clutch MAZDA 232 1990 Suplement User Guide

82 REMOVAL
03UOSX-81 t
93GOB2-723
82-l 8
2. Remove the No.1 and No.2 engine mount nuts. caution
l Be careful that the engine does not fall when remov-
ing the member.
3. Remove the engine mount member bolts and nuts and the
engine mount mem her.
Clutch release cylinder
I. Remove the release cylinder pipe bracket from the transaxle.
2. Position the release cylinder with the hose connected away
from the transaxle for
easier removal.
Caution
l Do not damage the pipe and hose.
Engine and transaxle assembly
Caution
l Do not damage any components in the engine com-
partment.
1, Remove the engine and transaxle assembly.

INSTAlLATION B2
93X82-72!
93G0BZ757
-
J 93GO32-730
Alternator and drive belt
1. Monut the alternator to the engine.
Tightening torque
@: 19-25 N-m (1.9-2.6
m-kg, 14-19 ft-lb)
@J: 37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
2. Install the drive belt. (Refer to page 82-Z)
Engine mount, clutch release cylinder
and engine mount
member
1. Install the No.3 engine mount rubber, and loosely tighten
the bott and nuts.
2. Install the No.4 engine mount rubber and bracket assem-
bly, and loosely tighten the bolts and nuts.
3. lnstalt the clutch release cylinder and pipe bracket assembly.
Tightening torque
@: 16-23 Nm [I .6-2.3 m-kg, 12-17 ft-lb)
0: 6.9-9.8 N-m (70-100 cm-kg, 61-87 in-lb)
4. Install the No.2 engine mount rubber and bracket assembly.
Tightening torque:
37-52 Nrn (3.8-5.3 m-kg, 27-38 R-lb)
B2-25

-- -
“-
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

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

F2 CONTROL SYSTEM
CONTROL
SYSTEM
STRUCTURAL VIEW
OXL STOPLIGHT SWITCH CLUTCH SWITCH
INJECTOR
P/S PRESSURE
SWITCH
‘GEN SE877
DtSTRIBUTOR
/ PUMP
CONTROL UNll
CONTROL UNIT
CONNECTOR
P REStSTORlRELAY
FUEL tNJ RELAY (MAIN RELAY)
AIRFLOW METER
SOLENOID VALVE
I NEUTRAL SWITCH
(PRESSURE REGULATOR)
WATER THERMOSENSOR
93GOf2.729

CONTROL SYSTEM
WE~DOST WARNlNG BUZZER [BP TURBO]
To improve engine reliability, the overboost warning buzzer installed in the instrument cluster sounds during
overboost conditions as detected by engine
speed and intake air amount caiculations within the ECU. The
driver is thus warned to reduce engine
speed.
DETECTtON
OVERBOOST
BUZZER
TURBOCHARGE INDICATOR [BP TURBO]
When the turbocharger boost pressure calcul’ated by intake air amount and engine speed reaches the predeter-
mined level and the transaxle is in gear, the turbocharge indicator illuminates to inform the driver of turbocharge
operation.
1
AIRFLOW METER
DISTRI BUTUR
rd” i
4 NEUTRAUCLUTCH
SWITCH ECU
* CALCULATION
-, OF
BOOST
PRESSURE
TURBOCHARGE
INDICATOR

F2 CONTROLSYSTEM
AK CUT-OFF SYSTEM (AI-X)
To improve the retiability of the engine at high temperature condition, the water thermoswitch on the radiator
is switched OFF above approx. II I “C (232OF) and stops the A/C operation.
ECU
NC OPERATION BLOWER FAN
WATER
THERMOSWITCH
IABOVE
111 OC (232OF): OFF]
NC SWITCH
IGNITION
T
l 1
BLOWER SWITCH
MAGNET
CLUTCH
93GOF2-73
F2-24

