Text preview for : 323F BJ Service Manual (2002+ proteg)1.pdf part of Mazda 323F Service Manual w. Parts List f. Mazda 323F / Protegé Model: BJ (1998-2002)



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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 01-03A
(ZM)]
SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM 01-03B
(FS)]
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
GENERAL INFORMATION 00SECTION
0000



Toc of SCT INFORMATION . . . . 00-00
GENERAL
Toc of SCT
0000 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00001 Dynamometer. . . . . . . . . . . . . . . . . . . . 000016
Range of Topics . . . . . . . . . . . . . . . . . . 00001 INSTALLATION OF RADIO SYSTEM. . . 000016
Service Procedure. . . . . . . . . . . . . . . . . 00002 ELECTRICAL SYSTEM. . . . . . . . . . . . . . 000016
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00003 Electrical Parts . . . . . . . . . . . . . . . . . . . 000016
Advisory Messages . . . . . . . . . . . . . . . . 00004 Wiring Harness. . . . . . . . . . . . . . . . . . . 000017
Troubleshooting Procedure. . . . . . . . . . 00005 Connectors . . . . . . . . . . . . . . . . . . . . . . 000017
Procedures for Use . . . . . . . . . . . . . . . . 00006 Terminals . . . . . . . . . . . . . . . . . . . . . . . 000018
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000011 Sensors, Switches, and Relays . . . . . . 000019
Conversion to SI Units (Systme International Wiring Harness. . . . . . . . . . . . . . . . . . . 000019
d'Units) . . . . . . . . . . . . . . . . . . . . . . . 000011 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . 000019
Rounding Off . . . . . . . . . . . . . . . . . . . . . 000011 Electrical Troubleshooting Tools . . . . . 000020
Upper and Lower Limits . . . . . . . . . . . . 000011 Precautions Before Welding . . . . . . . . 000020
FUNDAMENTAL PROCEDURES . . . . . . 000011 JACKING POSITIONS. . . . . . . . . . . . . . . 000021
Protection of the Vehicle . . . . . . . . . . . . 000011 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . 000021
Preparation of Tools and Measuring Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 000021
Equipment . . . . . . . . . . . . . . . . . . . . . . 000012 VEHICLE LIFT (2 SUPPORTS) AND SAFETY
Special Service Tools . . . . . . . . . . . . . . 000012 STAND (RIGID RACK) POSITION . . . . 000022
Oil Leakage Inspection . . . . . . . . . . . . . 000012 Vehicle Lift Positions . . . . . . . . . . . . . . 000022
Disconnection of the Negative Battery Safety Stand Positions . . . . . . . . . . . . . 000022
Cable. . . . . . . . . . . . . . . . . . . . . . . . . . 000013 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . 000022
Removal of Parts. . . . . . . . . . . . . . . . . . 000013 Tiedown Hooks . . . . . . . . . . . . . . . . . . 000023
Disassembly . . . . . . . . . . . . . . . . . . . . . 000013 IDENTIFICATION NUMBER LOCATIONS000024
Inspection During Removal, Vehicle Identification Number (VIN) . . . 000024
Disassembly . . . . . . . . . . . . . . . . . . . . 000013 Chassis Number. . . . . . . . . . . . . . . . . . 000024
Arrangement of Parts . . . . . . . . . . . . . . 000014 Engine Identification Number . . . . . . . . 000024
Cleaning of Parts. . . . . . . . . . . . . . . . . . 000014 SAE STANDARDS . . . . . . . . . . . . . . . . . 000025
Reassembly . . . . . . . . . . . . . . . . . . . . . 000014 ABBREVIATIONS . . . . . . . . . . . . . . . . . . 000026
Adjustment . . . . . . . . . . . . . . . . . . . . . . 000015 PRE-DELIVERY INSPECTION . . . . . . . . 000027
Rubber Parts and Tubing . . . . . . . . . . . 000015 Pre-Delivery Inspection Table . . . . . . . 000027
Hose Clamps. . . . . . . . . . . . . . . . . . . . . 000015 SCHEDULED MAINTENANCE . . . . . . . . 000029
Torque Formulas. . . . . . . . . . . . . . . . . . 000015 Scheduled Maintenance Table . . . . . . 000029
Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000016

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.




