Mazda 323 Protege 1992 Gebrauchsanweisung

1992

Mazda

CONTENTS

Protege

Workshop

Manual

FOREWORD

This workshop manual is intended for use

by service technicians of Authorized Mazda

Dealers to help them service Mazda vehicles.

For proper repair and maintenance, a

thorough familiarization with this manual is im-

portant, and it should always be kept in a han-

dy place for quick and easy reference.

All the contents of this manual, including

drawings and specifications, are the latest avail-

able at the time of printing. As modifications

affecting repair or maintenance occur, relevant

information supplementary to this volume will

be made available at Mazda dealers. This

manual should be kept up-to-date.

Mazda Motor Corporation reserves the right

to alter the specifications and contents of this

manual without obligation or advance notice.

be reproduced or used in any form or by any

means, electronic or mechanical-including

photocopying and recording and the use of

any kind of information storage and retrieval

system-without permission in writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

APPLICATION:

This manual is applicable to vehicles beginning

with the Vehicle Identification Numbers (VIN)

shown on the following page.

Title

General Information

Section

Pre-Delivery Inspection and

Scheduled Maintenance Services

SOHC

Engine DOHC

Lubrication System

Cooling System

Fuel and Emission Control System

Engine Electrical System

Clutch

FSM-R

Manual Transaxle GSM-R

Automatic Transaxle

Front and Rear Axles

Steering System

Braking System

Wheels and Tires

Suspension

Body

Body Electrical System

Heater and Air Conditioner Systems

Technical Data

Special Tools

Parts Index

Wiring DNvam IPart No. 5209-10-91 F)

9999~95-019(3-92)

o 1991 Mazda Motor Corporation

PRINTED IN USA, JUL. ‘91

1270-l O-91G

(9999-95-0178-92)

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-

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- 6

VEHICLE LIFT (P-SUPPORT TYPE)

POSITIONS ............................................ GI- 6

TOWING .................................................. GI- 9

IDENTIFICATION NUMBER LOCATIONS ..... 61-10

UNITS ..................................................... GI-10

ABBREVIATIONS ..................................... GI-10

CAUTION ................................................ GI-1 1

INSTALLATION OF 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

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.

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

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.

Example:

49 0118 850C removal of be-rod

9MUGIX-033

REPAIR PROCEDURE

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

NEEDED SST

SHOWS

APPLICATION

#T OF OIL,

SHOWS

PAGE FOR

SERVICE ----

\ \

3. Bearing cup

1. Bolt

2. Lock Dlate

4. Adjusting screw

5. Bearing outer race

6. Locknut

7. Washer

8. Companion flange

16. Bearing Inner race

@ Removal. ,,,..,,,..

lnstallatlon

page

page M--5

M-Z

i 7. Spacer

18. Drive pinion

Removal, .,,, ,.,, .,......... page M--i

Inspect spllnes and teeth for wear or damagl

Adjustment of height page M-2

Adurstp- w

SHOWS TIGHTENING

TORQUE

SPECIFICATION ‘2

SHOWS TIGHTENING

rORQlJE UNIT

SHOWS VISUAL

INSPECTION

INFORMATION

* 1: The numbering (ex.a) shows service procedure.

*2: Units shown in N.m (m-kg, ft-lb) unless otherwise specified.

9MUGIX-034

GI-3

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

Apply oil New engine oil or gear oil as appropriate

Apply brake fluid Only brake fluid

Apply automatic transaxle fluid Only ATF

Apply grease Appropriate grease

amal Apply sealant Appropriate sealant

0 Apply petroleum jelly Appropriate petroleum jelly

23UGIX-001

Note

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

SMUGIX-037

a-4

FUNDAMENTAL PROCEDURES

PROTECTION OF THE VEHICLE

Always be sure to cover fenders, seats, and floor areas be-

fore starting work.

FUNDAMENTALPROCEDURES

SMUGIX-0: B

47UOGX-00 5

‘3

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

Ifthe disassembly procedure is complex, 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

FUNDAMENTAL PROCEDURES

9MUGIX-04t 3

9MUGIX-041

9MUGIX.004 I

Depending on location:

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

1. Sealant should be applied or new gaskets used.

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.

23lJGIX.004

GI-6

FUNDAMENTALPROCEDURES

I 67UOGX-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 (2-SUPPORT TYPE) POSITIONS

JACK AND SAFETY STAND POSITIONS

FRONT END

Jack position:

At the front crossmember

03UGIX-007

REAR END

Jack position:

At the center of the rear crossmember

Safety stand positions:

On both sides of the body frame

Safety stand positions:

On both sides of the body frame

VEHICLE LIFT (29SUPPORT TYPE) POSITIONS

FRONT ENDFRONT END

FrameFrame

Side sillsSide sills

REAR END

Frame

Side sills

03UGIX-010

SMUGIX-01

- .’

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