Mazda 323 Protege 1992 Workshop Manual

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 han­dy place for quick and easy reference.

All the contents of this manual, including
drawings and specifications, are the latest avail­able 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.

All rights reserved. No part of this book may
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

I

Part No. 5209-10-91 F)
9999~95-019(3-92)

o 1991 Mazda Motor Corporation

PRINTED IN USA, JUL. ‘91
1270-l O-91 G
(9999-95-0178-92)

VEHICLE IDENTIFICATION NUMBERS (VIN)

PROTEGli

JMl BG223 * NO 400001-

JM1 86224

* NO 400001­JMl 86225 *NO 400001­JMl BG226 * NO 400001-

3-DOOR HATCHBACK

JMl BG231 *NO 400001­JMl 86232 *NO 400001­JMl 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

IMPORTANT INFORMATION

BASIC ASSUMPTIONS
This workshop manual assumes that you have certain special tools that are necessary for the safe and effi­cient 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 conse­quences 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 con­taminated with oil. Dry clean or launder such clothing at regular intervals.

9MUGIX-002

GI-2

HOW TO USE THIS MANUAL

GI

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 ser­vicing the related part.

Example:

SHOWS

NEEDED SST

\

SHOWS

APPLICATION

#T OF OIL,

SHOWS
RELATED

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