MAZDA 232 1990 Workshop Manual Suplement

E RADIATOR THERMUSWlTCki
RADIATOR THERMOSWITCH (BP DUHC TURBO)
REMOVAL I INSPECTION I INSTALLATION
I. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
3. Install in the reverse order of removal, referring to InstaHation Note.
7.8-13 H-m
(80-l 10 cm-kg, 69-95 h-lb)
(80-110 cm-kg,
69-95In4b)
REPLACE 1. Resonance chamber
2. Radiator cowling mounting bolts
3. Radiator thermoswitch connector
03WEX-027 4. Radiator thermoswitch
Inspection . . . . . . . . * . . . . . . . . . . . . . ..-. -.*,.a..- . . . . . . .I. below
Installation Note _.,............................._. below
1NSPECTlON 1. Place the switch and a thermometer in engine oil.
Warning
l Do not heat the engine oil above 12O*C (248OF) 2. Heat the engine oil gradually and check continuity of the
switch with
an ohmmeter.
Engine oil temperature “C (*F) Continuity
More than 105 (221) Yes I
t Less than 96 (205) No
1
3. If not as specified, replace the radiator thermoswitch.
Installation Note
Radiator thermoswitch
Caution
l Do not use an impact wrench for installation. 1. Install the radiator thermoswitch along with a new gasket.
Tightening torque: 5.9-12
Nom (60-120 cm-kg, 52-104 in-lb) 93GOEX.721 E-12

FAN RELAY E
FAN RELAY(BP DOHCTURBO)
REMOVAL / INSPECTION
1. Disconnect the negative battery cable.
2. Remove the fan relay.
No.2 FAN REUY
w. . . . . . .TYPE 1
@AND @ . . . TYPE 2
INSPECTDN
f . Check continuity as shown with an ohmmeter.
I
Terminal COMlLJlty
A-C No
B-D
Yes 2. Apply 12V between terminals B and D.
Check for continuity between terminals A and C.
3. If not as specified, replace the fan relay.
E-13

Fl
FUEL AND EMISSION
CONTROL SYSTEMS
(WITHOUT CATALYTIC CONVERTER)
I
INDEX . . . ..*.....*....**..............................~... Fl- 2
1 FEATURES 1
OUTLINE ................................................ Fl- 3
OUTLINE OF CONSTRUCTION ................ Ff- 3
SPECIFICATIONS ................................... Fl- 3
SYSTEM DIAGRAM
................................ FI- 4
WIRING DIAGRAM
................................. Fl- 5
FUEL SYSTEM
........................................ Fl- 6
OUTLINE .............................................. Fl- 6
FUEL TANK AND TRANSFER PUMP.. ...... Fl- 7
1 SERVICE j
SUPPLEMENTAL SERVICE INFORMATION. Fl- 9
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . ..I.... . . . . . . . . . . . . Fl- 9
PRECAUTION . . . . . . . ..,.. . ..*...... . . . . . . . . . . . . . . ..I Fl- 9
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I.. ..I Fl-ICI
TRANSFER PUMP CONTROL SYSTEM ..I... Ff-If
SYSTEM OPERATION . . . . . . . . . ..I................. Fl-11
4x4 CONTROL UNIT
(FUEL PUMP CONTROL UNIT-j . . . . . . ..I..... FI-12
TRANSFER PUMP SWITCH . . . . . . . . . . . . . . . . . . . . . F1-13
TRANSFER PUMP . . . . . . . . . ..l..................... Fl-13
EXHAUSTSYSTEM
. . . . ..I....... l . . . . . . . . . . . . . a. I... Ff-15
COMPONENTS . ..a.. . . . . . . . . . . . . . . . . . I..... . . . . . . . . Fl-15
93GOFf -701

Fl INDEX
1. Fuel tank
Removal I hspection /
I nstalIation
1. . . . . . . . . . . . . . * . . . ..I..... ,*,.
page Fl-10
2. 4x4 control unit (Fuel pump control unit)
Inspection .__...._..................__..._. page Fl-12
Replacement _. . _. _. _. _. . _ _ _. . . _ . _. _. . . . _.
page
Fl - 12
3. Transfer pump switch
Removal / lnstaltation . . . . . . . . . . . . . .._ page Fl-13
inspection .._......_.. . . ..-_. . . .._....... page F1 -I 3 93GOFl-702
4. Transfer pump
inspection _........._....._................ page Fl-13
Replacement.. . .__.-.. . . . . . . . . . . . . . . , U.-e
page
FI -13
5. Exhaust system components
Removat I hspection I
Installation
.**...**..a*..........*..*..__.
page fl-15
Fl-2

