engine oil MAZDA 323 1992 Workshop Manual Suplement

GI tMPORTANT INFORMATION
IMPORTANT INFORMATION
BASIC ASSUMPTIONS
This workshop manual assumes that you have certarn special tools that are necessary for the safe and
efficient performance of service operations on Mazda vehicles and that you know how to use them properly.
It also assumes that you are familiar with automobile systems and basic service and repair procedures.
YOU should not attempt to use this manual unless these assumpttons are correct and you understand the
consequences described below.
SAFETY RtSK
This manual contains certain notes, warnings, and other precautionary information that you should care-
fully read and follow to reduce the risk of personal injury to yourself or others and the risk of improper
service that may damage the vehicle or render it unsafe. If there IS no such information in regard to any
specific service method, this does not mean there is no possibility that personal safety or vehicle safety
wili be jeopardized by the use of incorrect methods or tools.
POSStBLE LOSS OF WARRANTY
The manufacturer’s warranty on Mazda vehicles and engines can be voided if improper service or repairs
are performed by persons other than those at an Authorked Mazda Dealer.
WARNtNG ON LUBRtCANTS AND GREASES
Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated
during service (e+g., engine sump oils) are more irritating and more likely to cause serious effects, includ-
ing skin cancer, in the event of gross and prolonged skin contact.
Wash skin thoroughly after work involving 011.
Protective hand cleaners may be of value provided they can be removed from the skin with water Do
not use gasoline, paraffin, or other solvents to remove oil from the skrn.
Lubricants and greases may be slightly irritating to the eyes.
Repeated or protonged skin contact shoutd be avoided by wearing protective clothing if necessary. Par-
ticular care should be taken with used oils and greases containing lead. Do not allow work clothing .to
be contaminated with oil. Dry clean or launder such clothing at regular intervals.
9MtlGIX-002
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A PRE-DELIVERY INSPECTION TABLE
PRE-DELIVERY INSPECTION TABLE
[EXTERlORI
INSPECT and ADJUST, of necessary. the followlng Items to
specrfrcatron:
0 Glass, exterior bright metal and paint for damage
0 Wheel lug nuts
0 Tire pressures
0 All weatherstrips for damage or detachment
0 Operation of bonnet release and look
0 Operation of trunk Ild, hatch and fuel lbd opener
(of equipped)
0 Door operation and alignment
0 Headtrght aiming
INSTALL the foltowrng parts
0 Wheel caps or rrngs (if equipped)
0 Outsrde mirror(s)
1 UNDER BONNET-ENGINE OFF j
INSPECT and ADJUST. If necessary, the following items to
specrflcatlon.
0 Fuel, coolant and hydraulic tines, fittings, connectlons and
components for leaks
0 Engine 011 level
0 Power steering fluid level (of equipped)
0 Brake master cylinder fluky levels
0 Clutch master cylinder fturcl levels (If equipped)
0 Wtndshreld washer reservojr flurd level
0 Radiator coolant level and specrfic gravity
0 Tightness of water hose clamps
0 Tightness of battery terminals, electrolyte level and specific
gravity
0 Manual transaxle oil level
0 Drive belt(s) tension
Cl Carburetor lrnkage (choke control, wrde open throttle posi-
tion. etc ) (carburetor model only)
q Accelerator cable and linkage for free movement
0 Headlight cleaner and flurd level (if equipped)
BLEED air from fuel line (diesel engrne only)
CLEAN the spark plugs (except for diesel engine)
piEi6F]
INSTALL the following parts
0 Rubber stopper for rnsrde rear view mirror (if equjpped)
0 Fuse for accessories
CHECK the operation of the following items.
0 Seat controls (sliding and reclining) and head rest
0 Seat belts and warning system
Cl Ign&on switch and steering lock
0 Power window (if equipped)
D Door tacks including child proof door locks
Cl Inhibitor switch (ATX only)
Cl All Ikghts rncluding warning and Indicator lbghts
0 Ignition key reminder buzzer (If equipped)
A-Z
0 Horn, wbpers and washers (front and rear, If equipped)
0 Antenna (tf equipped)
0 Cigarette Ibghter and clock (if equipped)
0 Remote control outside mirror (if equrpped)
0 Heater, defogger and air conditioner at various mode selec-
tions (if equlppedj
0 Sunroof (If equipped)
CHECK the following items
0 Presence of spare fuse
0 Upholstery and Interior finish
CHECK and ADJUST, If necessary, the followjng items:
IJ Operation and fit of windows
0 Pedal height and free play of brake and clutch pedal
0 Parking brake UNDER BONNET-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
0 Operation of Idle-up system for air condbtroner or power steer-
ing (if equrpped)
0 Automatic transaxle flurd levet
0 tnltial ignrtlon timing (except disel engine)
0 Idle speed
0 Operation of throttle positron. sensor (EGI engrne)
0 Operation of cold start device and glow plug warning light
(diesel engine only)
0 Operation of dash pbt (EGI.engine)
fTiGGJ
CHECK the following items.
0 Underside fuel, coolant and hydraulic Irnes, ftttlngs, connec-
tions and components for leaks
0 Trres for cuts or brurses
0 Steering Itnkage, suspensron, exhaust system and all under-
side hardware for .looseness or damage 1 ROAD TEST j
CHECK the following items
0 8rake operation
0 Clutch operation
0 Steering control
!ZI Operation of meters and gauges
Cl Squeaks, rattles or unusual noises
Cl Engine general performance
0 Emergency locking retractors 1 AFTER ROAD TEST ]
REMOVE the seat and floor mat protective covers
CHECK for the necessary owner information materials, took
and spare tire
m vehicle
93EOAX-002
-- MAIN Char3 t: In
A: PC R: F!t T: Ti! Emis! The ed : to t!

