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 a head cylinders/replacement of laying of a head of cylinders

1 — an air hose
2 — the resonant camera
3 — the gas drive
4 — the drive of a butterfly valve (only at the automatic transmission)
5 — hoses
6 — a plait of cables
7 — a nut, the perepuskny pipeline of the cooling system
8 — maple a belt

9 — a belt pulley of the water pump
10 — a cover of a head of cylinders
11 — the top casing of a gear belt
12 — a gear belt
13 — a reception pipe of the muffler
14 — fastening of an inlet collector
15 — bolts of a head of cylinders
16 — a head of cylinders
17 — laying of a head of cylinders

At removal of a head of cylinders the engine has to be cooled at least to room temperature. Final and inlet collectors remain are connected. Removal for VZ, V5, V6 and BP engines is described. At the end of the head there are instructions on the diesel engine. For a series of engines E it is specified differences in the certain head, see the Section Removal and installation cam-shaft/adjustment of phases of gas distribution.

The faulty head of cylinders comes to light on one or several following signs:

  • Loss of power.
  • Loss of cooling liquid. White exhaust clouds on the warm engine.
  • Oil loss.
  • Cooling liquid in engine oil, the level of oil does not decrease, and increases. Gray color of engine oil, foam traces on the measuring probe, oil is diluted.
  • Engine oil in cooling liquid.
  • Cooling liquid strongly rages.
  • There is no compression in two next cylinders.

Removal

The B6 engine with system of injection

 PERFORMANCE ORDER

  1. To disconnect a weight cable from the battery.

At the same time data from memory of malfunctions of the engine or a protective code of the radio receiver are erased. Before shutdown of the battery it is necessary to read instructions in the Section Removal also installation of the battery.

  1. Injector engine: To weaken collars and to remove an inlet hose.
  2. Carburetor engine: To remove the air filter, see the Head the Power supply system, the carburetor, system of injection of fuel, the Section Removal and installation of the air filter.
  3. If is available, to remove the resonant camera.
  4. To merge cooling liquid, see the Head Vvedeniye.
  5. To remove 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.
  6. Automatic transmission: To disconnect a cable of a butterfly valve.
  7. To disconnect all electric wires to a head of cylinders. For simplification of installation of a wire it is necessary to mark with an adhesive tape previously.
    • To unscrew a cable of weight-1-on the engine.
    • To disconnect the plug-2 a lambda probe.
    • To disconnect the combined plug-3-on the ignition distributor.
    • To disconnect the combined plug of-4 gates of injection.
    • To disconnect the combined plug of the sensor of a butterfly valve-5-and the regulator of single turns-6-.
    • To switch-off the plug 4 - 7-on the ignition coil.
    • To switch-off the combined cooling system thermoswitch plug-8.
    • To switch-off the plug-9 of the sensor of temperature of cooling liquid.
    • To disconnect a cable of weight-10-on the engine.
    • To switch-off the combined plugs of connections of the carburetor-11-.
  8. To disconnect a vacuum brake hose, previously having weakened a collar.

Injector engine

 Injector engine

 PERFORMANCE ORDER

  1. To weaken hose collars and to disconnect fuel hoses-2-. At shutdown to lay a rag that when easing fuel was not sprayed around fuel-supply lines. At once to close pipelines suitable traffic jams, for example, pure bolts of the corresponding diameter. For simplification of the subsequent installation to mark fuel-supply lines with an adhesive tape.
  2. If is available, to disconnect a vacuum hose-4 tempostat.
  3. To disconnect a ventilating vacuum hose-3-.

Carburetor engine

Carburetor engine

 PERFORMANCE ORDER

  1. To weaken hose collars and to disconnect fuel-supply lines on the mechanical fuel pump. At shutdown to lay a rag that fuel was not sprayed around fuel-supply lines. At once to close pipelines suitable traffic jams, for example, pure bolts of the corresponding diameter. For simplification of the subsequent installation to mark fuel-supply lines with an adhesive tape.
  2. To disconnect a hose from the control unit heating of the soaked-up air, for this purpose to weaken a collar.
  3. To disconnect hoses of a heater-5-, previously having weakened collars.
  1. Models from 10/89 g of the issue: To press a ledge - the shooter - a hose collar and to disconnect a heater hose.