TRUUBLESHOOT1NG GUIDE
TROUBLESHOOTING GUIDE [BP TURBO]
RELAT1ONSt-W CHART
,
i OUTPUT DEVICE
INPUT DEVfCE
KNOCK SENSOR
1
I
-
I-
3 DIAGNOSIS CONNECTOR
(TEN TERMfNAL)
IGNITION SWITCH
(START POSITION)
0 0 0 Cl
EIL SIGNAL * ’
0 0
0 0
P/S PRESSURE SWITCH
0
1
0 0 A/C SWITCH
0 0 0 0 NEUTRAt AND CLUTCH
SWfTCHES 0 0
0
STOPLIGHT SWITCH
0
0
0 0 0 ATMOSPHERIC PRESSURE
SENSOR (IN ECU) 0
0
THROTTLE SENSOR 0 0 0 0 0
0 INTAKE AfR THERMOSENSOR 0
AlRFLOW METER 0 0
I------ i
0 OXYGEN SENSOR
WATER THERMOSENSOR 0
0 0
O G-SIGNAL
DISTRIBUTOR
I---- Ne-SIGNAL I-L 0 0 L-
0
0
L.- 0 0
L 0 0
93GOF2-i45
*I E/L SIGNAL: Slower fan control switch Second position or higher, cooSing fan operating? headlights ON, or rear wtn-
dow defroster switch ON

F2 TROUBLESt=iUUTlNG GUIDE
SYMPTOM TROUBLESHOOTING
Regarding symptom troubleshooting except LACK OF POWER, POOR XCELERATION, KNOCKING, and
HIGH UIL CONSUMPTION, refer to Workshop Manual [I 203-l O-89F (Europe) or 1204-l O-89F (Australia)].
19 LACK OF POWER [BP TIJR801
DESCRIP- *Performance poor under load when throttle valve wide open
TION *Reduced maximum speed
l Idle condition normal
[TROUBLESHOOTING HINTS1
3 Wastegate always open or opens early
3 Turbocharger damage
@ Factors other than engine malfunction
*Clutch sllpping
l Brake dragging
*Low tire pressure
l Incorrect tire size l Overloaded vehicle
@ Low intake air amount
*Throttle valve not open fully
*Clogged intake air system
TEP INSPECTlON
1
Install pressure gauge in intake air pipe and
check boost pressure at engine speed of
4,000
wm
CT page F2-45
Boost pressure:
More than 2.0 kPa (0.02 kglcm2, 0.3
psi)
@ Air/Fuel mixture lean
l Fuel iine pressure decreases l Fuel injection malfunction
@ Poor ignrtjon
@ Low engine compression
@ Alcohol blended fuel used
@ Knock control system malfunction
ACTION
Yes Go to Step 3
NO Check for air leakage and exhaust gas
leakage
4 If OK, go to next step
4 In not OK, repair
2 Check wastegate
Yes Remove intake air pipe from turbo-
f7 page F2-45 charger and check if compressor wheel
rotates smoothly t7 page F2-46
4 If OK, check air cleaner element
and throttle valve
+ If not OK, replace turbocharger
3 Check factors other than engrne Yes
l Clutch slipping Go to next step
1 8rake dragging
’
l Low tire pressure NO Repair or adjust
l Incorrect tire srze
FZ-32

F2 TROUBLESHOOTING GUIDE
20 POOR ACCELERATION [BP TURBO]
IESCRIP- . Performance poor while accelerating
rm
l Idle condition normal
[TROUBLESHOOTING HINTS]
3 Wastegate always open or opens early @ Low intake air amount
3 Turbocharger damage
l Throttle valve not open fully
3 Factors other than engine malfunction *Clogged intake air system l
Ciutch slIpping @ Air/Fuel mixture Iean l Brake draggrng l fuel line pressure decreases
l low tire pressure l Fuel Injection malfunction
l Incorrect tire size @ Poor Ignition
. Overloaded vehicle @ Low engine compression
@ Atcohol blended fuel used
TEP INSPECTION ACTION
-l Install pressure gauge
in intake air pipe and I Yes
1 Go to Step 3
check boost pressure at engine speed of 4,000
rpm
w page F2-45
Boost pressure:
More than 2.0 kPa (0.02 kglcm2, 0.3 psi)
No Check for air leakage and exhaust gas
leakage
4 If OK, go to next step
4 If not OK, repair
2 Check wastegate w page F2-45
Yes Remove Intake air pipe from turbo-
charger and check if compressor wheel
rotates smoothly w page F2-46
c3 If OK, check air cleaner element
and throttle valve
4 If not ok, replace turbocharger
3 Check factors
other than engine
Yes Go to next step l Clutch stipprng l 5rake dragging l Low tire pressure
No l Incorrect ttre size Repair or adjust
FZ-36