SCHEDULED MAINTENANCE SERVICES A
SCHEDULED MAINTENANCE SERVICES
MAINTENANCE TABLE
Chafi symbols:
1 : Inspect: Visual examination and/or functional measurement of system’s operation or
performance , A: Adjust: Examination resulting in adjustment or replacement
n
R: Replace or change
T: Tighten
REMARKS
After 80,000 km or 48 months, continue to follow the described maintenance at the recommended intervals.
As for * marked items in this maintenance chart, note the following points.
+ 1 Major service interval at 12 months/20,000 km (12,000 miles).
Lubrication service based on distance only 10,000 km (6,000 miles) not time.
l 2 Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt
if equipped.
‘3 Replacement of the timing belt is required at every 100,000 km (60,000 mile). Failure to replace the tim-
ing bett may result in damage to the engine.
‘4 tf the vehicle is operated under any of the following conditions, it is suggested that the engine oil and
oil filter be changed more often than the recommended intervals.
a) Driving in dusty conditions. I
:
b) Extended periods of idling or low speed operation. i
i!
c) Driving for a prolonged periods in cold temperatures or regularly driving onty short distances.
*5 If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often
than at usual recommended intervals.
l 6 This IS a full function check of all electrical systems, i.e, atl
ltghts. washers (including condition of blades)
electric windows, sunroof, horn etc.
‘7 Replace every two years. $1
‘I
If there has been continuous hard driving, mountain
drivtng, or if the brakes are used extensively or the
vehicle is operated in extremely humid climates, the brake fluid should be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the-emission control and relat-
ed system, as well as for efficient engine operation. It is strongly recommended that all servicing related
to these systems be done by your Authorised Mazda Dealer.
13EOAX-302 -4
I!
A-3

