1992 MAZDA 323 Workshop Manual Suplement

B2
ENGINE
(DOHC)
1 FEATURES j
OUTLINE ................................................
B2- 2
OUTLINE OF CONSTRUCTION..
.............. B2- 2
SPEClFICATlONS
..................................
82- 2
INTERCHANGEABILITY ..........................
B2- 3
PISTON ...............................................
82- 4
CONNECTING ROD ...............................
82- 5
CRANKSHAFT PULLEY ..........................
B2- 6
EXHAUST VALVE ..................................
B2- 7
INSTRUCTION FOR HANDLING METALLIC
SODllJM~FlLLED EXHAUST VALVE .........
82- 8
SUPPLEMENTAL SERVICE INFORMATION 820 9
4
13E082-301

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.

B2 OUTl1NE
COOUNG CHANNEL RtNG CARRtER
61.5mm i 2.42 in ] - 56.5mm (2.22 in
Piston diameter Piston diameter
Measured at 90* Measured at 90°
to pin bore axis I+ to pin bore axis
and t6.5mm and 11 .Omm
IO.650 in 1 below 10.433 in 1 below
oil rmg groove. oil ring groove.
COOLING CHANNEL
*IL YTLET
OIL t NiET
l The piston skirt is shortened for reduced weight and friction. l A cast iron ring carrier is installed in the piston to reduce piston-ring groove wear. l A cooling channel is incorporated in the body of the piston. The 011 jet squirts oil into this cootrng channel
and the or! absorbs
the heat from around the ring lands, reducing piston ring and cylinder wat! wear
Bz-4

OUTLINE B2
CONNECTING ROD
18mm 10.17 in!
PAINT
MARK @VHITE) in t - 27mm Il.06 ml
CONNECTING ROD CAP
PiINT MARK (WHITE)
l The connecting rod beam is windened for increased strength.
l The connecting rod and cap are marked with white paint for identification.

B2 CXJTUNE
CRANKSHAFT PULLEY
ALTERNATOR, WATER PUMP V-RIBBED BELT PULLEY
/TORSIONAL DAMPER
P/S, A/C V-RI3BED BELT PULLEY
ALTERNATOR DRIVE PULLEY
Deflectton (98 N ( 10 kgf, 22 Ibf f ) mm ftn)
Owe belt New Used. Lrmlt
Alternator 5.5-7.0 6.0-7.5 8.0
{0.22-0.27 ) IO.24-0.29) to.31 )
fension
Owe belt
Alternator New
460-660
(46-68,
llO--140) Used
400-580
{‘IO-60,
88-130 1 N I kgf, Ibf]
Ltmit
340
135, 771
l The alternator and water pump pulleys are changed to V-ribbed type for improved performance l With the adoptjon of the V-ribbed betf. the belt adjustment specifications are changed.
B2-6

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

82 INSTRUCTlUN FOR HANDLING METALUC SODIUM-FltLED EXHAUST VALVE
1NSTRUCTION FOR IiANDLlNG METALLIC SODIUM-FILLED EXHAUST VALVE
improper handling of metallic sodium can cause sever burns, loss of eye sight, and the production of
htghty ftammabie hydrogen gas. Therefore, handle and dispose of such valves carefully.
First aid
l If metallic sodium get into your eyes, quickly fiush it out with large amounts of water. See a
physician.
l If it gets on your skin, wash it off with plenty of water. See a physician.
l If it catches fire, use a dry powder fire extinguisher or dry sand to put it out. Never use water.
Note
l Do not use the valve as tool.
l Do not drain the metaltic sodium from the vatve.
l Neutralize the metallic sodium-filled valve before its disposal.
Re!e;,nEe
l
T is embossed on the valve head to identify a metallic sodium-filled exhaust valve. 13E082-309
IDENTIFICATION MARK
0 C8
T
9Omm 13.5 in] Disposal procedure
Follow the procedure below to neutralize the valve.
(1) Prepare a water-filled bucket (10 Liters [ 11 US qt? 8.8
Imp qtj or more> and a dry powder fire extinguisher in
a well ventilated place.
(2) Wear safety glasses and gloves.
Note
l If the valve is broken skip Step (3).
I
1 X002-31 1
, (3) Secure the valve in a vice and, using a hacksaw, cut
a few 1.5mm [ 0.059 in) deep slits 30-90mm 11.2-3.5
in) from the valve stem end.
(4) Quickly submerge the valve in the bucket of water. vreat
up to eight valve at a time.)
:
1
t3EOB2-312 (5) Leave the valve in the water for about one hour until
the bubbles stop. (Stir occasionally with a metat rod for
complete reaction.)
Caution
l Do not reach into the solution or let it get on your
skin or clothing; burning may result.
(6) Remove the valve with tongs and dtspose of as for a
conventional part.
(7) Follow local regulations fbr disposal of the solution. /
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