OUTLINE Fl
OlJTLlNE OF CONSTRUCTION
The fuel and emission control systems of the New 3.23 BP SOHC-engine equipped 4WD model are basically
the same as those of the New 323 8P DOHC-engine equipped 2WD model, however, the fuel tank is designed
with separate right
and left sections due to the installation of the propeller shaft for the 4-wheel-drive system
and
a transfer pump is equipped to pump the fuel from the left to the right (fuei pump side) section of the
fue! tank. The following chart shows the differences between the major parts of the BP DO% 2WD model
and the BP SOHC 4WD model.
33GO”l-703
Difference
I t
Part BP DOHC 2WD 1 BP SOHC 4WD Remark Transfer pump -
0 Due to
installation of propeller shaft
Variable Inertra charging system 0 -
Two group fuel qectron Due to change of engine
-
G-slgnal (Drstnbutor) 0
I -
Due to abolishment of two group fuel Injection
93GOfl-70s
SPECIFICATIONS
Item
Idle speed
Ignition timing * Engine
vm
BTDC BP SOHC
850 * 50
5 * to
Fuel DUtTlD I
Fuel filter
Type Low-pressure side
Htgh-pressure side Nylon element
Paper element
Pressure regulator
Regulating pressure kPa (kglcm2, psi) 1 264-314 (2.7-3.2, 38.3-45.5)
In
jfXt0r
Type
Resistance High-ohmic
12-16
Idbup solenoid vatve
Resistance Solenoid A _.._. 17-23, Solenoid 5, C ._... 27-36
Water themosensor
R&stance -20% ( -4OF)
kQ - . 20°C ( 689=)
40% (104OFj
80°C (176OF) 14.6-l 7.8
2.2-I -2.69
1.0-l -3
0.29-0.35
l TEN terminal of dragnosrs connector grounded.
The a (shading) rndrcates newly equipped parts

I
(WITH INTAKE AIR
THERMOSENSOR) AIR CLEANER METER
RESONANCE
CHAMBER /
SOLENOID VALVE
(PRESSURE REGULATOR CONTROL) FUEL FILTER
(HIGH-PRESSURE
SIDE)
P-“---j
Ne-S’GtiAL * ----El
DlSTRlfjUTOR IDLE-UP
SOLENOID VALVE
* TO ENGINE CONTROL UNIT ,CHECKVALVE
(TWO-WAY)
FUEL VAPOR VALVE
*
THERMOSENSOR
‘FUEL PUMP
FUEL FILTER
I TRANSFER PUMP

-- -
“-
I t-
SQLENOlD VALVE AEAR WINOOW
(PRESSURE IQNITION HEADLIG t IT
DEFFIOSTER
REGULATOR SWITCH SWITCH
SWITCH
CONTROL)
lNJECTOR ELECTRICAL
MAIN RELAY , FAN
AX SWITCH
r DliiGNOSlS BLOWER Ivc
CONNECTOR SWITCH RELAY
ECU
AIRFLOW METER
Tt
WATE!
THERMOSENSOR
CLUTCH [/ t
-I
’ NEUTRAL
SWITCH SWITCH 4X4 CONTROL UNIT
1
FbEL
PUMP
TRANSFER PUMP TRANSFER
PUMP SWlTCtJ

Fl FUEL SYSTEM
FUEL SYSTEM
OUTLlNE
PRESSURE REGULATOR
1
FUEL FILTER
I TRANSFER PUMP
i WEL PUMP
1 FILTEF
FUEL TANK
4x4 CONTROL UNIT (FUEL PUMP CONTROL UNIT)
The fuel system consists of the fuel tank, the transfer pump, the fuel pump, the fuel filters, the pressure regu-
lator, the delivery pipe, the injectors, and the 4x4 control unit (fuel pump control unit).
Fl-6

c
I
FUEL SYSTEM Fl
FUEL TANK AND TRANSFER PUMP
TRANSFER PUMP SWITCH
4x4 CONTkOL UNIT
(FUEL PUMP CONTROL UNIT)
93GOF1-717
The fuel tank is designed with a separate right and left section due to the installation of the propeller shaft
for the 4-wheel-drive system.
A transfer pump is used to pump the fuel from the I& to the right (fuel pump) side. The transfer.pump is
installed in the fuel tank, and is controlled by the transfer pump switch and the fuel pump contra! unit (Includ-
ed in the 4x4 control unit).
A fuel vapor valve is instatted on the top of the fuet tank to prevent fuel from flowing out to the charcoal cansiter.
Fl-7