A SCHEDULED MAtNTENANCE SERVtCES (Europe)
Maintenance Number of months or km (miles), whichever comes first
Months” - 6 12 18 24 30 36 42 48
Kllometers 1,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
{Miles)
(600) (6,000) f[t2,000) (18,000) (24,000) (3U,OOO) (36,000) (42,000) {48,000), Engine
Intake and exhaust manrfold nuts (Bolts)
Drive belts”
i Engine trmlng beltW3
Engine oil (Turbo)‘4
01 filter
l *
Cool!ng system (Includtng
coolant level adlustment)
Engrne coolant T T T
A A A
A A
Replace every 100,000 km (60,000 miles)
Replace every 5,000 km (3,000 miles) or 6 months
R R R R R 1 R R R
I I I I
I
Replace every 2 years Fuel system
Idle speed
Air cleaner element * 5
Fuel
falter
Fuel Ilnes and hoses Ignition system
A f 1
I R I R
R R
I I f t I ~
lnlttal rgnrtloh trmlng 1 I I I I I I I I
Spark plugs A
A. A A
Spark plugs (Only for Sweden) Adjust every 30.000 km (t8.000 mrls) Evaporative emission control system
Throttle sensor Throttle sensor (Only for Sweden)
Evaporative system
Evaporatrve system (Only for Sweden) 1 A 1 1 A 1 1 A 1 ) A
Adjust every 80,000 km (48,000 miles)
1 I 1 1 I’ 1 1 I 1 1 I
Inspect every 80,000 km (48,000 mites) Electrical system
Battery electrolyte level and specific gravity 1 I f I I I
All Electrical system
l ’ 1 I
I 1 I I I
1 . 1 I I
Headlight alrgnment 1 A A A . A. Chassis and body
t 3EOAX-303
A-4 Chas
SW31 Rear
Tires
Hing
Seat

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.

F3 TRUUBtESHOOTlNG GUIDE
IDIAGNOSTiC tNDEX
No. TFtOUBLESHOOTtNG ITEM DESCRIPTtON PAGE
1.
WI/I not crank or cranks slowly Refer to Engine Electrrcal System ‘1
2 Cranks normally but No combustion Engine cranks at normal speed but shows no sign of F3-22
will not start flrlng
3 Partial corn bustlon- Engine cranks at normal speed but shows only par- ‘1
When engine cold tial combustion and will not continue to run
4 Partial combustron- Engine cranks at normal speed and shows partial F3-25
After warm-up combustion but ~111 not continue runnrng after being
hot soaked
Cranks normally but Always Engine cranks at normal speed but rqurres exces- ‘1
hard to start sive cranktng time before starting
When engine cold Same condition as No. 5 when engine IS cold ‘1
Restarts normally after warm-up
After warm-up Same condition as No. 5 after running and betng hot F3-27
soaked
Starts normaNy when cold
1 8 1 Rough idle/
tsl Engine stalls at idle 1 Always [ Engine stalls or vibrates excessively at idle
r - 1 F3-29
r
Before warm-up 1 Engine stalls or vibrates excessively at idle during
I ‘1
10
11
12 After warm-up
When A/C, P/S,
or IX ON
Rough rdle/Englne stalts lus: after starting warm-up
Engine runs normally at idle during warm-up but
stalls or vibrates excessively atter warm-up
Engrne stalls or vtbrates excessrvely at idle when
NC, P/S, or E/L ON
Engine stalts or vibrates excessively lust after starting
tacceleratton from Idle1 F3-3 f
‘1
‘1
I I ’ I
I 13 High Idle speed after warm-up tdle speed excessively hrgh after warm-up ‘1
14 Idle moves up and down/idle hunts Engine speeds up and down periodically at Idle
F3-33
15 Engme stalls on deceleratron Engine unexpectedly stops running durrng or after
F3-35
deceleration
16 Engine statts suddenly (intermrttent) Engine intermittently stops runnrng
F3-36
17 Hesitates/Stumbles on acceleratton Flat spot occurs just after accelerator is depressed,
‘1
or m/Id ierkina occurs dunna acceleration
L I I
t 18 1 Surges while crulsng
1 Unexpected change In engine speed that is usually 1 ‘1
1 repetrtive
19 tack of power
20 Poor acceleration
21 Runs rough durrng deceleration/Backfire
22 Knocktng
23 Fuel odor Performance poor under load when throttle valve IS
wide open
Maximum speed reduced
Performance poor during acceleration
Engtne runs rough during deceleratron, and abnor-
mal combustion occurs in exhaust system
Abnormal combust!on accompanied by audible
“pinging” noise
( Gasoline odor in cabln ‘2
‘2
‘1
‘2
+1
24 Exhaust sulfur smell Exhaust gas has an unusual odor
25 High oil consumption Oil consumption excessive
b
26 Poor fuel economy Fuel economy unsatisfactory
27 A/C does not work
Blower fan operates, but magnetic clutch does not
l 1.. .Refet to 323 Workshop Manual (t 203-l O-89F). l 2...Re#er to 323 4-Wheet Drive Workshop Manual (1229-IO-89L). ‘1
‘2
‘1
l 1
13EOFS327
F3-20 -..
REAR I
--
--

