1992 MAZDA 323 warning light

GI tMPORTANT INFORMATION
IMPORTANT INFORMATION
BASIC ASSUMPTIONS
This workshop manual assumes that you have certarn special tools that are necessary for the safe and
efficient performance of service operations on Mazda vehicles and that you know how to use them properly.
It also assumes that you are familiar with automobile systems and basic service and repair procedures.
YOU should not attempt to use this manual unless these assumpttons are correct and you understand the
consequences described below.
SAFETY RtSK
This manual contains certain notes, warnings, and other precautionary information that you should care-
fully read and follow to reduce the risk of personal injury to yourself or others and the risk of improper
service that may damage the vehicle or render it unsafe. If there IS no such information in regard to any
specific service method, this does not mean there is no possibility that personal safety or vehicle safety
wili be jeopardized by the use of incorrect methods or tools.
POSStBLE LOSS OF WARRANTY
The manufacturer’s warranty on Mazda vehicles and engines can be voided if improper service or repairs
are performed by persons other than those at an Authorked Mazda Dealer.
WARNtNG ON LUBRtCANTS AND GREASES
Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated
during service (e+g., engine sump oils) are more irritating and more likely to cause serious effects, includ-
ing skin cancer, in the event of gross and prolonged skin contact.
Wash skin thoroughly after work involving 011.
Protective hand cleaners may be of value provided they can be removed from the skin with water Do
not use gasoline, paraffin, or other solvents to remove oil from the skrn.
Lubricants and greases may be slightly irritating to the eyes.
Repeated or protonged skin contact shoutd be avoided by wearing protective clothing if necessary. Par-
ticular care should be taken with used oils and greases containing lead. Do not allow work clothing .to
be contaminated with oil. Dry clean or launder such clothing at regular intervals.
9MtlGIX-002
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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
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TD TECHNlCAt DATA -
BODY EtECTRtCAL SYSTEM
ttem
Headlight
Front fog light
Front turn signat light
Parking light
Front side turn light
StocYlailliaht Specifications (w)
ECE
I Swiss
60155
55
21
5
5
2115
Exterior tamps
Taillight &8) 5
Rear turn single tight 21
Back-up light
21
License plate light
5
Flash-to-pass light 55 (Austrra)
I -
Running Ilght
55 (Sweden, Norway, Iceland)
Rear fog light 21
Interior and spot lamp Interior 10
Spot 6
Interior Iamps
Interior lamp 10
Spot tamp (in overhead console) 8
Cargo compartment lamp
5
High beam
3.4
Turn light
3.4
Brake 3
Hold 3
Charge 3
011 pressure 3 -.
lndcator and n Washer 3
warning Iamps TUF~O 3
Fuel
1 3
Rear fog
I
! 3
1
ABS
Parktng brake
Illumination I 3
3 .
3.4
Rear
Cliff. lock f 3
3 I STANDARD BOLT AND NUT TIGHTENING TORQUE
! Diameter Pkh I 41
8T f&lb N-m I 81 mm {tn] mm fin] N-m 1 m-kg
dsf Wtb 1 Nm
mkg ft4b 6 IO.2361 1 {0.039] 4.2-6.2 /0.43-O-63 3.1-4.6
6.9-9.8 0.7-1.0 5.0-7.2 7.8-11.8 O-8-1.2 5.8-8.8
8 IO.3151 1.25 (0.049) 9.8-14.7 1 1.0-1.5 7.2-10.8 16-23 1 1.6-2.3 12-17 18-26 1.8-2.7 13-20
10 IO.3941
It.25 10.04911 20-28 1 2.0-2.9 1 14-21 31-46 1 3.2-4.7
23-34 36-54 3.7-5.5 27-40
I r
12 IO.4721
1.5 lO.OSSj 34-50 3.5-5-l 25-37 1 55-80
5.6-8.2 41-59 63-93 6.4-9.5 46-69
14 {0.551] 1.5 IO.059) - - - 75-103 7.7-10.5 56-76 102-137 lo-14 75-101
16 #0.630] 1.5 {O.OSSl - -
- f16-157 12-16 85-116 156-211 16-22 115-156
t8 (0.709) 1.5 [0.059] - - - 167-225 17-23
123-166 221-299 23-31 163-221
20 IO.7871 I,5 {0.059]
- - - 231-314 24-32 171-231 308-417 31-43
227-307
22 (0.866) 1.5 IO.0591
- 1 - - 334-423 32-43 231-312 417-564 43-58
' 307-416
24 10.945) 1.5 10.059) - 1
- - 1475-5461 41-56 298-403 1536-7261 55-74
396-536
c)
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-.
