Mazda 323

since 1985 of release

Repair and car operation



Mazda 323

+ Introduction
- Petrol engines
   Specifications
   Removal and engine installation
   Removal and installation of a gear belt of VZ engines, В5, B6 (SOHC), (SOHC) VR
   Removal and installation of a gear belt (DOHC)
   Removal and head installation cylinders/replacement of laying of a head of cylinders
   Mechanism of a chain drive
   Removal and installation cam-shaft/adjustment of phases of a gazoraspredeleniye
   Removal and camshaft installation
   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 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
   Compression check
   Removal and installation/tension of a maple belt
+ System of greasing of the engine
+ System of cooling of the engine
+ ignition System
+ 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 steering system
+ Brake system
+ Wheels and tires, body, car coloring, care of the car
+ electric equipment System
+ Heater, lighting system, devices
+ Governing bodies and operation receptions
+ Electric circuits






Removal and head installation cylinders/replacement of laying of a head of cylinders

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

9 — a remenny 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 exhaust silencer
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 should be cooled at least to room temperature. Final and inlet collectors remain are connected. Removal for VZ engines, В5, В6 and VR is described. At the end of head there are instructions on the diesel engine. Differences for a series of engines E it is specified in separate chapter, see. Section Removal and installation cam-shaft/adjustment of phases of a gazoraspredeleniye.

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

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

Removal

The B6 engine with injection system

 PERFORMANCE ORDER

  1. To disconnect a weight cable from the battery.

Data from memory of malfunctions of the engine or protective code of a radio receiver are thus erased. Before shutdown of the battery it is necessary to read instructions in the Section Removal and battery installation.

  1. Injector engine: To weaken collars and to remove an inlet hose.
  2. Carburetor engine: To remove the air filter, see. Head Power supply system, carburetor, system of injection of fuel, Section Removal and installation of the air filter.
  3. If is available, to remove the resonant chamber.
  4. To merge cooling liquid, see. Head Introduction.
  5. To remove a gas drive, see. Head Power supply system, carburetor, system of injection of fuel, Section Check/removal and installation of automatic equipment of cold start.
  6. Automatic transmission: To disconnect a butterfly valve cable.
  7. To disconnect all electric wires to a head of cylinders. For simplification of installation of a wire it is necessary to mark with a sticky tape previously.
    • To unscrew a cable of weight-1-on the engine.
    • To disconnect the tip-2 - a lambda probe.
    • To disconnect the combined tip-3-on the ignition distributor.
    • To disconnect the combined tip of-4-gates of injection.
    • To disconnect the combined tip of the sensor of a butterfly valve-5-and a regulator of single turns-6-.
    • To disconnect the plug 4-7-on the ignition coil.
    • To disconnect the combined tip-8-of a thermoswitch of system of cooling.
    • To disconnect the tip-9-of the sensor of temperature of cooling liquid.
    • To disconnect a cable of weight-10-on the engine.
    • To disconnect the combined tips 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 shlangovy collars and to disconnect fuel hoses-2-. At shutdown to lay around топливопроводов a rag that when easing fuel was not sprayed. At once to close pipelines suitable jams, for example, pure bolts of the corresponding diameter. For simplification of the subsequent installation to mark топливопроводы with a sticky tape.
  2. If is available, to disconnect a vacuum hose-4-темпостата.
  3. To disconnect a ventilating vacuum hose-3-.

Carburetor engine

Carburetor engine

 PERFORMANCE ORDER

  1. To weaken shlangovy collars and to disconnect топливопроводы on the mechanical fuel pump. At shutdown to lay around топливопроводов a rag that fuel was not sprayed. At once to close pipelines suitable jams, for example, pure bolts of the corresponding diameter. For simplification of the subsequent installation to mark топливопроводы with a sticky tape.
  2. To disconnect a hose from a control unit heating of 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 вып.: To press a ledge - an arrow - a shlangovy collar and to disconnect a heater hose.

On the union there is 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 system of cooling and to disconnect a bracket.
  2. To remove a gear belt, see. Sections Removal and installation of a gear belt of VZ engines, В5, B6 (SOHC), (SOHC) VR, 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 exhaust silencer from a final collector, see. Head System 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 sequence with 1 on 10 for the first pass on 1/2 turns, for the second pass on one whole turn and completely to turn out 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, completely open valves can be thus 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. Thus 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 the compressed air. If the compressed air is not present, it is possible to clear openings the small screw-driver which has been wrapped up by a rag.

