spring MAZDA 323 1989 Factory Repair Manual

Bl
ENGINE
(SOHC)
INDEX .......................................... Bl- 2
OUTLINE ...................................... Bl- 3
SPECIFICATIONS ........................
Bl- 3
TROUBLESHOOTING GUIDE ..........
Bl- 3
ENGINE TUNE-UP PROCEDURE ......
Bl- 5
PREPARATION ............................ Bl- 5
ENGINE OIL ............................... Bl- 5
ENGINE COOLANT.. ....................
Bl- 5
DRIVE BELT ............................... Bl- 5
HLA .......................................... Bl- 7
IGNITION TIMING, IDLE SPEED
..... Bl- 8
COMPRESSION ............................. Bl-10
INSPECTION ............................... 81-10
ON-VEHICLE
MAINTENANCE.. ........
Bl-1 1
PREPARATION ............................ Bl-11
TIMING BELT .............................. Bl-12
CYLINDER
HEAD GASKET ........... Bl-16
HLA .......................................... Bl-20
FRONT OIL SEAL.. ...................... 81-23
REAR OIL SEAL ..........................
Bl-25
REMOVAL ..................................... 81-28
PROCEDURE .............................. Bl-28
ENGINE STAND MOUNTING.. .........
Bl-35
PREPARATION
............................ 81-35
PROCEDURE ..............................
Bl-36
DISASSEMBLY .............................. Bl-38
PREPARATION ............................ Bl-38
AUXILIARY PARTS.. ..................... 81-40
TIMING BELT .............................. 81-41
CYLINDER HEAD.. ......................
81-43
CYLINDER BLOCK
(EXTERNAL PARTS)
................... 81-47
CYLINDER BLOCK
(INTERNAL
PARTS). ................... Bl-50 INSPECTION /
REPAIR.. .................
81-54
PREPARATION ............................ Bl-54
CYLINDER HEAD.. ...................... Bl-54
VALVE
MECHANISM.. .................. Bl-55
CAMSHAFT ................................ 81-58
HLA .......................................... Bl-60
CYLINDER BLOCK ......................
Bl-60
OIL JET ..................................... Bl-61
PISTON, PISTON RING, AND
PISTON PIN .............................. Bl-62
CONNECTING ROD.. ...................
Bl-63
CRANKSHAFT ............................ Bl-64
BEARING ................................... 81-64
TIMING BELT .............................. Bl-65
TENSIONER,
IDLER.. ................... 81-65
TENSIONER SPRING ...................
81-65
PULLEY ..................................... Bl-65
ASSEMBLY ................................... Bl-66
PREPARATION ............................ Bl-66
CYLINDER BLOCK
(INTERNAL PARTS). ................... Bl-68
CYLINDER BLOCK
(EXTERNAL PARTS) ...................
Bl-74
CYLINDER
HEAD.. ...................... 81-79
TIMING BELT .............................. Bl-86
AUXILIARY
PARTS.. ..................... Bl-89
ENGINE STAND DISMOUNTING.. .... Bl-92
PROCEDURE .............................. 81-92
INSTALLATION ............................. 81-94
PROCEDURE .............................. Bl-94
23UOBl-001

Bl TROUBLESHOOTING GUIDE
Problem
Insufficient power
Abnormal
combustion
Engine noise Possible Cause
Insufficient compression
Malfunction of HLA*
Compression leakage from valve seat
Seized valve stem
Weak or broken valve spring
Failed cylinder head gasket
Cracked or distorted cylinder head
Sticking, damaged, or worn piston ring
Cracked or worn piston Malfunction of fuel system
Malfunction of ignition system
Others
Slipping clutch
Dragging brakes
Wrong size tires Malfunction of engine-related components
Malfunction of HLA’
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber Malfunction of fuel system
Malfunction of ignition system
Crankshaft- or bearing-related parts
Excessive main bearing oil clearance
Main bearing seized or heat-damaged
Excessive crankshaft end play
Excessive connecting rod bearing oil clearance
Connecting rod bearing seized or heat-damaged Piston-related parts
Worn cylinder
Worn piston or piston pin
Seized piston
Damaged piston ring
Bent connecting rod Valves or timing-related parts
Malfunction of HLA*
Broken valve spring
Excessive valve guide clearance Malfunction of cooling system
Malfunction of fuel system
Others
Malfunction of water pump bearing
Improper drive belt tension
Malfunction of alternator bearing
Exhaust gas leakage
Malfunction of timing belt tensioner Action
Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section F
Refer to Section G
Refer to Section H
Refer to Section P
Refer to Section Q
Replace
Replace
Replace
Eliminate carbon
Refer to Section F
Refer to Section G
Replace or repair
Replace
Replace or repair
Replace or repair
Replace
Replace or repair
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section E
Refer to Section F
Refer to Section E
Adjust
Refer to Section G
Refer to Section F
Replace Page 81-20
Bl-57
81-55
81-58
81-16
81-54
81-62
al-62
81-20
81-55
81-58
-
61-71
Bl-64
81-72
81-73 8-i-64
Bl-60
81-63
81-62
81-62
El-63
Bl-20
El-58
81-55
Bl- 5
81-12
911 IORI .N)J LI.,“l. --
* Tappet noise may occur if the engine has set idle for an extended period. The noise should
normal operating temperature. (HLA troubleshooting: Refer to page Bl-7) dissipate after the engine has reached
81-4

