Mazda 1990 323 Instruction manual

;
;
,’
1990
Mazda 323
4-Wheel Drive
Workshop
Manual
Supplement
FOREWORD
This is a supplement to the workshop manu-
al(s) shown below. This supplement describes
service procedures of new or modified me-
chanical and/or electrical systems. For service
procedures and important safety notices not
contained in this supplement, please refer to
the previous workshop manual.
Workshop Manual:
Form No.1 195-l O-89E
All information in this supplement was the
latest available at the time of printing, all alter-
nations related to modifications will be notified
by Service Bulletin.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN)
shown on the following page.
CONTENTS Title Section
1Lubrication Systein
Wheels and Tires
Wiring Diagram (Form No. 51450IO-89G) I
o 1989 Mazda Motor Corporation
PRINTED IN JAPAN, SEP., ‘89 (ij)
1213-1~0-891

VEHICLE IDENTIFICATION NUMBERS (VIN)
JMl 86227 * LO IOOOOl-
JMl 86228 * LO 100001 -

GI
i
h
-
GENERAL INFORMATION
IMPORTANT INFORMATION ..................... GI- 2
BASIC ASSUMPTIONS ............................ GI- 2
SAFETY RISK ........................................ GI- 2
POSSIBLE LOSS OF WARRANTY ............. GI- 2
WARNING ON LUBRICANTS
AND GREASES .................................... GI- 2
HOW TO USE THIS MANUAL.. .................. GI- 3
PREPARATION ...................................... GI- 3
REPAIR PROCEDURE ............................. GI- 3
SYMBOLS ............................................. GI- 4
NOTES, CAUTIONS, AND WARNINGS.. ..... GI- 4
FUNDAMENTAL PROCEDURES.. ............... GI- 4
PROTECTION OF THE VEHICLE .............. GI- 4
A WORD ABOUT SAFETY ....................... GI- 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 ..................................... GI- 7
RUBBER PARTS AND TUBING ................ GI- 7
JACK AND SAFETY STAND POSITIONS .... GI- 8
VEHICLE LIFT (P-SUPPORT TYPE)
POSITIONS ............................................ GI- 8
TOWING .................................................. GI- 9
IDENTIFICATION NUMBER LOCATIONS ..... GI-10
UNITS ..................................................... GI-10
ABBREVIATIONS ..................................... GI-10
CAUTION ................................................ GI-11
INSTALLATION OF A MOBILE
TWO-WAY RADIO SYSTEM .................... GI-11
REMOVAL OF IGNITION KEY ON
AUTOMATIC TRANSAXLE MODEL.. ........ GI-1 1
ELECTRICAL TROUBLESHOOTING TOOLS GI-12
CAUTION WITH ELECTRICAL PARTS ........ GI-13
03UGIX-001

IMPORTANT INFORMATION
IMPORTANT INFORMATION
BASIC ASSUMPTIONS
This workshop manual assumes that you have certain special tools that are necessary for the safe and effi-
cient 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 assumptions are correct and you understand the conse-
quences described below.
SAFETY RISK
This manual contains certain notes, warnings, and other precautionary information that you should carefully
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 will be
jeopardized by the use of incorrect methods or tools.
POSSIBLE 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 Authorized Mazda Dealer.
WARNING ON LUBRICANTS 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, including
skin cancer, in the event of gross and prolonged skin contact.
Wash skin thoroughly after work involving oil.
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 skin.
Lubricants and greases may be slightly irritating to the eyes, ,-.dJ
Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particu-
lar care should be taken with used oils and greases containing lead. Do not allow work clothing to be con-
taminated with oil. Dry clean or launder such clothing at regular intervals.
9MUGIX-002
GI-2

