Mazda 323 1992 - Door Hatchback

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VEHICLE IDENTIFICATION NUMBERS (VIN)

PROTEGli

JMl BG223 * NO 400001-

JM1 86224

* NO 400001-

JMl 86225 *NO 400001-

JMl BG226 * NO 400001-

3-DOOR HATCHBACK

JMl BG231 *NO 400001-

JMl 86232 *NO 400001-

JMl BG233 * NO 400001-

Main Page

Door Hatchback2
Table of Contents3
General Information3
Important Information4
Basic Assumptions4
Safety Risk4
Possible Loss of Warranty4
Warning on Lubricants4
And Greases4
How to Use this Manual5
Preparation5
Repair Procedure5
Symbols6
Notes, Cautions, and Warnings6
Fundamentalprocedures7
A Word about Safety7
Special Tools7
Removal of Parts7
Disassembly7
Reassembly8
Bolt and Nut Tightening8
Adjustments9
Jack and Safety Stand Positions10
Vehicle Lift (P-Support Type)10
Positions10
Towing11
Units12
Abbreviations12
Caution13
Installation of Mobile13
Two-Way Radio System13
Electrical Troubleshooting Tools14
Caution with Electrical Parts15
Sensors, Switches, and Relays16
Scheduled Maintenance Services19
Pre-Delivery Inspection20
Pre-Delivery Inspection Table20
Schedule21
Canada)21
Schedule24
Troubleshooting33
Engine Tune-Up35
Tune-Up Procedure36
Drive Belt Tension Check36
Engine Tune-Up Procedure39
Maintenance41
Timing Belt42
Removal / Installation42
On-Vehicle Maintenance43
Head Gasket46
Front Oil Seal53
Rear Oil Seal55
Engine Stand Mounting65
Stand Mounting66
Auxiliary Parts70
Cylinder Head73
Cylinder Head Bolts75
Valve Seal76
Cylinder Block (Internal Parts)80
Inspection / Repair86
Cylinder Block90
Cylinder Bore91
Piston and Piston Rings92
Tensioner, Idler95
Tensioner Spring95
Torque Specifications98
Piston Ring99
Cylinder Head109
Valve and Valve Spring111
Camshaft Oil Seal112
Camshaft Pulley113
Timing Belt116
Torque Specifications116
Timing Belt Tensioner116
Intake Manifold Assembly121
Engine Stand Dismounting122
Exhaust Pipe129
Troubleshooting135
Engine Tune-Up137
Tune-Up Procedure138
Drive Belt Tension Check138
Maintenance143
Timing Belt144
On-Vehicle Maintenance144
Spark Plug147
Cylinder Head Gasket148
Removal / Installation154
Rear Oil Seal160
Stand Mounting170
Timing Belt175
Disassembly Note175
Cylinder Head177
Valve Seal179
Cylinder Block180
Cylinder Block (Internal Parts)183
Connecting Rod Cap183
Disassembly183
Connecting Rod183
Connecting Rod Bearing Inspection183
Inspection183
Main Bearing Cap183
Main Bearing Inspection183
Thrust Bearing183
Piston Pin184
Main Bearing Cap185
Valve Mechanism187
Valve Seat189
Oil Jet193
Inspection193
Piston and Piston Pin195
Connecting Rod195
Torque Specifications211
Cylinder Head Cover215
Installation225
Torque Specifications225
Automatic Transaxle226
Lubrication System235
Index236
Outline239
Specifications239
Oil Pressure240
Preparation240
Inspection241
Engine Oil241
Replacement241
Oil Filter242
Replacement242
Oil Cooler242
Removal242
Installation242
Oil Pan243
Removali Installation243
Oil Pump247
Inspection247
Cooling System249
Outline252
Specifications252
Troubleshooting Guide252
Engine Coolant253
Preparation253
Radiator256
Removal / Installation257
Inspection257
Radiator, Thermostat257
Water Pump259
Removal / Installation259
Electric Cooling Fan System261
System Circuit261
System Inspection262
Fan Motor262
Removal / Installation264
Water Thermoswitch264
Inspection264
Inspection265
Radiator Thermoswitch265
Removali Installation265
Inspection266
Fan Relay266
Removali Inspection266
Fuel and Emission Control System267
Vacuum Hose Routing Diagram272
Ec-At Control System277
Component Descriptions282
Troubleshooting286
Operation286
Troubleshooting Guide288
Using this Section291
Diagnostic Index291
