1992 MAZDA 323 Workshop Manual Suplement

..,. .
a
._
GI CAUTKN
PRECAUTIONS TO TAKE WHEN SERVICING AN ELECTRICAL SYSTEM l Note the following items when servicing the electrical system.
l Do not alter the wiring or electrical equipment in any way; this may damage the vehicle or cause a fire
from short-circuiting a circuit or overloading it.
l The negatrve (-) battery cable must be removed first and
rnstalled last. l Do not reptace with fuses exceedrng specified capacity
Cautron
l 8e sure that the ignitton and other switches are off
before disconnectrng or connecting the battery cables.
Failure to do so may damage the semrconductor
components. Caution l Repfacing a fuse with one of a larger capacrty than
desrgnated may damage components or cause a frre.
l Secure harnesses with provrded clamps to take up slack. l Tape areas of the harness
that may rub or bump l When mounting
components, be sure the
against sharp edges to
protect rt from damage. harness IS not caught or
damaged.
Caution
l Clamp all harnesses near vibratrng components (for
example, the engine) to remove slack and to prevent
contact resultrng from vibration. i Drsconnect heatsensitive l Make sure that the
parts (for example, relays
and ECU) when performing connectors are securely
connected when installed.
l Do not handle electrical components roughly or drop
them. maintenance (such as
weldrng) where
temperatures may exceed
80°C [176OFj.
-*
HI

CAUTION GI
HANDLING CONNECTORS
Caution
*‘Be sure to grasp the connectors, not the wires, when disconnecting them.
1. Raise the rear
2. Lift the tab with a
thin piece of metal
and remove the
poor termrnat contact.
Lift the tab with a thin
When using a matching Make sure the termmals
male terminal, make are
not pushed out of
sure there
IS no
c Round connectors >
1. Raise the cover.
2. Lift the termrnal to
3. Make sure the
terminal is securely
mounted in the
Pull lightty on individual
wires to check that they
are secured rn the 1. Raise the cover.
2. Remove A.
3. Lift the tab with a
thin piece of metal
and remove the

:
.
GI CAUTION
USING ELECTRICAL MEASURING EQUIPMENT
Use Handling precautions Operation Equpment
Test lamp Test to find open or shorted
crrcuits
l Connect the test lamp
between the circuit being
measured and a ground.
l The lamp will lrght if the
circurt is energized to the
point testedA
l Test lamps use 12V t.4W or
3.4W bulbs or light-emitting
diodes (LEOs). Using a
large-capacity bulb may
damage :he Ckil.
Jumper wrre Used to create a temporary
ctrcult . Connect the jumper wire
between the terminals of a
cjrcurt to bypass a switch. l 00 not connect the lumper
wrre from the power source
line to ground; this may
cause burning or other
damage to harnesses or
electrontc components.
Voltmeter Used for measuring the voltage
of a circutt to find possible
opens or shot-k.
l Connect the voltmeter in
parallel wrth the cjrcurt.
l Set the range to the dewed
voltage.
l Use the service hole when measuring the voltage at the
diagnosis connector.
l Connect the positive (+)
probe to the point where
voltage IS to be. measured
and the negatrve (-) probe to
a ground.
l Tie a thin wire to the
posrtive (+) probe to access
narrow terminals.
Ohmmeter Used to find opens and shorts
In the ctrcurt, to confrrm
contrnurty and to measure
reststance.
l Zero the ohmmeter. l Zero the meter after
switching to the measuring
range.
l Before using the ohmmeter,
make sure the ignitron
switch is off or the megatrve
(-) battery cable is
disconnected to prevent
burning or otherwise
damaging the ohmmeter. &--- l Verify that voltage IS not
applied to the circuit
l Connect the probes between
two points in a Circuit.,
t I t
+ Connect the ammeter in
series with the circuit by
touchtng the positive ( +)
probe to the power-srde
terminal and the negative (-
probe to the ground-srde
terminal. Ammeter
Used to check alternator output,
current supplied to the starter.
and dark current wrthrn a circutt. l Set the range to the desired
amperage.
l Connect the ammeter In
series with the circuit. The
ammeter may be burned or
otherwise damaged if it IS
connected in parallel. Note
Dark current IS the constant flow
of current whrle
the ignitron
switch is OFF.
13EGIX-31;
Gl-t 6

c
PRE-DELIVERY INSPECTION
AND
SCHEDULED MAINTENANCE
SERVICES
ME-DELIVERY INSPECTION TABLE . . . . . . . . . . A- 2
SCHEDULED MAINTENANCE SERVICES . . . . . A- 3
MAINTENANCE TABLE ..*.*.............,....**a,. A- 3
REMARKS . ..*...*...............**~.*...*.....t...*... A- 3
13EOAX.301

