Mazda 323

since 1985 release

Repair and operation of the car



Mazda 323

+ Introduction
+ Petrol engines
+ Engine lubrication system
+ Engine cooling system
+ System of ignition
+ Power supply system, carburetor, system of injection of fuel
+ Diesel engine
+ System of production of the fulfilled gases
+ Coupling
+ Manual transmission
+ Automatic transmission
- Suspension bracket and system of steering
   Forward suspension bracket — the general information
   Removal and installation of a depreciation rack
   Dismantling of a depreciation rack / removal and installation of the shock-absorber / screw spring
   Check of the shock-absorber
   Removal and installation of the cross lever / replacement of a rubber support
   Check/replacement of a support of the cross lever / rotary fist
   Removal and installation of a power shaft
   Removal and installation of an intermediate shaft
   Check/dismantling of a driving shaft / replacement of cuffs
   Bearing of a forward nave
   Back suspension bracket
   Removal and installation of a back depreciation rack
   Dismantling of a back depreciation rack / removal and installation of the shock-absorber / screw spring
   Cross levers / longitudinal lever / stabilizer
   Check of the hug bearing
   Removal and installation of the hug bearing
   Adjustment of a side play of the hug bearing
   Removal and installation of a nave
   Steering
   Removal and installation of a steering wheel
   Removal and installation of a tip of steering draft
   Removal and installation of a rubber cuff of the steering drive
   Servoupravleniye pump
   Angles of installation of wheels
   Values for check of MAZDA 323
+ Brake system
+ Wheels and tires, body, coloring of the car, care of the car
+ System of electric equipment
+ Heater, system of lighting, devices
+ Governing bodies and methods of operation
+ Electric circuits











Check/dismantling of a driving shaft / replacement of cuffs

Power shaft with the internal "star" hinge (the tripodny hinge)

1 — a cuff collar
2 — a cuff collar
3 — a bracket
4 — the hinge case
5 — a lock ring
6 — the tripodny hinge
7 — a cuff
8 — a collar

9 — a counterbalance only on the right side
10 — a cuff collar
11 — a cuff collar
12 — a cuff
13 — the external hinge with shaft. (Not to sort whenever possible to grease. To use lubricant from a repair kit.)

Power shaft with the internal spherical hinge

1 — a cuff collar
2 — a bracket
3 — an external holder
4 — a lock ring
5 — an internal holder
6 — a separator
7 — balls
8 — a cuff collar

9 — a cuff
10 — a cuff collar
11 — a counterbalance
Only on right side:
12 — a cuff collar
13 — a cuff
14 — the external hinge with shaft
Not to sort whenever possible.

Depending on model the power shafts having difference in the internal hinge are established: power shafts with the internal spherical hinge are established on cars to 9/89 g of the issue and on the station wagon model with the mechanical transmission. Power shafts with tripodny hinges are established on cars from 10/89 g of the issue, except the station wagon models. All all-wheel drive cars have power shafts with internal spherical hinges, in connection with an intermediate shaft for the right power shaft.

Check

 PERFORMANCE ORDER

  1. To visually check cuffs, at once to replace faulty cuffs. For replacement of casings the power shaft has to be removed and sorted. As the external hinge should not understand, for removal of its cuff it is necessary to remove also a cuff of the internal hinge.
  1. To clamp the removed power shaft in a vice with laying and to check mobility of hinges.
  1. To stretch and squeeze the external hinge a hand, it should not have a side play.
  2. The internal tripodny hinge has to move on a shaft.
  3. To try to turn the internal hinge on a shaft. He should not have a notable radial side play.
  4. If when checking malfunctions are revealed, the power shaft should be replaced.

Dismantling of a power shaft

 PERFORMANCE ORDER

  1. To mark edges of cuffs of hinges on a shaft before removing them, it will facilitate installation.
  1. To remove collars of cuffs on the internal hinge by means of the screw-driver.
  1. To shift cuffs of hinges on a shaft.

Power shaft with the internal tripodny hinge

 PERFORMANCE ORDER

  1. Before removal of the case to mark situation concerning an asterisk.
  1. To mark with a center punch the provision of a shaft concerning an asterisk, so it has to be established on the former place.
  1. To squeeze and remove a lock ring of an asterisk suitable nippers.
  1. To bring down an asterisk from a shaft by means of the hammer and a brass core, without striking at the same time blows to rollers.

