Mazda 323F BJ Service Manual.pdf

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19063869 UNPDF
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]
SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM
(ZM)]
SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM
(FS)]
MECHANICAL [ZM]
MECHANICAL [FS]
LUBRICATION
COOLING SYSTEM
INTAKE-AIR SYSTEM [ZM]
INTAKE-AIR SYSTEM [FS]
FUEL SYSTEM
EXHAUST SYSTEM
EMISSION SYSTEM
CHARGING SYSTEM
IGNITION SYSTEM
STARTING SYSTEM
CRUISE CONTROL SYSTEM
CONTROL SYSTEM [ZM]
CONTROL SYSTEM [FS]
TECHNICAL DATA
SERVICE TOOLS
SUSPENSION
02
GENERAL PROCEDURES
WHEEL ALIGNMENT
FRONT SUSPENSION
REAR SUSPENSION
TECHNICAL DATA
SERVICE TOOLS
DRIVELINE / AXLE
03
GENERAL PROCEDURES
FRONT AXLE
REAR AXLE
DRIVE SHAFT
TECHNICAL DATA
SERVICE TOOLS
BRAKES
04
ON-BOARD DIAGNOSTIC
SYMPTOM TROUBLESHOOTING
GENERAL PROCEDURES
CONVENTION BRAKE SYSTEM
PARKING BRAKE SYSTEM
ANTI-LOCK BRAKE SYSTEM
TECHNICAL DATA
SERVICE TOOLS
TRANSMISSION / TRANSAXLE
05
ON-BOARD DIAGNOSTIC
SYMPTOM TROUBLESHOOTING
CLUTCH
MANUAL TRANSAXLE [F25M-R]
MANUAL TRANSAXLE [G15M-R]
MANUAL TRANSAXLE SHIFT MECHANISM
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE SHIFT MECHANISM
TECHNICAL DATA
SERVICE TOOLS
STEERING
06
GENERAL PROCEDURES
ENGINE SPEED SENSING POWER STEERING
TECHNICAL DATA
SERVICE TOOLS
HEATER, VENTILATION & AC
07
SYMPTOM TROUBLESHOOTING
REFRIGERANT SYSTEM
BASIC SYSTEM
CONTROL SYSTEM
TECHNICAL DATA
SERVICE TOOLS
RESTRAINTS
08
ON-BOARD DIAGNOSTIC
SYMPTOM TROUBLESHOOTING
AIR BAG SYSTEM
SEAT BELT
SERVICE TOOLS
BODY & ACCESSORIES
09
ON-BOARD DIAGNOSTIC (POWER DOOR LOCK SYSTEM)
ON-BOARD DIAGNOSTIC (AUDIO)
SYMPTOM TROUBLESHOOTING
BODY PANELS
DOORS AND LIFT GATE
GLASS / WINDOWS / MIRRORS
SEATS
SECURITY AND LOCKS
SUNROOF
EXTERIOR TRIM
INTERIOR TRIM
LIGHTING SYSTEMS
WIPER / WASHER SYSTEM
ENTERTAINMENT
POWER SYSTEMS
INSTRUMENTATION / DRIVER INFO
TECHNICAL DATA
SERVICE TOOLS
GENERAL INFORMATION
00
SECTION
00–00
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.
00–00–1
Toc of SCT
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GENERAL INFORMATION
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
00–00–2
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GENERAL INFORMATION
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.
00–00
YLU000WA0
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 ma terials during service.
Symbol
Meaning
Kind
Apply oil
New appropriate
engine oil or gear
oil
00–00–3
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