service MAZDA 232 1990 Suplement User Guide

SCHEDULED MAlNTENANCE SERVICES (Europe)
Maintenance Number of months or km (miles), whichever comes first
Months” - 6 1 12 18 24 1 30
36 1 42 48
Maintenance Wometers 1,000 10,000 20,000 30,000 40,000 50,000 60,000 1 70,000 80,000
interval
(Miles) (600) (6,000) (12,000) (18,000) (24,000) (30,000) (36,000)~(42,000) (48,000)
Engine Intake
and exhaust manifold nuts (Bolts) Drive belts * 2
Engine ttming belt *’
Engine oi; (Non-Turboj’4
Oil filter * 4
Cooling system (Including coolant
level adjustment)
Enaine coolant T
1 1 1
1 1 ’
A
[ A I A 1 A ] [ A
Replace every t 00,000 km (60,000 miles)
R
R R R R R R R 1 R
R R R R R R R R
I I 1 I
Reolace everv 2 Years
Fuel system
Idle speed
Idle mixture
Air cleaner element *’ Fuel
filter
Fuel lines and hoses
I A I * A 1 A 1 A
I
A A A A
I R I R
R
I R I
1 I
t I 1 [ I
Ignition system
Initial ignition timing
Spark plugs I t I I 1 I 1 I
A A ( A A
Evaporative emission control system
Electrical system
Ejattery electrolyte level and specific gravity A
A 1 A A 1 A
Electrical system
l 6
I I I
I t I 1 I I
Headlight algnment
A A f A 1 A
Chassis and body
Clutch pedal
Clutch fluid
Brake lines, hoses and connections
Brake pedal
Brake flutd *7
Parking brake
Power brake unit and hoses
DGC brakes
Pow& steering fluid
Power steering system and hoses
Steering and front suspension
MTX oil
Rear axle oil
Transfer carrier
ui!
Rear suspension bail joint
Bolts, nuts on chassis and body
8ody condltlon (Visual onty)
-
I I I I I I I I
1 I I I I I I I
I
1 I I
i
1 I I I I I I
I I I
R I 1 I R
A A A 1 A
1
1 i 1 I
I
I I
I
I
I I I I I I I
I 1 I I
I 1 I 1 i
1 A
A R A A A R
iR,i A R A A A R
R ’
A . A R A A A R
f I
T
T T T
T
I Inspect annually
93GOAX-705
A-6

SCHEDULED MAINTENANCE ‘SERVICES (Europe) A
Maintenance Number of months or km (miles), whichever comes first
Monthso - 6 12 18 24 30 36 42 4%
Maintenance Kilometers
1,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
(Miles)
(600) (6,000) (12,000) 1(18,000) (24,000) (30,000) (36,000) (42,000) (48,000) Chassis and body (Cont’d)
TIES (lnctud~ng spare tires) wrth infiation
pressure adjustment
Hinges and catches
U nderslde of vehicle
Seat belt
Roao test
Driveshaft dust boots
93GOAX-706
A-7

A SCHEDULED MAINTENANCE sERvw3 (Europe)
SCHEDULED MAfNTENANCE SERWCES (Europe)
MAWTENAN CE TABLE (Unlead Fuel Model)
Chati symbols:
I : Inspect: Visual examination and/or functional measurement of system’s operation or performance
A: Adjust: Examination resulting in adjustment or replacement
R: Replace or change
T: Tighten
REMARKS
After 80,000 km or 48 months, continue to follow the described maintenance at the recommended intervals.
As for * marked items in this maintenance chart, note the following points.
* 1 Major service interval at 12 months120,OOO km (12,000 miles).
Lubrication service based on distance only 10,000 km (6,000 miles) not time.
*2 Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt
if equipped.
“3 Replacement of the timing belt is required at every 100,000 km (60,000 mile). failure to replace the tim-
ing belt may result in damage to the engine.
“4 If the vehicle is operated under any of the following conditions, it is suggested that the engine oil and
oil filter be changed more often than the &commended intervals.
a) Driving in dusty conditions.
b) Extended periods of idling or low speed operation.
c> Driving for a prolonged periods in cold temperatures or regularly driving only short distances.
*5 If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more oten
than at usual recommended intervals.
*6 This is a full function check of all electrical systems, i.e, all lights, washers (including condition of blades)
electric windows, sunroof, horn etc.
“7 Replace every two years.
If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the
vehicle is operated in extremely humid climates, the brake fluid should be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the emission control and related
system, as well as for efficient engine operation. It is strongly recommended that all servicing related to these
systems be done by your Authorised Mazda Dealer.
93GOAX-707
A-8

