clutch 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

MAlNTENANCE NOTE GI
.
FREE ROLLER
I t 3EGlX-304
MAlNTENANCE NOTE
SPEEDOMETER TESTER CHECK
Caution
l Do not clutch abruptly.
l Do not attempt rabbit starts or accelerate quickly. 13EGIX-302
[Front wheel free-roller method]
1. Set the free roller securely on the floor under the front wheels
by matching it to the wheel base and front tread.
2. Place the vehicle softly on the tester and free roller.
3. Start the engine, and engage the clutch softly at a low speed
in 2nd gear; then gradually increase the speed.
4. Upon completion of the test, stop the engine by gradually
decelerating with soft braking.
[Front wheel jack-up method1
1’. Place the rear wheels on the roller.
2. Jack up the front wheels and mount on a safety stand.
3. Start the engine, and engage the clutch softly at a low speed
in 2nd gear; then gradually increase the speed.
Caution
l When using either the front wheel free-roller meth-
od or front wheel jack-up method, secure the vehi-
cle to prevent forward and lateral movement by
attaching towing hardware (chain or wire) to the
front and rear tow hook or tie-down hook.
BRAKE TESTER CHECK
Caution
. To stabilize the drag force of the viscous coupling,
conduct the brake test after the speedometer test.
1. Place the wheels to be tested (front or rear) on the roller.
2. Shift itit0 NEUTRAL.
3. Drive the tester roller and check.
a-9

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.

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!

F3 OIJTUNE
SPE
* TEN
The @
ECU RELATtONSHtP DtAGRAM
1NPUT DEVICE
KNOCK SENSOR
c AIRFLOW METER
KNOCK
DlSTRlBUTOR
91c YfTC”
THERMOSENSOR
OXYGENSENSOR N EUTRAti
CLUTCH SWITCH
CONNECTOR
(TEN TERMINAL,)
INTAKE AIR
OUTPUT
DEVtCE THERMOSENSOR
{AIRFLOW METER)
CIRCUIT
OPENING
TURBOCHARGE
jAGNOSE
ONNECTOR
EN/MEN TERMINA
h SOLENOID VALVE
(PRESSURE REGUL+TOR
CONTROL)
WASTEGATE
SOLENOID VALVE IGNITER
- - (TURBtiHARGER)
FUEL PUMP
RESlSTORlRELAY
SOLENOID VALVE
(PURGE CONTROL)
F3-8 13EOF3-311

F3 TROUBLESHUOTING GUIDE
TROU8LESHOOTlNG GUIDE
RELATIONSHIP CHART
.

OUTPUT DEVICE
INPUT DEVICE

w
3
s
s
KNOCK SENSOR
0
0 0 0 DtAGNOStS CONNECTOR
(TEN TERMINAL)
0 0 0 IGNITION SWlTCH
(START POSITION) 0 0
0
0
0 0
0 0
0 0
0
0
0
0
0 0 0 0
E/L SIGNAL* 0
P/S PRESSURE SWITCH 0
0
A/C SWtTCH
NEUTRAL AND CLUTCH
SWITCHES
STOPLIGHT SWITCH
ATMOSPHERIC PRESSURE
SENSOR (IN ECU)
THROTTLE SENSOR
0 0 0 0
0
0
0 0’
0
0 0
0
0 0
0
’ 0
0
0 0 0 0 0 0 0
0 I
0 ~ INTAKE AIR THERMOSENSOR 0 0 0 0
0 -~
OXYGEN SENSOR
0 0 0 0 WATER THERMOSENSOR
A
0
* 0 0 0 c 0
13
3F3-32 IN, o . E/L SIGNAL: Blower fan control switch second position or higher, electric cooling fan operating, headlights
rear window defroster ON.
F3-19
i