On the union there are a consolidation of round section and an intermediate ring. Not to forget them at installation.

  1. To unscrew a nut of fastening of the perepuskny pipeline of the cooling system and to disconnect a bracket.
  2. To take off a gear belt, see the Sections Removal and installation of a gear belt of VZ, V5, B6 (SOHC), BP engines (SOHC), Removal and installation of a gear belt (DOHC).
  3. To unscrew a cover of a head of cylinders.
  4. To unscrew a reception pipe of the muffler from a final collector, see the Head Sistem of production of the fulfilled gases.
  5. Injector engine: To remove fastening of an inlet collector.
  1. To weaken bolts of a head of cylinders in the sequence with 1 on 10 for the first pass on 1/2 turns, for the second pass on one whole turn and to turn out completely on the third pass.

Weakening of bolts of a head of cylinders in an inadequate order can lead to deformation or cracks in a head of cylinders.

  1. To check whether all hoses going from a head of cylinders to the engine and a body are disconnected.
  2. To remove a head of cylinders by means of the assistant.

Not to put a head of cylinders after removal on a sealing surface, at the same time completely open valves can be damaged. To lay a head of cylinders on two wooden whetstones.

Installation

 PERFORMANCE ORDER

  1. Before installation to clear a shaber the block and a head of cylinders of the consolidation remains. At the same time sealing surfaces should not be scratched. To watch that the remains of consolidation did not fall in cylinders. To cover openings with a rag.
  2. To check that in openings of bolts of a head of cylinders there was no oil, if necessary to remove oil with compressed air. If there is no compressed air, it is possible to clear openings the small screw-driver which is wrapped up by a rag.

Anyway oil has to be removed.


  1. To check a head of cylinders for deformation existence by a steel ruler and the probe.
  1. To check deformation in the specified directions. The most admissible roughness makes 0,15 mm. If boundary value is exceeded, the head of cylinders should be processed (it is carried out in a workshop).
  2. To check a head of cylinders for existence of cracks. If there are cracks, the head needs to be replaced.
  3. To check water, oil and fuel hoses for existence of cracks and gaps if it is required, to replace.
  4. To check valves and guides of valves for existence of wear and damages.
  5. To impose laying of a head of cylinders that openings in the block of cylinders and laying coincided.
  6. To grease with a small amount of oil of a surface of a prileganiye and a carving of bolts of a head of cylinders.
  1. To wrap 10 bolts to a prileganiye to a head of cylinders by effort of a hand. Then bolts should be tightened in three passes. On each pass bolts drag on in the sequence from the 1st on the 10th.

1st pass: 40 Nanometers

2nd pass: 60 Nanometers

3rd pass: 80 Nanometers

The inhaling of bolts of a head of cylinders should be made very attentively. Before an inhaling it is necessary to check the accuracy of a dynamometer key. Besides, it is necessary to follow the sequence of an inhaling precisely.

  1. Injector engine: To delay fastenings of an inlet collector with efforts of 25 Nanometers and 45 Nanometers.
  1. To screw a reception pipe of the muffler on a final collector with effort of 45 Nanometers.
  1. DOHC engine: To apply on the shaded places sealant on a silicone basis (for example, DOW CORNING Q3-7057). To establish new laying of a cover of valves.
  2. SOHC engine: To apply in a laying groove in a cover of a head of cylinders sealant on a silicone basis (for example, DOW CORNING Q3-7057). To impose new laying of a cover.
  3. To establish a cover of a head of cylinders and to screw 10 Nanometers with effort.
  4. To establish a gear belt, see the Sections Removal and installation of a gear belt of VZ, V5, B6 (SOHC), BP engines (SOHC), Removal and installation of a gear belt (DOHC).
  5. To install perepuskny the pipeline of the cooling system and to tighten a fastening nut with effort of 20 Nanometers.
  1. 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.
  1. To attach all electric wires and vacuum hoses according to the put tags.
  1. To put on heater hoses, and depending on model to latch or fix by collars.
  2. To connect the giving and returnable fuel-supply lines and to fix by collars.
  3. To install the air filter, see the Head the Power supply system, the carburetor, system of injection of fuel, the Section Removal and installation of the air filter.
  4. To check frost resistance of cooling liquid and to fill in it in system, see the Head Vvedeniye.
  5. To connect a cable of mass of the battery.
  6. If are available, to determine time on hours and to set a protective code of the radio receiver.
  7. To replace engine oil, see the Head Vvedeniye.
  8. To check the ignition moment if it is required, to adjust, see the Head Sistem of ignition, the Section Check/adjustment of the Moment of Ignition.
  9. To check idling, if necessary to adjust, see the Head the Power supply system, the carburetor, system of injection of fuel.
  10. To warm up the engine, to check the level of cooling liquid and tightness of all hose connections.
  11. If it is required, to check a gap of valves, see the Section Check/adjustment of a Gap of Valves.