SCHEDULED MAtNTENANCE SERVICES (Europe) A
Maintenance Number of months or km (miles), whichever comes first
Months” - 6 1 12 18 ‘24 30136 42 48
Maintenance Kilometers 1,000 10,000 20,000 30,000 40,000 50,000 ( 60,000 70,000 80,000
(Miles) (600) (6,000) (12,OOO)~(l8,0~0) (24,000) (3O,UOO))(36,000) (42,000) j48,OOU)
Engine
!nrake and exhaust manifold nuts (80&j
Owe belts *’
Engrne timing belt l 3
Engine oil flurbo)‘4
Engine oil (Non-turbo)“4
Oil filter’4
Cooling system (I ncludrng
coolant level adjustment)
Engine coolant T 1 T T
A 1 1 A A 1 A A
Reptace every 100,000 km
{60,000 miles)
Replace every 5,000 km (3,000 miles) or 6 months
R R 1 R R R R ‘ R R R
R R R R R R R ’ R
I I I I
Replace every 2 years
Fuel system
Idle soeed
I A 1
Air cleaner elemenf*5 I f R E
R
Fuel fitter
R R
fuel 11~s and hoses 1
t 1 I I I I
Ignition system
lrritiai ignition timing
Spark plugs
Spark plugs (Only for Sweden) 1 I I I 1 I I 1 I I 1 I
A 1 A A 1 A
Adjust every 30,000 km {
18,000 mils)
Evaporative emission control system
Throttle sensor
Throttle sensor (Only for
Sweden)
Evaporative system Evaporatwe system Khlv
for Sweden) 1 1 Aj 1 A ( [ A ] 1 A
Adjust every 80,000 km (48,000 miles)
I 1 I [ I 1
I I [ 1 I
lnsoect everv 80.000 km (48.000 miles)
Electrical system
Battery electrolyte level and specific gravity
A 1 A A ’ 1 A ; A *
All Electrical system *’ I I 1 I I I I I I
Headlight alignment A A A I
c I A ,
Chassis and body
clutch Dedal
Clutch fluid
Brake lines, hoses and connectrons
Brake pedal
Brake fluid”’
Parking brake
Power brake unit and hoses
Disc brakes
Power steering fluid
Power steering system and hoses I
I I 1 1 1 I I
I I
I
I I I I 1 1 I
1
1 I I
I I I I t ! I I
I I I R I 1 I R
A A A A
I I I I
I 1 I 1
I 1 I I I I j I ,
I
I 1 I 1
I
93GOAX-708
A-9

A SCHEDULED MAINTENANCE SERVICES (Europe)
Maintenance Number of months or km (mires), whichever comes first
Months” - 6 12 18 24 30 1 36 42 48
Maintenance KIlometers 1,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
(Miles)
(600) 1 (6,000) j(12,OOO) (18,000) (24,000) (30,000) (36,000) (42,000) \(48,000) Chassis and body [Cont’d)
Steerrng and front suspension I
I
1 1 I I
MTX oil
A A A
R A A A R
Rear axle oil R A A R 1 A A A R
Trabsfercarrter oil
I R I A A R A A A R
B&s. nuts on chassis and body T 1 1 T T
T I T
Body condition (Visual
onfy) t nspect annually
Exhaust system hear shields I i
Tires (tncluding spare ttres) wtth rnflation
pressure adjustment t I I 1
Hinges and catches
A
bA4 ,A3 A
Understde of vehicle
i I I I I
Seat belt
I I I t
Road test
1 I I 1
Driveshafi dust bouts
I I I 1
93GOAX-709
A-10

91
ENGINE
(SOHC)
INDEX . ..* ..I.... *...*... . . . . . ..I. . . ..‘.I.. . . . . ..I........ Bl- 2
1 FEATURES 1
OUTLINE
................................................ Bf- 3
OUTLINE OF CONSTRUCTION.. .............. BI- 3
SPECIFICATIONS .................................. Bf- 3
lNTERGHANGEABILtP( .......................... Bl- 4
FLYWHEEL
.......................................... Bl- 5
SUPPLEMENTAL SERVICE INFORMATION Bl- 6
REMOVAL
. . . . . . . . . . . . l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I. Bf- 6
PROCEDURE . . . . I..... ..,.... .*...*.. . . . . . . . . . . . . . . . Bl- 6
INSTALLATION . . . . . . I... . . . . . I ,... . ..*..... . . . . . . . . . . Bl-14
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . ..I . . . . . . .I . . . . . . . Bl-14
93GOBl-701