00001
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




00002
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 0000
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.




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 materials during service.
Symbol Meaning Kind

New appropriate
Apply oil engine oil or gear
oil


00003
GENERAL INFORMATION
Symbol Meaning Kind

New appropriate
Apply brake fluid
brake fluid


New appropriate
Apply automatic
automatic
transaxle/
transaxle/
transmission fluid
transmission fluid


Appropriate
Apply grease
grease



Appropriate
Apply sealant
sealant



Apply petroleum Appropriate
jelly petroleum jelly



O-ring, gasket,
Replace part
etc.



Use SST or
Appropriate tools
equivalent


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.




00004
GENERAL INFORMATION
Troubleshooting Procedure
Basic flow of troubleshooting



0000




WGIWXX0001E



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.




00005
GENERAL INFORMATION
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




00006
GENERAL INFORMATION
Using the DTC troubleshooting flow
DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each
DTC.


0000




YLU000WA1




00007
GENERAL INFORMATION
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




00008
GENERAL INFORMATION
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. 0000




YLU000WAA




00009
GENERAL INFORMATION
Using the symptom troubleshooting
Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to take for
each trouble symptom.




YLU000WA2

End Of Sie




000010
GENERAL INFORMATION
UNITS
A3U000000002W01

Electric current A (ampere) Nm (Newton meter)
Electric power W (watt) kgfm (kilogram force meter)
Electric resistance (ohm) Torque kgfcm (kilogram force centimeter)
ftlbf (foot pound force) 0000
Electric voltage V (volt)
mm (millimeter) inlbf (inch pound force)
Length L (liter)
in (inch)
kPa (kilo pascal) US qt (U.S. quart)
Negative pressure mmHg (millimeters of mercury) Imp qt (Imperial quart)
inHg (inches of mercury) Volume ml (milliliter)
kPa (kilo pascal) cc (cubic centimeter)
kgf/cm2 (kilogram force per square cu in (cubic inch)
Positive pressure
centimeter) fl oz (fluid ounce)
psi (pounds per square inch) g (gram)
Weight
Number of oz (ounce)
rpm (revolutions per minute)
revolutions




Conversion to SI Units (Systme International d'Units)
All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.

Rounding Off
Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

Upper and Lower Limits
When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:

210--260 kPa {2.1--2.7 kgf/cm2, 30--38 psi}
270--310 kPa {2.7--3.2 kgf/cm2, 39--45 psi}

The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
FUNDAMENTAL PROCEDURES
A3U000000004W01
Protection of the Vehicle
Always be sure to cover fenders, seats and floor
areas before starting work.




X3U000WAG




000011
GENERAL INFORMATION
Preparation of Tools and Measuring Equipment
Be sure that all necessary tools and measuring
equipment are available before starting any work.




X3U000WAH



Special Service Tools
Use special service tools or equivalent when they
are required.




X3U000WAJ



Oil Leakage Inspection
Use either of the following procedures to identify the type of oil that is leaking:

Using UV light (black light)
1. Remove any oil on the engine or transaxle.

Note
Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or
ATF (or transaxle oil).

2. Pour the fluorescent dye into the engine oil or ATF (or transaxle oil).
3. Allow the engine to run for 30 minutes.
4. Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
If no dye leakage is found, allow the engine to run for another 30 minutes or drive the vehicle then
reinspect.
5. Find where the oil is leaking from, then make necessary repairs.

Note
To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the
fluorescent dye instruction manual.

Not using UV light (black light)
1. Gather some of the leaking oil using an absorbent white tissue.
2. Take samples of engine oil and ATF (or transaxle oil), both from the dipstick, and place them next to the leaked
oil already gathered on the tissue.




