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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mazda 323 (1985 release)

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Mazda 323
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Mazda
323
Introduction
Gasoline engines
Specifications
Removing and installing engine
Removal and installation of a gear belt of engines VZ, B5, B6 (SOHC), BP (SOHC)
Removing and installing toothed belt (DOHC)
Removal and installation of the cylinder head / cylinder head gasket replacement
The mechanism of chain drive
Removing and installing the camshaft / camshaft adjustment
Removal and installation of a camshaft
Camshaft / timing gear
The camshaft / camshaft drive mechanism
Removal and installation of camshafts
Removal and installation of valves
Replacing valve stem seals
Checking the valve guides
Chamfering the valve seats in the cylinder head / IT valves
Lapping Valves
Checking / adjusting valve clearance
Compression Test
Removing and installing / belt tension
Engine oil
Engine cooling system
Ignition system
The power supply system, the carburettor, fuel injection system
Diesel engine
Exhaust
Coupling
Manual gearbox
Automatic Transmission
Suspension and steering system
Brakes
Wheels and tires, a body, car coloring, care of the car
Electrical system
Heater, illumination system, devices
Controls and operation receptions
Electrical diagrams
 


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Removing and installing engine



Removal of the engine is possible only with the gearbox. Therefore, you should read before taking also Chapter Removing and installing gearbox. Exhaust and intake manifolds, and a carburetor and a generator are mounted on the engine. To remove the engine required a crane. In no case can not be lowered down the engine via the guild lift as the lift can seriously damage the engine. Before installation in the engine compartment must be covered wings.

It recommended mark before disconnecting all the electrical cables and vacuum lines with adhesive tape, so that when you install they can be easily connected to their former places.

Depending on the model year and equipment of electrical wires or vacuum and water hoses can be installed in the engine compartment in different ways. So how to describe all the individual options are not possible, it is recommended before unplugging the mark corresponding piping and wiring with tape. The next chapter describes removal and installation of the petrol engine of 1.4 liters with fuel injection system.

Withdrawal

B6 injection engines with injection system

PERFORMANCE ORDER

  1. Disconnect the battery, follow the instructions. See section Removing and installing the battery.
  2. Unscrew the battery holder.
  3. Remove the air filter. See Chapter Removing and installing air filter.
  4. Drain coolant and remove the cooler, see chap. Engine cooling system.
  5. Drain the transmission oil, see. Chapter Introduction.
  6. Remove the hood, see chap. Wheels and tires, a body, car coloring, care of the car.
  7. Remove the drive gas.
  1. Disconnect the vacuum brake hose -1-, after loosening the clamp.
  1. Release clamps and disconnect fuel hoses -2-. If you turn off the fuel to put around the rag to the weakening could sprayed fuel. Close immediately pipelines suitable stoppers. To this paste into the holes, for example, clean bolts corresponding diameter. To facilitate the installation of the fuel mark tape.
  2. Disconnect the breather hose -3- vacuum.
  3. If present, disconnect the vacuum hose -4- Tempostat.

