wheel 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

c
>
3
3
Gf
m
GENERAL INFORMATION
1MPORTANT INFORMATION
..................... GI- 2
BASIC ASSUMPTIONS ............................ a- 2 I
SAFETY RISK
........................................ Gl- 2
POSSIBLE LOSS OF WARRANTY
............. Gl- 2
WARNING ON LUBRICANTS
AND GREASES
.................................... GI- 2
HOW TO USE THIS MANUAL..
.................. GI- 3
PREPARATION
...................................... GI- 3
REPAtR PROCEDURE .............................
GI- 3
SYMBOLS .............................................
GI- 4
NOTES, CAUTIONS, AND WARNINGS.. .....
Gl- 4
FUNDAMENTAL PROCEDURES
................. GI- 4
PROTECTION OF THE VEHICLE .............. G1- 4
A WORD ABOUT SAFE-T-Y
....................... Gl- 5
PREPARATION OF TOOLS
AND MEASURING EQUIPMENT ............. Gi- 5
SPECIAL TOOLS ....................................
GI- 5
REMOVAL OF PARTS .............................
GI- 5
DISASSEMBLY ......................................
GI- 5
REASSEMBLY
....................................... GI- 6
ADJUSTMENTS .....................................
Gl- 7
RUBBER PARTS AND TUBtNG ................ GI- 7
JACK AND SAFETY STAND POStTlONS .... GI- 8
VEHICLE LIFT (20SUPPORT TYPE)
POSITIONS ............................................
GI- 6
MAINTENANCE NOTE ..............................
GI- 9
SPEEDOMETER TESTER CHECK
............. GI- 9
BRAKE TESTER CHECK
......................... GI- 9
CHASSIS DYNAMOMETER CHECK.. ......... Gl-I 0
WHEEL BALANCE.R ...............................
GI-I 0
TOWtNG ...............................................
GI-I 0
IDENTlFiCATlON NUMBER LOCATIONS
..... GI-I
2 .UNlTS .....................................................
GI-I 2
ABBREVIATIONS
.....................................
GI-12
CAUTION
................................................ GI-13
INSTALLATlON OF MOBILE TWO-WAY
RADIO SYSTEM ...................................
Gl-13
PRECAUTIONS TO TAKE WHEN
SERVICING AN ELECTRICAL SYSTEM ..i GI-f4
HANDLING CONNECTORS ..................... GI-f 5
USING ELECTRICAL
MEASURlNG EQUIPMENT ........................................
GI-16
13EGIX-30 1

FUNDAMENTAL PROCEDURES GI
A WORD ABOUT SAFETY
The following precautions must be followed when jacking up
the vehicle.
t . Block the wheels.
2. Use only the specfred jacking positions.
3. Support the vehicle with safety stands.
Start the engine only after making certain the engine compart-
ment is clear of tools and people. j
9MUGtX-003 PREPARATION OF TOOLS AND MEASURING
EQUIPMENT
8e sure that al! necessary toois and measuring equipment
are available before starting any work.
SPECIAL TOOLS
Use special tools when they are required.
47UOGX-Cm I 1 REMOVAL OF PARTS
While correcting a problem, try also to determine its cause
Begin work only after first learning which parts and subas-
semblies must be removed and disassembled for replace-
ment or repair. >
DISASSEMBLY
If the disassembly procedure is complex, requiring many
parts to be disassembled, all parts should be disassembled
in a.way that wiii not affect their performance or external
appearance and identified so that reassembly can be per-
formed easily and efficiently. I J
9MUGIX 039
a-5
I 1

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.

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)
!

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

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!

The following chart shows interchangeability of the main parts of the previous BP DOHC Turbo engine
and the new BP DOHC Turbo engine for 4WD models.
S ymiols: 0 _. lnterc hangeable X . . . Not Interchangeable
Part name tnterchangeability
Remark
Cytlnder head 0
Camshaft 011 seal 0
Cvllnder head bolt 0
CB :
Cyh nder
blcck
related
Crankshaft
related
Timing belt
related
Valve
related
Lubrication
system
related Cylrnder head gasket 0
Wnder head cover 0
Cylinder head cover gasket
Cylinder block
MaEn bearina cao 0
0
0
Ma+n bearino suo~oFt elate I
0 I ” ,I I
Oil pan
Timrno belt cover I X
0 I
Turbocharger oil return pipe hole increased from
13mm IO.51 in) to 17mm IO.67 in)
Seal elate
Front orl seal I 0 I
I I 0
1
Rear 011 seal 0
Crankshaft 0
Marn bearina 0
Thrust bearing
Connectmg rod
Connecting rod beartng
Piston 0
;J
X
Shape different
Piston skirt shortened
I Piston pm cl
Tw
X Sectional shape different
Piston rrng Piston ring end gap increased from 0:?5--0.30mm
Second
X ~0.006-0.011 in ) to 0.35-0.50mm IO.01 4-0.019
in ] (Measured In cylinder)
Crankshaft pulley Shape different
Rear cover ;5
Flywheel
I 0
Flywheel bolt 0
Tbmlng belt 0
Timing belt crank pulley 0
Camshaft pulley 0
Timing belt tensioner and spring
0
Idler 0
Camshaft 0
AA
Valve Intake
Exhaust
cl
0
X Metallic sodium-filled valve
Valve spring Intake
I 0
and seat
Exhaust 0
Vatve wide I 0
Valve seal
Oil pump 0
Oil pump gasket 0
oil strainer 0
Oil strainer gasket 0
Oil cooler
X Heat dissi patlon capacity increased
Oil jet
Oil filter Shape different
1 Water pump 0
Coohng Thermostat 0
system
related Radiator 0
Cooling fan 0
I 3EO32.304
BZ-3.

SUPPLEMENTAL SERVICE INFORMATION .
I
The following points in this section are changed in comparison to the Mazda 323 4-Wheel Drive Work-
shop Manual [I 229-l O-89t].
Turbocharger
l Removal / Installation
Wastegate solenoid valve
l Inspection
htercooter
l Removal I Installation
Fuel pump (main)
l Inspection
Fuel pump resistor/relay
l System operation
l Inspection
Injector
l Inspection
l Volume test
Injector resistor
l Inspection
Pressure regulator control system
l Solenoid valve (pressure regulator control}
Engine control unit (ECU)
l Inspection 13EOF3.320
F3-I 5