Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Turbocharger

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REMOVAL & INSTALLATION



1988-89 323

See Figure 1

When replacing the turbocharger, always check the oil level and condition, along with the turbo oil inlet and outlet lines. If the oil is dirty or the lines are damaged, replace them.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. From underneath the vehicle, remove the engine undercover.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Turbocharger system used on 1988-89 323

  1. Disconnect the two air hoses that are attached to the throttle body inlet hose and remove the air pipe.
  2.  
  3. Remove the exhaust manifold insulator covers.
  4.  
  5. Remove the water hoses.
  6.  
  7. Remove the oil pipe and the oil return hose.
  8.  
  9. Support the turbocharger by hand, then remove the nuts and bolts from the exhaust manifold. Remove the turbocharger and the exhaust manifold as an assembly. Remove the mounting gasket.
  10.  
  11. Remove the nuts and lift the turbocharger from the exhaust manifold studs. Cover the exhaust manifold ports with a clean rag or masking tape to prevent the entry of foreign matter. If the gasket is bent or cracked, replace it with a new one. If the turbocharger mounting nuts are damaged, install only Mazda genuine replacement nuts.
  12.  


CAUTION
Be careful to avoid dropping the turbocharger or handling it roughly. Be careful not to bend the wastegate actuator mounting or rod.

To install:
  1. Attach the turbocharger to the exhaust manifold with the mounting gasket, and torque the nuts to 20-25 ft. lbs. (27-34 Nm).
  2.  
  3. Place the assembly onto the engine with a new gasket and torque the manifold nuts to specification.
  4.  
  5. Connect the oil return hose and oil pipe.
  6.  
  7. Connect the water hoses.
  8.  
  9. Install the manifold insulator covers.
  10.  
  11. Install the air pipe and air hoses.
  12.  
  13. Install the engine under cover.
  14.  
  15. Refill the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the engine and inspect for leaks.
  20.  

1986-87 626

When replacing the turbocharger, always check the oil level and condition, along with the turbo oil inlet and outlet lines. If the oil is dirty or the lines are damaged, replace them.


CAUTION
This work should be performed with the engine cold.

  1. Drain the cooling system. Rotate the engine until the No. 1 piston is at TDC. (Use the front timing marks as a reference, and remove the distributor cap to check the position of the rotor.) Tag and disconnect the high tension wires. Unfasten the distributor mounting bolt, then remove the distributor, as described earlier in this section.
  2.  
  3. Loosen the clamps and remove the hose leading from the air cleaner to the turbo compressor intake. Do the same for the duct leading from the compressor discharge to the intake manifold.
  4.  
  5. Remove the thin secondary air injection pipe from the exhaust manifold. Remove the lower insulator cover from around the turbocharger turbine (the exhaust side of the unit).
  6.  
  7. Remove the thicker secondary air injection pipe from the exhaust manifold. Remove the oil supply line from the turbocharger. Disconnect the oil drain line.
  8.  
  9. Remove the upper insulator cover from the exhaust manifold. Remove the EGR pipe.
  10.  
  11. Disconnect and remove the turbo's cooling water hoses. Disconnect and remove the oxygen sensor.
  12.  
  13. Disconnect and support the front exhaust pipe at the catalytic converter. Remove the bolts attaching the turbo mounting bracket to the turbocharger.
  14.  
  15. Support the manifold and remove the manifold mounting bolts, then remove the manifold, turbocharger, and catalytic converter as an assembly. Remove the attaching nuts, then separate the converter from the turbocharger, and the turbocharger from the manifold. Cover all openings in the turbocharger.
  16.  


CAUTION
Be careful to avoid dropping the turbocharger or handling it roughly. Be careful not to bend the wastegate actuator mounting or rod.