Bl ON-VEHICLE MAINTENANCE
TIMING BELT
Removal / Installation
1. Disconnect the negative battery cable.
2. Raise the vehicle on a lift and remove the right front wheel.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal, referrina to Installation Note.
7.6-11 N.m
[SO-110 cm-kg, 69-95 in-lb)

7.6-11 N.m
(60-l 10 cm-kg,
0 69-95 in-lb)
, .v- I . (60-110 cm-kg, 69-95 in-lb)
157-167 (16-17, 116-123) /@ 7.i11 N.m
(60-110 cm-kg,
69-95 in-lb)
N.m (m-kg, ft-lb]
23UOBl-01
1. Under cover and side cover 10. Timing belt cover, lower
2. P/S and/or A/C drive belt 11. High-tension leads
3. Alternator drive belt 12. Spark plugs
4. Water pump pulley 13. Timing belt
5. Plate Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-13
6. Pulley lock bolt Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-13
Removal Note ..,.,,.,....,....,...,...,, page Bl-13 14. Tensioner
installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-14 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 81-13
7. Crankshaft pulley 15. Tensioner spring .__
8. Pulley boss Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 61-13
9. Timing belt cover, upper
131-12

-
. . .
ON-VEHICLE MAINTENANCE Bl
13EOBl-010
Removal Note
Pulley lock bolt
1. Hold the pulley with the SST.
2. Using the SST, loosen the pulley lock bolt.
3. Remove the pulley lock bolt and pulley boss.
MARKS
13EOBl-02
MARK -
DIRECTION
ROTATION
13EOBl-02
OBUOBX-0;
TIMING MARK
13EOBl.022
Timing belt
1. Install the pulley boss and pulley lock bolt.
2. Turn the crankshaft to align the timing marks.
Note
l The pin on the pulley boss must face upward.
Caution
l After setting the marks, do not turn the crankshaft
when removing the pulley lock bolt and pulley boss.
3. Remove the timing belt.
Note
l Mark the timing belt rotatlon for proper relnstal-
latlon.
Installation Note
Tensioner, tensioner spring
1. Install the tensioner and the tensioner spring.
2. Temporarily secure the tensioner with the spring fully ex-
tended.
Timing belt
1. Verify that the timing belt pulley and camshaft pulley mark
is aligned with the timing mark.
Bl-13

Bl ON-VEHICLE MAINTENANCE
13EOBl-023
MARKS
13EOBl-02, 4
I
03UOBl-02
98 N
(10 kg, 22 lb)
13EOBl-02 15
2. Install the timing belt so that there is no looseness at the
tension side.
Caution
l Do not turn the crankshaft. .-
3. Install the pulley boss and lock bolt.
4. Turn the crankshaft two turns clockwise, and face the pin
on the pulley boss upward.
5. Verify that the camshaft pulley marks are aligned with the
cylinder head cover marks.
If not aligned, remove the timing belt and repeat from ten-
sioner installation.
6. Loosen the tensioner lock bolt to apply tension to the tim-
ing belt.
Caution
l Be sure not to apply tension other than that of the
tensioner spring.
7. Tighten the tensioner lock bolt.
--
Tightening torque:
19-25 N,m (1.9-2.6 m-kg, 14-19 ft-lb)
8. Turn the crankshaft 2 turns clockwise and verify that the
marks are again correctly aligned.
9. Check the timing belt deflection by applying moderate pres-
sure (96 N,
10 kg, 22 lb) midway between the crankshaft
pulley and the camshaft pulley.
If the timing belt deflection is not correct, temporarily se-
cure tensioner lock bolt so the spring is fully extended.
Repeat Steps 4-8 above or, if necessary, replace the ten-
sioner spring.
Deflection:
11 .O-13.0mm (0.43-0.51 in) at 96 N (10 kg, 22 lb)
10. Using the SST remove the pulley lock bolt and pulley boss.
Pulley lock bolt
1. Install the crankshaft pulley boss, and using the SST, tight-
en the pulley lock bolt.
Tightening torque:
157-167 N,m (16-17 m-kg, 116-123 ft-lb)
91-14