000012
GENERAL INFORMATION
3. Compare the appearance and smell, and identify
the type of oil that is leaking.
4. Remove any oil on the engine or transaxle.
5. Allow the engine to run for 30 minutes.
6. Check the area where the oil is leaking, then
make necessary repairs. 0000




YMU000WAH



Disconnection of the Negative Battery Cable
Before beginning any work, turn the ignition switch to LOCK position, then disconnect the negative battery
cable and wait for more than 1 minute to allow the backup power supply of the SAS control module to deplete
its stored power. Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc.
Therefore, it is necessary to verify those memories before disconnecting the cable.

Removal of Parts
While correcting a problem, also try to determine
its cause. Begin work only after first learning
which parts and subassemblies must be removed
and disassembled for replacement or repair. After
removing the part, plug all holes and ports to
prevent foreign material from entering.




X3U000WAK



Disassembly
If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.




X3U000WAL



Inspection During Removal, Disassembly
When removed, each part should be carefully
inspected for malfunction, deformation, damage,
and other problems.




X3U000WAM




000013
GENERAL INFORMATION
Arrangement of Parts
All disassembled parts should be carefully arranged for reassembly.
Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.




X3U000WAN



Cleaning of Parts
All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.

Warning
Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.




X3U000WAP



Reassembly
Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, these parts should be replaced with
new ones:
-- Oil seals
-- Gaskets
-- O-rings
-- Lockwashers
-- Cotter pins
-- Nylon nuts
Depending on location:
X3U000WAQ
-- Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before sealant hardens to prevent leakage.
-- Oil should be applied to the moving components of parts.
-- Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.




X3U000WAR




000014
GENERAL INFORMATION
Adjustment
Use suitable gauges and/or testers when making
adjustments.


0000




X3U000WAS



Rubber Parts and Tubing
Prevent gasoline or oil from getting on rubber
parts or tubing.




X3U000WAT



Hose Clamps
When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.




X3U000WAU



Torque Formulas
When using a torque wrench-SST or equivalent
combination, the written torque must be
recalculated due to the extra length that the SST
or equivalent adds to the torque wrench.
Recalculate the torque using the following
formulas. Choose the formula that applies to you.
Torque Unit Formula
Nm Nm [L/(L+A)]
kgfm kgfm [L/(L+A)]
kgfcm kgfcm [L/(L+A)]
ftlbf ftlbf [L/(L+A)]
X3U000WAV
inlbf inlbf [L/(L+A)]

A : The length of the SST past the torque wrench drive.
L : The length of the torque wrench.



000015
GENERAL INFORMATION
Vise
When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.




X3U000WAW



Dynamometer
When test-running a vehicle on a dynamometer:
-- Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
-- Connect an exhaust gas ventilation unit.
-- Cool the exhaust pipes with a fan.
-- Keep the area around the vehicle uncluttered.
-- Watch the water temperature gauge.

Note
When the vehicle is on a chassis roller and only the front wheels rotate, the ABS warning light may
illuminate. (Refer to 04101 PRECAUTION (BRAKES) to turn off the warning light.)

End Of Sie
INSTALLATION OF RADIO SYSTEM
A3U000000005W01
If a radio system is installed improperly or if a high-powered type is used, the CIS and other systems may be
affected. When the vehicle is to be equipped with a radio, observe the following precautions:
Install the antenna at the farthest point from control modules.
Install the antenna feeder as far as possible from the control module harnesses.
Ensure that the antenna and feeder are properly adjusted.
Do not install a high-powered radio system.
End Of Sie
ELECTRICAL SYSTEM
A3U000000006W01
Electrical Parts
Battery cable
Before disconnecting connectors or removing
electrical parts, disconnect the negative battery
cable.




