The transversely mounted inline fourcylinder engines used in these models are equipped with electronic fuel injection. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the vehicle into a garage and going there twice to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs the garage must charge to cover its labour and overheads. The manual has drawings and descriptions show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver’s seat facing forwards. Mazda 323 3-door Hatchback Acknowledgements We are grateful for the help and cooperation of the Mazda Motor Corporation for their assistance with technical information and certain illustrations. The technical writer who contributed to this project is Jay Storer. Thanks are due to Draper Tools Limited, who provided some of the workshop tools. Special thanks are due to all those people at Sparkford who helped in the production of this manual. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from the information given. assistance spring/strut dampers is used at the rear. The Your Mazda 323 manual to power available as an option. The brakes are disc at the front and drums or disc at the rear, with servo assistance as standard. An Anti-lock Brake System (ABS) Mazda 323 4-door Saloon Safety first! o-s Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.
General hazards Scalding e Don’t remove the radiator or expansion tank cap while the engine is hot. e Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running. Burning e Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use. Crushing e When working under or near a raised vehicle, always supplement the jack with axle stands, ae hed use ramps. (|=a =i ay (Qed -d Never venture under a car which is only supported by a jack. ¢ Take care if loosening or tightening hightorque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground. e Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker. Fume or gas intoxication * Exhaust fumes are poisonous; they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine ina confined space such as a garage with the doors shut. e Fuel vapour is also poisonous, as are the vapours from some antifreeze, brake hydraulic fluid and Diesel fuel. Don’t syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. e Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags in your pocket. e Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact. e Ignition HT sc voltage canbe & dangerous, S especially to IP people with heart problems or a pacemaker. Don’t work on or near the ignition system with the engine running or the ignition switched on. ohos% the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. e When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use. The battery Air bags e Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage instructions may apply. Diesel injection equipment e Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results. Remember... e Don’t attempt to lift a heavy component which may be beyond your capability - get e Do wear gloves or use barrier cream to protect your hands when necessary. ¢ Do get someone to check periodically rsa substance containing the acid. Once formed, when topping-up or carrying the battery. e The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads. e Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially e Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos. Electric shock in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400°C. The rubber changes into a charred or sticky Poisonous or irritant substances ¢ Fuel is highly flammable; fuel vapour is explosive. e Don’t let fuel spill onto a hot engine. e Fuel vapour is heavier than air, so don’t work on the fuel system with the vehicle over an inspection pit. e Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. e Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires. e This extremely corrosive acid is formed when certain types of synthetic rubber, found e Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care Asbestos (electrically or by use of tools). Hydrofluoric acid cleaning solvents and paint thinners. Fire ¢ Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks Special hazards assistance. e Don’t rush to finish a job, or take unverified short cuts. that all is well when working alone on the vehicle. ¢ Don’t use ill-fitting tools which may slip and cause injury. ¢ Do keep loose clothing and long hair well out of the way of moving mechanical parts. e Don’t leave tools or parts lying around where someone can trip over them. Mop e Do remove rings, wristwatch etc, before working on the vehicle - especially the electrical system. up oil and fuel spills at once. oo Roadside repairs Jump starting When jump-starting a car using a booster battery, observe the following precautions: HAYNES Y VY Before connecting the booster battery, make sure that the ignitionis switched off. Y Y Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off. If the battery is being jump-started from the battery in another vehicle, the two vehicles MUST NOT TOUCH each other. eZ Take note of any special precautions printed on the battery case. 5| Connect one end of the red jump lead to the positive (+) terminal of the flat battery Ii Make sure that the booster battery is the same voltage as the discharged one in the vehicle. 