HOW TO USE THIS MANUAL
GI
HOW TO USE THIS MANUAL
PREPARATION
Lc-’ PREPARATION points out the needed
Special Service Tool (SST) for the service operation that it pro-
ceeds. Gather all necessary SST before beginning work.
Example:
MANUAL STEERING
PREPARATION
SST
49’0118 85OC
Puller, ball joint
SST NUMBER USAGE
t t
49 0118 850C For
For 4 removal of tie-rod
removal of tie-rod end
end
REPAIR PROCEDURE
I I ,
SST NAME SST ILLUSTRATION
9MUGlX-033
1. 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 illustration. Refer to this information when ser-
vicing the related part.
Example:
SHOWS
APPLICATION
r;FpT OF OIL,
SHOWS
RELATED
PAGE FOR
SERVICE ‘--,
,
1. Bolt 16. Bearing inner race
2. Lock plate
3. Bearing cup
4. Adiustina screw
e M-2:
-
e M-2,
5. B&ring&tar race
6. Locknut
7 Washer
i 7. Spacer
18. Drive pinion
Removal . . paae M-2
* 1: The numbering (ex.a) shows service procedure.
*2: Units shown in N.m (m-kg, ft-lb) unless otherwise specified.
SHOWS TIGHTENING
TORQUE
SPECIFICATION l 2
SHOWS TIGHTENING
TORQUE UNIT
*SHOWS VISUAL
INSPECTION
INFORMATION
9MUGIX-034
GI-3

GI
HOW TO USE THIS MANUAL/FUNDAMENTAL PROCEDURES
SYMBOLS
There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such
materials during service.
Symbol Meaning Kind
-If
Apply oil New engine oil or gear oil as appropriate
Apply brake fluid Only brake fluid
Apply automatic transmission fluid Only ATF
Apply grease Appropriate grease
am Apply sealant Appropriate sealant
0 Apply petroleum jelly Appropriate petroleum jelly
‘---/
OWGIX-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 for a specific purpose. NOTES give you added information that will help you to complete a
particular procedure. CAUTIONS 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 per-
sonal injury. The following list contains some general WARNINGS you should follow when you work on
a vehicle.
9MUGIX-036
9MUGIX-037
FUNDAMENTAL PROCEDURES
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas be-
fore starting work.
GI-4

FUNDAMENTAL PROCEDURES
9MUGIX-00: 3
SMUGIX-03 8
47UOGX-005
47UOGX-001
9MUGIX-03
A WORD ABOUT SAFETY
The following precautions must be followed when jacking up
the vehicle.
1. Block the wheels.
2. Use only the specified 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.
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT
Be sure that all necessary tools and measuring equipment are
available before starting any work.
SPECIAL TOOLS
Use special tools when they are required.
REMOVAL OF PARTS
While correcting a problem, try also to determine its cause.
Begin work only after first learning which parts and subassem-
blies must be removed and disassembled for replacement or
repair.
DISASSEMBLY
If the disassembly procedure iscomplex, requiring many parts
to be disassembled, all parts should be disassembled in a way
that will not affect their performance or external appearance
and identified so that reassembly can be performed easily and
efficiently.
GI-5

GI
FUNDAMENTAL PROCEDURES
SMUGIX-040
SMUGIX-04
47UOGX-01
1
9MUGIX-00
9MUGIX-042
1. Inspection of parts
When removed, each part should be carefully inspected for
malfunctioning, deformation, damage, and other problems.
2. Arrangement of parts
All disassembled parts should be carefully arranged for re-
assembly.
Be sure to separate or otherwise identify the parts to be
replaced from those that will be reused.
3. Cleaning parts for reuse
All parts to be reused should be carefully and thoroughly
cleaned in the appropriate method.
REASSEMBLY
Standard values, such as torques and certain adjustments,
must be strictly observed in the reassembly of all parts.
Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE
in Section TD for tightening torques not mentioned in the main
text.
If removed, these parts should be replaced with new ones:
1. Oil seals 2. Gaskets
3. O-rings 4. Lock washers
5. Cotter pins 6. Nylon nuts
Depending on location:
1. Sealant should be applied to gaskets.
2. Oil should be applied to the moving components of parts.
3. Specified oil or grease should be applied at the prescribed
locations (such as oil seals) before reassembly.