Carburetor engine

Carburetor engine

PERFORMANCE ORDER

  1. Loosen the hose clamps and disconnect the fuel hoses of the mechanical fuel pump. If you turn off the fuel to put around the rag to the weakening could sprayed fuel. Close immediately pipelines suitable stoppers. To this paste into the holes, for example, clean bolts corresponding diameter. To facilitate the installation of the fuel mark tape.
  2. Disconnect the vacuum hose to the carburetor. To facilitate the installation mark hoses with adhesive tape.
  3. Disconnect heater hoses -5-, after loosening the clamps.
  4. Turn off the motor electrical connections. To facilitate the installation of the pre-mark the wire with tape.
    • Unscrew earth cable -1- on the engine.
    • Turn off the generator connection -2-, this thick cable unscrew B + and disconnect plug.
    • Disconnect the oil pressure sensor -3.
    • Disconnect combo connector throttle sensor and regulator -4- idle speed -5-.
    • Disable connection -6- starter, this thick cable to unscrew and remove the combined plug.
    • Disconnect -7- lambda probe.
    • Pull the plug valve injection combined -8.
    • Disconnect -9 sensor neutral (manual transmission only).
    • Disconnect terminal 4 -10 on the ignition coil.
    • Unscrew the earth cable to the motor -11-.
    • Pull the plug -12- combined on the ignition distributor.
    • Disconnect the combined plug -13- coolant temperature switch.
    • -14- Disconnect the coolant temperature sensor.
    • Disconnect the mass -15-.
    • Disconnect the combo connector on the switch -16- reverse (manual transmission only).
    • -17- Unscrew the earth cable on the gearbox.
    • Pull the plug -18- combined starter switch.
    • Disable the plug -19- temperature sensor.
    • If present, disconnect the plug -20- heating home automation.
    • Disable combo connector -21- carburetor.
  1. Models with 10/89 Vol.: Press the tip -strelka- hose clamp and disconnect the heater hose.

On the fitting seal is of circular cross section, and an intermediate ring, do not lose them during installation.

  1. Raise the vehicle.
  2. If there is, remove the lower trim the engine compartment.

Vehicles with power steering (servo)

PERFORMANCE ORDER

  1. Remove the V-belt with the pumps'. See section Removing and installing / belt tension.
  2. Unscrew the pump holder and hung on a wire with a hose connection so that the pump does not interfere with the further removal and hoses are not stretched.

Cars with air conditioning

Circuit conditioner does not have to be opened. Refrigerant contains substances from entering the skin that may cause frostbite. The engine can be removed without opening the circuit of the air conditioner.


PERFORMANCE ORDER

  1. Remove the V-belt, see. Section Removal and installation / belt tension.
  2. Unscrew air conditioner compressor from bracket and hang the wire connected to the hose so that it does not interfere with the further removal and hoses are not stretched.

Manual Transmission

PERFORMANCE ORDER

  1. Disconnect shift rod and extension rod on the gearbox. See Section Removal and installation of the gearbox.
  2. Models with hydraulic clutch: Unscrew the clutch slave cylinder with hydraulic piping and set aside so that it does not prevent further withdrawals. See also Chapter Clutch.

Hydraulic piping is connected, or after the installation of the system will be necessary to remove the air. When removed, the slave cylinder, do not push the clutch pedal. On some models, the conduit coupling is removed after dismantling the engine mounts.

  1. Models with a cable-operated clutch: disconnect coupling cable, see chap. Clutch, Section Adjustment of a pedal / clutch cable.
  2. Automatic transmission: Remove the cotter pin and pull the shift cable on the gearbox. Unscrew the cable bracket on the gearbox.
  1. Remove the tachometer shaft, see. Chapter Manual gearbox.
  1. Unscrew the front exhaust pipe from the exhaust manifold, see. Chapter Exhaust.
  2. Remove the drive shafts, see. Chapter suspension and steering system, Section Removal and installation of the drive shaft.
  1. Attach a suitable chain earrings engine and raise the engine to offload its support.
  1. Unscrew the nuts of the engine ?��1 and ?��2.
  1. Unscrew the dynamic damper and nuts -A-.
  1. Unscrew the nut -B-, remove the bolt and remove engine support.
  1. Unscrew the bolts -A- and -B-engine support on the side of the gearbox and remove the support complete with holder.
  2. Check whether all hoses leading from the engine to the body, are removed. Then remove the motor up by crane.

Carefully guide engine when picked to avoid damage to the body.