In any case oil should be removed.


  1. To check a head of cylinders on existence of deformation by a steel ruler and shchupy.
  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 (is carried out in a workshop).
  2. To check a head of cylinders on existence of cracks. If there are cracks, it is necessary to replace a head.
  3. To check water, oil and fuel hoses on existence of cracks and gaps if it is required, to replace.
  4. To check valves and directing valves on 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 effort of a hand. Then bolts should be tightened in three passes. On each pass bolts are tightened in 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 accuracy of a dinamometrichesky key. Besides, it is necessary to follow sequence of an inhaling precisely.

  1. Injector engine: To tighten fastenings of an inlet collector with efforts of 25 Nanometers and 45 Nanometers.
  1. To screw a reception pipe of the exhaust silencer on a final collector with effort of 45 Nanometers.
  1. DOHC engine: To put on the shaded places hermetic on a silicone basis (for example, DOW CORNING Q3-7057). To establish new laying of a cover of valves.
  2. SOHC engine: To put in a laying groove in a cover of a head of cylinders hermetic 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 with effort of 10 Nanometers.
  4. To establish a gear belt, see. Sections Removal and installation of a gear belt of VZ engines, В5, B6 (SOHC), (SOHC) VR, Removal and installation of a gear belt (DOHC).
  5. To establish perepuskny the pipeline of system of cooling and to tighten a fastening nut with effort of 20 Nanometers.
  1. To establish and adjust a gas drive, see. Head Power supply system, carburetor, system of injection of fuel, Section Check/removal and installation of automatic equipment of cold start.
  1. To attach all electric wires and vacuum hoses according to the put labels.
  1. To put on heater hoses, and depending on model to latch or fix collars.
  2. To connect submitting and returnable топливопроводы and to fix collars.
  3. To establish the air filter, see. Head Power supply system, carburetor, system of injection of fuel, Section Removal and installation of the air filter.
  4. To check frost resistance of cooling liquid and to fill in it in system, see. Head Introduction.
  5. To connect a cable of weight of the battery.
  6. If are available, to establish time on hours and to set a protective code of a radio receiver.
  7. To replace engine oil, see. Head Introduction.
  8. To check the ignition moment if it is required, to adjust, see. Head ignition System, Section Check/adjustment of the moment of ignition.
  9. To check idling, if necessary to adjust, see. Head Power supply system, carburetor, system of injection of fuel.
  10. To warm up the engine, to check level of cooling liquid and tightness of all shlangovy connections.
  11. If it is required, to check a gap of valves, see. 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. Head electric equipment System, Section Removal and battery installation.
  2. To remove the air filter, see. Head Power supply system, carburetor, system of injection of fuel, Section Removal and installation of the air filter.
  3. To remove injection pipelines, see. Head Diesel engine.
  4. To unscrew submitting and returnable pipelines.
  1. Holding a cam-shaft an adjustable spanner, for example, 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 in easy blows of a 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 sequence with 1 on 10 for the first pass on 1/2 turns, for the second pass on one whole turn and completely to turn out 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 on deformation. The most admissible deformation on a sealant ache surfaces can make 0,1 mm. If deformation exceeds boundary value, the head of cylinders should be processed (is carried out in a workshop).
  2. To measure size of a vystupaniye of a stopper. Demanded value: 7-8 mm. If necessary to hammer a stopper a hammer till the specified size. To cover new consolidation of round section by 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 till the end of a core. The maximum length of 114,5 mm should not be exceeded. If value does not correspond to the requirement, it is necessary to replace a bolt.
  1. To wrap 10 bolts of a head of cylinders effort of a hand while they will not adjoin to a head. Then to tighten bolts in three passes. On each pass bolts are tightened in the sequence represented on an illustration from the 1st on the 10th.

1st pass: dinamometrichesky natural 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 with effort of 10 Nanometers.
  1. To establish a cogwheel and a wedge. For a tightening of a bolt of fastening to hold a cam-shaft a key. Inhaling moment: 50 Nanometers.
  2. To establish a gear belt, see. Head Diesel engine.
  3. To establish submitting and returnable топливопровод, and also the injection pipeline, see. Head Diesel engine.
  4. To establish the air filter, see. Head Power supply system, carburetor, system of injection of fuel, Section Removal and installation of the air filter.
  5. To establish the holder of the battery and to screw with effort of 10 Nanometers.
  6. To establish the battery, see. Head electric equipment System, Section Removal and battery installation.