Bl SUPPLEMENTAL SERVICE tNFORMAT1ON, REMOVAL
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Workshop Manual [Europe (I 203-I U-89F),
Australia (1204- 1 O-89!=)].
Engine
l Removal
l Installation 93GOF31-705
REMOVAL
Warning
w Release the fuel pressure.
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil.
3. Remove in the order shown in the figure, referring to Removal Note.
Step 1
t
I
*ATX ONLY 1
93GOBl-706
1. Undercovers
2. Side covers
3. Resonance chamber and air cleaner assembly
4. Battery bracket, cover and bafiery
5. Battery carrier and battery duct
6. Accelerator cable
7. Radiator hose
8. Coolant reservoir hose
9. Cooling fan connector
IO. Radiator switch connector (ATX)
1 f . A/C cut switch connector (ATX) 12. Oil cooler hoses (ATX)
13. Radiator bracket
14. Radiator and cooling fan assembly
15. P/S and/or A/C drive belt
16. P/S oil pump and bracket
Removal Note .._...._...__......... . . . . . . . page BY -7
17. A/C compressor
Removal Note.. . . . . . . . . . . . . . .._. . . . . . . . ._. page Es1 -7
i 8. Crossmem ber
19. A/C compressor bracket
20. Coolant reservoir
61-6

B2
ENGINE
(DOHC)
INDEX . . . . . . . ..**......... . . . . . . . ...* . . . . . . . . . . . . . . . . . . . l . BZ- 2
OUTLINE
................................................ BZ- 3
OUTLINE OF CONSTRUCTION.. .............. BZ- 3
SPEClFlCATlONS .................................. BZ- 4
INTERCHANGEABiLITY
.......................... BZ- 5
CYLINDER HEAD
.................................. BZ- 6
CYLINDER BLOCK AND OIL PAN ........... BZ- 7
PISTON ............................................... BZ- 8
FtYWtiEEL .......................................... BZ- 9
CAMSHAFT .......................................... BZ-10
SUPPLEMENTAL SERVICE INFORMATION BZ-11
COMPRESSION
....................................... 82-I 1
INSPECTION ........................................ B2-11
REMOVAL .............................................. BZ-12
PROCEDURE ........................................ BZ-12
ENGINE STAND MOUNTING.. ................... BZ-20
PROCEDURE ........................................ BZ-20
ENGINE STAND DISMOUNTING.. ..............
BZ-21
PROCEDURE ........................................ 82-21
INSTALLATION
....................................... BZ-23
PROCEDURE ........................................ BZ-23
93GOB2-701

D
D
SUPPLEMENTAL SERVICE iNFORMATION, COMPRESSION 82
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Workshop Manual [Europe (7 203~IO-899,
Australia (I 204-1 U-89F) 1.
Compression
l Inspection
Engine
l Removal
l Engine stand mounting
l Engine stand dismounting
l Ins:attaIion 93GQ32-77 I
COMPRESStON
If the engine exhibits low power, poor fuel economy, or poor idle, check the following:
1. Ignition system (Refer to Section G.)
2. Compression
3. Fuel system (Refer to Section F3.)
93G032-774 93GO32-712
1NSPECTION
1. Verify that the battery is fully charged. Recharge it if
necessary.
2. Warm up the engine to normal operating temperature.
3. Turn the engine OFF.
4. Remove all of the spark plugs.
5. Disconnect the ignition coil connector.
6. Connect a compression gauge to the No.7 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder in the same manner.
Compression:
1,059 kPa (IO.8 kg/cm2, 154 psi)-300 rpm
Minimum:
785 kPa (8-O kg/cm2, 114 psi)-300 t-pm
Allowable difference between cylinders:
196 kPa (2.0 kglcm2, 28 psi) max.
IO. If the compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder waII may be worn.
(2) If the compression stays tow, the valve may be stuck
or seating improperly.
(3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be defective or the cylinder
head distorted.
1 I. Connect the ignition coit connector.
12. Apply antiseize compound or molybdenum-based lubricant
to the spark plug threads.
73. Install the spark plugs.
Tightening torque:
15-23 N-m (1.5-2.3 m-kg, If-17 ft-Ib)
82-11

E
COOLING SYSTEM
1NDEX . ..*....*~.....*..*~~**~=~~.~~.~...~..**.~.....*...~.. E- 2
OUTLINE .................................................. E- 4
OUTLlNE OF CONSTRUCTION.. ................ E- 4
COOLANT FLOW CHART.. ....................... E- 4
SPECIFICATKINS
.................................... E- 5
TWO-STAGE THERMOSTAT.. .................... E- 6
RADIATOR AND COOLING FAN.. .............. E- 7
ELECTRIC COOLING FAN SYSTEM ........... E- 8
SUPPLEMENTAL SERVICE INFORMATION E- 9
THERMOSTAT
.......................................... E- 9
INSPECTION
.......................................... E- 9
ELECTRIC COOLING FAN SYSTEM ............ E-l 0
SYSTEM INSPECTlON
.............................. E-l 0
FAN MOTOR
............................................. E-If
iNSPECTION .......................................... E-l 1
WATER THERMOSWITCH
.......................... E-l I
INSPECTION .......................................... E-f 1
RADIATOR THERMOSWITCH
..................... E-l 2
REMOVAL I INSPECTION I INSTALLATION.. E-12
FAN RELAY .............................................. E-l 3
REMOVAL I tNSPECTlUN .......................... E-l 3
93GOEX-701