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4

SYSTEM INDEX
ENGINE-RELATED SYSTEMS STARTING SYSTEM...............2 4
CHARGING SYSTEM...............2 6
ENGINE CONTROL SYSTEM.........2 8
COOLING FAN SYSTEM............3 6
CHASSIS-RELATED SYSTEMS ANTI-LOCK BRAKE SYSTEM........82
INSTFUJMENT CLUSTER-RELATED SYSIEMS IrS$;MENT CLUSTER 6 WARNING
........................ 38
BODY-F&LATEX) SYSTEMS
WINDSHIELD WIPER 6 WASHER.....4 0
HEADLIGHT CLEANER.............4 0
REAR WIPER & WASHER...........4 2
HORNS...................,......6 0
REAR WINDOW DEFROSTER.........6 4
SOUND WARNING SYSTEM..........6 6
POWER WINDOWS.................7 4
POWER DOOR LOCK...............7 6
POWER OUTSIDE MIRRORS.........7 8
SLIDING SUNROOF...............8 0
SEAT WARMERS..................8 4
INTERIOR LIGHTING SYSTEMS IG KEY CYLINDER LAMP..........6 6
INTERIOR 6 SPOT LAMPS.........6 6
COURTESY LAMPS................6 8
TRUNK COMPARTMENT LAMP........6 8
ILLUMINATION LAMPS............7 0
EXTERIOR LIGHTING SYSTEMS
HEADLIGHTS
EXCEPT F.R.GERMANY...........44
F.R.GERMANY..................46
HEADLIGHT LEVELING SYSTEM.....46
TAILLIGHTS
EXCEPT F.R.GERMANY...........48
F.R.GERMANY..................5 0
LICENSE PLATE LIGHTS
EXCEPT F.R.GERMANY...........4 8
F.R.GERMANY..................5 0
POSITION LIGHTS
EXCEPT F.R.GERMANY...........4 4
F.R.GERMANY..................!i? 0
FRONT 6 REAR FOG LIGHTS.......52
TURN 6 HAZARD FLASHER
LIGHTS.......................54
STOPLIGHTS
F.R.GERMANY.a................5 6
EXCEPT F.R.GERMANY...........5 8
BACK-UP LIGHTS................6 0
AIR CONDITIONING-RELATED SYSTEMS HEATER........................6 2
ACCESSORIES CIGARETTE LIGHTER.........<....64
DIGITAL CLOCK.................64
AUDIO SYSTEM..................72
OTHER DIAGNOSIS CONNECTOR...........86

d-II __ EXCEPT F.R.GERMANY -CURRENT FROM BATTERY
-----CURRENT FROM IGl. IG2
-I 1--~-l-l-a-r-~ A, ,.,TiTl-TLITr r-.-a ar.1. ?I,-% ----CIJARENT FROM ACC
“-‘e 30A
I -mILLUMINATION LAMPS I-4
HiZP
r--- “f E-l
MAIN 00A FUSE l5A
q
-GA- I’LIE iHTS
---mm_
n POSITION LIGHTS E-l
TAIL 15A
-W/B
I
+-.
i-. I
i REAR WIPER
15A
-0J‘o ---- L/G _--- ;-.-&+v ---.
WIPER 20A .---$- ---. l REAR WIPER E WASHER o-2
m--c____ L _____ ;--:-; ____. l ;:E;H;E:;SHm
O-l
HEATER 30A
-- _-__ ,,,-j __-__; --me., HEATER
G
t
METER 15A : - - l COURTESY LAMPS I-3
-------B/y ---- + I
ZiUNROOF 15A : --•INTERIOR 6 SPOT LAMPS I-2
t
-oJy)--
G/O---:--- -t----.mSLIOING SUNROOF M
~~~~ .--- __ ___ n SOUN0 WARNING SYSTEM I-2
48s VALV
30A I
i
AES 60A +--t-
I mSTOF’LIGHTS F-3
ABS iOA
--- ’ ‘I ---
GNITION ! ;
iWITCH 1 I
TRUNK COMPARTMENT
‘LAMP I-3
‘mPOWER DOOR LOCK A
K-2
FUSE 30A
y-------t- --~--G/!---j--& .--- - l HEADLIGHT CLEANER O-l
I
’ . ---B/R---+-* ----
K-l
I PowE~~om!,IJ,+~~ -..---- -...;PO,.,ER WI,.,,,OWS
! I ENGINE 15A
’ I (’ I :
:.