To install:
  1. Carefully clean all gasket surfaces. Pour 1.5 cu. in. (25cc) of clean engine oil into the opening for the turbo oil line.
  2.  
  3. Install the turbocharger onto the exhaust manifold, replacing the gasket if it is bent or cracked. Torque the attaching nuts to 23-32 ft. lbs. (31-43 Nm). Connect the catalytic converter to the turbocharger with a new gasket and tighten the mounting nuts.
  4.  
  5. Install the exhaust manifold/turbocharger/catalytic converter assembly onto the cylinder head with new gaskets and torque the nuts to 16-21 ft. lbs. (22-28 Nm). Secure the turbocharger to the turbo mounting bracket.
  6.  
  7. Connect the front exhaust pipe to the catalytic converter, using a new gasket.
  8.  
  9. Install and connect the oxygen sensor and the cooling water hoses.
  10.  
  11. Install the EGR pipe and the upper insulator cover.
  12.  
  13. Connect the turbocharger's oil supply and oil drain lines.
  14.  
  15. Connect the secondary air injection pipes to the exhaust manifold.
  16.  
  17. Install the lower insulator cover.
  18.  
  19. Connect the hose leading from the air cleaner to the turbo compressor intake. Do the same for the duct leading from the compressor discharge to the intake manifold.
  20.  
  21. Install the distributor and connect the high tension wires, as described earlier in this section.
  22.  
  23. Refill the cooling system.
  24.  
  25. Before starting the engine, disconnect the negative (-) primary wire at the coil. Then, crank the engine for 20 seconds to build up oil pressure. Reconnect the coil wire, then start the engine without applying throttle; idle it for 30 seconds to purge air from the turbo oil lines before the throttle is applied. Check all parts for leaks and correct as necessary.
  26.  
  27. Check the ignition timing and adjust as necessary. For further information on this procedure, refer to Engine Electrical .
  28.  

1988-89 626/MX-6

See Figure 2

When replacing the turbocharger, always check the oil level and condition, along with the turbo oil inlet and outlet lines. If the oil is dirty or the lines are damaged, replace them.

  1. Disconnect the negative battery cable and drain the cooling system.
  2.  
  3. Remove the air hoses and air bypass hose.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Turbocharger system used on 1988-89 626 and MX-6

  1. Remove the exhaust manifold insulators.
  2.  
  3. Disconnect the oil inlet and return pipes from the turbocharger, then plug the ends.
  4.  
  5. Disconnect the water hoses from the water pipe and plug the ends.
  6.  
  7. Disconnect the EGR pipe from the exhaust manifold.
  8.  
  9. Remove the oxygen sensor.
  10.  
  11. Disconnect the front exhaust pipe from the turbocharger and set the gasket aside. Remove the bolt from the turbocharger joint pipe.
  12.  
  13. Support the turbocharger by hand and remove the exhaust manifold retaining nuts. Remove the turbocharger and manifold as an assembly. Cover the exhaust manifold ports with a clean rag or masking tape to prevent the entry of foreign matter.
  14.  


CAUTION
Do not drop the turbocharger or carry it around by the actuating handle. When laying the unit down, do so with the turbine shaft in the horizontal position. Be careful not to bend the actuator mounting or rod.

To install:
  1. Remove all the sealant and gasket material from the turbocharger and exhaust manifold mating surfaces.
  2.  
  3. Pour 1.5 cu. in. (25cc) of clean engine oil into the opening for the turbo oil line.
  4.  
  5. Attach the turbocharger to the exhaust manifold and torque the nuts to 20-29 ft. lbs. (27-39 Nm). Attach the assembly to the engine using new gaskets and torque the nuts to specification. Torque the turbocharger joint pipe bolt to 27-46 ft. lbs. (37-62 Nm) and the turbocharger bracket bolts to 23-30 ft. lbs. (31-41 Nm).
  6.  
  7. Connect the front exhaust pipe.
  8.  
  9. Install the oxygen sensor.
  10.  
  11. Connect the EGR pipe to the exhaust manifold and the water hose to the inlet pipe.
  12.  
  13. Connect the oil inlet and return pipes to the turbocharger. Install the exhaust manifold insulators.
  14.  
  15. Install the air bypass valve and air hoses.
  16.  
  17. Refill the cooling system and connect the negative battery cable.
  18.  
  19. Unfasten the connector from the ignitor and crank the engine for 20 seconds. Reattach the connector, then start the engine and run it at idle for 20 seconds. Stop the engine and disconnect the negative battery cable. Depress and hold the brake pedal for 5 seconds to clear the malfunction code. Reconnect the negative battery cable.
  20.  

 
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