A PRE-DELIVERY INSPECTION TABLE
PRE-DELIVERY INSPECTION TABLE
[EXTERlORI
INSPECT and ADJUST, of necessary. the followlng Items to
specrfrcatron:
0 Glass, exterior bright metal and paint for damage
0 Wheel lug nuts
0 Tire pressures
0 All weatherstrips for damage or detachment
0 Operation of bonnet release and look
0 Operation of trunk Ild, hatch and fuel lbd opener
(of equipped)
0 Door operation and alignment
0 Headtrght aiming
INSTALL the foltowrng parts
0 Wheel caps or rrngs (if equipped)
0 Outsrde mirror(s)
1 UNDER BONNET-ENGINE OFF j
INSPECT and ADJUST. If necessary, the following items to
specrflcatlon.
0 Fuel, coolant and hydraulic tines, fittings, connectlons and
components for leaks
0 Engine 011 level
0 Power steering fluid level (of equipped)
0 Brake master cylinder fluky levels
0 Clutch master cylinder fturcl levels (If equipped)
0 Wtndshreld washer reservojr flurd level
0 Radiator coolant level and specrfic gravity
0 Tightness of water hose clamps
0 Tightness of battery terminals, electrolyte level and specific
gravity
0 Manual transaxle oil level
0 Drive belt(s) tension
Cl Carburetor lrnkage (choke control, wrde open throttle posi-
tion. etc ) (carburetor model only)
q Accelerator cable and linkage for free movement
0 Headlight cleaner and flurd level (if equipped)
BLEED air from fuel line (diesel engrne only)
CLEAN the spark plugs (except for diesel engine)
piEi6F]
INSTALL the following parts
0 Rubber stopper for rnsrde rear view mirror (if equjpped)
0 Fuse for accessories
CHECK the operation of the following items.
0 Seat controls (sliding and reclining) and head rest
0 Seat belts and warning system
Cl Ign&on switch and steering lock
0 Power window (if equipped)
D Door tacks including child proof door locks
Cl Inhibitor switch (ATX only)
Cl All Ikghts rncluding warning and Indicator lbghts
0 Ignition key reminder buzzer (If equipped)
A-Z
0 Horn, wbpers and washers (front and rear, If equipped)
0 Antenna (tf equipped)
0 Cigarette Ibghter and clock (if equipped)
0 Remote control outside mirror (if equrpped)
0 Heater, defogger and air conditioner at various mode selec-
tions (if equlppedj
0 Sunroof (If equipped)
CHECK the following items
0 Presence of spare fuse
0 Upholstery and Interior finish
CHECK and ADJUST, If necessary, the followjng items:
IJ Operation and fit of windows
0 Pedal height and free play of brake and clutch pedal
0 Parking brake UNDER BONNET-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
0 Operation of Idle-up system for air condbtroner or power steer-
ing (if equrpped)
0 Automatic transaxle flurd levet
0 tnltial ignrtlon timing (except disel engine)
0 Idle speed
0 Operation of throttle positron. sensor (EGI engrne)
0 Operation of cold start device and glow plug warning light
(diesel engine only)
0 Operation of dash pbt (EGI.engine)
fTiGGJ
CHECK the following items.
0 Underside fuel, coolant and hydraulic Irnes, ftttlngs, connec-
tions and components for leaks
0 Trres for cuts or brurses
0 Steering Itnkage, suspensron, exhaust system and all under-
side hardware for .looseness or damage 1 ROAD TEST j
CHECK the following items
0 8rake operation
0 Clutch operation
0 Steering control
!ZI Operation of meters and gauges
Cl Squeaks, rattles or unusual noises
Cl Engine general performance
0 Emergency locking retractors 1 AFTER ROAD TEST ]
REMOVE the seat and floor mat protective covers
CHECK for the necessary owner information materials, took
and spare tire
m vehicle
93EOAX-002
-- MAIN Char3 t: In
A: PC R: F!t T: Ti! Emis! The ed : to t!