WGIWXX0038E




000016
GENERAL INFORMATION
Wiring Harness
To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.
0000




WGIWXX0039E



Connectors
Disconnecting connectors
When disconnecting connector, grasp the
connectors, not the wires.




WGIWXX0041E

Connectors can be disconnected by pressing or
pulling the lock lever as shown.




WGIWXX0042E



Locking connector
When locking connectors, listen for a click
indicating they are securely locked.




WGIWXX0043E




000017
GENERAL INFORMATION
Inspection
When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from
the wiring harness side.
Inspect the terminals of waterproof connectors
from the connector side since they cannot be
accessed from the wiring harness side.




WGIWXX0044E
Caution
To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.




WGIWXX0045E



Terminals
Inspection
Pull lightly on individual wires to verify that they
are secured in the terminal.




X3U000WB4



Replacement
Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it
locks securely.
Insert a thin piece of metal from the terminal side
of the connector and with the terminal locking tab
pressed down, pull the terminal out from the
connector.




WGIWXX0046E




000018
GENERAL INFORMATION
Sensors, Switches, and Relays
Handle sensors, switches, and relays carefully.
Do not drop them or strike them against other
objects.
0000




WGIWXX0047E



Wiring Harness
Wiring color codes
Two-color wires are indicated by a two-color code symbol.
The first letter indicates the base color of the wire
and the second the color of the stripe.
CODE COLOR CODE COLOR
B Black O Orange
BR Brown P Pink
G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow
LG Light Green
WGIWXX0048E



Fuse
Replacement
When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse fails again, the circuit
probably has a short and the wiring should be inspected.
Be sure the negative battery terminal is
disconnected before replacing a main fuse.




WGIWXX0049E

When replacing a pullout fuse, use the fuse
puller.




WGIWXX0050E




000019
GENERAL INFORMATION
Electrical Troubleshooting Tools
Jumper wire
A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit
to bypass a switch.

Caution
Do not connect a jumper wire from the
power source line to a body ground. This
may cause burning or other damage to
wiring harnesses or electronic
components.




X3U000WBB



Voltmeter
The DC voltmeter is used to measure circuit
voltage. A voltmeter with a range of 15 V or more
is used by connecting the positive (+) probe (red
lead wire) to the point where voltage will be
measured and the negative (-) probe (black lead
wire) to a body ground.




WGIWXX0051E



Ohmmeter
The ohmmeter is used to measure the resistance between two points in a circuit and to inspect for continuity
and short circuits.

Caution
Do not connect the ohmmeter to any
circuit where voltage is applied. This will
damage the ohmmeter.




WGIWXX0052E



Precautions Before Welding
A vehicle has various electrical parts. To protect the parts from excessive current generated when welding, be sure
to perform the following procedure.
1. Turn the ignition switch to the LOCK position.




000020
GENERAL INFORMATION
2. Disconnect the battery cables.




0000




WGIWXX0007E

3. Securely connect the welding machine ground
near the welding area.
4. Cover the peripheral parts of the welding area to
protect them from weld spatter.
End Of Sie




WGIWXX0008E

JACKING POSITIONS
A3U000000007W01

Warning
Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious
injury. Use only the correct front and rear jacking positions and block the wheels.

Use safety stands to support the vehicle after it has been lifted.

Front
At the center of the crossmember




WGIWXX0060E



Rear
At the center of the crossmember
End Of Sie




X3U000WBF




000021
GENERAL INFORMATION
VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITION
A3U000000008W01
Vehicle Lift Positions
Front and rear

Warning
Unstably lifting a vehicle is dangerous.
The vehicle can slip off the lift and cause
serious injury and/or vehicle damage.
Make sure that the vehicle is on the lift
horizontally by adjusting the height of
support at the end of the arm of the lift.




X3U000WBH



Safety Stand Positions
Front
Both sides of the vehicle, on side sills.