Diesel engine

Removal

 PERFORMANCE ORDER

  1. To remove the battery and to unscrew the holder of the battery, see the Head Sistem of electric equipment, the Section Removal and installation of the battery.
  2. To remove the air filter, see the Head the Power supply system, the carburetor, system of injection of fuel, the Section Removal and installation of the air filter.
  3. To remove injection pipelines, see the Head the Diesel engine.
  4. To unscrew the giving and returnable pipelines.
  1. Holding a cam-shaft an adjustable spanner, for example, of HAZET 279-15, to unscrew a bolt of fastening of a cogwheel of a cam-shaft. To remove a cam-shaft wheel, if necessary to bring down easy blows of the rubber hammer.

When keeping a cam-shaft not to damage a head of cylinders a wrench.

  1. To unscrew a back casing of a gear belt.
  1. To unscrew fastening bolts - shooters - a forward support of the engine.
  1. To weaken bolts of a head of cylinders in the sequence with 1 on 10 for the first pass on 1/2 turns, for the second pass on one whole turn and to turn out completely on the third pass.

Weakening of bolts of a head of cylinders in an inadequate order can lead to deformation or cracks in a head of cylinders.

Installation

 PERFORMANCE ORDER

  1. To check a head of cylinders for deformation. The most admissible deformation on a sealant ache 0,1 mm can make surfaces. If deformation exceeds boundary value, the head of cylinders should be processed (it is carried out in a workshop).
  2. To measure stopper vystupaniye size. The required value: 7 - 8 mm. If necessary to hammer a stopper with the hammer to the specified size. To cover new consolidation of round section with a small amount of oil and to insert it into a stopper groove.
  3. To measure length of bolts of a head of cylinders from bottom edge of a head until the end of a core. The maximum length of 114,5 mm should not be exceeded. If value does not conform to the requirement, the bolt should be replaced.
  1. To wrap 10 bolts of a head of cylinders by effort of a hand so far they will not adjoin to a head. Then to tighten bolts in three passes. On each pass bolts drag on in the sequence represented on an illustration from the 1st on the 10th.

1st pass: a dynamometer key with effort of 30 Nanometers

2nd pass: to tighten on 1/4 turns a rigid key, without removing a key

3rd pass: to tighten on 1/4 turns a rigid key, without removing a key

  1. To screw a forward support of the engine with effort of 45 Nanometers.
  1. To establish a back casing of a gear belt and to screw 10 Nanometers with effort.
  1. To establish a cogwheel and a wedge. For tightening of a bolt of fastening to hold a cam-shaft a key. Inhaling moment: 50 Nanometers.
  2. To establish a gear belt, see the Head the Diesel engine.
  3. To establish the giving and returnable fuel-supply line, and also the injection pipeline, see the Head the Diesel engine.
  4. To install the air filter, see the Head the Power supply system, the carburetor, system of injection of fuel, the Section Removal and installation of the air filter.
  5. To establish the holder of the battery and to screw 10 Nanometers with effort.
  6. To install the battery, see the Head Sistem of electric equipment, the Section Removal and installation of the battery.