warning MAZDA 232 1990 Suplement User Guide

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

Fl FUEL. SYSTEM
FUEL TANK
Removal / inspection I Installation
Warning
l Before performing the following operation, release the fuel pressure from the fuel system to
reduce the possibiIity of injury or fire. (Refer to page Fl-9.)
l When removing the fuel tank, keep sparks, cigarettes, and open flames away from it.
l Before repairing the fuel tank, clean it throughly with steam to remove all explosive gas.
1. Remove in the order shown in the figure.
2. Inspect the fuel tank components visually and repair or replace as necessary.
3. Install in the reverse order of removal, referring to Installation Note.
FUEL PUMP (MAIN) TRANSFERPU
4341 (4.4-6.2, 3245)
GASKET, REPLACE
ET, REPLACE
4it-55 (4.3 -5.6, 3041)
Nm (m-kg, ft-lb)
a?cnc% .7*7

FUEL SYSTEM, TRANSFER PUMP CONTROL SYSTEM Fl
Note
l Drain the fuel from the fuel tank before removing the tank.
I. Fuel pump cover
2.
Fuel pump connector
3. Fuel hoses
Installation
Note . . . . . . . . . . . . , . . . . . . . . . . . . . . _ . . . . . below
4. Exhaust pipe
Removal / lnstaltatjon . . . . . . . . . . . . .._. page Fl -I 5
5. Propeller shaft
Removal / installation ._..._....,_.._..._.. Section L 6. Fuel fiIler hose, breather hose, and
evaporation
hoses
Installation Note . . . ..*..**......*........~_.....~.
below
7. Fuel tank straps
8. Fuel tank
inspect for cracks and corrosion
93m=: -708
I B FUEL FILLER HOSE
22%
-.
-L
0 F /
@,
M
E -J
03UOFX-Bf 4
93GOFl-709
Installation Note
1. Push the ends of the main fuel hose, fuel return
hose, and
evaporative hoses onto the fuel tank fittings at least 25mm
(1.0 in).
2. Push the fuel filler hose onto the fuel tank pipe
and filler pipe
at ieast 35mm (1.4 in).
TRANSFER PUMP CONTROL SYSTEM
SYSTEM OPERATION ’
1. Turn the ignition switch ON and verify that the fuel
gauge
indicates more than half and that the transfer pump oper-
ating sound is heard.
Warning
l If the fuel level is less than one half, this inspec-
tion cannot be performed.
2. Ground the transfer pump connector terminal-wire (Y/L) with
a jumper wire and verify that the transfer pump stops.
3. Remove the jumper wire and verify that the transfer pump
begins operation after approx. 50 sec.
4. If not as specified, check the following parts.
l 4x4 control unit (Fuel pump control unit).
(Refer to page F-I-1 2.)
l Transfer pump. (Refer to page FI-I 3.)
l Transfer pump switch. (Refer to page Ff -13.)

TRANSFER PUMP CONTROL SYSTEM Fl
TRANSFER PUMP SWITCH
I
93GOF I -7 14
OWOFX-824
TRANSFER PUMP SWITCH
Removal / Installation
.
1. Refer to “Transfer pump replacement”.
(Refer to below.)
inspection
1. Check continuity between transfer pump connector termi-
nal C and ground terminal.
Float position Contrnuity
UD
NO
I Down
I YES I
2. If not as specified, replace the transfer pump switch.
TRANSFER PUMP
Inspection
f . Remove the rear seat cushion.
2. Disconnect the transfer pump connector.
3. Check for continuity between transfer pump connector
terminal-wires (SAW) and (v).
4. If no continuity exists, replace the transfer pump.
Replacement
Warning
l When servicing the fuel system, keep sparks,
cigarettes, and open flames away from the fuel.
1. Remove the rear seat cushion.
FI-13

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

FUEL SYSTEM F2
FUEL TANK
Removal I inspection / Instatlation
Warning
l Before performing the following operation, release the fue1 pressure from the fuet system to
reduce the possibitity of injury or fire. (Refer to page F2-50.)
l When removing the fuel tank, keep sparks, cigarettes, and open flames away from it.
l Before repairing the fuel tank, clean it throughly with steam to remove all explosive gas.
1. Remove in the order shown in the figure.
2. Inspect the fuel tank
components and repair or replace as necessary.
3. tnstall in the reverse order of removal, referring to Installation Note.
FUEL PUMP TRANSFER PUMP
0 SEAL RUBBER, REPLACE 7
A SSL
40-55 (4.1-56, 30-41)
N-m {m-kg, Mb)
93GOF2-771
F2-51