TROUBLESHOOTING GUiDE F3
15 ENGINE STALLS ON DECELERATION
IESCRIP-
l Engrne unexpectedly stops running dunng or after deceleration
[iON l Idle condition normal.
TROUBLESHOOT1NG HtNTS]
ingrne speed drops too much when releasrng accelerator
3 Idle-speed misadjustment @I Loose connector disconnected by force of deceleration
3 Fuel-cut contrd malfunction
TEP lNSPECTlON ACTION
1 1s idle condition normal? Yes Go to next step
tdle speed: 800 f 50 rpm (in neutral)
NO Adjust or perform Troubleshooting, Nos.
8-I 1 “ROUGH IDLE”
(Refer to Workshop Manual
(1203-I o-89F))
2 Is “00” displayed on Self-Diagnosis Checker Yes Go to next step
with ignition switch ON?
SYSTEM SELECT: 1 NO Service Code No. displayed
Check for cause (Refer to specified
check sequence) ET page F3-16
“88” flashes
Check ECU termrnal 1 F voltage
Voltage: Battery voltage
(ignition switch ON) r;r page F346
W:SELFTEST
e If OK, replace ECU CI page F3-3
4 If not OK, check wirtng
(ECU - Self-Diagnosis Checker)
3 Does Self-Diagnosis Checker Monitor Lamp with Yes Go to next step
lgnttlon switch UN show that switches operate
correctly?
NO Lamp not ON or OFF with specified
switch
Check for cause (Refer to specified
check sequence)
W: SEtF TEST Lamp slways ON
Check wiring between
(ECU terminal 1 D - Self-Diagnosis
Checker)
4 Are ECU ?erminal voltages OK? Yes Go to next step
(especially IV, 20, 20, ZU, 2V.
and 20) v page F346 No
Check for cause
5 Check for poor connection of foltowing parts YC?S Repair or replace
l ignrtion coil l Igniter l Olstribdor l High-tension lead
NO Go to next step l Injector. l Injector resistor l Ctrcuit-opening relay . l ECU
F3-35

F3 TROUBLESHOOTING GUIDE
STEP INSPECTION ACTlON
6 Is dashpot correctly adjusted? Yes Go to next step
c
Dashpot set speed: Approx. 3,500 rpm
No Adjust dashpot
7
Try known good ECU; does condition
Improve?
w page F3-3
13EOF3-336
16 ENGINE STALLS SUDDENLY (INTERMITTENT)
DESCRIP.
l Engine intermittently stops running
TION l Before stalling, engine conditron is OK
TROUBLESHOOTING HINTS]
@ intermittently no spark or no fuel injection caused by ve-
hlcle vibratron, acceleratton, or deceleration
l Poor connectlon in wiring harness
iTEP INSPECTION ACTfON
1 Is “00” displayed on Self-Oiagnoss Checker Yes Go to next step
with lgnltlon swrtch ON?
NO Service Code No. displayed
Check for cause (Refer to speclfled
check sequence).
Note CT page F3-16
l When checking wiring harness and
connectors, tap, move, and wiggle
suspect sensor and/or harness to
recreate problem
“88” flashes ’
Check ECU terminal IF voltage
Voltage: Battery voltage
{ignition swttch ON) w page F3-45
4 If OK, replace ECU
4 If not OK, check wiring
(ECU - Self-Diagnosis Checker)
2 Check for poor connection of foliowrng parts
Yes Reparr or replace
l lgnltfon coil l Igniter l Distributor l t-flgh-tensron lead
No Go to next step l Injector l Injector reststor l Circutt-opening relay l ECU
3 Are ECU terminal voltages OK? Yes Go to Troubleshbotrng No. 2
(especially 16, 2A, 2B, and 2C) .“CRANKS NORMALLY BUT WILL NOT
w page F3-45 START (NO COMBUSTION)”
w page F3-20
Note
. No Check for cause
l When. checking voltages, tap, move, and
wiggle harness and connector to recreate
problem
* lrlrl m-7
F3-36
7.8-l