X3U000WBJ



Rear
Both sides of the vehicle, on side sills.
End Of Sie




X3U000WBK

TOWING
A3U000000009W01
Proper lifting and towing are necessary to prevent damage to the vehicle. State and local laws must be
followed.
A towed vehicle usually should have its front wheels off the ground. If excessive damage or other conditions
prevent this, use wheel dollies.




000022
GENERAL INFORMATION
When towing with the rear wheels on the ground,
release the parking brake.

Caution
Do not tow with sling-type equipment.
This could damage your vehicle. Use 0000
wheel-lift or flatbed equipment.




YLU000WA5




Caution
Do not tow the vehicle backward with
driving wheels on the ground. This may
cause internal damage to the transaxle.




YLU000WA7



Caution
Do not use the hook loops under the
front and rear for towing. They are
designed ONLY for tying down the
vehicle when it is being transported.
Using them for towing will damage the
bumper.




YLU000WA6



Tiedown Hooks
Front




X3U000WBP




000023
GENERAL INFORMATION
Rear




X3U000WBQ

End Of Sie
IDENTIFICATION NUMBER LOCATIONS
A3U000000010W01
Vehicle Identification Number (VIN)




X3U000WBV



Chassis Number




X3U000WBR



Engine Identification Number




X3U000WBS




000024
GENERAL INFORMATION
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0000




X3U000WBT
SAE STANDARDS
A3U000000003W01
In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and
abbreviations are now used in this manual. The table below lists the names and abbreviations that have been
used in Mazda manuals up to now and their SAE equivalents.
SAE Standard SAE Standard
Remark Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal MAP Manifold Absolute Pressure
ACL Air Cleaner MAF sensor Mass Air Flow Sensor
A/C Air Conditioning MFI Multiport Fuel Injection
BARO Barometric Pressure OBD On-Board Diagnostic
B+ Battery Positive Voltage OL Open Loop
CMP sensor Camshaft Position Sensor OC Oxidation Catalytic Converter
CAC Charge Air Cooler O2S Oxygen Sensor
CLS Closed Loop System PNP Park/Neutral Position
CTP Closed Throttle Position PSP Power Steering Pressure
CPP Clutch Pedal Position PCM Powertrain Control Module #3
CIS Continuous Fuel Injection PAIR Pulsed Secondary Air Pulsed
Injection injection
System
CKP sensor Crankshaft Position Sensor AIR Secondary Air Injection Injection
with air
DLC Data Link Connector pump
DTM Diagnostic Test Mode #1 SAPV Secondary Air Pulse Valve
DTC Diagnostic Trouble Code(s) SFI Sequential Multipoint Fuel
DI Distributor Ignition Injection
EI Electronic Ignition #2 3GR Third Gear
ECT Engine Coolant Temperature TWC Three Way Catalytic
EM Engine Modification Converter
EVAP Evaporative Emission TB Throttle Body
EGR Exhaust Gas Recirculation TP sensor Throttle Position Sensor
FC Fan Control TCC Torque Converter Clutch
FF Flexible Fuel TCM Transmission (Transaxle)
Control Module
4GR Fourth Gear
TR Transmission (Transaxle)
GEN Generator
Range
GND Ground
TC Turbocharger
HO2S Heated Oxygen Sensor With
VSS Vehicle Speed Sensor
heater
VR Voltage Regulator
IAC Idle Air control
VAF sensor Volume Air Flow Sensor
IAT Intake Air Temperature
WUTWC Warm Up Three Way #4
KS Knock Sensor
Catalytic Converter
MIL Malfunction Indicator Lamp
WOT Wide Open Throttle

#1 : Diagnostic trouble codes depend on the diagnostic test mode
#2 : Controlled by the PCM
#3 : Device that controls engine and powertrain
#4 : Directly connected to exhaust manifold