F2 FUELSYSTEM
Note
l Drain the fuei from the fuel tank before removing the tank.
1. Fuel pump cover
2. FueI pump connector
3. Fuel hoses
Installation Note ..___........_.....__......_...._. below
4. Exhaust pipe
Removal / installation . . . . . . . .__._. . , . . . FZ-57, 58
5. Propeller shaft
Removal ! Installation .._._...._....._.._.. Section L 6. Fuel filier hose, breather hose, and
evaporation hoses
tnstal!ation Note ..m..,* . . . . ...*-. *..,- . . . . m...-e.. below
7. Fuel tank straps
8. Fuel tank
Inspect for cracks and corrosion
93GOF2-772
0 FUEL FILLER HOSE
03UOFX- 13! installation Nate
1. Push the ends of the main fuel hose, fuel return hose, and
evaporative hoses onto the fuel tank fittings at least 25mm
(1 .O in).
2. Push the fuel filler hose onto the fuel tank pipe and filler pipe
at least 35mm (1.4 in).
TRANSFER PUMP CONTROL SYSTEM
System Operation
I. Turn the ignition switch ON and verify that the fuel gauge
indicates more than half and that the transfer pump oper-
ating sound is heard.
Warning
l If the fuel level is less than one half, this inspec-
tion cannot be performed.
2. Ground the transfer pump connector terminai-wire (Y/L) with
a jumper wire and verify that the transfer pump stops.
3. Remove the jumper wire and verify that the transfer pump
begins operation after approx. IO sec.
4. If not as specified, check the following parts.
l Fuel pump control unit. [BP turboJ
(Refer to page F2-53.)
4x4 control unit [BP SOHC] (Refer to page Fl-12.)
l Transfer pump. (Refer to page F2-54.)
. Transfer pump switch. (Refer to page F2-54.)
93GOF2-774
F2-52

F2 FUELSYSTEM -.
03UOFX-82: 93GOF2-777
2
r
TRANSFER PUMP SWlTCH
Removal I Installation
1. Refer to replacement of the transfer pump.
(Refer to below.)
Inspection
1. Check continuity between transfer pump connector termi-
nal C and ground terminal.
r Float Dosition I Comnuity
I
I Down I Yes
I
2. If not as specified, reptace the transfer pump switch.
TRANSFER PUMP
Inspection
1. Remove the rear seat cushion.
03UOFX-823 2. Disconnect the transfer pump connector.
3. Check for continuity between transfer pump connector
terminal-wires (ES) and (t/V).
4. If no continuity exists, replace the transfer pump.
03UOFX-825
F2-54
Replacement
Warning
l When servicing the fuel system, keep sparks,
cigarettes, and open flames away from the fuel.
1. Remove the rear seat cushion.

F2 FUEL SYSTEM
93GOF2-775
1 93GOF2-78(
93GOF2-78:
1
93GOF2-78;
-
93GOF2-783
FUEL PUMP RESISTOR/RELAY
System Operation
I. Remove the rear seat cushion.
2,
Measure the voltage at the fuel pump connector terminal
A {G/O).
Voltage
r Crankinq Approx. 12V
I
I- Others t ACKXOX. I OV i
3. If not within specification, perform the following inspection,
and repair or replace if necessary.
l Fuel pump resistor/relay resistance. (Refer to below.)
l ECU II terminal voltage. (Refer to page F2-60.)
l Wiring harness and connector.
inspection
1.. Disconnect the connector.
2. Ground the fuel pump resister relay terminal D.
3. Apply 12V to terminal C and check for continuity between
terminals A and B.
Terminal C
12 applied
ov Continutty between A and B
NO
Yes
4. Measure the resistance between terminals E and F.
Resistance : 0.62-0.66Q [at 20% (68OF)l
INJECTOR
Volume Test
1. Remove the injectors with the delivery pipe.
2. Affix the injectors to the delivery pipe with wire.
Caution
l Affix the injectors firmly to the delivery pipe so that
no movement of the-injectors is possible.
Warning
l Be extremely careful when working with fuel.
Always work away from sparks or open flames.
3. Connect the SST to the battery and injector.
4. Check the injection volume with a graduated container.
Injection volume:
BP SUHC....44-47 cc (2.68-2.87 cu in)/15 sec.
BP Turbo
. ...87-105 cc (5.31 -6.41 cu in)/15 sec.
Caution
l When using the SST, make sure of the SST num-
ber and use correct one.
5. If nut correct, replace the injector(s).

F2 CONTROLSYSTEM
Terminal I Input Output Connected to Test condition Correct voltage Remark
25 0
Overboost warning lgnltion switch ON Approx. 12V
-
buzzer
2T 0 1 Solenoid valve 180 seconds atter engine started when Below 1 SV
(Pressure regulator) engine coolant temperature above 90%
(I 94OF) and Intake air temperature above -
58OC (13WF)
1 Other condition at Idle Approx. 12V
2u 0 Injector (Nos. I 1 3) Ignrtion switch ON Approx. 12V * Engine Signal
Idle Approx. 12V’ Monitor: Green
and red lamps
Engrne speed above 2,000 rpm on de- Approx. f2V
flash
celeratlon (Atter warm-up)
2v 0 Injector (Nos. 2, 4) lgnitlon swrtch ON Approx. 12V
Idle Approx. 12V’
Engine speed above 2,000 rpm on de- Approx. 12V
ceieration (After warm-up)
2W 0
ISC valve Ignition switch ON Approx. 7V
-
Idle Approx. 9V
2x 0 Solenoid valve Ignition switch ON Approx. 12V
(Purge control)
t Idle -
Approx. f2V
t
2Y 0 Cmxit opening Ignition switch UN Approx. 12V
-
relay
Idle Below 1 .OV
22 - - - - - -
-L J
u-
v I U-1 l-
2y 2w 2u 2s 20 20 2M 2K 21 2G 2E 2C
2A 1U 1S IQ 10 1M 1K 11 1G 1E IC 1A
22 2X 2V 2T 2R 2P 2N 2L 2.J i’t-( 2F 2D 2B 1V 1T 1R tP IN IL I..! ItI IF
tD 18
F2-66