Troubleshooting Hints292
Inspection292
Surges While Cruising325
System Select325
Lack of Power327
Poor Acceleration331
Engine Tune-Up344
Basic Inspection344
Ignition Timing345
Specification345
Self-Diagnosis348
Circuit Diagram353
Diagnosis Connector359
Air Thermosensor360
Switch Monitor Function371
Intake Air System375
Air System376
Throttle Body378
Intake Manifold379
Accelerator Pedal380
Accelerator Cable380
Idle Speed Control (Isc) System382
Isc Valve382
Air Valve382
Charging System384
Fuel System386
Fuel Filter390
Pressure Regulator395
Exhaust System402
Positive Crankcase Ventilation404
Pcv Valve404
Emission Control System406
Check Valve406
Charcoal Canister407
Deceleration Control System408
Fuel Cut Control409
System Operation409
Dechoke Control System411
Engine Control Unit (ECU)415
Removal / Installation415
Inspection415
Terminal Voltage416
Clutch Switch (MTX)419
Airflow Meter (with Intake Air Thermosensor)420
Solenoid428
Water Thermosensor428
Inspection434
Water Thermosensor434
Throttle Sensor435
Oxygen Sensor437
Clutch Switch (Mtx)438
Power Steering Pressure Switch439
Engine Electrical System441
Specifications443
Charging System446
Circuit Diagram446
Specific Gravity of Electrolyte448
Quick Charging449
Ignition System455
Switch (MTX)457
Specification457
High-Tension Lead457
Inspection458
Spark Test460
Removal I Installation461
Starting System464
Wear Limit469
Interlock Switch Inspection471
Specifications475
Troubleshooting475
Clutch Fluid476
Removal / Inspection / Installation478
Clutch Pedal478
Clutch Master Cylinder480
Air Bleeding480
Assembly Note483
Clutch Release484
Release Cylinder484
Release Bearing489
Clutch Cover489
Clutch Disc489
Pilot Bearing490
Manual Transaxle491
Index492
Outline493
Specifications493
Power Flow495
Troubleshooting Guide496
Transaxle Oil497
Transaxle497
Inspection497
Park the Vehicle on Level Ground497
Replacement497
Removal500
Clutch Release Cylinder501
Disassembly504
Inspection505
Assembly507
Clutch Hub Sleeve512
Shim Selection527
Installation538
Differential542
Preparation542
Disassemblyi Inspection / Assembly543
Shift Mechanism546
Overhaul546
Manual Transaxle549
Outline551
Specifications551
Reverse Idler Gear552
Power Flow553
Troubleshooting Guide554
Transaxle Oil555
Inspection555
Replacement555
Transaxle555
Preparation556
Removal558
Disassembly560
Bearing Inner Race (Primary Shaft End)569
Inspection570
Assembly574
Assembly Note579
Bearing Preload Adjustment580
Bearing Preload584
Installation589
Differential591
Preparation591
Disassembly / Inspectioni Assembly J2-44592
Shift Mechanism594
Overhaul594
Front and Rear Axles597
Troubleshooting599
Front Axle600
Wheel Hub, Steering Knuckle601
Drum Brake Type607
Disc Brake Type610
Drive Shaft613
Removal / Installation614
Disassembly Procedure616
Assembly Procedure617
Steering System625
Manual Steering628
Tie Rod End Boot631
Removal / Installation633
Steering Shaft Assembly635
Steering Gear and Linkage637
Tie Rod End640
Speed Sensing649
Power Steering649
Steering Wheel and Column650
Engine Speed Sensing Power Steering653
Engine Speed658
Power Steering Oil Pump661
Braking System667
Outline669
Specifications669
Brake System671
Air Bleeding672
Brake Hydraulic Line672
Brake Fluid674
Brake Pedal674
Master Cylinder676
Power Brake Unit679
Dual Proportioning Valve682
Fluid Pressure682
Front Brake (Disc684
Caliper685
Disassembly / Inspection687
Rear Brake (Disc689
Caliper690
Rear Brake (Drum694
14. Wheel Cylinder696
Parking Brake System697
Troubleshooting Guide697
Parking Brake Shoe697
Parking Brake (Lever Type697
Parking Brake Cable698
Removal / Inspection / Installation698
Parking Brake Lever699