.--
1 ----L ---- l -* ---- OJY) ---- FJ,w----l-q -..--
FUEL INJ ’ .-------------------:-L.---
’ I UENGINE CONTROL SYSTEM B-l
FUSE 20A
l REAR WINOOW DEFROSTER I-l
-- mCIGARETTE LIGHTER I-l
mAUOI0 SYSTEM J
aSTARTING SYSTEM A-l

,c -
-
3
F.R.GERMANY F.R.GERMANY -CURRENT FROM BATTERY -CURRENT FROM BATTERY
-----CURRENT FROM IGl. 1G2 -----CURRENT FROM IGl. 1G2
l
ELECTRICAL WIRING SCHEMATIC =&$&jT FRoM ACC l ELECTRICAL WIRING SCHEMATIC =&$&jT FRoM ACC w-2 w-2
I I l ILLUMINATION LAMPS l ILLUMINATION LAMPS
MAIN BOA MAIN BOA , ,
485 VALVI
30A
HAZARO
30A ET’&” REAA FOG
i il E-5
t ‘=POSITION LIGHTS E-4
0
n LICENSE PLATE LIGHTS E-4
i ’ l TAILLIGHTS E-4
!rJJ:GHT LEVELING
.
i il E-2 REAR WIPER
15A a....*.
--- ~--
4
~FIEAR WIPER 6 WASHER i il o-2 I ----- - ---_ L/G _--...----A-___ 7
I WIPER 20A
,---.... - ----_ L ----
I
HEATER 30A
+-----w-.-L/W-+ -----; --__. l ,,,ZATER
G
I I
I
I METER 15A
I - l COURTESY LAMPS I-3
,--+ ---- (xro ---- FJ,y ----, I
I : I -mINTERIOR 6 SPOT LAMPS
I I SUNROOF 15A I I-2
b----------G/o ---- [ ---..- ~----,mSLIOING
I I SUNROOF
I
i i
I I SEAT WARMER
I
I I +g&)
ETN 30A t : ROOM 1OA
; ; i I ,
I : &---------,WBUCK-UP LIGHTS F-4
I
HORN iOA
STOP :
l- : !
.^. t , B/R l HORNS F-4
I , ABS iOA
- ~-
ABS 60A
9--t-“---
1 t
I :
t
I 1
FLASHER LIGHTS STOPLIGHTS
CHARGING SYSTEM
TRUNK COMPARTMENT
POWER DOOR LOCK K-2
INSTRUMENT CLUSTER
6 WARNING LAMPS C
?:m-“_“_“.B/W ---- +.+,v.-{~POWE~ ,.,INOOWS
K-l
l i .-m-e_ cx/v _____ G _-__ +.:m.
I , i il I-l
L_-----_-, l COOLING FAN SYSTEM B-2
B/L---------------------
R l STARTING SYSTEM A-l
21

SYSTEM CIRCUIT DIAGRAM/
CONNECTOR LOCATIONS
ENGINE-RELATED SYSTEMS EXTEFlIOFl LIGHTING SYSTEMS STARTING SYSTEM...............24 HEADLIGHTS
CHARGING SYSTEM...............26 EXCEPT F.R.GERMANY...........44
ENGINE CONTROL SYSTEM.........28 F.R.GERMANY..................46
COOLING FAN SYSTEM............36 HEADLIGHT LEVELING SYSTEM.....46
TAILLIGHTS
CHASSIS-RELATED SYSTEMS EXCEPT F.R.GERMANY...........48
ANTI-LOCK BRAKE SYSTEM........82 F.R.GERMANY.a................50
LICENSE PLATE LIGHTS
INSTFUMENT CLUSTEA-FiELATED SYSTEMS EXCEPT F.R.GERMANY...........48
INSTRUMENT CLUSTER 6 WARNING
I LAMPS........................38
BOOY-ELATED SYSTEMS WINDSHIELD WIPER 6 WASHER.....40
HEADLIGHT CLEANER.............40
REAR WIPER 6; WASHER...........42
HORNS.........................6 0
REAR WINDOW DEFROSTER.........6 4
SOUND WARNING SYSTEM..........6 6
POWER WINDOWS.................7 4
POWER DOOR LOCK...............7 6
POWER OUTSIDE MIRRORS.........7 8
SLIDING SUNROOF...............8 0
SEAT WARMERS..................8 4 F.R.GERMANY..............u.i5 ii
POSITION LIGHTS
EXCEPT F.R.GERMANY...........4 4
F.R.GERMANY..................5 0
FRONT 6 REAR FOG LIGHTS.......5 2
T;l%&HAZARD FLASHER
sTopLIGHi ..... ...............