Power shaft with the internal spherical hinge

 PERFORMANCE ORDER

  1. Before removal of a shaft to mark its provision of rather external holder.
  1. To hook a lock bracket the flat screw-driver. To remove the internal hinge.
  1. To squeeze a lock ring of an internal holder suitable nippers and to remove it. To put with a tag center punch concerning a shaft that it could be established in former situation.
  1. To bring down an internal holder from a shaft by means of the hammer and a brass core.
  1. If necessary to sort an internal holder. For this purpose to insert the narrow screw-driver between an internal holder and a separator and to squeeze out balls.
  1. To mark the provision of a separator of rather internal holder. To turn a separator on 30 ° and to remove from an internal holder.

All power shafts

 PERFORMANCE ORDER

  1. To remove a cuff of the internal hinge from a shaft.
  2. Right power shaft: If is available, to weaken a collar of a counterbalance and to remove the balance weight.

To mark the provision of a counterbalance on a shaft that it could be established on the former place.

  1. If are debugged on the external hinge: To remove a cuff of the external hinge through the party of the internal hinge, previously having weakened collars of cuffs.

The external hinge should not understand.

  1. To carefully wipe internal cavities of the hinge, internal details, flanges, caps and cuffs. To remove old lubricant with solvent or compressed air. If dirt got into the hinge, to wash out it.
  2. To check working surfaces for wear existence, if necessary to replace the hinge.

Assembly

 PERFORMANCE ORDER

  1. To replace the cracked and faulty cuffs. Anyway it is necessary to replace all collars of cuffs, and also lock rings.
  1. To slightly grease a shaft surface that cuffs slid better. Besides to wrap up shaft vents a polymeric tape that at installation of a cuff not to damage it.
  1. To put on a cuff of the external hinge with collars, still not to fix collars yet. Not to mix a cuff of hinges: To pick up a cuff according to the external diameter of the hinge, the table belongs to cars from 10/89 g of the issue (except the station wagon models).

Engine diameter And, mm diameter In, mm
1,3 l. Diesel 82,0 85,3
1,6 l 85,9 80,8
1,9 l of SOHC 84,0/80,0189,0
1,9 l of DOHC 89,9 85,2

1 — the left power shaft

The direction of installation of collars corresponds to rotation of a shaft forward, i.e. the bent end of collars has to be turned in the direction of rotation of a shaft.

  1. Right power shaft: If is available, to put on a counterbalance, the collar of fastening has to lie in a groove of a power shaft. If there is no groove, to level a counterbalance on the mark put at removal.
  2. To put on a cuff of the internal hinge with collars.

Power shaft with the internal tripodny hinge

 PERFORMANCE ORDER

  1. To put on an asterisk a power shaft, at the same time the center punch marks put at removal have to coincide. To chuck in an asterisk a shaft with the hammer and a brass core. At the same time not to apply force, to establish a core serially on various points.
  1. To insert a new lock ring into a shaft groove.
  1. To fill cavities of the external hinge between internal details on both sides special lubricant (black color). To watch that whenever possible less lubricant got to cuffs. Special lubricant is put in a repair kit of cuffs of MAZDA. To distribute all amount of lubricant, about 80 g; SOHC engine of 1,9 l: 140 g.
  1. To distribute on the case of the internal hinge also all lubricant from a repair kit (yellow color). Amount of lubricant of 130 g; except the right power shaft of the SOHC engine of 1,9 l: 220 g.
  1. To insert a hinge asterisk into the case in the same situation as at removal and to pull a cuff.

Power shaft with the internal spherical hinge

 PERFORMANCE ORDER

  1. To collect an internal holder with balls and a separator in the sequence, return in relation to removal. The put tags have to coincide.
  1. To put on an internal holder a power shaft, at the same time the center punch marks put at removal have to coincide. To insert a new lock ring.
  1. To insert an external holder of the hinge and to insert a new lock bracket.
  2. To fill cavities of the external hinge between internal details on both sides special lubricant (black color) from a repair kit of MAZDA. The amount of new lubricant compensates amount of remote lubricant. If all old lubricant was removed, it is necessary to use all lubricant from a repair kit.

All power shafts

 PERFORMANCE ORDER

  1. To fix cuffs on big diameter by collars. Cuffs have to sit reliably in shaft grooves. To bend collars of cuffs the screw-driver and to fix, having bent fastenings.
  1. To shift cuffs on small diameter to a tag or a groove on a shaft. Cuffs in the established state should not be neither are stretched, nor compressed.
  2. To raise a little a cuff on small diameter the small screw-driver to compensate pressure. Then to pull a collar of a cuff and to fix it.
  3. To establish a power shaft.