1998-2003 Mazda 323 / Protege Service & Repair Manual

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

GENERAL INFORMATION 00–00–9 00–00 Using the quick diagnosis chart • The chart lists the relation between the symptom and the cause of the malfunction. • The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It also specifies the area of the common cause when multiple malfunction symptoms occur. • The appropriate diagnostic inspection relating to malfunction cause as specified by the symptoms can be selected by looking down the diagnostic inspection column of the chart. YLU000WAA

GENERAL INFORMATION 00–00–10 Using the symptom troubleshooting • Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to take for each trouble symptom. End Of Sie YLU000WA2

1998-2003 Mazda 323 / Protege Service & Repair Manual

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