000025
GENERAL INFORMATION
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ABBREVIATIONS
A3U000000011W01

AAS Air adjusting screw
ABS Antilock brake system
ACC Accessories
ATF Automatic transaxle fluid
ATX Automatic transaxle
BDC Bottom dead center
BTDC Before top dead center
CDCV Canister drain cut valve
CCM Comprehensive component monitor
CM Control module
DC Drive cycle
DRL Daytime running light
E/L Electric load
ELR Emergency locking retractor
EX Exhaust
HI High
HU ABS hydraulic unit
HVAC Heater, ventilation, and air conditioning
IG Ignition
IN Intake
INT Intermittent
LF Left front
LH Left hand
LO Low
LR Left rear
M Motor
MAX Maximum
MTX Manual transaxle
O/D Overdrive
OFF Switch off
ON Switch on
PCV Positive crankcase ventilation
PRC Pressure regulator control
P/S Power steering
RF Right front
RH Right hand
RR Right rear
SST Special service tool
SW Switch
TAS Throttle adjusting screw
TDC Top dead center
TNS Tail number side lights
TR Transmission range
VICS Variable inertia charging system
VTCS Variable tumble control system
1GR First gear
2GR Second gear
4SD 4 door sedan
5HB 5 door hatchback

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000026
GENERAL INFORMATION
PRE-DELIVERY INSPECTION
A3U000000012W01
Pre-Delivery Inspection Table
Exterior
INSPECT and ADJUST, if necessary, the following items to specification:
Glass, exterior bright metal and paint for damage
Wheel lug nuts 0000
All weatherstrips for damage or detachment
Operation of hood release and lock
Operation of trunk lid and fuel lid opener
Door operation and alignment
Headlight aiming
INSTALLthe following parts:
Wheel caps

Under hood--engine off
INSPECTand ADJUST, if necessary, the following items to specification:
Fuel, engine coolant, and hydraulic lines, fittings, connections, and components for leaks
Engine oil level
Power steering fluid level
Brake and clutch fluid level
Windshield washer reservoir fluid level
Radiator coolant level and specific gravity
Tightness of water hose clamps
Tightness of battery terminals, electrolyte level and specific gravity
Drive belt(s) tension
Accelerator cable and linkage for free movement CLEAN the spark plugs

Interior
INSPECT the operations of the following items:
Seat controls (slide and recline) and headrests
Folding rear seat (if equipped)
Door locks, including childproof door locks (if equipped)
Seat belts and warning system
Ignition switch and steering lock
Air bag system using warning light
Cruise control system (if equipped)
Shift-lock system (if equipped)
Starter interlock
All lights including warning, and indicator lights
Sound warning system
Horn, wipers, and washers
Wiper blades performance
Clean wiper blades and windshield, if necessary
Antenna
Audio system (if equipped)
Cigarette lighter and clock
Power windows (if equipped)
eater, defroster, and air conditioner at various mode selections (if equipped)
INSPECT the following items:
Presence of spare fuse
Upholstery and interior finish
INSPECT and ADJUST, if necessary, the following items:
Operation and fit of windows
Pedal height and free play of clutch pedal
Parking brake

Under hood--engine running at operating temperature
INSPECT the following items:
Automatic transaxle fluid level
Operation of idle-up system for electrical load, air conditioner or power steering (if equipped)
Ignition timing
Idle speed




000027
GENERAL INFORMATION
On hoist
INSPECT the following items:
Manual transaxle oil level
Underside fuel, coolant and hydraulic lines, fittings, connections, and components for leaks
Tires for cuts or bruises
Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage
Road test
INSPECT the following items:
Brake operation
Clutch operation
Steering control
Operation of gauges
Squeaks, rattles, and unusual noises
Engine general performance
Emergency locking retractors and automatic locking retractors
Cruise control system (if equipped)
After road test
INSPECT for necessary owner information materials, tools, and spare tire in vehicle
The following items must be done just before delivery to your customer.
Load test battery and charge if necessary (Load test result: Volts)
Adjust tire pressure to specification (Specified tire pressure is indicated on the door label.)
Clean outside of vehicle
Install fuses for accessories
Remove seat and cabin carpet protective covers
Vacuum inside of vehicle
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000028
GENERAL INFORMATION
SCHEDULED MAINTENANCE
A3U000000013W01
Scheduled Maintenance Table
Schedule 1 : (Normal driving conditions) U.S.A.
The vehicle is mainly operated where none of the "unique driving conditions" apply.
Maintenance Interval (Number of months or kilometers(miles), whichever comes first) 0000
Months 6 12 18 24 30 36 42 48
Maintenance Item
1000 km 12 24 36 48 60 72 84 96