FUNDAMENTAL PROCEDURES
GI
67UOGX-00
9MUGIX-00
ADJUSTMENTS
Use suitable gauges and/or testers when making adjustments.
RUBBER PARTS AND TUBING
Prevent gasoline or oil from getting on rubber parts or tubing.
GI-7

GI JACK AND SAFETY STAND POSITIONS/VEHICLE LIFT (IL-SUPPORT TYPE) POSITIONS
JACK AND SAFETY STAND POSITIONS
FRONT END
Jack position:
At the front crossmember
03UGIX-00
REAR END
Jack position:
At the center of the rear crossmember
ww
At the rear differential (4WD)
03UGIX-801
Safety stand positions:
On both sides of the body frame
03UGIX-008
Safety stand positions:
On both sides of the body frame
FRONT END
Frame
Side sills
-
VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS
03UGIX-010
REAR END
Frame
Side sills
SMUGIX-010
GI-8
YMUUIX-Ul

TOWING
GI
WHEEL dOLLlES
03UGIX-00
TOWING
Proper towing equipment is necessary to prevent damage to
the vehicle.
Laws and regulations applicable to vehicles in tow must al-
ways be observed.
As a general rule, towed vehicles should be pulled with the
driving wheels off the ground. If excessive damage or other
conditions prevent towing the vehicle with the driving wheels
off the ground, use wheel dollies.
With either automatic or manual transaxle:
1. Set the ignition switch in the ACC position;
2. Place the selector lever or shift lever in N (Neutral);
3. Release the parking brake.
Caution
l Do not tow the vehicle backward with driving wheels
on the ground. This may cause internal damage to
the transaxles.
l Do not use the hook loops under the front and rear
of the vehicle for towing purposes. These hook
loops are designed ONLY for transport tie-down. If
tie-down hook loops are used for towing, the
front/rear bumper will be damaged.
TIE-DOWN HOOKS - FRONT
TIE-DOWN HOOKS - REAR
GIL9

GI
IDENTIFICATION NUMBER LOCATIONS/UNITS/ABBREVIATIONS
IENTIFICATION NUMBER LOCATIONS
VEHICLE IDENTIFICATION NUMBER (VIN) AUTOMATIC TRANSAXLE MODEL AND NUMBER
UNITS
N.m (m-kg or cm-kg,
ft-lb or in-lb) .. .. ... ... .. Torque
rpm .... .. . ..... . .. .. .. Revolutions per minute
A .,.,..,.,.,..,.,...,............... Ampere(s)
v ..,,...,.,..,., ,.. .. .. ... Volt(s)
8 .,.,.,..,..,..,.................... Ohm(s) (resistance)
kPa (kg/cm2, psi)... .. .. Pressure
(usually positive)
mmHg (inHg) ... . .. .. Pressure
(usually negative)
W ,.,....,.,........................ Watt
iters (US qt, Imp qt) Volume
nm (in) .,.,..,.................. Length
89UOGX-00
ABBREVIATIONS
ABDC ........................... After bottom dead
center
A/C.. ............................. Air conditioner
ACC ............................. Accessories
ATX .............................. Automatic 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 processing unit
EC-AT.. ......................... Electronically-controlled
automatic transmission
ECU ............................. Engine control unit
EGI ............................... Electronic gasoline
injection
E/L.. .............................. Electrical load
EX ................................ Exhaust
IC ................................. Integrated circuit
IGN.. ............................. Ignition
IN ................................. Intake
INT ............................... Intermittent
ISC ............................... Idle speed control
LH ................................ Left hand
M.. ................................ Motor
MIL.. ............................. Malfunction indicator
lamp
MTX .............................. Manual transaxle
OD ................................ Overdrive
OFF .............................. Switch off
ON ................................ Switch on
PCV .............................. Positive crankcase
ventilation
PRC.. ............................ Pressure regulator
control
P/S ................................ Power steering
P/W .............................. Power window
RH. ............................... Right hand
SST.. ............................. Special service tool
ST.. ............................... Start
SW ................................ Switch
TDC .............................. Top dead center
4WD.. ........................... 4-wheel drive
03UGIX-EC
..i
._c
GI-10

