engine MAZDA 323 1992 Suplement User Guide

B2 OUTLINE
OUTLINE
OUTLINE OF CONSTRUCTION
l Theengine is the same as of the previous BP-DOHC Turbo engine. However, some of the components
are modified for greater reliability and performance.
l Metallic sodium-filled exhaust valves are adopted. 13E032-302
SPECtFlCATIONS
Item
TYPe
Cyhnder arrangement and number
Combustion chamber
Valve system
Displacement cm3 tcu in]
Bore and stroke mm {in)
Compressron ratio
Compressron pressure kPa [ kgf/cm2, psi 1
-rpm
Open
BTDC
IN
Close ABDC
Valve tlmlng
EX Open BBDC
Close ATDC
IN
Valve clearance mm (in]
EX
Idle speed *
rpm
Ignltlon trmrng’ BTDC
Fwng order
*.. TEN terminal of dragnosrs connector grounded. Gasoline, 4-cycle
tn-line, 4 cyljnders
Pentroof
DOHC, belt-driven
1,839 { 112.2)
83.0 x 85.0 13.27 x 3.35)
8.2
1,127 lt1.5, 164)-300
2O
510
590
8O
0. Maintenance-free
0: Maintenance-free
800 f 50
100 f 70
l-3-4-2
13EOB2-303
82-2
1NTERC
The f<
and 0
S ym&l
-
Cytinder
block
related
Crank&;
related
Timing b
related
Vatve
related
Lubricatrc
system related
Coohng
. . system
related

The following chart shows interchangeability of the main parts of the previous BP DOHC Turbo engine
and the new BP DOHC Turbo engine for 4WD models.
S ymiols: 0 _. lnterc hangeable X . . . Not Interchangeable
Part name tnterchangeability
Remark
Cytlnder head 0
Camshaft 011 seal 0
Cvllnder head bolt 0
CB :
Cyh nder
blcck
related
Crankshaft
related
Timing belt
related
Valve
related
Lubrication
system
related Cylrnder head gasket 0
Wnder head cover 0
Cylinder head cover gasket
Cylinder block
MaEn bearina cao 0
0
0
Ma+n bearino suo~oFt elate I
0 I ” ,I I
Oil pan
Timrno belt cover I X
0 I
Turbocharger oil return pipe hole increased from
13mm IO.51 in) to 17mm IO.67 in)
Seal elate
Front orl seal I 0 I
I I 0
1
Rear 011 seal 0
Crankshaft 0
Marn bearina 0
Thrust bearing
Connectmg rod
Connecting rod beartng
Piston 0
;J
X
Shape different
Piston skirt shortened
I Piston pm cl
Tw
X Sectional shape different
Piston rrng Piston ring end gap increased from 0:?5--0.30mm
Second
X ~0.006-0.011 in ) to 0.35-0.50mm IO.01 4-0.019
in ] (Measured In cylinder)
Crankshaft pulley Shape different
Rear cover ;5
Flywheel
I 0
Flywheel bolt 0
Tbmlng belt 0
Timing belt crank pulley 0
Camshaft pulley 0
Timing belt tensioner and spring
0
Idler 0
Camshaft 0
AA
Valve Intake
Exhaust
cl
0
X Metallic sodium-filled valve
Valve spring Intake
I 0
and seat
Exhaust 0
Vatve wide I 0
Valve seal
Oil pump 0
Oil pump gasket 0
oil strainer 0
Oil strainer gasket 0
Oil cooler
X Heat dissi patlon capacity increased
Oil jet
Oil filter Shape different
1 Water pump 0
Coohng Thermostat 0
system
related Radiator 0
Cooling fan 0
I 3EO32.304
BZ-3.

