service MAZDA 232 1990 Suplement Owner's Manual

SUPPLEMENTAL SERVICE INFORMAT1ON, THERMOSTAT E
SUPPLEMENTAL SERVICE INFURMATtON
The following points in the section are changed in comparison with Workshop Manual [Europe (1203-l 0-89F),
Australia (I 204-I 0-89f)].
Thermostat (BP DUHC Turbo only)
l Inspection
Electric cooling fan system (BP DOHC Turbo only)
l System inspection
Fan motor
l 1 nspection
Water thermoswitch (BP DOHC Turbo only)
l tnspection
Radiator thermoswitch (BP DOHC Turbo only)
l Removal I Inspection I Installation
Fan relay (BP DOHC Turbo only)
l Removal ! Inspection 93GOEX-710
-
THERMOSTAT (BP DOHC TURBO)
SUB-V E
‘A
/ INSPECTKM
1. Visually check that the thermostat valve is airtight.
2. Place the thermostat and a thermometer in water.
3. Heat the water and check the following:
Initial-opening temperature:
Main: 86.5-89.5% (188--t93°F)
Sub : 83.5-86.5OC (f82--f88QF)
Full-open temperature: 100°C (212°F)
Full-open lift
Main: 8.Umm CU.31 in) min.
Sub : f.5mm (0.06 in) min.
E-9

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

SUPPLEMENTAL SERVICE INFORMATION, FUEL SYSTEM Fl
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Mazda 323 Workshop Manuals
(I 203-I U-89F, 1204-I O-89F, I2061 O-89F).
fuel tank
l Removal I Inspection I Installation
4x4 control unit (Fuel pump control unit)
l Inspection procedure added
l Replacement procedure added
Transfer pump switch
l Inspection procedure added
l Replacement procedure added
Transfer pump
l Inspection procedure added
l Replacement procedure added
Exhaust system components
l Removai I Inspection I installation 93GOF? -706
FUELSYSTEM
PRECAUTION
Fuel Pressure Release and Sewicing Fuel System
Fuel in the fuel system remains under high pressure when the
engine is not running.
a) Before disconnecting any fuel line, release the fuel
pres-
sure from the fuel system to reduce the possibility of injury
or fire.
1. Start the engine.
2. Push the rear seat cushion buttons and remove the
cushion.
3. Disconnect the fuel pump connector.
4. After the engine stalls, turn off the ignition switch.
5. Reconnect the fuel pump connector and install the rear
seat cushion.
b) Use a rag as protection from fuel spray when disconnect-
ing the hoses.
Plug the hoses after removal.
c> When inspecting the fuel system, use a suitable fuel pres-
sure gauge.
Caution
l Install hose clamps to secure tile fuel pressure
gauge to the fuel filter and the fuel main hose to pre-
vent fuel leakage.
Priming Fuel System
After releasing the fuel pressure for repairs or inspection, the
system must be primed to avoid excessive cranking when first
starting the engine. Follow the
steps below.
I. Connect the diagnosis connector terminals F/P and GND
with a jumper wire.
2. Turn the ignition switch ON for approx. IO sec. and check
for fuel leaks.
3. Turn the ignition switch OFF and remove the jumper wire.
Fl-9

TRANSFER PUMP CONTROL SYSTEM
2. Remove the service hole cover of the transfer pump.
3. Disconnect the transfer pump connectors.
4. Disconnect the fuel hose.
5. Remove the transfer pump.
Caution
l Install a new seal rubber.
6. Install in the reverse order of removal.
03UOFX-626
Disassembly / Assembly
Caution
l Prevent contaminants from entering the transfer pump,
I. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
3. Verify that the transfer pump operates
correctly after assembling it.
EAL RUBBER, REPLACE
1 . Fuel filter
2. Rubber mount
3. Transfer pump 4. Fuel hose
5. Transfer pump
switch
Ft-14