CAUTION
CAUTION
INSTALLATION OF MOBILE TWO-WAY RADIO SYSTEM
If a mobile two-way radio system is installed improperly or if a high-powered type is used, the EGI system
and other systems may be affected.
When the vehicle is to be equipped with a mobile two-way radio, observe the following precautions:
1. Install the antenna at the farthest point from control units.
2. Install the antenna feeder as far as possible from the control unit harnesses (at least 30 cm [11.8 in]).
3. Ensure that the antenna and feeder are properly adjusted.
4. Do not install a high-powered mobile two-way radio system.
CRUISE CONTROL UNIT
FEEDyT7N,T HARNESS I’ MOBIT-WAY RADIO
AT LEAST 30 cm
[i 1.8 in)
ENGINE CONiROL UNIT /
FARTHEST POINT
05UGK01
03UGIX-OO!
REMOVAL OF IGNITION KEY ON AUTOMATIC
TRANSAXLE MODEL
The selector lever must be in P (PARK) to turn the ignition key
to the OFF position. If the switch seems to be off but the key
cannot be removed, the switch may still be in the ACC posi-
tion, or the selector lever may not be in P (PARK). Shift the
selector lever to P (PARK), and turn the ignition key to the
LOCK position. The key should now be free for removal.
GI-11

GI
CAUTION
I
9MUGIX-019
SMUGIX-021
VOLTMETER
SLACK
CE
LINE
GRChND
SMUGIX-02
O!WGIX-02.
ELECTRICAL TROUBLESHOOTING TOOLS
Test Light
The test light, as shown in the figure, uses a 12V bulb. The
two lead wires should be connected to probes.
The test light is used for simple voltage checks and for check-
ing for short circuits.
Caution
l When checking the control unit, never use a bulb
over 3.4W.
Jumper Wire
The jumper wire is used for testing by shorting across switch
terminals and ground connections.
Caution
l Do not connect a jumper wire from the power source
line to a body ground; this may cause burning or
other damage to harnesses or electronic com-
ponents.
Voltmeter
The DC voltmeter is used to measure of circuit voltage. A volt-
meter with a range of 15V or more is used by connecting the
positive (+) probe (red lead wire) to the point where voltage
is to be measured and the negative (-) probe (black lead
wire) to a body ground.
Diagnosis Connector
Insert the probe into the service hole when connecting a jum-
per wire to the diagnosis connector.
Caution
l Do not insert the jumper wire probe into the diag-
nosis connector terminal, which may damage the
terminal.
Ohmmeter
The ohmmeter is used to measure the resistance between two
points in a circuit and also to check for continuity and diagno-
sis of short circuits.
Caution
l Do not attempt to connect the ohmmeter to any cir-
cuit to which voltage is applied; this may burn or
otherwise damage the ohmmeter.
9MUGIX-045
GI-12

CAUTION
CAUTION WITH ELECTRICAL PARTS
Battery Cable
GI
Before disconnecting connectors or replacing electrical parts,
disconnect the negative battery cable.
QMUGIX-022
I
QMUGIX-023
QMUGIX-024
QMUGIX-025
03UGIX-01
Connectors
Removal of connector
Never pull on the wiring harness when disconnecting con-
nectors.
Connectors can be removed by pressing or pulling the lock
lever as shown.
Locking of connector
When locking connectors, make sure to listen for a click that
will indicate they are securely locked.
Inspection
1. When a tester is used to check for continuity or to measure
voltage, insert the tester probe from the wire harness side.
GI-13

CAUTION
OSUGIX-02
9MUGIX-02;
9MUGlX-02
I
a
Same as the female type.
..::$$::., ,.::&:;
..:::::::::::::::::.. A...,.,..., .. ..
.:~:si:~:i:~i:~:i$i:i::,,
..:::::::::;:i
‘.y. ..:y
I
9MUGIX-03(
GI-14
2. Check the terminals of waterproof connectors from the con-
nector side, as they cannot be accessed from the wire har-
ness side.
Caution
l Use fine wire to prevent damage to the terminal.
l Do not damage the terminal when inserting the
tester lead.
Terminals
Inspection
Pull lightly on individual wires to check that they are secured
in the terminal.
Replacement of terminals
Use the appropriate tools to remove the terminal as shown.
When installing the terminal, be sure to insert it until it locks
securely.
< Female >
Insert a thin piece of metal from the terminal side of the con-
nectar, and then, with the terminal locking tab pressed down,
pull the terminal out from the connector.
< Male >
Sensors, Switches, and Relays
Handle sensors, switches, and relays carefully. Do not drop
them or strike them against other parts.