  1. Remove the gearbox from the engine. See Chapter Manual gearbox, Section Removal and installation of the gearbox.

Setting

PERFORMANCE ORDER

  1. Check engine mounts, water, oil and fuel hoses for cracks or tears and replace if necessary.
  2. Check the ease of movement of the release bearing and release lever, if necessary.
  3. Check the thickness and condition of the friction lining clutch disc, if necessary.
  4. Clean the clutch shaft splines and grease lubrication of MoS 2.
  5. Attach the gearbox to the engine, see. Chapter Manual gearbox.
  6. Carefully introduce the engine in the engine compartment from above with a crane. When lowering, make sure that the bolts of the lower engine mounts into the holes in the beam.
  7. Install nuts lower engine mounts.
  8. Install the mounting bolts of the upper engine mounts. On some models before installing the supports necessary to build a pipeline to the clutch slave cylinder.
  9. Align engine.
  10. Tighten the nuts on the lower engine support with a force of 70 Nm to 9/89 MY .; with a force of 50 Nm starting with 10/89 Vol.
  11. Tighten the nuts -A- engine support with a force of 80 Nm.
  12. Tighten the nut -B-. Torque: up to 9/89, the no. 60 Nm, starting with 10/89 Vol. 80 Nm.
  13. If so, screw the dynamic damper with 70 Nm of torque.
  14. Models with 10/89 Vol .: Tighten bolts -B- engine support in this order from 1 to 4 with a force of 50 Nm. Tighten the nuts -A- with torque 80 Nm.
  15. Install drive shafts, see. Chapter suspension and steering system, Section Removal and installation of the drive shaft.
  16. Install the front exhaust pipe and exhaust pipe or catalytic converter.

Manual Transmission

PERFORMANCE ORDER

  1. Attach post switching and extension rod on the gearbox. Screw the extension rod with a force of 40 Nm, the switching rod with a force of 20 Nm.
  1. Models with hydraulic clutch: Install the clutch slave cylinder with hydraulic lines and tighten the bolts -B- to 20 Nm of torque, with a torque -A- 10 Nm.
  1. Tighten the clutch slave cylinder with a force of 20 Nm.

The models with cable operated clutch

PERFORMANCE ORDER

  1. Install the clutch cable, see chap. Clutch, Section Adjustment of a pedal / clutch cable.
  2. If you have, set the lower engine compartment lining.
  3. Lower the vehicle.
  4. Install and adjust the drive gas, see. Chapter power supply system, the carburettor, fuel injection system, Section Check / removal and installation of automatic cold start.
  5. Install the speedometer shaft.

Automatic transmission

PERFORMANCE ORDER

  1. Connect to a transmission shift cable and insert the cotter pin. Tighten the cable on the gearbox with torque 10 Nm.

Vehicles with Servo

PERFORMANCE ORDER

  1. Place the pump with the holder and screw to 50Nm.
  1. Install the V-belt pumps'. See section Removing and installing / belt tension.

Cars with air conditioning

PERFORMANCE ORDER

  1. Install air conditioning compressor and screw holder with a force of 30 Nm.
  2. Install the V-belt air conditioning compressor. See section Removing and installing / belt tension.
  1. Connect and tighten all electrical wires and vacuum hoses according to the labeling.
  1. Wear heater hoses, and depending on the model to fix collars.
  2. Connect the supply and return fuel lines and secure with hose clips.
  3. Install the heat sink. See chapter engine cooling system, Removing and installing radiator.
  4. Pour the oil in the engine and gearbox, see. Chapter Introduction.
  5. Check coolant frost and pour it, see. Chapter Engine cooling system, Section Replacement of a cooling liquid.
  6. Set the air filter, see. Chapter Removing and installing air filter.
  7. Install the hood, see chap. Wheels and tires, a body, car coloring, care of the car, Section Removal and installation / adjustment of the hood
  8. Screw the battery holder with a torque of 20 Nm.
  9. Install the battery, see chap. Electrical system, Section Removing and installing the battery.
  10. If necessary, adjust the valve clearance. See Section Checking / adjusting valve clearance.
  11. Check the ignition timing, adjust if required, see. Chapter Ignition system, Section Checking / adjusting the moment of ignition.
  12. Check idle speed and adjust if necessary, see chap. The power supply system, the carburettor, the fuel injection system.
  13. Warm up the engine, check the coolant level and the tightness of all connections.





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Removal and installation of a gear belt of engines VZ, B5, B6 (SOHC), BP (SOHC)

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