2003 Mazda 323/Protege/Familia Service & Repair Manual

GENERAL INFORMATION 00-00 ENGINE 01 ON-BOARD DIAGNOSTIC [ENGINE CONTROL SYSTEM (ZM) 01-02A ON-BOARD DIAGNOSTIC [ENGINE CONTROL SYSTEM (FS)] 01-02B ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] 01-02C SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)] 01-03A SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)] 01-03B MECHANICAL [ZM] 01-10A MECHANICAL [FS] 01-10B LUBRICATION 01-11 COOLING SYSTEM 01-12 INTAKE-AIR SYSTEM [ZM] 01-13A INTAKE-AIR SYSTEM [FS] 01-13B FUEL SYSTEM 01-14 EXHAUST SYSTEM 01-15 EMISSION SYSTEM 01-16 CHARGING SYSTEM 01-17 IGNITION SYSTEM 01-18 STARTING SYSTEM 01-19 CRUISE CONTROL SYSTEM 01-20 CONTROL SYSTEM [ZM] 01-40A CONTROL SYSTEM [FS] 01-40B TECHNICAL DATA 01-50 SERVICE TOOLS 01-60 SUSPENSION 02 GENERAL PROCEDURES 02-10 WHEEL ALIGNMENT 02-11 FRONT SUSPENSION 02-13 REAR SUSPENSION 02-14 TECHNICAL DATA 02-50 SERVICE TOOLS 02-60 DRIVELINE / AXLE 03 GENERAL PROCEDURES 03-10 FRONT AXLE 03-11 REAR AXLE 03-12 DRIVE SHAFT 03-13 TECHNICAL DATA 03-50 SERVICE TOOLS 03-60 BRAKES 04 ON-BOARD DIAGNOSTIC 04-02 SYMPTOM TROUBLESHOOTING 04-03 GENERAL PROCEDURES 04-10 CONVENTION BRAKE SYSTEM 04-11 PARKING BRAKE SYSTEM 04-12 ANTI-LOCK BRAKE SYSTEM 04-13 TECHNICAL DATA 04-50 SERVICE TOOLS 04-60

TRANSMISSION / TRANSAXLE 05 ON-BOARD DIAGNOSTIC 05-02 SYMPTOM TROUBLESHOOTING 05-03 CLUTCH 05-10 MANUAL TRANSAXLE [F25M-R] 05-15A MANUAL TRANSAXLE [G15M-R] 05-15B MANUAL TRANSAXLE SHIFT MECHANISM 05-16 AUTOMATIC TRANSAXLE 05-17 AUTOMATIC TRANSAXLE SHIFT MECHANISM 05-18 TECHNICAL DATA 05-50 SERVICE TOOLS 05-60 STEERING 06 GENERAL PROCEDURES 06-10 ENGINE SPEED SENSING POWER STEERING 06-12 TECHNICAL DATA 06-50 SERVICE TOOLS 06-60 HEATER, VENTILATION & AC 07 SYMPTOM TROUBLESHOOTING 07-03 REFRIGERANT SYSTEM 07-10 BASIC SYSTEM 07-11 CONTROL SYSTEM 07-40 TECHNICAL DATA 07-50 SERVICE TOOLS 07-60 RESTRAINTS 08 ON-BOARD DIAGNOSTIC 08-02 SYMPTOM TROUBLESHOOTING 08-03 AIR BAG SYSTEM 08-10 SEAT BELT 08-11 SERVICE TOOLS 08-60 BODY & ACCESSORIES 09 ON-BOARD DIAGNOSTIC (POWER DOOR LOCK SYSTEM) 09-02A ON-BOARD DIAGNOSTIC (AUDIO) 09-02B SYMPTOM TROUBLESHOOTING 09-03 BODY PANELS 09-10 DOORS AND LIFT GATE 09-11 GLASS / WINDOWS / MIRRORS 09-12 SEATS 09-13 SECURITY AND LOCKS 09-14 SUNROOF 09-15 EXTERIOR TRIM 09-16 INTERIOR TRIM 09-17 LIGHTING SYSTEMS 09-18 WIPER / WASHER SYSTEM 09-19 ENTERTAINMENT 09-20 POWER SYSTEMS 09-21 INSTRUMENTATION / DRIVER INFO 09-22 TECHNICAL DATA 09-50 SERVICE TOOLS 09-60

