Mazda 323

since 1985 release

Repair and operation of the car



Mazda 323

+ Introduction
- Petrol engines
   Specifications
   Removal and installation of the engine
   Removal and installation of a gear belt of VZ, V5, B6 (SOHC), BP engines (SOHC)
   Removal and installation of a gear belt (DOHC)
   Removal and installation of a head cylinders/replacement of laying of a head of cylinders
   Mechanism of the chain drive
   Removal and installation cam-shaft/adjustment of phases of gas distribution
   Removal and installation of the camshaft
   Cam-shaft/drive of the distributive mechanism
   Distributive shaft / drive of the distributive mechanism
   Removal and installation of camshafts
   Removal and installation of valves
   Replacement of maslootrazhatelny caps
   Check of the directing valves
   Processing of facets of saddles of valves in a head cylinders/processing of valves
   Grinding in of valves
   Check/adjustment of a gap of valves
   Check of a compression
   Removal and installation/tension of a maple belt
+ 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
+ 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






Removal and installation of the engine

Snyatiye of the engine perhaps only together with the transmission. Therefore before removal it is necessary to read also the Head Snyatiye and installation of the transmission. Final and inlet collectors, and also the carburetor and the generator remain established on the engine. The crane is necessary for removal of the engine. It is impossible to lower the engine at all down by means of the shop elevator as the elevator can seriously damage the engine. Before installation in a motive compartment it is necessary to cover wings.

It is recommended to mark before shutdown all electric cables and vacuum pipelines an adhesive tape that at their installation easily it was possible to connect on former places.

Depending on year of release and equipment electric wires or vacuum and water hoses can be laid in a motive compartment differently. As it is not possible to describe all separate options, it is recommended to mark before shutdown the corresponding pipelines and wires an adhesive tape. In the following chapter removal and installation of the petrol engine of 1,4 l with system of injection of fuel will be described.

Removal

The injector B6 engine with system of injection

 PERFORMANCE ORDER

  1. To switch-off the battery, to observe instructions, see the Section Removal and installation of the battery.
  2. To unscrew the holder of the battery.
  3. To remove the air filter, see the Head Snyatiye and installation of the air filter.
  4. To merge cooling liquid and to remove a radiator with the fan, see the Head the engine Cooling system.
  5. To merge gearbox oil, see the Head Vvedeniye.
  6. To remove a cowl, see the Head Kolesa and tires, a body, coloring of the car, care of the car.
  7. To remove the gas drive.
  1. To disconnect a vacuum brake hose-1-, previously having weakened a collar.
  1. To weaken collars and to disconnect fuel hoses-2-. At shutdown to put a rag that when easing fuel could not be sprayed around a fuel-supply line. To close at once pipelines suitable traffic jams. For this purpose to insert into openings, for example, pure bolts of the corresponding diameter. For simplification of installation to mark fuel-supply lines with an adhesive tape.
  2. To disconnect a ventilating vacuum hose-3-.
  3. If is available, to disconnect a vacuum hose-4 tempostat.

Carburetor engine

Carburetor engine

 PERFORMANCE ORDER

  1. To weaken collars and to disconnect fuel hoses of the mechanical fuel pump. At shutdown to put a rag that when easing fuel could not be sprayed around a fuel-supply line. To close at once pipelines suitable traffic jams. For this purpose to insert into openings, for example, pure bolts of the corresponding diameter. For simplification of installation to mark fuel-supply lines with an adhesive tape.
  2. To disconnect vacuum hoses to the carburetor. For simplification of installation to mark hoses with an adhesive tape.
  3. To disconnect hoses of a heater-5-, previously having weakened collars.
  4. To disconnect all electric connections from the engine. For installation simplification previously to mark wires with an adhesive tape.
    • To unscrew a cable of weight-1-on the engine.
    • To turn off connections of the generator-2-, for this purpose to unscrew the B+ thick cable and to disconnect the plug.
    • To disconnect the oil-3-pressure sensor plug.
    • To disconnect the combined plug of the sensor of a butterfly valve-4-and the regulator of speed of idling-5-.
    • To turn off connections of a starter-6-, for this purpose to unscrew a thick cable and to disconnect the combined plug.
    • To disconnect the plug-7 a lambda probe.
    • To disconnect the combined plug of gates of injection-8-.
    • To disconnect the neutral sensor plug-9 (only mechanical transmission).
    • To disconnect the plug 4 - 10-on the ignition coil.
    • To unscrew a cable of weight-11-on the engine.
    • To disconnect the combined plug-12-on the ignition distributor.
    • To disconnect the combined plug of a thermoswitch of-13-cooling liquid.
    • To disconnect the plug-14 of the sensor of temperature of cooling liquid.
    • To disconnect the plug of weight-15-.
    • To disconnect the combined plug-16-on the backing switch (only mechanical transmission).
    • To unscrew a cable of weight-17-on the transmission.
    • To disconnect the combined starter switch plug-18.
    • To switch-off temperature sensor plug-19.
    • If is available, to disconnect the plug-20 of heating of starting automatic equipment.
    • To switch-off the combined carburetor plug-21.
  1. Models from 10/89 g of the issue: To press a nose - the shooter - a hose collar and to disconnect a heater hose.