.54
F.R.GERMANY..................5 6
EXCEPT F.R.GERMANY...........5 8
BACK-UP LIGHTS................6 0
INTERIDFI LIGHTING SYSTEMS IG KEY CYLINDER LAMP..........6 6
INTERIOR 6; SPOT LAMPS.........6 6
COURTESY LAMPS................6 8
TRUNK COMPARTMENT LAMP........6 8
ILLUMINATION LAMPS............7 0
A;~ATOEOS;DITIONING~LATED SYSTE
........................
ACCESSORIES
CIGARETTE LIGHTER.............64
DIGITAL CLOCK.................6 4
AUDIO SYSTEM..................7 2
OTHER
DIAGNOSIS CONNECTOR...........86

PARTS INDEX
PARTS NAME PAGE
PARTS NAME PAGE
I KNOCK CONTROL UNIT...................30
KNOCK SENSOR.........................30 .82
.82
.82
.82
.82
.32
.26
.72
a LICENSE PLATE LIGHT...............48.5 0
B MAIN RELAY(FUEL INJ)
............... ..2 8
1 NEUTRAL SWITCH.......................3 2
$3 OIL PRESSURE SWITCH..................3 8
OXYGEN SENSOR........................2 8
J PANEL LIGHT CONTROL..................7 0
PARKING BRAKE SWITCH.................3 8
POSITION LIGHT....................44,5 0
POWER DDOR LOCK SWITCH...............7 6
POWER DDOR LOCK TIMER UNIT...........7 6
POWER DOOR LOCK ACTUATOR.............7 6
POWER OUTSIDE MIRROR MOTOR...........7 0
POWER OUTSIDE MIRROR SWITCH..........7 8
POWER STEERING PRESSURE SWITCH.......3 2
POWER WINDOW MAIN SWITCH.............7 4
POWER WINDOW MOTOR...................7 4
e
1 BACK-UP LIGHT SWITCH.................60
BACK-UP LIGHT....
BLOWER MOTOR.....:::::::::::::::::::’
.E
BLOWER SWITCH........................62
BRAKE FLUID SWITCH...................38
POWER WINDOW SWITCH..................74
J D REAR FOG LIGHT RELAY.
REAR FOG LIGHT SWITCH
REAR FOG LIGHT.......
REAR SPEAKER......... ................
................ zz
................
52
................
................ E
................ 42
............... .
..: 2
.Riik+‘::::::::..6 4
SWITCH.........6 4
................
................ :z
................ 62
............. 44, 48
I CIGARETTE LIGHTER..
CIRCUIT OPENING REL
CLUTCH SWITCH...
COMBINATION SWITCH:
CONDENSER.......
COOLING FAN MOTOR::
COOLING FAN RELAY..
COURTESY LAMP.....,
CPU................ . .64
/ii’::::::::::::::..2 8
..................
... 44, 46, 48, 50, 52, %
..................
.................. 2:
..................
.................. 2:
............... 42, 66
B DIAGNOSIS CONNECTOR.....
DIGITAL CLOCK...........
n-rnnc ............
............ E
............
............ %
............
............ ZE
TURN LIGHT....
WASHER MOTOR.. REAR
REAR
REAR
REAR
REAR
REAR
REAR
REAR
-ih .ER
-ER
RESISTOR ASSEMBLY..
RUNNING LIGHT RELAY
il SEAT WARMER...........