Wheels and Tires701
Uneven Wear705
Tire Rotation706
Wheel Balance Adjustment706
Outline710
Specifications710
Troubleshooting Guide712
Wheel Alignment713
Pre-Inspection713
Front Wheel Alignment713
Rear Wheel Alignment715
Front Suspension (Strut)716
Preparation716
Frontshockabsorberandspring717
Disassembly / Inspection718
Front Lower Arm722
Front Stabilizer724
Stabilizer Bar725
Rear Suspension (Strut)726
Preparation726
Rear Shock Absorber and Spring727
Lateral Link and Trailing Link732
Rear Stabilizer733
Rear Crossmember735
Removal / Installation735
Front Fender Panel743
Front Door744
Rear Power Window Switch753
Rear Side Window754
Rear Hatch756
Troubleshooting760
Door Lock System760
Power Door Lock760
Power Door Lock System761
Power Window System763
Window System765
Power Window766
Inspection767
Power Switch (ON/OFF)767
Power Window Sub-Switch (Passenger Side)768
Inspection768
Power Window Sub-Switch (Rear)768
Trunk Lid769
Removal / Installation769
Page S-L 11773
Removal / Installation773
Fuel Filler774
Front Bumper775
Removal / Installation775
Rear Bumper776
Rear Spoiler777
Hatchback778
Roof Molding782
Side Protector785
Protege788
Cowl Grille789
Outside Mirror790
Inspection791
Removal / Installation792
Window Glass798
Rear Window Glass799
Page S-L799
Troubleshooting803
Wiper and Washer803
Wiper Motor806
Inspection806
Washer Motor807
Windshield Wiper and Washer Switch807
Removal / Installation808
Washer Nozzle809
Rear Wiper and Washer810
Troubleshooting Guide810
Rear Wiper Motor813
Rear Washer Motor813
Sliding Sunroof816
Motor Assembly817
Limit Switch818
Sliding Panel Assembly820
Lower Panel821
Floor Mat835
Belt System839
Troubleshooting840
Speed Sensor843
Seat Assembly849
Underbody Dimensions852
Straight-Line855
Body Electrical857
Electrical Symbols866
Troubleshooting867
Fuse and Joint Box868
Structural View868
Specifications870
Circuit Breaker870
Headlight Relay874
Hazard Warning Switch876
Ignition Switch877
Cruise Control Main Switch877
Combination Switch879
Lighting System886
Troubleshooting886
RIGHT or LEFT891
Rear Combination Light899
Exterior Lighting System903
Stoplight Switch903
License Plate Light903
Structural View905
Troubleshooting906
Cargo Compartment Lamp910
Courtesy Lamp910
System Diagram911
Removal / Installation912
Warning System914
Seat Belt Warning Lamp918
Instrument Cluster919
Fuel Gauge Sender Unit929
Rear Window Defroster930
Troubleshooting931
Rear Window Defroster Switch933
Principle of Code Cycle936
Cruise Control Unit941
Removal / Installation941
Clutch Switch, Brake Switch943
Front View946
Noise Suppression953
Door Speaker954
Rear Speaker955
Antenna Feeder955
Heater and Air Conditioner Systems957
Blower Switch958
Troubleshooting961
Step 1 Check Fuses968
Heater Unit977
Blower Unit979
Heater Control Unit982
Air Conditioner986
Safety Precaution987
Sight Glass993
Checking Refrigerant Charge993
Cooling Unit994
Magnetic Clutch1007
Refrigerant Lines1010
Condenser Fan1013
Removal / Installation1013
Technical Data1024
Special Tools1037
Clutch and Manual Transaxle1040
Front and Rear1043
Heater and Air Conditioner1046
Contents1054
Wiring Color Code1056
Using Wiring Diagrams1058
Ground Points1059
System Circuit Diagram/Connector Diagram1060
Fuel Injection1061
Routing Diagram1062
Symbols1062
Logic Symbols1066
Troubleshooting1068
Handling Connectors1068
Measuring1070
Measuring Continuity/Resistance1071
Finding Short Circuits1072
Ground Point1074
Control System1084
Fan System1098
Daytime Running Lights1114
Audio System1136
Cruise Control System1146
Common Connector1157

Mazda 323 1992 - Door Hatchback

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