EXHAUST ViitVE
EXHAUST SIDE
VALVE GUIDE
METALLIC SODIUM
(ABOUT 30% VOLUME)
VALVE STEM
.‘.‘*
:::I
:::I
VALVE HEAD
CYttNDER HEAD
IDENTlFtCATION OF METALLIC SODIUM-FILLED EXHAUST VALVE
l Superior he& dissipating .metallic sodium-filled exhaust valves are adopted. During engine operation, the
metalic sodium inside the valve stem melts. As the valve moves up and down, the sodium splashes around
inside the valve and helps to absorb heat from the cylinder head and to transfer it back to the engine
coolant through the valve guide. In this way, the combustion chamber temperature is reduced, reducing
knocking and improving fuel efficeincy.
l Special handling of sodium filled valves is required for personal safety. (See next page.)
B2-7

SUPPLEMENTAL SERVICE HWURMATION B2
SUPPLEMENTAL SERVICE 1NFORMATION
The following points in this section are changed in comparison with 323 Workshop Manual [Europe, AUS- tfilia (I 229-I O-89L)j.
Engine
l Removal
. Installation
I
m I
l The intercooler installation position is changed because the intercooler is enlarged. With this change, the
engine can be removed and ‘installed without removing the intercooler. The engine removal I installation
procedure is the same as of the previous BP-DOHC Turbo engine.
13E082-313
82-9

F3
c
FUEL AND EMISSION
CONTROL
SYSTEMS
i
INDEX . . . . . . . . l ..,.... *..,. . . . . . . m...*.*...*..... F3- 2
UUTLtNE
...................................... F3- 4
OUTLINE OF CONSTRUCTION.. ....
F3- 4
SYSTEM DIAGRAM ...................... F3- 5
VACUUM HOSE ROUTING
DIAGRAM
................................. F3- 6
WIRING DIAGRAM.. .....................
F3- 7
ECU RELATIONSHIP DIAGRAM ...... F3- 8
SPECIFICATIONS.. ....................... F3- 9
TURBOCHARGER CONTROL .......... F3-IO
OUTLINE
.................................... F3-10
SYSTEM DIAGRAM ...................... F3-10
WASTEGATE CONTROL ............... F3-11
FUEL SYSTEM
.............................. F3-12
OUTLINE ....................................
F3-12
CONTROL SYSTEM .......................
F3-13
STRUCTURAL VIEW .....................
F3-13
PRESSURE REGULATOR
CONTROL SYSTEM ....................
F3-14 SUPPLEMENTAL SERVICE
tNFOF?MATtON
............................. F3-I 5
SELF-DtAGNOStS FUNCTtON.. ........
F3-16
OUTLINE ....................................
F3-16
SERVICE CODE NUMBERS..
......... F3-16
TROU8LESHOOTtNG GUtDE
........... F3-19
RELATIONSHtP
CHART.. F3-19 ..............
DIAGNOSTIC JNDEX
.................... F3-20
PRECAUTIONS
............................
F3-21
SYMPTOM TROUBLESHOOTING .... F3-22
TURBOCHARGERCONTROL
SYSTEM ......................................
F3-37
TURBOCHARGER F3-37 ........................
WASTEGATE SOLENOID VALVE.. .. F3-38
INTERCOOLER ............................
F3-39
FUELSYSTEM ..............................
F3-40
FUEL PUMP ................................
F3-40
FUEL PUMP RESISTOR/RELAY ......
F3-40
PRESSURE
REGULATOR .............. F3-41
INJECTOR ..................................
F3-42
INJECTOR RESISTOR
................... F3-42
PRESSUR REGULATOR CONTROL
SYSTEM ......................................
F3-43
SOLENOID VALVE (PRESSURE
REGULATOR CONTROL)
............. F3-43
CONTROL SYSTEM
....................... F3-44
PREPARATION ............................ F3-44
ENGINE CONTROL UNIT (ECU) ..... F3-45
7 3EOF3-301

F3 INDEX
INDEX
I
J
D1AGNOSIS
CONNECTOR
SELF-DlAGNOSIS
1. Turbocharger
Removal I installation . . . . . . . . . . . . . . . . page F3-37
2. Wastegate solenoid valve
inspection . .__._. ._. . . . . . . . . . page W-38
3. Injector resistor
Inspection __ __,., __ . page F3-42 4, I ntercooler
Removal / Installation . . . . . . . .._...... page F3-39
5. Engine control unit (ECU)
lnspect~on . . . . . .._........... . . . . . . . . . . . page F3-45
F3-2
--
I. Inject
IfI;
Vr,
2. Press
In3
3. Sole-l
Ins