( 1000 Miles) (7.5) (15) (22.5) (30) (37.5) (45) (52.5) (60)
ENGINE
Engine valve clearance I
Inspect at 96,000 km (60,000 miles).
Engine timing belt
Replace every 168,000 km (105,000 miles).
Drive belts (tension) I I
Engine oil R R R R R R R R
Oil filter R R R R R R R R
COOLING SYSTEM
Cooling system I I
Replace at first 72,000 km (45,000 miles) or 36 months;
Engine coolant
after that, every 48,000 km (30,000 miles) or 24 months.
FUEL SYSTEM
Idle speed I I
Air cleaner element R R
Fuel lines & hoses *1 I I
Hoses & tubes for emission *1 I
IGNITION SYSTEM
Spark plugs R R
CHASSIS & BODY
Brake lines, hoses & connections I I
Disc brakes I I
Drum brakes I I
Steering operation & linkages I I
Front suspension ball joints I I
Drive shaft dust boots I I
Bolts & nuts on chassis & body I I
Exhaust system heat shields I I
All locks & hinges L L L L L L L L
AIR CONDITIONER SYSTEM (if installed)
Refrigerant amount I I I I
Compressor operation I I I I

Chart symbols
I : Inspect and repair, clean, adjust, or replace if necessary. (Oil-permeated air cleaner elements cannot be
cleaned using the air-blow method.)
R : Replace
L : Lubricate

Remarks
After the described period, continue to follow the described maintenance at the recommended intervals.
Refer below for a description of items marked in the maintenance chart.
1
* : According to state and federal regulations, failure to perform maintenance on these items will not void your
emissions warranties. However, Mazda recommends that all maintenance services be performed at the
recommended time or mileage period to ensure long-term reliability.




000029
GENERAL INFORMATION
Schedule 2 : Canada, Puerto Rico and (Unique driving conditions) U.S.A.
Unique driving conditions consist of :
Repeated short-distance driving.
Driving in dusty conditions.
Driving with extended use of brakes.
Driving in areas where salt or other corrosive materials are used.
Driving on rough or muddy roads.
Extended periods of idling or low-speed operation.
Driving for long periods in cold temperatures or extremely humid climates.
Maintenance Interval (Number of months or kilometers (miles), whichever comes first)
Months 4 8 12 16 20 24 28 32 36 40 44 48
Maintenance Item
1000 km 8 16 24 32 40 48 56 64 72 80 88 96

( 1000 Miles) (5) (10) (15) (20) (25) (30) (35) (40) (45) (50) (55) (60)
ENGINE
Engine valve clearance I
Inspect at 96,000 km (60,000 miles).
Engine timing belt *2 Replace every 168,000 km (105,000 miles).
Drive belts (tension) I I
except for Puerto Rico R R R R R R R R R R R R
Engine oil
for Puerto Rico Replace every 5,000 km (3,000 miles) (or 3 months)
Oil filter R R R R R R R R R R R R
COOLING SYSTEM
Cooling system I I
Replace at first 72,000 km (45,000 miles) or 36 months;
Engine coolant
after that, every 48,000 km (30,000 miles) or 24 months.
Engine coolant level I I I I I I I I I I I I
FUEL SYSTEM
Idle speed I I
Air cleaner element 1 R I*1 R
I*
Fuel lines & hoses *1 I I
Hoses & tubes for emission *1 I
IGNITION SYSTEM
Spark plugs R R
ELECTRICAL SYSTEM
Function of all lights I I I I I I I I I I I I
CHASSIS & BODY
Brake lines, hoses & connections I I
Brake & clutch fluid level I I I I I I I I I I I I
Disc brakes I I I I
Drum brakes I I
Tire inflation pressure & tire wear I I I I I I I I I I I I
Steering operation & linkages I I
Power steering fluid level I I I I I I I I I I I I
Front suspension ball joints I I
Driveshaft dust boots I I
Bolts & nuts on chassis & body I I I I
Exhaust system heat shields I I
All locks & hinges L L L L L L L L L L L L
Washer fluid level I I I I I I I I I I I I
AIR CONDITIONER SYSTEM (if installed)
Refrigerant amount I I I I
Compressor operation I I I I