00 GENERAL INFORMATION 00–00–1 SECTION 00–00 Toc of SCT GENERAL INFORMATION . . . . 00-00 Toc of SCT 00–00 GENERAL INFORMATION HOW TO USE THIS MANUAL . . . . . . . . . 00–00–1 Range of Topics . . . . . . . . . . . . . . . . . . 00–00–1 Service Procedure. . . . . . . . . . . . . . . . . 00–00–2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00–00–3 Advisory Messages . . . . . . . . . . . . . . . . 00–00–4 Troubleshooting Procedure . . . . . . . . . . 00–00–5 Procedures for Use . . . . . . . . . . . . . . . . 00–00–6 UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–11 Conversion to SI Units (Système International d'Unités) . . . . . . . . . . . . . . . . . . . . . . . 00–00–11 Rounding Off . . . . . . . . . . . . . . . . . . . . . 00–00–11 Upper and Lower Limits . . . . . . . . . . . . 00–00–11 FUNDAMENTAL PROCEDURES . . . . . . 00–00–11 Protection of the Vehicle . . . . . . . . . . . . 00–00–11 Preparation of Tools and Measuring Equipment . . . . . . . . . . . . . . . . . . . . . . 00–00–12 Special Service Tools . . . . . . . . . . . . . . 00–00–12 Oil Leakage Inspection . . . . . . . . . . . . . 00–00–12 Disconnection of the Negative Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–13 Removal of Parts. . . . . . . . . . . . . . . . . . 00–00–13 Disassembly . . . . . . . . . . . . . . . . . . . . . 00–00–13 Inspection During Removal, Disassembly . . . . . . . . . . . . . . . . . . . . 00–00–13 Arrangement of Parts . . . . . . . . . . . . . . 00–00–14 Cleaning of Parts. . . . . . . . . . . . . . . . . . 00–00–14 Reassembly . . . . . . . . . . . . . . . . . . . . . 00–00–14 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00–00–15 Rubber Parts and Tubing . . . . . . . . . . . 00–00–15 Hose Clamps. . . . . . . . . . . . . . . . . . . . . 00–00–15 Torque Formulas . . . . . . . . . . . . . . . . . . 00–00–15 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–16 Dynamometer . . . . . . . . . . . . . . . . . . . . 00–00–16 INSTALLATION OF RADIO SYSTEM. . . 00–00–16 ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00–00–16 Electrical Parts . . . . . . . . . . . . . . . . . . . 00–00–16 Wiring Harness . . . . . . . . . . . . . . . . . . . 00–00–17 Connectors . . . . . . . . . . . . . . . . . . . . . . 00–00–17 Terminals . . . . . . . . . . . . . . . . . . . . . . . 00–00–18 Sensors, Switches, and Relays . . . . . . 00–00–19 Wiring Harness . . . . . . . . . . . . . . . . . . . 00–00–19 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–19 Electrical Troubleshooting Tools . . . . . 00–00–20 Precautions Before Welding . . . . . . . . 00–00–20 JACKING POSITIONS. . . . . . . . . . . . . . . 00–00–21 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–21 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–21 VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITION . . . . 00–00–22 Vehicle Lift Positions . . . . . . . . . . . . . . 00–00–22 Safety Stand Positions . . . . . . . . . . . . . 00–00–22 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–22 Tiedown Hooks . . . . . . . . . . . . . . . . . . 00–00–23 IDENTIFICATION NUMBER LOCATIONS00–00–24 Vehicle Identification Number (VIN) . . . 00–00–24 Chassis Number . . . . . . . . . . . . . . . . . . 00–00–24 Engine Identification Number . . . . . . . . 00–00–24 SAE STANDARDS . . . . . . . . . . . . . . . . . 00–00–25 ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00–00–26 PRE-DELIVERY INSPECTION . . . . . . . . 00–00–27 Pre-Delivery Inspection Table . . . . . . . 00–00–27 SCHEDULED MAINTENANCE . . . . . . . . 00–00–29 Scheduled Maintenance Table . . . . . . 00–00–29 End of Toc HOW TO USE THIS MANUAL A3U000000001W01 Range of Topics • This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: — Removal/Installation — Disassembly/Assembly — Replacement — Inspection — Adjustment • Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.

GENERAL INFORMATION 00–00–2 Service Procedure Inspection, adjustment • Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations. ZLU0000W208

GENERAL INFORMATION 00–00–3 00–00 Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown. 3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. Refer to this information when servicing the related part. Symbols • There are eight symbols indicating oil, grease, fluids, sealant, ane the use of SST or equivalent. use. These symbols show application points or use of these materials during service. YLU000WA0 Symbol Meaning Kind Apply oil New appropriate engine oil or gear oil

GENERAL INFORMATION 00–00–4 Advisory Messages • You'll find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this manual. Warning • A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution • A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored. Note • A Note provides added information that will help you to complete a particular procedure. Specification • The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits • The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments. Apply brake fluid New appropriate brake fluid Apply automatic transaxle/ transmission fluid New appropriate automatic transaxle/ transmission fluid Apply grease Appropriate grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Replace part O-ring, gasket, etc. Use SST or equivalent Appropriate tools Symbol Meaning Kind

GENERAL INFORMATION 00–00–5 00–00 Troubleshooting Procedure Basic flow of troubleshooting DTC troubleshooting flow (on-board diagnostic) • Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction. • The on-board diagnostic function is used during inspection. When a DTC is shown specifying the cause of a malfunction, continue the diagnostic inspection according to the items indicated by the on-board diagnostic function. Diagnostic index • The diagnostic index lists the symptoms of specific malfunctions. Select the symptoms related or most closely relating to the malfunction. Quick diagnosis chart (If mentioned) • The quick diagnosis chart lists diagnosis and inspection procedures to be performed specifically relating to the cause of the malfunction. Symptom troubleshooting • Symptom troubleshooting quickly determines the location of the malfunction according to symptom type. WGIWXX0001E

GENERAL INFORMATION 00–00–6 Procedures for Use Using the basic inspection (section 05) • Perform the basic inspection procedure before symptom troubleshooting. • Perform each step in the order shown. • The reference column lists the location of the detailed procedure for each basic inspection. • Although inspections and adjustments are performed according to the reference column procedures, if the cause of the malfunction is discovered during basic inspection, continue the procedures as indicated in the remarks column. YLU000WA8

GENERAL INFORMATION 00–00–7 00–00 Using the DTC troubleshooting flow • DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each DTC. YLU000WA1

GENERAL INFORMATION 00–00–8 Using the diagnostic index • The symptoms of the malfunctions are listed in the diagnostic index for symptom troubleshooting. • The exact malfunction symptoms can be selected by following the index. YLU000WA9

2003 Mazda 323/Protege/Familia Service & Repair Manual

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