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
   Removal and installation of the transmission
   Gear shifting mechanism
   Four-wheel drive
+ 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 transmission

1 — a forward wheel
2 — a mudguard
6 — the holder of the battery
7 — a speedometer Shaft
8 — the plug of lamps of a backing
9 — the plug of the switch of neutral situation
10 — a starter
11 — draft of switching of I
12 — draft of switching of II

13 — a beam of the engine/transmission
14 — a lobby of the support engine/transmission
15 — the working cylinder of the drive of coupling
16 — a tip of steering draft
17 — the stabilizer
18 — a power shaft
19 — a back support of the engine/transmission
20 — the transmission

The transmission is removed down. The elevator with a platform or 4 reliable support, and also the elevator with suitable wooden laying is for this purpose necessary for lowering of the transmission. The crane is necessary for a suspension bracket of the engine remaining on the car.

Removal

 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. To disconnect a plus cable of the battery, to weaken fastening and to take out the battery.
  2. To unscrew and remove the holder of the battery.
  3. 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.
  1. Injector and diesel engine: To remove an inlet pipe and the preliminary camera of an inlet collector, for this purpose to weaken collars and to remove an air hose.
  1. Diesel engine: To remove the fuel filter, see the Head Vvedeniye.
  2. To unscrew a cap nut of a shaft of a speedometer. To take out a speedometer shaft. On cars from 9/89 g of the issue to unscrew a speedometer shaft gear wheel bolt.
  1. Petrol front-wheel models to 9/89 g the issue and all station wagon models: To disconnect a cable on the lever of switching off of coupling and to unscrew a counter support on the transmission.
  1. Hydraulic drive: To unscrew the working cylinder of coupling on a transmission case (2 bolts). Not to weaken hydraulic pipelines! To take out the giving pipeline from fastening. To suspend the working cylinder on a wire sideways to a body.
  1. To disconnect a cable of lamps of a backing on the transmission.
  2. To unscrew a weight cable on the top party of the transmission.
  3. If are available, to unscrew fastenings of the directing cables and fastening of a tube of cooling liquid on a transmission case.
  4. To remove a starter, having weakened for this purpose bolts. Previously to disconnect on a starter a cable and the plug, see also Head Sistem of electric equipment.
  5. To weaken bolts of forward wheels, without unscrewing.
  6. To lift a forward part of the car.
  7. To remove forward wheels and to unscrew the left side mudguard in a wheel arch.
  8. To merge gearbox oil, see the Head Vvedeniye.
  1. To unscrew both drafts of switching on the transmission and to suspend on a wire to the bottom.
  1. To remove the left and right power shafts. For this purpose tips of steering drafts, then the lower cross levers on both sides have to be removed at first. In conclusion to squeeze out power shafts on internal hinges, see the Head Podvesk and system of steering, the Section Removal and installation of a power shaft.
  2. To remove (if is available) the forward stabilizer, see the Head Podvesk and system of steering.
  1. To fasten a cable to engine earrings and to pull a little it, t. е to raise a little the engine.
  1. To unscrew the transmission from an average beam of an engine mount. Then to unscrew a beam from a body and to remove it.
  1. To unscrew a coupling cover.

Only the four-wheel drive

 PERFORMANCE ORDER

  1. To remove forelocks and to remove drafts of switching from transmission levers. To remove brackets on countersupport.
  1. To unscrew bolts of the basic console of an intermediate shaft of power shafts.
  2. To remove a reception pipe of the muffler, and also a cross beam on the driveshaft tunnel.
  1. To remove the driveshaft, before weakening of bolts to mark the provision of flanges in front and behind with a felt-tip pen that the shaft could be established in former situation.
  1. Only BP engines - SOHC (identification of engines see the Head Petrol engines): To unscrew at waters of blocking of differential (4 bolts), previously having turned draft of switching by the screw-driver (it is carried out in a workshop).
  2. To unscrew a back engine mount on a body.
  3. To lower the engine/transmission by means of a waist on the left side.
  1. To unscrew a forward support of the engine on the transmission.
  1. To install the elevator under the transmission, to use suitable wooden laying.
  1. To turn out 2 flange bolt available from above, the connecting engine and the transmission. On models to 87 g of the issue (engines E) instead of the 2nd there are 4 top bolts.
  1. To turn out the lower bolts of fastening of the engine and transmission from the lower party. On diesel engines it is necessary to unscrew in addition 2 corners between the transmission and the engine from below at the left and on the right.
  1. To slightly raise the transmission a hand and to wring out from the engine mount.
  2. To lower the transmission by means of the elevator and to roll out by means of the assistant.