F2
FUEL AND EMISSION
CONTROL SYSTEMS
(WITH CATALYTIC CONVERTER)
.
INDEX ..*.........**.*.........*..........*...... F2- 2
OUTLINE ...................................... F2- 4
OUTLINE OF CONSTRUCTION.. .... F2- 4
SYSTEM DIAGRAM ...................... F2- 5
VACUUM HOSE ROUTING
DIAGRAM [BP TURBO] ............... F2- 7
WIRING DlAGRAM.. ..................... FZ- 8
ECU REtATlONSHIP DIAGRAM
[BP TURBO] .............................. F2-10
SPEClFtCATlONS. ........................ F2-11
TURBOCHARGER CONTROL
[BP TURBO] ................................ F2-I 2
OUTLINE .................................... F2-I 2
SYSTEM DIAGRAM ................. .; ... F2-12
WASTEGATE CONTROL ...............
F2-13
FUEL,SYSTEM
.............................. F2-15
OUTLINE
.................................... F2-15
CONSTRUCTlON ......................... F2-15
FUEL VAPOR VALVE ................... F2-16
FUEL PUMP CONTROL SYSTEM.. . F2-16
FUEL PUMP RESISTOR/RELAY ...... F2-18
TRANSFER PUMP CONTROL. ....... F2-I 8
CONTROL SYSTEM ....................... F2-20
STRUCTURAL VIEW.. ................... F2-20
OVERBOOST WARN!NG BUZZER
[BP TURBO] .............................. F2-21
TURBOCI-IARGE INDICATOR
[BP TURBO] .............................. F2-21
KNOCK CONTROL SYSTEM
[BP TURBO] .............................. F2-22
OXYGEN SENSOR [BP TURBO]. .... F2-23
PRESSURE REGULATOR CONTROL
SYSTEM [BP TURBO] ................. F2-23
A/C CUT-OFF SYSTEM (ATX) .........
F2-24 SUPPLEMENTAL SERVICE
INFORMATION ............................. F2-25
SELF-DIAGNOSIS FUNCTION .......... F2-26
OUTLINE
.................................... F2-26
MALFUNCTION CODE NUMBERS . . F2-26
TROUBLESHOOTtNG GUIDE
[BP TURBO1
................................ F2-31
RELATlONSHlP CHART ................ F2-31
SYMPTOM TRUUBLESH0OTlNG .... F2-32
tNTAKE AIR SYSTEM ..................... F2-43
COMPONENTS ............................ F2-43
TURBOCHARGERCONTROL
SYSTEM ...................................... F2-45
PREPARATION ............................ F2-45
SYSTEM OPERATION ................... F2-45
WASTEGATE ............................... F2-45
WASTEGATE SOLENOID VALVE.. .. F2-46
TURBOCHARGER ........................ F2-46
AIR BYPASS VALVE ..................... F2-48
INTERCOOLER ............................ F2-49
FUEL SYSTEM .............................. F2-50
PREPARATION ............................ F2-50
PRECAUTION ............................. F2-50
FUEL TANK
................................ F2-51
TRANSFER PUMP CONTROL
SYSTEM ................................... F2-52
FUEL PUMP CONTROL UNIT ........ F2-53
TRANSFER PUMP SWITCH ........... F2-54
TRANSFER PUMP.. ...................... F2-54
FUEL PUMP RESISTOR/RELAY ...... F2-56
INJECTOR
.................................. F2-56
EXHAUST SYSTEM
COMPONENTS .................................................... ;ff;
CONTROL SYSTEM ....................... F2-59
PREPARATION
............................ F2-59
ENGINE CONTROL UNIT (ECU) ..... F2-59
OXYGEN SENSOR ....................... F2-68
KNOCK SENSOR ......................... F2-69
93GOF2.701

lNDEX F2
4x4 CONTROL UNIT
(FUEL PUMP
CONTROL UNIT)
SERVICE, SECTION SEAT
1. Fuel tank
Removal / Inspection I
lnstailation . . . . .._........._._....... 1 . . . . page F2-51
2. Injector _
Volume test ~..........~..~..,...~..~....~. page F2-56
3. Fuel pump resistor/relay [BP TURBO]
System operation . . ._. . . ._. _ . . . . . . . . . . . page F2-56
Inspection . . . . . . . . . . . . . . . . . . . *. . . . . . . . . . . . . page F2-56 4. Fuel pump control unit [BP TURBO]
Inspection *....,...,.........I..... * . . . . . . . page F2-53
Replacement . . . . . . . . . . . . . . . . . . . . . . . . ..-... page F2-53
5. Transfer pump switch
Removal I InstaNation . . . . . . . . . , ..,... page F2-54
Inspection ..a . . . . . . . . . . . . . . . . . . * . . ..I.. e... page F2-54
6. Transfer pump
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F2-54
Replacement ,...,_..... b . .._._......_.... page F2-54
1. Exhaust system
RemovA I Inspection I InstaNation
BP SOHC . . . . __.._......... _........... page F2-57
BP TURBO _.. . . . . . .._.. . . . . . . . . . . . . . . . page FZ-58
F2-3

