Mazda 323 Protege Gebrauchsanweisung

IV -- .-. .- --

I .

Mazda 323

4-Wheel Drive

Workshop

Manual

CONTENTS

Title Section

Current ) NeH

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. 1203-I O-89F (Vol. I> Europe

1204-I O-89F (vol. I > Australia

I ZM-1 o-89F (vol.2)

Ali information in this supplement was the

latest available at the time of printing, all alter-

nations related to modifications wili be notified

by Service Bulletin.

Mazda Motor Corporation

HIROSHlMA, JAPAN

APPLlCATlON:

This manual is applicable to vehicles beginning

with the Vehicle Identification Numbers (UN)

shown on the following page.

Electronically Controlled

Wiring

Diagram

Refer to the form No.

5161-l O-89L

5162-t O-89L

Thrs manual explarns only the sectIons marked with

shadows ( )

0 1989 Mazda Motor

Corporation

PRlNTED IN JAPAN, Dec., ‘88 @$

1229-l O-891

VEHICLE IDENTlFlCATlUN NUMBERS (VIN)

Europe

JMZ BG8262 00 1000Uf-

JMZ BG8362 00 IUOOOl -

JMZ BG82F2 00

lOOOOl-

JMZ BG83F2 00 IOU001 -

JMZ

BG83H2 00 100001-

Australia

JMO BGI WI 00 IO0001 -

GENERAL INFORMATION

IMPORTANT INFORMATION ..................... GI- 2

BASIC ASSUMPTtONS ............................ a- 2

SAFETY RlSK

........................................

GI- 2

POSSBLE LOSS OF WARRANTY ............. GI- 2

WARNiNF ON LUBRICANTS

AND GREASES .................................... GI- 2

HOW TO USE THIS MANUAL.. .................. Gl- 3

PREPARATION ...................................... Gl- 3

REPAIR PROCEDURE ............................. Gl- 3

SYMBOLS

.............................................

a- 4

NOTES, CAUTIONS, AND WARNINGS ....... Gl- 4

FUNDAMENTAL PROCEDURES ................. Gl- 4

PROTECTION OF THE VEHICLE .............. Gi- 4

A WORD ABOUT SAFETY ....................... Gl- 5

PREPARATION OF TOOLS

AND MEASURING EQUIPMENT ............. GI- 5

SPECIAL TOOLS

....................................

Gt- 5

REMOVAL OF PARTS

............................. GI- 5

DISASSEMBLY ...................................... Gi- 5

REASSEMBLY ....................................... Gl- 6

ADJUSTMENTS

.....................................

GC- 7

RUBBER PARTS AND TUBING ................ Gl- 7

JACK AN5 SAFETY STAN5 POSITDNS .... Gl- 8

VEHICLE LIFT (Z-SUPPORT TYPE)

POSITIONS ............................................ GI- 8

TOWING .................................................. GL 9

IDENTIFICATION NUMBER LOCATIONS ..... GI-10

UNITS

..................................................... GI-I 0

ABBREVIATIONS ..................................... Gl-I 0

CAUTION ................................................ Gl-I 1

1NSTALLATtON OF A MOBlLE

TWO-WAY RADIO SYSTEM .................... GI-II

REMOVAL OF tGNIT1ON KEY ON

AUTOMATIC TRANSAXLE MODEL .......... Gl-11

ELECTRICAL TROUBLESHOOTlNG TOOLS GI-12

CAUTION WITH ELECTRICAL PARTS ........ Gl-13

03UGIX-001

IMPORTANT tNFORMATlUN

IMPORTANT INFORMATION

.ftl

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 RlSK

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

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 toots.

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 08s 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 intervafs.

9MUGiX-502

HOW TO USE TtiIS MANUAL

HOW TO USE THIS MANUAL

PREPARATION

PREPARATON points out the needed SpeciaI Service Tool (SST) for the service operation that it pro-

ceeds. Gather all necessary SST before beginning work.

Example:

MANUAL STEERING

PREPARATION

remova! of W-rod

REPAIR PROCEDURE

Most repair operations begin with an overview illustration. It identifies

the

components, shows how the

parts fit together, and visual parts inspections. If

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

iItustration.

3. Pages related to service procedures are shown under the illustration. Refer to this information when ser-

vicing the related part.

Example:

--__ __-

EXPENDABLE iI -

SHOWS TlGHTENlNG

TORQUE UNIT

SHOWS

REiAT&

PAGE

FOR

1 8oit

16 Bearing lnne

2. Lock plate Removal ..

3. Bearrng cup I!.~ f%

fnstallatbon ._... ._. .....

Adirtstma drew

- _‘.v,--..s ----.

5. Bearing outer race :7 Spacer

G I h-tnllt

hriu* mninn

I V.LVYR*IY. .” I.~.1

7Washer Rerr&l'~ .._. ......__ .........__......... page M---21

- -0mpanlon f&we inspect spllnes and teeth for

wear or damage

Adlustment of heloht ._._..... ..... DaPe k&Z? I

r..r...~r.--~.~r....e.-..c~~...~.,~.-* Q

SERVICE x

9MUGlx-034

‘I : The numbering (ex.@))

shows service procedure.

‘2: Units shown

N-m (m-kg, Wb) unless otherwise specified.

HOW TO USE -MS lVlANUAL/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

transmission fluid

Apply grease

Only ATF

Appropriate grease

Appty sealant Appropriate sealant

0 Apply petroleum jelty Appropriate petroleum jelly

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. CAUTlUNS 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-

sona! injury. The foliowing list contains some general WARNINGS you should follow when you work on

vehicle.

9MUGlX-036

FUNDAMENTAL PROCEDURES

PROTECTON OF THE VEHICLE

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

fore starting work.

FUNDAMENTAL PROCEDURES

9MUGIX-003

SMUGIX-038

A WORD ABOUT SAFETY

The following precautions must be followed when jacking up

the vehicle,

3. 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 toots when they are required.

REMOVAL OF PARTS

White 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.

47ilOGX-006

DISASSEMBLY

If the 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.

9MlJGIX439

FUNDAMENTAL PROCEDURES

9MUGtX-040

SMLIGIX-041

SMUGIX-004

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.

removed,

these parts should be replaced with new

ones:

1. Oil seals 2. Gaskets

3. O-rings

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

applied at the prescribed

locations (such as oil seals) before reassembly.

‘31-6

FUNDAMENTAL PROCEDURES

GI’

ADJUSTMENTS

Use suitable gauges and/or testers when making adjustments.

67UOGX-002

RUBBER PARTS AND TUBING

Prevent gasoline or oil from getting on rubber parts or tubing.

Gl-7

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