHT RELAY
Inspection
1. Disconnect the headlight relay connector and remove the
relay.
2. Check for continuity between terminals of the relay.
Va: Battery voltage
Connecting to a b C d VB Ground
- -
0 cl
a b 0 0
O--O: Indicates continuity
TNS RELAY
Inspection
1. Disconnect the TNS relay connector and remove the relay.
2. Check for continuity between terminals of the relay. Ve: Battery voltage
4
Connecting to
a b C d VB Ground
- -
0 0
a b 0 0
O--O: Indicates continuity
DRL RELAY (CANADA)
Inspection
1. Disconnect the DRL relay connector and remove the relay.
2. Check for continuity between terminals of the relay. Ve: Battery voltage
lnnecting to
a b C d
V0 Ground
- -
0 0
a b 0 0
o---O: Indicates continuity
T-l 8