F3 II TURBOCHARGER CONTROL SYSTEM ‘1
1’
:j
TURBOCHARGER CONTROL
SYSTEM
TURBOCHARGER
Re’inovaf / Installation
Caution
l Be careful of the following points after turbocharger removal.
l Do not carry the turbocharger by the actuator rod or actuator hose.
l Do not drop the turbocharger.
l Set the turbocharger down with the turbine shaft horizontat.
l Cover the intake, exhaust, and oil passages to prevent dirt or other material from entering
the turbocharger.
l Use the specified new studs when installing the turbocharger.
1, Disconnect the negative battery cable.
2. Raise the vehicle and support it on safety stands.
3. Remove the undercover.
4. Orain the engine coolant.
5. Remove in the order shown in the figure, referring to Removal Note.
6. Install in the reverse order of removal, referring to Installation Note.
I-- 7.8-1 1 N-m ~80-110 kgfcm. 69-96 idbf j
3946 13.94.7, 2% 3842 13.94.3, 28-
31--46 13.2-4.7, 23-341
T, REPLACE .
12-18 1 f-2-1.8, 8.7-13 I
GASKET, REPLACE
19-26 1 t .9-2.6, 14-19 1
7.6-11 Mm t80-?lO kgfcm, 69-95 hlbfl
~-t-n 1 kgf-m, Wlbt]
13EOF3 3.31
F3-3i

F3 TURBOCHARGERCONTROLSYSTEM
1. Radiator
2. Insulator 3. Air hose, and air pipe
4. Oxygen sensor connector
5. Front exhaust pipe
13EOF534
F3-38 6. Water hose
7. Oil pipe
8. Exhaust manifold and turbocharger
Removal Note ,.........I.....f.~.~l....... II.I.... below
Installation Note . . . . , , l.. . . . . . . , ,.. ,..*, , . . . . . . . . . below
13EOF3-339
Removal Note Exhaust
manifold and turbocharger 1. Remove the exhaust manifold and the turbocharger as an
assembly.
2. Separate the turbocharger assembly from the exhaust
manifold.
Installation Note
Exhaust manifold and turbocharger’ I I Remove .all old gaskets and
sealant. 2. Install new gaskets.
3. Supply 25 cc ( 1.5 cu in ] of oil through the oil passage
of the turbocharger.
4. Mount the turbocharger assembly to the exhaust manifold.
5. Install the turbocharger and the exhaust manifold assem-
bly to the engine and loosely tighten the nuts.
6. Install the bracket and the front exhaust pipe, and tighten
the turbocharger mounting nut%
WASTEGATE SOLENOD VALVE
Caution
l The wastegate solenoid valve must be replaced with
the turbocharger, it cannot be replaced by itself.
Inspection 1. Disconnect the connector.
2. Measure the resistance of the solenoid valve.
Resistance: 35-45 !‘l (at 20°C f68OFj) 3. M not as specified, replace the wastegate solenoid valve and
turbocharger as an assembly, if necessary.
(Refer to page F3-37.)
3. Instc