battery MAZDA 232 1990 Suplement User Guide

B2 INSTALLATION
93GOB2-74 1
93GOB2-743
82-32
4. Connect the air pipe to the throttle body, and tighten the
hose clamp.
5. Connect air hose @ to the wastegate diaphragm,
and se-
curely tighten the hose clamp.
6. Install nut @
Tightening torque:
19-25 Narn (1.9-2.6 m-kg, 14-19 ft-lb)
7. Install the intercooter bracket and tighten nuts @J .
Tightening torque:
7.8-l 1 Narn (80-I IO cm-kg, 69-95 in-lb)
Air pipe and air bypass valve assembly
1. Connect the air pipe to the turbocharger, and securely tight-
en the hose clamp.
2. Install and tighten the bolt @ .
Tightening torque:
7.8-l 1 Nom (80-I 10 cm-kg, 69-95 in-ib)
3. Connect air hose @and Q1 and securely tighten the hose
clamps.
Battery duct
1. install the battery duct.
Radiator and tooting fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.8-l 1 Nm (80-l 10 cm-kg, 69-95 Mb)
2. Connect the tooting fan connector.
3. Connect the radiator switch connector.
4. Connect the oil cooler hose.
5. Connect the coolant reservoir hose.
6. Connect the upper and lower radiator hoses.

INSTALLATION
93G082-7ti
HERE
/+Ju 7
93GOB2-74!
Caution
l Position the hose clamp in the original location on
the hose, and squeeze it lightly with large pliers to
ensure a good fit.
Accelerator cable
1. Install the accelerator
cable.
Tightening torque
@): 7.8-l 1 N4m (80-l 10 cm-kg, 69-95 in-lb)
2. Adjust the cable deflection by turning nuts @ .
Deflection: I-3mm (U&4--0.12 in)
Battery carrier and battery
1 . Install the battery carrier.
Tightening torque:
7.8-l 1 N4m (80-I IO cm-kg, 69-95 in-lb)
2. Install the battery and the battery cover.
3. Install the battery bracket.
Tightening torque:
2.9-5.9 N.m (30-60 cm-kg, 26-52 in-lb)
4. Connect the positive battery cable.
Air cleaner assembly
1. Install the air cleaner assembly.
Tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
2. Connect the airflow sensor connector.
3. Connect the hoses shown in the figure.
Strut tower bar
I. Instail the strut tower bar.
Tightening torque:
88-108 Narn (9.0-11 .U m-kg, 65-80 ft-lb)
Undercover and side cover
1. Install the undercovers and side covers.
93GOB2-746
82-33

82 INSTALLATION
Steps after installation
1. If the engine oil was drained, refill with the specified amount and type of engine oil.
2. Fill the radiator with the specified amount and type of engine coolant.
3. Fill the transaxie with the specified amount and type of transaxle oil. (Refer to page J3-36.)
4. Connect the negative battery cable.
5. Start the engine and check the following:
(I) Engine oiI, transaxle oil, and engine coolant for leakage
(2) Ignition timing and idle speed
(3) Operation of emission control system
6. Perform a road test.
7. Recheck the engine oil and engine coolant levels.
93G032-747
-
BZ-34

FAN MOTOR, WATER THERMOSWITCH E
93GOEX-71:
93GOEX-714
93GOEX-720
tNSPECTlON
Single-speed Type (For BP SOW MTX)
I. Verify
that the battery is fully charged.
2. Disconnect the fan motor connector.
3. Connect the battery and an ammeter to the fan motor
con-
nector.
4. Verify that current is as specified.
Current (A): 6.6 k 1
5. If current is not within specification and/or the fan does not
turn smoothly, replace the fan motor.
Two-speed Type (Except BP SUHC MTX)
I. Verify that the battery is fully charged.
2. Disconnect the fan motor connector.
3. Connect the battery and an ammeter to the fan motor con-
nectors for low-speed inspection.
4. Verify that the fan motor operates smoothly at the standard
cu vent.
Current (A): 8.8 + 10% max.
5. Connect the battery, an ammeter, and switch to the fan mo-
tor connectors for high-speed inspection.
6. Verify that the fan motor operates smoothly
at the standard
current or less with the switch ON.
Current (A): 13.3 + 10% max.
7. If not as specified, replace the fan motor.
WATER THERMOSWITCH
(BP DOHC TURBO)
INSPECTlUN
I . Place the switch and a thermometer in water.
2. Heat the water gradually and check continuity of the switch
with an ohmmeter.
Coolant temperature OC (OF) 1 Contrdy
I
More than 97 (207) Yes
Less than 90 (194)
NO
3. If not as specified, replace the water thermoswitch.
93GOEX.715