F3 OUTLINE
OUTLINE
OUTLINE OF CONSTRUCTION
Theefuel and emission control system of the new 323 4WD model 1s basically the same as that of the prevr-
ous 323 4WD model; however some parts are changed. The changed parts and interchangable parts
are shown betow.
13EOF3-304
Changed parts
1 ~ components Contents and purpose Reference pagl
INTAKE AlR
SYSTEM Turbocharger
Intercooler
l Size Increased for greater boost pressure l Wastegate solenord valve IS lozated on Intake port of F3-10
turbocharger to make system more compact F3-37
Volume increased for Improved F3-10
t F3-39
Wastegate sojenold valve
l Wastegate solenoid valve changed to duty solenoid
type for Increased engine power and response
l Wastegate solenoid valve is located on Intake port of
turbocharger to make system more compact F3-1 f
F3-38
I r
Pressure regulator One-stage operattlon changed to two-stage operatron F3-14
to improve hot restarting f3-41
L
FUEL SYSTEM High-ohmic type change to low-ohmrc type with exter-
Fuel qector na solenoid reslstor for improved fuel supply during F3-12
high-speed driving F3-42
Fuel pump reslstor Resistance reduced for
surer fuel supply F3-40
CONTROL
SYSTEM Pressure
regulator control system
Atr flow meter Two-stage operatton used to Improve hot restarting
Measures larger amount of air flow Increased power
Resistance values changed F3-t4
F3-43
F3- 9
f3EOF3-305 lnterchangable parts
tntake air system
l
Air valve
l Air bypass valve
l Air cleaner
l Air cleaner element
Fuel system
l Fuel filter assembly
l Fuel pu.mp (transfer
l Fuel vapor valve Control system
. l Throttle sensor
l Water thermosensor
l Knock sensor and control unit
l Oxygen sensor
l Fuel pump control unit
l Main relay
l Circuit opening relay
l Check valve (two-way) .
Evaporative system
l Charcoal canister
l Check valve (two-way)
13EOF3-306
F3-4

CHECK VALVE SOLENOID VALVE
(PURGE CONTROL)
llll
*
SOLENOID VALVE
(PRC LOW TEMP.)
3 ~NTERCOOLERII’ I ,‘/ I
II II
’ f frrmvmlHHt-----lHt I -1 II II
IIt - --M:l, i -KNmK~[I~ ,
’ ISC VALVE
VALVE WATER CHAkCOAL
CANISTOR
CHECK VALVE
I FUEL FUEL FILTER
PUMP
I FUEL FILTER
TRANSFER
PUMP
AIRkLOW METER
(WITH INTAKE AIR THERMOSENSOR)
DISTRIBUTOR
CATALYTIC CONVERTER
l TO ENGINE CONTROL UNIT

OUTLINE F3
SPEClFiCATlONS
Iten
Idle speed’
tgnltion trming * Engine
m
BTDC BP TURBO
800 f 50
IO f 10
Fuel pump
Maximum output pressure kPa { kgflcm’, psi 1 1 490-736 {SO-7.5, 7t-110)
Transfer pump
Maximum output pressure
Fuel filter kPa { kgf/cm2, psi ) 1 , 39 10.4, 5.7 1 or higher
Nylon element (in fuel pump)
Idle-speed control (fSC) valve
Type
Resistance I Rotary
nt
11-13 [at 2O*C [68*F)]
Solenoid va tve (purge contra I)
,I
Resistance -2o*c I -4Of 1 14.6-I 7.8
2.21-2.69
.kQ , 2o”c { 68OF)
40% f104*f 1 1.0-l .3
Resistance
Fuel tank
Capacity
Air cleaner
Etement type
Fuel
Specification L {US gal, Imp gal) [ Approx. 6 [at 20°C f 68*FJ]
60 (15.9, 13.2)
01 permeated
Unleaded premium (RON 95 or higher)
11FrlC?.7 11
l TEN terminal of diagnosis connector grounded.
The I; mark indicates newly equipped Parts. l”L”l “VI I
F3-9

F3 TURBOCHARGERCONTROL
TURBOCHARGERCONTROL
OUTLINE
l The-capacity of the air-to-air intercooler is increased to reduce the intake air temperature and to the tm-
prove engine performance.
l With addition of the improved wastegate control system, the engine’s high rpm torque is increased.
TURBOCHARG
INTERCOOLER
SYSTEM DIAGRAM
WASTEGATE SOLENOrD VALVE
F3-10