SCHEDULED MAINTENANCE SERVICES A
SCHEDULED MAINTENANCE SERVICES
MAINTENANCE TABLE
Chafi symbols:
1 : Inspect: Visual examination and/or functional measurement of system’s operation or
performance , A: Adjust: Examination resulting in adjustment or replacement
n
R: Replace or change
T: Tighten
REMARKS
After 80,000 km or 48 months, continue to follow the described maintenance at the recommended intervals.
As for * marked items in this maintenance chart, note the following points.
+ 1 Major service interval at 12 months/20,000 km (12,000 miles).
Lubrication service based on distance only 10,000 km (6,000 miles) not time.
l 2 Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt
if equipped.
‘3 Replacement of the timing belt is required at every 100,000 km (60,000 mile). Failure to replace the tim-
ing bett may result in damage to the engine.
‘4 tf the vehicle is operated under any of the following conditions, it is suggested that the engine oil and
oil filter be changed more often than the recommended intervals.
a) Driving in dusty conditions. I
:
b) Extended periods of idling or low speed operation. i
i!
c) Driving for a prolonged periods in cold temperatures or regularly driving onty short distances.
*5 If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often
than at usual recommended intervals.
l 6 This IS a full function check of all electrical systems, i.e, atl
ltghts. washers (including condition of blades)
electric windows, sunroof, horn etc.
‘7 Replace every two years. $1
‘I
If there has been continuous hard driving, mountain
drivtng, or if the brakes are used extensively or the
vehicle is operated in extremely humid climates, the brake fluid should be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the-emission control and relat-
ed system, as well as for efficient engine operation. It is strongly recommended that all servicing related
to these systems be done by your Authorised Mazda Dealer.
13EOAX-302 -4
I!
A-3

A SCHEDULED MAtNTENANCE SERVtCES (Europe)
Maintenance Number of months or km (miles), whichever comes first
Months” - 6 12 18 24 30 36 42 48
Kllometers 1,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
{Miles)
(600) (6,000) f[t2,000) (18,000) (24,000) (3U,OOO) (36,000) (42,000) {48,000), Engine
Intake and exhaust manrfold nuts (Bolts)
Drive belts”
i Engine trmlng beltW3
Engine oil (Turbo)‘4
01 filter
l *
Cool!ng system (Includtng
coolant level adlustment)
Engrne coolant T T T
A A A
A A
Replace every 100,000 km (60,000 miles)
Replace every 5,000 km (3,000 miles) or 6 months
R R R R R 1 R R R
I I I I
I
Replace every 2 years Fuel system
Idle speed
Air cleaner element * 5
Fuel
falter
Fuel Ilnes and hoses Ignition system
A f 1
I R I R
R R
I I f t I ~
lnlttal rgnrtloh trmlng 1 I I I I I I I I
Spark plugs A
A. A A
Spark plugs (Only for Sweden) Adjust every 30.000 km (t8.000 mrls) Evaporative emission control system
Throttle sensor Throttle sensor (Only for Sweden)
Evaporative system
Evaporatrve system (Only for Sweden) 1 A 1 1 A 1 1 A 1 ) A
Adjust every 80,000 km (48,000 miles)
1 I 1 1 I’ 1 1 I 1 1 I
Inspect every 80,000 km (48,000 mites) Electrical system
Battery electrolyte level and specific gravity 1 I f I I I
All Electrical system
l ’ 1 I
I 1 I I I
1 . 1 I I
Headlight alrgnment 1 A A A . A. Chassis and body
t 3EOAX-303
A-4 Chas
SW31 Rear
Tires
Hing
Seat

SCHEDULED MAINTENANCE SERVICES (Europe) A
Maintenance Number of months or km (miles), whichever comes first
Months’ ’
- 6 12 18 1 24 30 36 ] 42 48
Kllometers 1,000
10,000 20,000 30,000 1 40,000 50,000 60,000 1 70,000
80,000
(Miles) (600)
(6,000) j(12,000)~(18,000)~(24,000) (30,000) (36,000)~(42,000) (48,000)
Chassis and body (Cont’d)
Steering and front suspension
I ’ I
I 1 I
MTX oil A R
Rear axle oil
I R A A R
A A A R I
Trabsfercarrier oil R A 1 A
R A A A R
Bolts, nuts on chassis and body T T 1
T , T T
Body condltlon (Visual only) Inspect annually
Exhaust system heat shields I 1 I
Tires (Including spare tjresj with inflation
pressure adjustment I
I I I
Hinges and catches A A
A 1 A
Underside of vehicle I
I i 1 I I
Seat belt I
I f
I ’ I
Dnveshafl dust boots I I 1 I I
13EOAX.304
A-5