On the union there is a consolidation of round section and an intermediate ring, not to lose them at installation.

  1. To lift the car.
  2. If is available, to remove the lower facing of a motive compartment.

Cars with the amplifier of steering (servoupravleniye)

 PERFORMANCE ORDER

  1. To take off a maple belt from a servonasos, see the Section Removal and an installation/tension of a maple belt.
  2. To unscrew the pump with the holder and to suspend on a wire with the connected hoses so that the pump did not prevent further removal and hoses were not tense.

Cars with the conditioner

The contour of the conditioner should not be opened. Coolant contains substances which hit on skin can cause a frostbite. The engine can be removed, without opening a contour of system of the conditioner.


 PERFORMANCE ORDER

  1. To take off maple a belt, see the Section Removal and an installation/tension of a maple belt.
  2. To unscrew the conditioner compressor with the holder and to suspend on a wire with the connected hoses so that it did not disturb at further removal and hoses were not tense.

Mechanical transmission

 PERFORMANCE ORDER

  1. To disconnect a bar of switching and a lengthening bar on the transmission, see the Section Removal and installation of the transmission.
  2. Models with the hydraulic drive of coupling: To unscrew the working cylinder of the drive of coupling with the hydraulic pipeline and to put aside that it did not interfere with further removal, see also Head Stsepleniye.

The hydraulic pipeline remains is connected, otherwise after installation it will be necessary to remove air from system. At the removed working cylinder it is impossible to press a coupling pedal. On some models the pipeline of coupling is removed after dismantle of a support of the engine.

  1. Models with the hummock drive of coupling: To disconnect a coupling cable, see the Head Stsepleniye, the Section Adjustment of a Pedal/cable of Coupling.
  2. Automatic transmission: To take out the forelock and to disconnect a switching cable on the transmission. To unscrew fastening of a cable on the transmission.
  1. To remove a speedometer shaft, see the Head the Manual transmission.
  1. To unscrew a reception pipe of the muffler from a final collector, see the Head Sistem of production of the fulfilled gases.
  2. To remove power shafts, see the Head Podvesk and system of steering, the Section Removal and installation of a power shaft.
  1. To attach a suitable chain to engine earrings and to raise the engine to unload its support.
  1. To unscrew nuts of fastening of the engine No. 1 and No. 2.
  1. To unscrew a dynamic damper and nuts of fastening - And-.
  1. To unscrew a nut - In - to take out a bolt and to remove an engine support.
  1. To unscrew fastening bolts - And - and - engine V-support on the party of the transmission and to remove a support complete with the holder.
  2. To check whether all hoses conducting from the engine to a body are removed. Then to take out the engine by means of the crane up.

It is careful to direct the engine at a raising in order to avoid damages on a body.

  1. To remove the transmission from the engine, see the Head the Manual transmission, the Section Removal and installation of the transmission.