2 Jump starting will get you out of trouble, but you must correct HINT whatever made the battery go flat in the first place. There are three possibilities: The battery has been drained by repeated attempts to start, or by leaving the lights on. The charging system is not working properly (alternator drivebelt slack or broken, alternator wiring fault or alternator itself faulty). Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission). Connect the other end of the red lead to the positive (+) terminal of the booster battery. The battery itself is at fault (electrolyte low, or battery worn out). Bc} Connect one end of the black jump lead to the negative (-) terminal of the booster battery | 4 Pe 4: 4 % 4 ‘ a Connect the other end of the black jump lead to a bolt or bracket on the engine block, well away from the battery, on the vehicle to be started. Make sure that the jump leads will not come into contact with the fan, drive- belts or other moving parts of the engine. _y. . Stari the engine using the booster hattery and run it at idle speed. Switch on the lights, rear window demister and heaicr blower motor, then disconnect the jump leads in the reverse order of connection. Turn off the lights etc. Roadside repairs 0-7 Jacking and wheel changing Warning: The jack supplied with the vehicle should only be used for changing a tyre or placing axle stands under the frame. Never work under the vehicle or start the engine while this jack is being used as the only means of support. The vehicle should be on level earth. Place the shift lever in Park, if you have an automatic, or Reverse if you have a manual transmission. Chock the wheel diagonally opposite the wheel being changed. Set the handbrake. Remove the spare tyre and jack from stowage. Remove the wheel cover and trim ring (if so equipped) with the tapered end of the wheel nut spanner by inserting and twisting the handle and then levering against the back of the wheel cover. Loosen the wheel nuts about 1/4-to-1/2 turn each. Place the scissors-type jack under the side of the vehicle and adjust the jack height until it fits in the notch in the flange nearest the wheel to be changed. There is a front and rear jacking point on each side of the vehicle (see illustration). Turn the jack handle clockwise until the tyre clears the ground. Remove the wheel nuts spare. vehicle. Remove the jack and wheel nuts in a diagonal pattern. Refit the wheel nuts with the beveled edges facing in. Tighten them snugly. Don’t attempt to tighten them completely until the vehicle is lowered or it could slip off the jack. Turn the jack handle anti-clockwise to lower the be sure it’s snapped into place all the way around. Stow the tyre, jack and spanner. Unchock the wheel. and pull the wheel off. Replace it with the tighten the Refit the cover (and trim ring, if used) and The jack fits under the vehicle, indicated by notches in the sills og Roadside repairs Identifying leaks Warning: Most automotive oils and fluids are poisonous. Wash them off skin, and change out of contaminated clothing, without delay. Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies. The smell of a fluid leaking from the car may provide a clue to what’s leaking. Some fluids are distinctively coloured. It may help to clean the car and to park it over some clean paper as an aid to locating the source of the leak. Remember that some leaks may only occur while the engine is running. Sump a oil Oil from filter ...or from the base of the oil filter. Gearbox oil can leak from the seals at the inboard ends...
Základní servis a každodenní údržba
Podporujeme pravidelný servis a prohlídky podle plánu uvedeného v manuálu:
- Olej motorový - výměna co 15 tis. km (v náročných podmínkách až každých 10 tis.); doporučený 5W30, povolené 5W40, 10W40; objem podle verze motoru 3,2 l až 5,8 l.
- Převodový olej - výměna co 90 tis. km (manuální převodovka); doporučený 75W90 GL-4/GL-5; objem 2,7 l.
- Převodovka automatická - ATF M-III (Dexron II); objem 7,2 l.
- Chlazení - kapalina chladicí; výměna co 2 roky; objem 6,0-9,0 l podle motoru.
- Přehřátí brzd a spojky - kapalina chladicí; kapalina brzdová DOT-3/DOT-4; výměna dle nástřelu.
- Náplně systému posilovače - ATF M-III nebo Dexron II; objem 0,8-1,0 l (benzínové), 1,1 l (diesel).
- Pneumatiky - základní rozměry 175/65R14, 185/65R14, 195/55R15, 195/50R16; tlak 2,1-2,8 bar podle nákladu a rozměru.
- Filtry a rozvodový řetězec - výměny podle obdobných intervalů; svíčky NGK/DENSO; akumulátor s odpovídající kapacitou.
Bezpečnost práce na silnici a servisní zásahy na místě vyžadují adekvátní vybavení a postupy. Roadside repairs a Jump starting popisují postupy pro nouzové situace, včetně zapojení horního a spodního připojení akumulátoru a bezpečné rozsvěcení světel při startování.
Jak se starat o bezpečnost baterií
Technické souvislosti a dílčí návody
Identifikace úniků kapalin a jejich lokalizace podle barvy a zápachu, kontrola hladin oleje, kapaliny brzd a chladicí kapaliny, tlaků v pneumatikách a kontrola stavu dílů jsou uvedeny v manuálu. Popisy zahrnují diagnostiku a seřizovací postupy pro motor, klimatizaci, palivový a výfukový systém, elektroinstalaci, převodovky a brzdový systém.
Prostor pro praktické tabulky a poznámky
- Tabulka: Kapacity kapalin a intervaly výměn (motorový olej, závěs brzd, kapalina posilovače, chladicí kapalina).
- Tabulka: Rozměry kol a tlaků pro letní a zimní pneumatiky s konkrétními hodnotami.
- Seznam výměnných dílů a alternativ (filtry, svíčky, lysy, akumulátor) s doporučenými výrobci.