Installation

 PERFORMANCE ORDER

  1. Before installation of the transmission it is necessary to check coupling and the release bearing, see the Head Stsepleniye.
  2. To clear shlitsevy connection of a main shaft and to grease slightly with molybdenic paste or spray.

If too much lubricant is applied, in use it can get on a frictional overlay of the conducted disk that will lead to malfunctions in work.

  1. To roll the transmission on the elevator under the car.
  2. If at installation of the transmission the main shaft does not enter the conducted clutch plate, to turn a little a box shaft (to include transfer), or to ask the assistant to turn a little the engine crankshaft.
  3. To level the transmission. In most cases on a flange of the engine there are directing pins which have to enter openings in a coupling case.
  4. To insert all bolts of fastening and to screw the transmission on the engine. To tighten bolts with effort of 90 Nanometers.

At the same time not to attract the transmission to the engine by means of an inhaling of bolts at all. At first evenly to wrap all bolts, after it to tighten a dynamometer key.

  1. To screw a forward support of the engine on a transmission case, to tighten bolts with effort of 50 Nanometers.
  2. To install the engine by means of a waist in the correct adjusting situation.
  3. To screw an average beam of an engine mount on the transmission, to tighten 4 bolts - And - with effort of 50 Nanometers.
  1. To screw an average beam on a body with effort of 80 Nanometers, bolts - In-.
  1. To screw a back support of the engine on a body with effort of 80 Nanometers.
  1. To remove the elevator and the holder of the engine.
  2. Only the four-wheel drive: To level driveshaft flanges on tags, to insert bolts with washers, to tighten nuts with effort of 30 Nanometers.
  3. Four-wheel drive: To establish drafts of switching and an exhaust pipe, if necessary to install the drive of blocking of differential (it is carried out in a workshop), see the paragraph Removal.
  4. Four-wheel drive: To screw bolts of the basic console of an intermediate shaft of power shafts in the given sequence with effort of 50 Nanometers, see an illustration.
  5. To insert a cover of coupling and to screw it. At the diesel engine in addition to screw side intensifying plates.
  6. To insert a starter and to tighten 3 bolts with effort of 40 Nanometers.
  7. To connect the plug and a cable to a starter.
  8. To establish both power shafts with new lock rings, see the Head Podvesk and system of steering, the Section Removal and installation of a power shaft.
  9. To install the stabilizer and tips of steering drafts, see the Head Podvesk and system of steering.
  1. To screw drafts of switching on the transmission. To tighten a so-called lengthening bar with effort of 40 Nanometers, draft of switching with effort of 20 Nanometers.
  1. To screw a mudguard in the left wheel arch.
  2. If is available, to screw the lower guard of the engine.
  3. To fill in gearbox oil, see the Section Routine maintenance.
  1. To establish a speedometer shaft on the transmission and to screw a cap nut. On cars from 9/89 g of the issue previously to insert a gear wheel of a speedometer and to screw a bolt - an arrow-.
  1. To screw the working cylinder of coupling on a transmission case, to tighten bolts with effort of 20 Nanometers. To lay hydraulic pipelines in fastening on the transmission. In option with the hummock drive to attach and adjust a coupling cable, see the Head Stsepleniye, the Section Adjustment of a Pedal/cable of Coupling.
  2. To screw forward wheels and to lower the car.
  3. To tighten nuts of wheels cross-wise with effort of 100 Nanometers.
  4. To connect the plug to the switch of lamps of a backing.
  5. To screw a cable of mass of the transmission.
  6. If is available, to screw the holder of a cable and fastening of a tube of cooling liquid on a transmission case.
  7. To install the air filter and an inlet air hose, see the Head the Power supply system, the carburetor, system of injection of fuel, the Section Removal and installation of the air filter.
  8. Diesel engine: To install the fuel filter.
  9. To insert and screw the holder of the battery.
  10. To establish and connect the battery, at first plus, then a weight cable.
  11. If are available, to determine time on hours and to set a protective code of the radio receiver.
  12. Whenever possible it is rather to measure the angles of installation of wheels.