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

F2 OUTLINE
ECU RELATIONSHIP DlAGRAM [BP TURBO]
INPUT DEVICE KNOCK SENSOR
KNOCK
i( CONTROL
DlSTRlBUTOR ,-, UNIT
NC SWITCH
--k/L SWITCHS
{REAR WINDOW DEFROSTER SWITCH.
HEADLIGHT SWITCH, BLOWER SWITCH,
ELECTRICAL FAN SWITCH)
BATTERY A
THRO77LE
SENSOR
NEUTRAL/ IDENTIFICATION
CLUTCH SWITCH
DIAGNOSIS
CONNECTOR
(TEN TERMINAL) INTAKE AIR
THERMOSENSOR
OUTPUT DEVICE
CIRCUIT
OPENING
SOLENOID VALVE
(PRESSURE REGULATOR
WASTEGATE
SOLENOID VALVE
RESISTOR/RELAY
SOLENOID VALVE
(PURGE CONTROL)
93GOFZ-71
F2-10

FUEL SYSTEM F2
Two-stage WeI pump operation
Engine running (Except heavy load or cranking)
The ECU 1 I circuit is ON, opening the contact plate in the fuel pump resistor/relay. Current from the circuit
opening relay to the fuel pump flows through the resistor in the fuel pump resistor/relay, and the voltage
to the fuel pump is reduced to approx. WV, causing the fuel pump to operate at a reduced speed to im-
move fuel pump longevity.
MAIN RELAY
Engine under heavy load or cranking
The ECU 1 I circuit is OFF and the contact plate in the fuel pump resistor/relay is closed. Unreduced battery
current flows to the fuel pump through the contact plate, causing the fuel pump speed and output to be
increased to meet the demands of the engine.
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93GW2-725
FZ-17

F2 FUEL SYSTEM
93GOF2-726
FUEL PUMP RESISTOR/RELAY [BP TURBO]
The fuel pump resistorlretay supplies battery voltage to the
fuel pump when the ECU 11 circuit is OFF, and approx. 1 OV
when the ECU 11 circuit is ON. It is mounted on the firewall.
TRANSFER PUMP CONTROL
Outline
The fuel tank is buitt with separate right and left sections to accommodate the. installation of the propeller
shaft. As fuel is puited from the right side of the tank, the transfer pump pumps the fuel from the left to the
right (fuel pumb) side to balance the fuel level.
FUEL IN LEFT TANK
I
FUEL PUMP CONTROL. UNIT
/ TRANSFER PUMP
TRANSFER PUMP SWITCH: OFF
NO FUEL IN LEFT
TANK
FUEL PUMP CONTROL UNIT / TRiNSFER PUMP
TRANSFER PUMP SWITCH: UN
93GOF2-727
Operation 1. Whenever the ignition switch is ON and fuel is in the left (transfer pump)
side of the fuel tank the fuel pump switch is open, the transfer pump circuit in the fuel pump control unit is
closed, and the transfer pump
operates.
2. When the fuel in the left side of the tank drips betow a specified point, the fuel pump switch is grounded
and the transfer pump stops operation.
3. To prevent the transfer pump from
being turned ON and OFF repeatedly, possibly shorting the life of the
pump, when the vehicle is driven on a rough
road and the fuel level is low, there is a ten-second delay
circuit in the control unit to delay the turning ON and OFF the pump.
f2--I 8

CONTROL SYSTEM F2
t OXYGEN SENSOR [BP TURBO]
I
CERAMlC HEATER
93GOF2-733
Because the temperature of the exhaust gas is inherently low in turbocharged engines, the BP Turbo model
uses a rapid heating ceramic heater to detect the air/fuel ratio,
PRESSURE REGULATOR CONTROL SYSTEM [BP TURBO]
PRESSURE
REGULATOR
I SOLENOID VALVE
(PRESSURE REGULATOR CONTROL)
FUEL
+ (FROM
DELIVERY PIPE1
II
FUEL INJ I
RELAY
(MAIN REU\Y)
I
II Ir
-__. _ - -’ VACUUM
CT0 DYNAMIC
Ill
CHAMBER)
BATTERY -
c
FUEL
(TO FUEL TANK)
nme*rn -.-a
To prevent percolation of the fuel during hot restart idle, vacuum to the pressure regulator k cut for 180
sec., and the fuel injection pressure is increased to slightly more than 284 kPa (2.90 kg/cm’, 41.2 psi).
Operating condition
l Coolant temperature: Above 90°C (194OF)
l Intake air temperature: Above 58OC (136OF)
g No-load condition
FZ-23