CAUTION
GI
9MUGIX-03
FUSE
PULLER
9MUGIX-032
SMUGIX-029
Fuse
Replacement
1. When replacing a fuse, be sure to replace it with one of
specified capacity.
If a fuse again fails after it has been replaced, the circuit
probably has a short circuit and the wiring should be
checked.
2. Be sure the negative battery terminal is disconnected be-
fore replacing a main fuse (80A).
3. When replacing a pullout fuse, use the fuse puller supplied
in the fuse box cover.
Wiring Harness
Wiring color codes
Two-color wires are indicated by a two-color code symbol.
The first letter indicates the base color of the wire and the sec-
ond the color of the stripe.
--
GI-15

PRE-DELIVERY INSPECTION
AND
SCHEDULED MAINTENANCE
SERVICES
PRE-DELIVERY INSPECTION ..................... A- 2
PRE-DELIVERY INSPECTION TABLE .......... A- 2
SCHEDULED MAINTENANCE SERVICES ..... A- 3
SCHEDULE 1
(NORMAL DRIVING CONDITION) ............. A- 3
SCHEDULE 2
(UNIQUE DRIVING CONDITION) .............. A- 6
9MUOAX-001

PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Glass, exterior bright metal and paint for damage
Cl Wheel lug nuts
88-l 18 N.m (9-l 2 m-kg, 65-87 ft-lb)
Cl Tire pressures (Refer to section Q)
q All weatherstrips for damage or detachment
I? Operation of hood release and lock
0 Operation of trunk lid, back door, and fuel lid opener
0 Door operation and alignment
0 Headlight aiming
INSTALL the following parts:
0 Wheel caps or rings (if equipped)
0 Outside rear view mirror(s)
1UNDER HOOD-ENGINE OFF ]
INSPECT and ADJUST, if necessary, the following items to
the specifications:
Cl Fuel, coolant and hydraulic lines, fittings, connections and
components for leaks
0 Engine oil level
Cl Power steering fluid level
0 Brake and clutch master cylinder fluid level
ci Windshield washer reservoir fluid level
0 Radiator coolant level and specific gravity
~1
0 Tightness of water hose clamps (including heater hoses)
0 Tightness of battery terminals
0 Manual transaxle oil level
Cl Drive belt tensions
0 Accelerator cable and its linkage for free movement
CLEAN spark plugs
piteiiq
INSTALL the following parts:
0 Rubber stopper for inside rear view mirror
q Fuse for accessories
CHECK the operations of the following items:
Seat controls (sliding,and reclining) and head restraint
Folding rear seat
Door locks including childproof door locks (if equipped)
Seat belts and warning system
Ignition switch and steering lock
Inhibitor switch (ATX only)
Starter interlock switch (clutch pedal, MTX only)
All lights including warning and indicator lights
Sound warning system
Horn, wipers and washers (front and rear, if equipped)
0 Audio system (if equipped)
0 Cigarette lighter and clock
0 Heater, defroster and air conditioner at various mode
selection (if equipped)
CHECK the following items:
0 Presence of spare fuse
cl Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
II Operation and fit of windows
El Pedal height and free play of brake and clutch pedal
Pedal height mm (in) Free play mm (in)
Clutch pedal
‘Q8yg y$$03) 5-13 (0.197-0.512) I
Brake pedal 1193-196 (7.60-7.72)1 4-7 (0.16-0.28) 1
q Parking brake
5-7 notches198 N (10 kg, 221b)
UNDER HOOD-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
0 Automatic transaxie fluid level
0 Initial ignition timing (with TEN terminal of diagnosis con-
nector grounded)
5 f 1o BTDC: BP SOHC
0 Idle speed (ATX: P range, MTX: Neutral)
750 * 50 rpm: (With parking brake applied)
1ON HOIST 1
CHECK the following items:
0 Underside fuel, coolant and hydraulic lines, fittings, con-
nections and components for leaks
0 Tires for cuts or bruises
0 Steering linkage, suspension, exhaust system and all un-
derside hardware for looseness or damage
1 ROAD TEST 1
CHECK the following items:
Brake operation
Clutch operation
Steering control
Operation of meters and gauge
Squeaks, rattles or unusual noise
Engine general performance
Emergency locking retractors
Cruise control system (if equipped)
1AFTER ROAD TEST 1
REMOVE seat and floor mat protective covers
CHECK for necessary owner information materials, tools and
spare tire in vehicle
03UOAX-801
A-2