1992 MAZDA 323 maintenance

Mazda 323
o Workshop
b Manual CONTENTS
r Title Section
IG eneral Information
Pre-Delivery inspection and
Scheduled Maintenance
Supplement
I Lubrication System
j Cooling System
FOREWORD
This is a supplement to the workshop manu-
a!(s) shown below. This supplement describes
service procedures of. new or modified me-
chanicat and/or ekctrical systems. For service
procedures and important safety notices not
contained in this supplement, please refer to
the previous workshop manual.
Workshop Manual:
Form No.1 203-l O-89F (vol. 1)
1206-1 O-89F (Vol.2)
1229-l O-89L
1275-l O-91 c
b
All information in this supplement was the
latest available at the time of printing, ail alter-
nations related to modifications will be notified
by Service Sulletin. Carburetor
m !I
Fuel and
Emission
Controt
System EGi unieaded Fuel BP (DOHC
and S
Diesel
-Electrica I System
I-- Clutch
Manual
Transaxie
1 Electronically Co Introlled
I
Automatic
Transaxle Hydraulicaf~y’Co~~~rull=;u
1 Transfer
Mazda Motor Corporation
HIROSHIMA, JAPAN [ Propefier Shaft
1 Front and Rear Axles
P ISteerIng System
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN)
shown on the following page. Braking System
IWheels and Tires
ISusiension
1 Bodv Electricat System
1 Heater and Air Conditioner System
1 Technical Data
Special Toots
Parts Index
/ Wiring Refer to the form No.
, Diagram 5232-l 0-92A
--
This manual explains onty the secticlns marked with shadows (-1
0 1992 Mazda Motor Corporation
PR1NTED tN JAPAN, JAN., ‘92 @I
1318010192A

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GENERAL INFORMATION
1MPORTANT INFORMATION
..................... GI- 2
BASIC ASSUMPTIONS ............................ a- 2 I
SAFETY RISK
........................................ Gl- 2
POSSIBLE LOSS OF WARRANTY
............. Gl- 2
WARNING ON LUBRICANTS
AND GREASES
.................................... GI- 2
HOW TO USE THIS MANUAL..
.................. GI- 3
PREPARATION
...................................... GI- 3
REPAtR PROCEDURE .............................
GI- 3
SYMBOLS .............................................
GI- 4
NOTES, CAUTIONS, AND WARNINGS.. .....
Gl- 4
FUNDAMENTAL PROCEDURES
................. GI- 4
PROTECTION OF THE VEHICLE .............. G1- 4
A WORD ABOUT SAFE-T-Y
....................... Gl- 5
PREPARATION OF TOOLS
AND MEASURING EQUIPMENT ............. Gi- 5
SPECIAL TOOLS ....................................
GI- 5
REMOVAL OF PARTS .............................
GI- 5
DISASSEMBLY ......................................
GI- 5
REASSEMBLY
....................................... GI- 6
ADJUSTMENTS .....................................
Gl- 7
RUBBER PARTS AND TUBtNG ................ GI- 7
JACK AND SAFETY STAND POStTlONS .... GI- 8
VEHICLE LIFT (20SUPPORT TYPE)
POSITIONS ............................................
GI- 6
MAINTENANCE NOTE ..............................
GI- 9
SPEEDOMETER TESTER CHECK
............. GI- 9
BRAKE TESTER CHECK
......................... GI- 9
CHASSIS DYNAMOMETER CHECK.. ......... Gl-I 0
WHEEL BALANCE.R ...............................
GI-I 0
TOWtNG ...............................................
GI-I 0
IDENTlFiCATlON NUMBER LOCATIONS
..... GI-I
2 .UNlTS .....................................................
GI-I 2
ABBREVIATIONS
.....................................
GI-12
CAUTION
................................................ GI-13
INSTALLATlON OF MOBILE TWO-WAY
RADIO SYSTEM ...................................
Gl-13
PRECAUTIONS TO TAKE WHEN
SERVICING AN ELECTRICAL SYSTEM ..i GI-f4
HANDLING CONNECTORS ..................... GI-f 5
USING ELECTRICAL
MEASURlNG EQUIPMENT ........................................
GI-16
13EGIX-30 1

GI MAINTENANCE NOTE
VIEWED
.OM BELOW
‘REE
13EGfX-307
I
I t3EGIX-308 CHASSIS DYNAMOMETER CHECK
Caution
l Do not clutch abruptly. l Do not attempt rabbit starts or accelerate quickly.
1. Remove the propeller shaft.
2. Lock the center differential (2WD).
3. Place the front wheets on the roller.
4. Lock the rear wheels and apply the parking brake.
5. Drive the tester roller and check.
6. Upon completion of the test, gradually decelerate with soft
braking and stop the engine.
7. When the test is done, return the differential lclck rod to the
free condition (4WD) and reinstall the propeller shaft.
WHEEL BALANCER (On-the-car Balance)
1.
Jack up all four wheels. Support the wheels to be checked
(front or rear) with the wheel balancer sensor stand and the
remainrng wheels with safety stands.
2. Set the on-the-car balancer. With the center differential in
free condition, drove the tires with the engine; then check.

MAINTENANCE NOTE
TOWlNG
Caution
g Use method @I to tow vehicles having problems in the steering system or drivetrain.
Towing method
0 Rope towing items to confirm
Parking brake Transaxle shtft posttton Remarks
Released Neutral
@ Towlng with front wheels off
ground
Released Neutral Remove propeller shaft
@ Towtng by wrecker truck
Released Neutral
Rempve propetler shaft
@Towing or hauling with all wheels
off ground
Engaged Any posItIon
13EGIX.30
TIE-DOWN HOOKS - FRONT TIE-DOWN HOOKS
- REAR (HATCHBACK)
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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

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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

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
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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
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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