000030
GENERAL INFORMATION
Chart symbols
I : Inspect and repair, clean, adjust, or replace if necessary. (Oil-permeated air cleaner elements cannot be
cleaned using the air-blow method.)
R : Replace
L : Lubricate
0000
Remarks
After the described period, continue to follow the described maintenance at the recommended intervals.
Refer below for a description of items marked * in the maintenance chart.
*1 : According to state and federal regulations, failure to perform maintenance on these items will not void your
emissions warranties. However, Mazda recommends that all maintenance services be performed at the
recommended time or mileage period to ensure long-term reliability.
*2 : If vehicle is operated in cold districts {below -18 C (0 F)}, replace the timing belt at 96,000 km (60,000
miles).

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000031
ON-BOARD DIAGNOSTIC [ENGINE CONTROL SYSTEM (FS)]
0102B ON-BOARD DIAGNOSTIC [ENGINE CONTROL
SYSTEM (FS)]
CONTROL SYSTEM WIRING DIAGRAM DTC P0118 [FS] . . . . . . . . . . . . . . . . . . . 0102B42
[FS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102B2 DTC P0121 [FS] . . . . . . . . . . . . . . . . . . . 0102B43
CONTROL SYSTEM DEVICE AND CONTROL DTC P0122 [FS] . . . . . . . . . . . . . . . . . . . 0102B46
RELATIONSHIP CHART [FS]. . . . . . . . 0102B4 DTC P0123 [FS] . . . . . . . . . . . . . . . . . . . 0102B47 0102B
Engine Control System . . . . . . . . . . . . 0102B4 DTC P0125 [FS] . . . . . . . . . . . . . . . . . . . 0102B49
Monitoring System . . . . . . . . . . . . . . . . 0102B5 DTC P0126, P0128 [FS] . . . . . . . . . . . . . 0102B50
FOREWORD [FS] . . . . . . . . . . . . . . . . . . 0102B6 DTC P0131 [FS] . . . . . . . . . . . . . . . . . . . 0102B52
OBD-II PENDING TROUBLE CODES DTC P0132 [FS] . . . . . . . . . . . . . . . . . . . 0102B55
[FS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102B6 DTC P0133 [FS] . . . . . . . . . . . . . . . . . . . 0102B57
OBD-II FREEZE FRAME DATA [FS] . . . 0102B6 DTC P0134 [FS] . . . . . . . . . . . . . . . . . . . 0102B61
OBD-II ON-BOARD SYSTEM DTC P0138 [FS] . . . . . . . . . . . . . . . . . . . 0102B63
READINESS TEST [FS] . . . . . . . . . . . . 0102B6 DTC P0140 [FS] . . . . . . . . . . . . . . . . . . . 0102B64
OBD-II DIAGNOSTIC MONITORING TEST DTC P0171 [FS] . . . . . . . . . . . . . . . . . . . 0102B67
RESULTS [FS] . . . . . . . . . . . . . . . . . . . 0102B6 DTC P0172 [FS] . . . . . . . . . . . . . . . . . . . 0102B70
OBD-II R