1989-1994 Mazda 323 / Protege Service & Repair Manual

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Mazda 323 4-Wheel Drive Workshop Manual CONTENTS Title Section Current ) NeH Supplement FOREWORD This is a supplement to the workshop manual(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

GI IMPORTANT tNFORMATlUN IMPORTANT INFORMATION 1 .ftl 1 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 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 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 contaminated with oil. Dry clean or launder such clothing at regular intervafs. 9MUGiX-502

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1989-1994 Mazda 323 / Protege Service & Repair Manual

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