SUPPLEMENTAL SERVICE INFORMATION F2
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison to the Mazda 323 Workshop Manual
[I 203-I U-89F (Europe) or 120410-89F {Australia)].
intake air system components [BP Turbo]
l Removalllnspectionll nstaltation
WASTEGATE [BP Turbo]
l Inspection
WASTEGATE SULENOlD VALVE [BP Turbo]
l Inspection
Turbocharger [BP Turbo]
l Inspection
l Removalllnstaltation
Air bypass valve [BP Turbo]
l Removal/hstallation
l 1 nspection
lntetcoolet [BP Turbo]
l RemovaMnspection/tnstaltation
Fuel tank
l Removal ! Inspection I Installation
Fuel pump control unit [BP Tubto]/4x4 control unit [BP SOHC]
l 1 nspection
l Replacement
Transfer pump switch
l Inspection
l Replacement
Transfer pump
l Inspection
l Replacement
Fuel pump resistor/relay
l System operation
l Inspection
injector [8P Turbo]
l Volume test
Exhaust system components
l Removal / 1 nspection / Installation
Engine control unit (ECU) [BP Turbo]
l Terminal voftage
Oxygen sensor [BP Turbo]
l Inspection
l Replacement
Knock sensor [BP Turbo]
l Replacement 93GOFZ736
F2-25

FUEL SYSTEM F2
2. Remove the service hole cover of the transfer pump.
3. Disconnect the transfer pump connectors.
4. Disconnect the fuel hose,
5.
Remove the transfer pump.
6. Install in the reverse order of removal. Caution
l Install a new seat rubber.
03UOFX-826
Disassembly I Assembly
Caution
l Prevent contaminants from entering the transfer pump.
1. Disassemble in the order shown in ,the figure.
2. Assemble in the reverse order of disassembly.
3. Verify that the transfer pump operates correctly after assembling it.
HOSE, REPLACE
@
1. Fuel filter
2. Rubber mount
3. Transfer pump 4. Fuel hose
5. Transter pump switch assembly
93GOF2-77:
FZ-55

G
ENGINE ELECTRICAL SYSTEM
INDEX . ..I 1.. . . . . . . . . . . . . . . . . . . . . . . ..*. . . ..I..... . . . . . ..I...
G- 2
j FEATURES 1
OUTLINE . . . . . . . . . ...*....* .I.............. .I . . . . . . . . . . . . . .
G- 3
OUTLINE. OF CONSTRUCTION ..I... . . . . . . . . . . . G-
3
SPECtFICATiONS . . . . . . . . . . . . ..I............... . . . . . .
G- 3
1 SERVICE 1
SUPPLEMENTAL SERVICE INFORMATION . . G- 4
STARTING SYSTEM
. ..I. . . . . . . . . a.. . . . . . . . . . . . . . . . . . . G- 4
STARTER
l ..I.... . . . . . . . . . . . . . . . . . . l .*.....* .I....... . . . G- 4
CHARGlNG SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G- 5
PREPARATION
. . . . . . . . . . . . ..I..-... . . . . l . . . . . . . . 1. . . . . G- 5
ALTERNATOR (RHD)
. . . . . . . . . . . . . . . . . . . . . . . . . . ...*. G- 5
93GOGX-701

G SUPPLEMENTAL SERVICE INFORMATION, STARTING SYSTEM
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Mazda 323 Workshop Manual
[1203-l O-89F (Europe), ? 204-I O-89F (Australia)].
Starter
l Removal / InstaHation
Atternator (RI-ID)
l Removal I InstatIation 93GOGX-705
STARTING SYSTEM
STARTER
Removal I Installation
I. Remove in the order shown in the figure.
2. Inspect all parts, and repair or replace as necessary.
3. lnstail in the reverse order of removal.
37-52 (3.8-5.3, 27-38)
9.8-t2 N-m
(IOO-120 cm-kg, 87-104 in-lb)
(3.8-5.3, 27-38)
9.8-12.N.m
It t \
I. Battery
(100-120 cm-kg, 87-104 in-lb)
37-52 27-38)
(3.8-5.3, 27-38)
N-m (m-kg, ft-lb)
5. Starter
Remove tram above
6.
Starter bracket 2. intake manifold bracket
3. S terminal wire
4. B terminal wire
G-4