Bl ON-VEHICLE MAINTENANCE
HLA
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. Install in the reverse order of removal, referring to Installation Note.
-
4.9-0.8 N.I
@ BP SOHC

22-28
12.2-2.9. 16-2 m (SO-SO cm-kg, 43-78 in-lb)
N.m (m-kg, ft-lb)
03UOBl-03
1. Cylinder head cover
Installation
Note . . . . . . . . . . . . . . . . . . . . . . . . page 4. Rocker arm spring
81-22
5. Rocker shaft
2. Rocker arm and rocker shaft assembly
6. HLA
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . .
page 81-21
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Installation Note ,.........,............. page 81-21
---
81-21
3. Rocker arm 7. O-ring
8140

ON-VEHICLE MAINTENANCE Bl
Removal note
Rocker arm and rocker shaft assembly
1. Loosen the rocker arm bolts in two or three steps in the or-
der shown in the figure.
2. Remove the rocker arms and rocker shaft assembly.
3. Code all rocker arms and springs so that they can be rein-
stalled in the same places from which they were removed.
I
23UOBi-02 1
Installation note
HLA
1. Pour engine oil into the oil reservoir in the rocker arm.
2. Apply engine oil to the new HLA.
3. Install the HLA in the rocker arm.
Caution
l Be careful not to damage the O-ring when installing.
Oli RESERVOIR
o3uoB1-o?
Rocker arm and rocker shaft assembly
B6 SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure. No.1 CYLINDER No.4 CYLINDEF
[ ’ ” 0 D 0
0311081-034
Caution
l Be sure both rocker arm shaft oil holes face
downward.
l The installation bolt holes are different for the ex-
haust and intake sides as shown in the figure. No.1 CYLINDER
No.4 CYLINDER
INTAKE

l---A--l
0 = ‘, I I
Y Y
0 \L
.a Y
r Y)
/
6
EXHAUST
A>B
Note
l There are two types of rocker arms with different
offsets. One type for No.1 and No.2 cylinders ex-
haust and intake. And the other for cylinders No.3
and No.4.
No. 1.2 CYLINDERS No.3,4 CYLINDERS
(IN & EX) (IN & EX)
81-21

Bl DISASSEMBLY
DISASSEMBLY
PREPARATION
SST
49 EOl 1 1AO
Ring gear brake
49 EOll 104
49 EOl 1 1 AO)
49 0636 100A
Arm, valve spring removal of valve
49 B012 006
Pivot, valve
49 8012 012
49 8012 014
49 LO11 006
Puller 84 installer
(Part of
49 LO1 1 OAO)
81-38

DISASSEMBLY Bl
I I
49 LO11 010
Centering tool
(Part of
49 LO1 1 OAO) For
removal I
installation of
piston pins 49 LO11 011
Holder
(Part of
49 LO1 1 OAO) For
removal I
installation of
piston pins
49 HO11 OOlA
Support block
head For
removal /
installation of
piston pins
1. Code all identical parts (such as piston, piston rings, connecting rods, and valve springs) so that they
can be reinstalled in the cylinder from which they were removed.
2. Clean the parts with a steam cleaner. Blow off any remaining water with compressed air.
Note
l During disassembly of any part or system, be sure to study its order of assembly. Also, note
any deformation, wear, or damage.
05UOBX-091
81-39

DISASSEMBLY Bl
TIMING BELT
23UOBl-032
1. Water pump pulley
2. Crank shaft pulley bolt 6. Crankshaft pulley boss
3. Plate 7. Timing belt cover, upper
4. Pulley lock bolt 8. Timing belt cover, lower
9. Timing belt
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page Bl-42
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page
81-42
5. Crankshaft pulley
10. Tensioner and tensioner spring
Bl-41