fuel 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

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

EXHAUST ViitVE
EXHAUST SIDE
VALVE GUIDE
METALLIC SODIUM
(ABOUT 30% VOLUME)
VALVE STEM
.‘.‘*
:::I
:::I
VALVE HEAD
CYttNDER HEAD
IDENTlFtCATION OF METALLIC SODIUM-FILLED EXHAUST VALVE
l Superior he& dissipating .metallic sodium-filled exhaust valves are adopted. During engine operation, the
metalic sodium inside the valve stem melts. As the valve moves up and down, the sodium splashes around
inside the valve and helps to absorb heat from the cylinder head and to transfer it back to the engine
coolant through the valve guide. In this way, the combustion chamber temperature is reduced, reducing
knocking and improving fuel efficeincy.
l Special handling of sodium filled valves is required for personal safety. (See next page.)
B2-7

F3
c
FUEL AND EMISSION
CONTROL
SYSTEMS
i
INDEX . . . . . . . . l ..,.... *..,. . . . . . . m...*.*...*..... F3- 2
UUTLtNE
...................................... F3- 4
OUTLINE OF CONSTRUCTION.. ....
F3- 4
SYSTEM DIAGRAM ...................... F3- 5
VACUUM HOSE ROUTING
DIAGRAM
................................. F3- 6
WIRING DIAGRAM.. .....................
F3- 7
ECU RELATIONSHIP DIAGRAM ...... F3- 8
SPECIFICATIONS.. ....................... F3- 9
TURBOCHARGER CONTROL .......... F3-IO
OUTLINE
.................................... F3-10
SYSTEM DIAGRAM ...................... F3-10
WASTEGATE CONTROL ............... F3-11
FUEL SYSTEM
.............................. F3-12
OUTLINE ....................................
F3-12
CONTROL SYSTEM .......................
F3-13
STRUCTURAL VIEW .....................
F3-13
PRESSURE REGULATOR
CONTROL SYSTEM ....................
F3-14 SUPPLEMENTAL SERVICE
tNFOF?MATtON
............................. F3-I 5
SELF-DtAGNOStS FUNCTtON.. ........
F3-16
OUTLINE ....................................
F3-16
SERVICE CODE NUMBERS..
......... F3-16
TROU8LESHOOTtNG GUtDE
........... F3-19
RELATIONSHtP
CHART.. F3-19 ..............
DIAGNOSTIC JNDEX
.................... F3-20
PRECAUTIONS
............................
F3-21
SYMPTOM TROUBLESHOOTING .... F3-22
TURBOCHARGERCONTROL
SYSTEM ......................................
F3-37
TURBOCHARGER F3-37 ........................
WASTEGATE SOLENOID VALVE.. .. F3-38
INTERCOOLER ............................
F3-39
FUELSYSTEM ..............................
F3-40
FUEL PUMP ................................
F3-40
FUEL PUMP RESISTOR/RELAY ......
F3-40
PRESSURE
REGULATOR .............. F3-41
INJECTOR ..................................
F3-42
INJECTOR RESISTOR
................... F3-42
PRESSUR REGULATOR CONTROL
SYSTEM ......................................
F3-43
SOLENOID VALVE (PRESSURE
REGULATOR CONTROL)
............. F3-43
CONTROL SYSTEM
....................... F3-44
PREPARATION ............................ F3-44
ENGINE CONTROL UNIT (ECU) ..... F3-45
7 3EOF3-301

INDEX F3
t
3EOf3.303
1. Injector 4. Solenoid valve (PRC high temp.)
Inspection ................................. page F3-42 Inspection ;. ............................... page F3-43
Volume test.; ............................. page F3-42 5. Fuel pump resistor/relay
2. Pressure regulator System operation ...................... page F3-40
Inspection ................................. page F3-4 1 Inspection ....... . .........................
page F3-4 1
II
3. Solenoid valve (PRC low temp.) 6. Fuel pump (main)
Inspection ................................. page F3-43 Inspection .......... . ...................... page F3-40

F3 OUTLINE
OUTLINE
OUTLINE OF CONSTRUCTION
Theefuel and emission control system of the new 323 4WD model 1s basically the same as that of the prevr-
ous 323 4WD model; however some parts are changed. The changed parts and interchangable parts
are shown betow.
13EOF3-304
Changed parts
1 ~ components Contents and purpose Reference pagl
INTAKE AlR
SYSTEM Turbocharger
Intercooler
l Size Increased for greater boost pressure l Wastegate solenord valve IS lozated on Intake port of F3-10
turbocharger to make system more compact F3-37
Volume increased for Improved F3-10
t F3-39
Wastegate sojenold valve
l Wastegate solenoid valve changed to duty solenoid
type for Increased engine power and response
l Wastegate solenoid valve is located on Intake port of
turbocharger to make system more compact F3-1 f
F3-38
I r
Pressure regulator One-stage operattlon changed to two-stage operatron F3-14
to improve hot restarting f3-41
L
FUEL SYSTEM High-ohmic type change to low-ohmrc type with exter-
Fuel qector na solenoid reslstor for improved fuel supply during F3-12
high-speed driving F3-42
Fuel pump reslstor Resistance reduced for
surer fuel supply F3-40
CONTROL
SYSTEM Pressure
regulator control system
Atr flow meter Two-stage operatton used to Improve hot restarting
Measures larger amount of air flow Increased power
Resistance values changed F3-t4
F3-43
F3- 9
f3EOF3-305 lnterchangable parts
tntake air system
l
Air valve
l Air bypass valve
l Air cleaner
l Air cleaner element
Fuel system
l Fuel filter assembly
l Fuel pu.mp (transfer
l Fuel vapor valve Control system
. l Throttle sensor
l Water thermosensor
l Knock sensor and control unit
l Oxygen sensor
l Fuel pump control unit
l Main relay
l Circuit opening relay
l Check valve (two-way) .
Evaporative system
l Charcoal canister
l Check valve (two-way)
13EOF3-306
F3-4

CHECK VALVE SOLENOID VALVE
(PURGE CONTROL)
llll
*
SOLENOID VALVE
(PRC LOW TEMP.)
3 ~NTERCOOLERII’ I ,‘/ I
II II
’ f frrmvmlHHt-----lHt I -1 II II
IIt - --M:l, i -KNmK~[I~ ,
’ ISC VALVE
VALVE WATER CHAkCOAL
CANISTOR
CHECK VALVE
I FUEL FUEL FILTER
PUMP
I FUEL FILTER
TRANSFER
PUMP
AIRkLOW METER
(WITH INTAKE AIR THERMOSENSOR)
DISTRIBUTOR
CATALYTIC CONVERTER
l TO ENGINE CONTROL UNIT

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