F3 TRUUBtESHOOTlNG GUIDE
IDIAGNOSTiC tNDEX
No. TFtOUBLESHOOTtNG ITEM DESCRIPTtON PAGE
1.
WI/I not crank or cranks slowly Refer to Engine Electrrcal System ‘1
2 Cranks normally but No combustion Engine cranks at normal speed but shows no sign of F3-22
will not start flrlng
3 Partial corn bustlon- Engine cranks at normal speed but shows only par- ‘1
When engine cold tial combustion and will not continue to run
4 Partial combustron- Engine cranks at normal speed and shows partial F3-25
After warm-up combustion but ~111 not continue runnrng after being
hot soaked
Cranks normally but Always Engine cranks at normal speed but rqurres exces- ‘1
hard to start sive cranktng time before starting
When engine cold Same condition as No. 5 when engine IS cold ‘1
Restarts normally after warm-up
After warm-up Same condition as No. 5 after running and betng hot F3-27
soaked
Starts normaNy when cold
1 8 1 Rough idle/
tsl Engine stalls at idle 1 Always [ Engine stalls or vibrates excessively at idle
r - 1 F3-29
r
Before warm-up 1 Engine stalls or vibrates excessively at idle during
I ‘1
10
11
12 After warm-up
When A/C, P/S,
or IX ON
Rough rdle/Englne stalts lus: after starting warm-up
Engine runs normally at idle during warm-up but
stalls or vibrates excessively atter warm-up
Engrne stalls or vtbrates excessrvely at idle when
NC, P/S, or E/L ON
Engine stalts or vibrates excessively lust after starting
tacceleratton from Idle1 F3-3 f
‘1
‘1
I I ’ I
I 13 High Idle speed after warm-up tdle speed excessively hrgh after warm-up ‘1
14 Idle moves up and down/idle hunts Engine speeds up and down periodically at Idle
F3-33
15 Engme stalls on deceleratron Engine unexpectedly stops running durrng or after
F3-35
deceleration
16 Engine statts suddenly (intermrttent) Engine intermittently stops runnrng
F3-36
17 Hesitates/Stumbles on acceleratton Flat spot occurs just after accelerator is depressed,
‘1
or m/Id ierkina occurs dunna acceleration
L I I
t 18 1 Surges while crulsng
1 Unexpected change In engine speed that is usually 1 ‘1
1 repetrtive
19 tack of power
20 Poor acceleration
21 Runs rough durrng deceleration/Backfire
22 Knocktng
23 Fuel odor Performance poor under load when throttle valve IS
wide open
Maximum speed reduced
Performance poor during acceleration
Engtne runs rough during deceleratron, and abnor-
mal combustion occurs in exhaust system
Abnormal combust!on accompanied by audible
“pinging” noise
( Gasoline odor in cabln ‘2
‘2
‘1
‘2
+1
24 Exhaust sulfur smell Exhaust gas has an unusual odor
25 High oil consumption Oil consumption excessive
b
26 Poor fuel economy Fuel economy unsatisfactory
27 A/C does not work
Blower fan operates, but magnetic clutch does not
l 1.. .Refet to 323 Workshop Manual (t 203-l O-89F). l 2...Re#er to 323 4-Wheet Drive Workshop Manual (1229-IO-89L). ‘1
‘2
‘1
l 1
13EOFS327
F3-20 -..
REAR I
--
--

