service 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

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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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

GI HOW TO USE THIS MANUAL/FUNDAMENTAL PROCEDURES
SYM00LS
There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such
matertals during service
*
Symbol
w-
l Apply otl Meaning Kind
New engtne 011 or gear 011 as approprkate
Apply brake fluid Only brake fluId
I
Apply automatic transmtsslon fluid Only ATF
Apply grease Appropriate grease
Apply sealant Approprrate sealant
0
Apply petroleum Jelly
Appropriate petroleum jetty
05UGIX-005 Note
l When special oil or grease is needed, this is shown in the illustration.
NOTES, CAUTIONS, AND WARNINGS
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each
one IS there fur a specific purpose.
NOTES give you added information that wilt help you to complete
a particular procedure. CAUTlONS are given to prevent you from making an error that could damage
the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause
personal injury. The following list contains some general WARNINGS you should follow when you work
on a vehrcle
. 9MUGlX.036
FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE
Always .be sure to cover fenders, seats, and
fore starting work. floor areas be-
1
T.
i
8
s
Q
8
e

GI IDENTIFICATION NUMBER tOCATlONS/UNlTS/ABBREVIATlONS
IDENTIFICATION NUMBER LOCATIONS
VEHICLE tDENTtRCATtUN NUM8ER (VIM) ENGINE MODEL AND NUMBER
I
UNITS
N.rn { kgf m or kgfcm,
f-t&f or tn.lbf 1 . . . . . . . . . . . . . . . . Torque
rpm ._ . . . Revolutions per minute
A.. ,_...___.... Ampere(s)
v I... Volt(s)
$2 . .._..__......_.....__... Ohm(s) (resls‘tance)
kPa { kgflcm*, psr] . . . . . . . Pressure
{usually positive)
mmHg I inl-lg ] . . . . . . . . . Pressure
(usually negatrve)
W . . . ._ .._.__ .._ . . . . . . ..,......... Watt
titers [US qt, Imp qt 1 . V&me
mm { rn 1 . . . . . . . . . . . . . . . . . . . . . . . Length
89UOGX-006
ABBREWATIONS
ABDC _. . . . . . . . . . . After bottom dead
center
A/C . . . . . . . ._.. _. . . . . . . . . Air conditioner
ACC .__ . . . . . . . Accessones
ATX .._ ._ . . . . . . . . . . . . . . Automate transaxle
ATDC _.. __ _. . . . . After top dead center
ATF ,... ._....__._.. Automatic transmission
fluid
BAC ._ . . . . . . . . . . . . . . ,. Bypass air control
BBDC _. . . . . . . . . . . . . .._. Before bottom dead
center
BTDC ., ._._... . . . Before top dead center
CPU . . . . . . . . . Central processrng unit EC-AT
........................... Electronrcally-controlled
automatic transmlsslon
ECU ._ ....................... Engine control unit
EG 1 ..................... Electronc gasoll ne
injectron
E/L. ............................ Electrrcal load
EX .............................. Exhaust
IC ................................ Integrated clrcult
IGN ........................... lgnrtlon
IN ..... ........................ Intake
INT
............................... Intermittent
ISC ............................ Idle speed control
U-l ................................
Left hand
M..
........................... Motor
MIL
........ ...................... MatfunctIon Indicator
iamp
MTX. ........................... Manual transaxle
00.. .............................. Overdnve
Of F .............................. Swrtch off
ON
............................... Switch
on
PCV .............................. Positive crankcase
ventilation
PRC .......................... Pressure regulator
control
P/S ............................. Power steerrng
P/W ............................
Power window
RH ............................... Rlght hand
SST
............................. Special service tool
ST.. ............................... Starl
SW.. ............................. Switch
TDC. ............................ Top dead center
4WD .............................
4-wheel drive
03UGIX-802
INS7
If a t’
and
Whe
1, II-!
2. II-!
3. E-
4. Dr
W-1 2

:
.
GI CAUTION
USING ELECTRICAL MEASURING EQUIPMENT
Use Handling precautions Operation Equpment
Test lamp Test to find open or shorted
crrcuits
l Connect the test lamp
between the circuit being
measured and a ground.
l The lamp will lrght if the
circurt is energized to the
point testedA
l Test lamps use 12V t.4W or
3.4W bulbs or light-emitting
diodes (LEOs). Using a
large-capacity bulb may
damage :he Ckil.
Jumper wrre Used to create a temporary
ctrcult . Connect the jumper wire
between the terminals of a
cjrcurt to bypass a switch. l 00 not connect the lumper
wrre from the power source
line to ground; this may
cause burning or other
damage to harnesses or
electrontc components.
Voltmeter Used for measuring the voltage
of a circutt to find possible
opens or shot-k.
l Connect the voltmeter in
parallel wrth the cjrcurt.
l Set the range to the dewed
voltage.
l Use the service hole when measuring the voltage at the
diagnosis connector.
l Connect the positive (+)
probe to the point where
voltage IS to be. measured
and the negatrve (-) probe to
a ground.
l Tie a thin wire to the
posrtive (+) probe to access
narrow terminals.
Ohmmeter Used to find opens and shorts
In the ctrcurt, to confrrm
contrnurty and to measure
reststance.
l Zero the ohmmeter. l Zero the meter after
switching to the measuring
range.
l Before using the ohmmeter,
make sure the ignitron
switch is off or the megatrve
(-) battery cable is
disconnected to prevent
burning or otherwise
damaging the ohmmeter. &--- l Verify that voltage IS not
applied to the circuit
l Connect the probes between
two points in a Circuit.,
t I t
+ Connect the ammeter in
series with the circuit by
touchtng the positive ( +)
probe to the power-srde
terminal and the negative (-
probe to the ground-srde
terminal. Ammeter
Used to check alternator output,
current supplied to the starter.
and dark current wrthrn a circutt. l Set the range to the desired
amperage.
l Connect the ammeter In
series with the circuit. The
ammeter may be burned or
otherwise damaged if it IS
connected in parallel. Note
Dark current IS the constant flow
of current whrle
the ignitron
switch is OFF.
13EGIX-31;
Gl-t 6

c
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
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

B2
ENGINE
(DOHC)
1 FEATURES j
OUTLINE ................................................
B2- 2
OUTLINE OF CONSTRUCTION..
.............. B2- 2
SPEClFICATlONS
..................................
82- 2
INTERCHANGEABILITY ..........................
B2- 3
PISTON ...............................................
82- 4
CONNECTING ROD ...............................
82- 5
CRANKSHAFT PULLEY ..........................
B2- 6
EXHAUST VALVE ..................................
B2- 7
INSTRUCTION FOR HANDLING METALLIC
SODllJM~FlLLED EXHAUST VALVE .........
82- 8
SUPPLEMENTAL SERVICE INFORMATION 820 9
4
13E082-301