steering MAZDA 323 1992 Workshop Manual Suplement

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

3
3
,
>
1.
3
>
>
HOW TO USE THIS MANUAL GI
HOW TO USE THIS MANUAL
PREPARATION
PREPARATION points out the needed Special Service Tool (SST) for the service operation that it pro- m
ceeds. Gather all necessary SST before beginning work.
Examde:
MANUAL STEERING
PREPARATlON
SST
49’0118 85oC
Puller, ball tolnt For
removal of he-rod
end SST NUMBER
1
49 0118 85oC USAGE
1
For
removal of Wrod
end
S&T NAME SS; ILLUSTRATlON
REPAIR PROCEDURE
I. Most repair operations begin with an overview illustration. It identifies the components, shows how the
parts fit together, and visual parts inspections. If a damaged or worn part is found, repair or replace it
as necessary.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration.
3. Pages related to service procedures are shown under the tllustration. Refer to this informatron when ser-
vicing the related part
Example:
SHOWS
yA;ytDABLE
.
SHOWS
APPLICATION
;v’dT OF OlL, _
SH
RE
2
3ws .ATED
3E FOR
?VICE . 1 Bolt
2 Lock Nate
3 Bearmg cup
4 Adtustmg screw
5 Bearing outer race
6 Locknut
7 Washer 16 Beanno Inner race
Rem&al
17 Spacer page M-24
18 lhve olnion
Daoe M-21
hspect sphes and teeIh for wear ordaqge SHOWS TIGHTENING
TORQUE
SPECIFICATION
l 2
SHOWS TIGHTENING
TORQUE UNIT
:
SHOWS VISUAL
INSPECTION
INFORMATION
9MlJGIX~034
*I The numbering (ex.@> shows service procedure.
l 2 Unrts shown in N m 1 kgf m, ftlbf ] unless otherwlse speclfted
Gl-3

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)
!

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

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

FRONT AND REAR AXLES
INDEX ..*** . . . . . l . . . ...* . . . . . . . ..**...I* . . . . . .*..*.* . . . . . . . M- 2
1 FEATURES 1
OUTIJNE .................................................
M- 3
OUTLINE Of CONSTRUCTION
................. M- 3
SPECIFICATIONS ....................................
M- 3 t
SUPPLEMENTAL SERVICE INFORMATION.. M- 4
FRONT AXLE
l ,..,..,..............,.....*.............. M- 5
PREPARATION . . . . . . . . ..*.*...........m..........*... M- 5
WHEEL HUB, STEERING KNUCKLE . . . ..I.... M- 6
REAR AXLE *...............*............................ M-l 1
PREPARATION
l . . . . ..*..*...................*..*..... M-l 1
WHEEL HUB, KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . .
M-12
)I
13EOMX.301
q

INDEX
13EOMX-302
1, Front axle
2. Rear axle
Wheel hub, steering knuckle
Wheel hub, knuckle
Removal I Inspection I
Removal I Inspection I
Installation
..1*.,..*............*......*... page M- 6
Installation . . . . . . . . . . . . . . , . . . . . . . . . . , , . ..-.
Disassembly ! Inspection I
Disassembly / lrispection I p&ge M-l 2
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I.. page M- 8
Assembly ,..........................,..... page M-l 4
M-2
.
SPEC
Joint
--
Lengt
SE”
--
Rear
--
Joint
--
Lengt
-e
Shak
--
Johi
-m
tengt
--
Shat:
Front
I3eari
&z
--
Bear jr --
Rear
Redrll -- Difl et-t
Di#ert
Numt

M FRONT AXLE
WHEEL HUB, STEERING KNUCKLE
RemovaI / Inspection I Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. InstaH in the reverse order of removal, referring to Installation Note.
Caution
l Loosely tighten the shock absorber bolts. Lower the vehicle and tighten the bolts to the specified
torque with the vehicle unladen.
4. Adjust the front wheel alianment.
16-22 ]1.6-2.3, 12-161 I
19.0-l 2.0, 65-86.7 I
1. Wheel hub nut
2. Wheel and tire
3. Locknut
Removal Note . . . . . . .._.. . . . . . . . . . . . . . . . . . . . page M-7
installation Note .I.........,..,............ page M-7
4. Brake caliper assembly
Service . _. . . . . . . . . ,__. . . , , . ._. _. , , . . . , . ._ ._. . . . . . Section P
5. Disc plate
lnspectioti .~~*.......*~...,......,,,.....*~...~. Section P
6. ABS wheel speed sensor (if equipped)
7. Tie rod end
Removal Note . . . . . . .._.......... I . .._.....= page M-7
lnstallatiofi Note . . .._... _.__......,....... page M-7
M-6
8. Lower ball joint
9. Steering knuckle, wheel hub, and dust cover
Inspect-wheel hub for cracks and damage
Inspect knuckle spindle for cracks and
damage
Inspect dust cuver for damage and dis-
tortion
Disassembly I Inspection I
Assembly . ..C1..............~...,.....,.....
page M-8

M FRONT AXLE
Disassembly / Inspection / Assembly
1 I Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse
order of disassemblv. referring to Assembly Note.
13EOMX-312
1 Oil. seal 5. Dust cover
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page M-l 0
2. Front wheel hub assembly Disassembly Note.. .,.._ 1 . . . . . . . . . . . . . . page M-
9
Disassembly Note I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly Note . . . . 1 . . . . . . . . . . . . . . . . . . . . . M-10
below
Assembly Note .......,.II.,...,...I..... page M-l 0
3. Retaining ring
4. Wheel bearing
Disassembly Note.. . . . .,=.............. page M- 9
Assembly Note . . , . . . . . . . . . . . . . . . . , . . . . . . page M-l 0 6. Steering knuckle page
7. Hub bolt
Disassembly Note . . . . . . . . . , ..,,..-...., page M- 9
Assembly Note .........I..,............. page M- 9
c I
13EOMX-313
r
L 1 l3EOMX 314 M-8
Disassembly note
Front wheel hub assembly
1. Remove the front wheel hub assembly by using the SST.
2. Make an opening between the wheel hub and the bearing
race to allow for use of the SST.