Installation

 PERFORMANCE ORDER

  1. To check engine support, water, oil and fuel hoses for existence of cracks and gaps, if necessary to replace.
  2. To check ease of the course of the release bearing and lever of switching off of coupling, if necessary to replace.
  3. To check thickness and a condition of a frictional overlay of the conducted clutch plate, if necessary to replace.
  4. To clear shlitsevy connection of a shaft of coupling and to grease with MoS2 lubricant.
  5. To attach the transmission to the engine, see the Head the Manual transmission.
  6. It is careful to enter the engine from above into a motive compartment by means of the crane. When lowering to watch that bolts of the lower support of the engine entered openings in a beam.
  7. To establish nuts of fastening of the lower support of the engine.
  8. To establish bolts of fastening of the top support of the engine. On some models before installation of support it is necessary to lay the pipeline to the working cylinder of coupling.
  9. To level the engine.
  10. To tighten fastening nuts on the lower support of the engine with effort of 70 Nanometers to 9/89 g of the issue; with effort of 50 Nanometers since 10/89 g of the issue.
  11. To tighten fastening nuts - And - engine support with effort of 80 Nanometers.
  12. To tighten a nut - In-. Inhaling moment: to 9/89 g of the issue of 60 Nanometers, since 10/89 g of the issue of 80 Nanometers.
  13. If is available, to screw a dynamic damper with effort of 70 Nanometers.
  14. Models from 10/89 g of the issue: To tighten fastening bolts - In - engine support in that order with 1 on 4 with effort of 50 Nanometers. To tighten nuts - And - with effort of 80 Nanometers.
  15. To establish power shafts, see the Head Podvesk and system of steering, the Section Removal and installation of a power shaft.
  16. To establish a reception pipe of the muffler and an exhaust pipe or the catalytic converter.

Mechanical transmission

 PERFORMANCE ORDER

  1. To attach a bar of switching and a lengthening bar on the transmission. To screw a lengthening bar with effort of 40 Nanometers, a switching bar with effort of 20 Nanometers.
  1. Models with the hydraulic drive of coupling: To install the working cylinder of the drive of coupling with the hydraulic pipeline and to tighten bolts - In - with effort of 20 Nanometers, - And - with effort of 10 Nanometers.
  1. To tighten bolts of fastening of the working cylinder of the drive of coupling with effort of 20 Nanometers.

Models with the hummock drive of coupling

 PERFORMANCE ORDER

  1. To establish a coupling cable, see the Head Stsepleniye, the Section Adjustment of a Pedal/cable of Coupling.
  2. If is available, to establish the lower facing of a motive compartment.
  3. To lower the car.
  4. To establish and adjust the gas drive, see the Head the Power supply system, the carburetor, system of injection of fuel, the Section Check/removal and installation of automatic equipment of cold start.
  5. To establish a speedometer shaft.

Automatic transmission

 PERFORMANCE ORDER

  1. To attach a cable of switching to the transmission and to insert the forelock. To delay fastening of a cable on the transmission with effort of 10 Nanometers.

Cars with a servoupravleniye

 PERFORMANCE ORDER

  1. To install the pump with the holder and to screw 50 Nanometers with effort.
  1. To establish maple a belt of a servonasos, see the Section Removal and an installation/tension of a maple belt.

Cars with the conditioner

 PERFORMANCE ORDER

  1. To install the conditioner compressor with the holder and to screw 30 Nanometers with effort.
  2. To establish maple a conditioner compressor belt, see the Section Removal and an installation/tension of a maple belt.
  1. To connect and screw all electric wires and vacuum hoses according to the put tags.
  1. To put on hoses of a heater and depending on model to fix by collars.
  2. To connect the giving and returnable fuel-supply lines and to fix by hose collars.
  3. To establish a radiator, see the Head the engine Cooling system, Removal and installation of a radiator.
  4. To fill in oil in the engine and the transmission, see the Head Vvedeniye.
  5. To check cooling liquid for frost resistance and to fill in it, see the Head the engine Cooling system, the Section Replacement of Cooling Liquid.
  6. To install the air filter, see the Head Snyatiye and installation of the air filter.
  7. To establish a cowl, see the Head Kolesa and tires, a body, coloring of the car, care of the car, the Section Removal and installation/adjustment of a cowl
  8. To screw the holder of the battery with effort 20 Nanometers.
  9. To install the battery, see the Head Sistem of electric equipment, the Section Removal and installation of the battery.
  10. If it is required, to adjust a gap of valves, see the Section Check/adjustment of a Gap of Valves.
  11. To check the ignition moment, to adjust if it is required, see the Head Sistem of ignition, the Section Check/adjustment of the Moment of Ignition.
  12. To check idling, if necessary to adjust, see the Head the Power supply system, the carburetor, system of injection of fuel.
  13. To warm up the engine, to check the level of cooling liquid and tightness of all connections.