F3 CONTROL SYSTEM
Ve: Battery voltage
Termina
1N ’
10
1P
IQ
IR
IS
1T
tlJ
IV Jnput Outpul
0
0
0
0
0
0
0
0
0 Connected to
Throttle sensor
(idle switch) Test condition
Correct voltage Remark
Accelerator pedal released
Below 1.0V
lgnltlon switch
Accelerator pedal depressed
VI3 ON
Foglrght relay
P/S pressure
switch Fogtight switch ON
Fogfight switch OFF
Ignition switch ON
P/S pressure switch ON at Idle
PIS pressure switch OFF at idle Va
ov
V3
Below 1 .OV
VB -
-
A/C switch A/C switch ON
A/C switch OFF Below 23 Ignition switch
Va ’ ON and blower
motor ON
1 f Ekctrtc cooltng fan Fan operating (coolant temperature over
Below 1 .OV
switch
97OC 1207OF 1 or diagnosis connector
terminal TFA grounded) -
Fan not operating (Idle)
VI3
Blower control Blower control switch OFF or 1st position
.Va
swbtch Ignitton switch
Blower control switch 2nd or hjgher po-
Below 1 .OV ON
sition
Rear window
defroster switch Rear window defroster OFF
Rear window defroster ON Below 1 .OV Ignition switch
V0 ON
Headlight switch
Headfights ON Va
Headlights OFF -
Below 1.OV
Neutral/Clutch
Neutral position or clutch pedal
9eJow I .OV
switches
depressed
Others
Va
7
r u-.
I-I-I
f
2y 2w 2u 2s 20 20 2M 2K 21 2G 2E 2C 2A 1U 1s 10 10 1M 1K 11 rG IE tC ;A
22 2% 2V 2T 2R 2P ZN 2L 25 2H 2F 2D 28 tV 1T ‘IR IF 1N It ;J. IH IF ID 18
i
A
F3-48
-- Alwa@
Always
Always
Always
--
Always
--
Always
--
Always
--
Always
--
Always
(electric
--
Alway<;
--
Always
-e
Afway?;
I .ov
Always
--
Always
--
Alway:;
--

-. _.. . . . . . _ - ._.
-w
CONTROL SYSTEM F3
I .
-.
Ve: Battery voltaae I
Incorrect voltage
Atwafi below 1 .OV
Always VB
Always VS (foglight switch OK)
Always below 1 .OV
Always below 1 .OV
Always Vs
Always
below 23 (blower fan OK)
Always VB (blower fan OK)
Always below 1 .OV
(electric cooling fan OK) -
1-
Possible cause
l Throttle sensor mrsadjustment l Short circuit in wtrrng from throttle sensor to ECU terminal 1 N l ECU malfunction
l Throttle sensor mrsadjustment l Open circuit in wiring from throttle sensor to ECU terminal fN l Open circuit in mnng from throttle sensor to ECU terminal 20
l Foglight relay malfunctron
l Foglrght relay malfunction
l P/S pressure switch maltunctron l Short crrcurt In wrrlng from P/S pressure switch to ECU terminal 1 P l ECU malfunction
l P/S pressure switch malfunction l Open circuit in wlnng from P/S pressure switch to ECU terminal 7 P l Open circuit in wiring from P/S pressure switch to ground
l A/C switch malfunctron l Short circuit tn wiring from A/C switch to ECU terminal 1Q l Poor connection at ECU connector l ECU malfunction
l #C swatch malfunction l Open circuit in wiring from A/C switch to ECU terminal 1Q l Open circuit in wiring from A/C switch to blower control switch
l Open or short circuit in wiring from fan relay to ECU terminal 1R l ECU matfunction
Always below 1 .OV (blower fan OK}
Always Vs (btower fan OK)
Always betow illumination lamp
1 .ov ON when rear
window defroster
switch ON
Illumination lamp
never ON
Atways below 1 .OV (headttghts OK)
l Short circuit in wrrtng from blower control switch to ECU terminal IS l Poor connection at ECU connector l ECU m&function
l Open crrcuit in wrrrng from blower control switch to ECU terminal 1s
l Open or short crrcuit In wiring from rear window defroster switch to ECU
terminal t T
l Open circuit in wiring from ignitron switch to rear window defroster switch l Rear window defroster switch malfunction
l Open or short circuit in wiring from headlight relay to ECU terminal 1 U
Always below 1 .OV
l Neutral switch malfunction l Clutch switch malfunction l Short circuit in wiring from ECU terminal IV to neutral or clutch switch
Always VB
l Neutral switch malfunction l Clutch switch malfunction l Open circuit in wiring from ECU terminal 1V to neutral or clutch swdch l Poor connection at ECU connector
13FOl=3-36 .
F3-49
.:i

CLUTCH
1 FEATURES 1
OUTL!NE
..................................................
OUfLlNE OF CONSTRUCTION
.................
;I f SPECIFtCATlONS
....................................
H- 2
13EOtiX-301
H
3
,
1
$
i
r’ :