SEAT WARMER REALY.....
SEAT WARMER SWITCH....
SHORT CONNECTOR.......
SLIDING SUNROOF MOTOR.
SLIDING SUNROOF RELAY.
SLIDING SUNROOF SWITCH
SLIDING SUNROOF.......
SOLENOID RESISTOR.....
SOLENOID VALVES
PRC HIGH TEMP........
PRC LOW TEMP.........
PURGE CONTROL........
WASTEGATE............
SPEED SENSOR..........
SPOT LAMP.............
STARTER...............
STOPLIGHT CHECKER..... ........
........
........
........
........
........
........
........
........ ....... 84
.......
....... ::
.......
.... 66.2
.......
.... 66, Ei
.......
....... ........
........
........
........
........
........
........
........
........
........
.
. . . . . . z:
. . .
. . . . zoo
. 1 .
. . . . E
. . . .
56, ::
. . 56, 58
. . 56, 58
“J.“LJL................. DISTRIBUTOR ............
DOOR SPEAKER ........... .
DOOR SWITCH........: .... 8
3 ENGINE CONTROL UNIT............ ,28, 30. 32
3 FLASHER UNIT...
FRONT FOG LIGHT
FRONT FOG LIGHT
FRONT FOG LIGHT
FRONT SIDE TURN
FRONT TURN LIGH
FUEL METER.....
FUEL PUMP REALY
FUEL PUMP UNIT.
FUEL PUMP......
-. -- ............
............ 22 .
. . RiiA‘i 1
SWITCH
i&ii 1 ............ 52
............ .
............ 22
.....................
..................... %
.....................
..................... %
..................... 28 -
tust ....................
B
G SENSOR ................
13 HAZARD SWITCH............
HEADLIGHT CLEANER MOTOR..
HEADLIGHT CLEANER SWITCH.
HEADLIGHT LEVELING ACTUAT
HEADLIGHT LEVELING SWITCH
HEADLIGHT RELAY..........
ENI- IGHT. . . . . .
HORN RELAY...............
HORN SWITCH.............. ...
40, 46, 52, 64
: ........... 82
............ 54
........... .
..: ii
&::::::::..4 6
HORN..................I 1
HYDRAULIC UNIT ..........
01 IC REGURATOR ............
IG KEY CYLINDER LAMP ....
IGNITER .................
IGNITION COIL ...........
ILLUMINATION LAMP .......
AUDIO SYSTEM ...........
BLOWER SWITCH .......... ............
46
............ 44
......... 44, 46
............
............ E
............
............ E
...........
........... 2:
...........
........... 2
...........
........... 5:
...........
........... 5:
...........
........... 5::
...........
........... 5:
..........
.%
;ci:::::::.;;
........... CIGARETTE LIGHTER: ;.I:;::
FRONT FOG LIGHT SWITCH...
HAZARD SWITCH...........
HEADLIGHT CLEANER SWITCH:
HEADLIGHT LEVELING SWITCH
INSTRUMENT CLUSTER.......
REAR FOG LIGHT SWITCH....
REAR WINDOW DEFROSTER SW1
SEAT WARMER SWITCH.......
INDICATOR LAMP...........
...........
........... 33:: ...........
30 STOPLIGHT SWITCH ......
STOPLIGHT .............
0 TAChOMETER...........................3 8
TAILLIGHT.........................48,5 0
TEMP METER...........................3 8
THROTTLE SENSOR......................3 2
TRANSFER PUMP........................2 8
TRUNK COMPARTMENT LAMP SWITCH........6 8
TRUNK COMPARTMENT LAMP...............6 8
TURN SWITCH..........................5 4
q WARNING LAMP.........................3 8
WASHER LEVEL SENSOR..................3 8
WATER THERMOSENSOR................30,3 8
WATER THERMOSWITCH................... 6
WINDSHIELD WASHER MOTOR..............4 0
WINDSHIELD WASHER SWITCH.............4 0
WINDSHIELD WIPER MOTOR...............4 0
WINDSHIELD WIPER SWITCH..............4 0 INJECTOR..........:;.:::::
INJECTOR RESISTOR .........
INSTRUMENT CLUSTER .....
INTERIOR LAMP..........:::
ISC VALVE .................
. . . . . , . . . . .
. . . . . . . . . . . iz:
,..........
30