torque MAZDA 232 1990 Suplement Owner's Guide

TURBOCHARGER CONTROL [BP TURBO] F2
WASTEGATE CONTROL
The engine control unit controls the wastegate solenoid valve to give higher boost to the engine in the higher
rpm range, increasing engine torque
and power.
System
Diagram
I
t
1 ECU
i i
AIRFLOW METER ACTUATOR
WASTEGATE
WASTEGATE
SOLENOID VALVE
r ACTUATOR
WASTEGATE SOLENOID VALVE
: OFF (VALVE CLOSED)
ACTUATOR
BOOST
PRESSURE
WASTEGATE SULENOlD VALVE
: ON (VALVE OPEN) Operation
Engine speed below 5,300 rpm
The
wastegate solenoid valve is OFF. Boost pressure is ap-
plied directly to the actuator and the wastegate opens when
the boost pressure exceeds 49 kPa (0.5 kg/cm , 7.1
psi).
Engine speed above 5,300 rpm
The wastegate
solenoid valve is UN. Some boost pressure is
bypassed to the intake manifold, limiting the opening of the
wastegate to increase boost pressure and
improve engine per-
formance.
F2-13

F2 lNTAKE AlR SYSTEM
I. Air cleaner
2. Air cleaner element
Inspect fur dirt, damage, or oil
3. Airflow meter
4. Air hose
5. Air pipe and air hose
6. Accelerator cable 7. Throttle body
8. ISC valve
9. Air valve
IO. Dynamic chamber
I 1. Intake manifold
Installation Note . . . . . . . . ..__..........._._..._._.. below
93GOF2-751
93GOF2-75:
F2-44
installation Note
Intake manifold 1. Tighten the bolts in steps in the order shown in the figure.
Tightening torque:
19-25 Nm (1.9-2.6 m-kg, 140-f9 ft-lb)

F2 CONTROL SYSTEM
93GOF2-79; 2
93GOF2-793
93GOFZ794
1
OXYGEN SENSOR [BP TURBO]
Inspection
Sensor
1. Warm up the engine to normal operating temperature.
2. Disconnect the oxygen sensor connector.
3. Connect a voltmeter to the oxygen sensor terminal @.
4. Run the engine at 4,500 rpm untiI the voltmeter indicates
approx. 0.7V.
5. Increase and decrease the engine speed suddenly and
measure the vottage.
Voltage
Engme speed Voltage (v-)
Decelerating o-0.4
Accelerating 0.5-l .o 6. Connect the
SSTs to the diagnosis connector.
7. Set the system selector select switch to 1 and the test switch
to 02 MONITOR.
8. Increase the engine speed to
between 2,000 and 3,000
rpm, and verify that the monitor lamp flashes for 10 seconds.
Specification:
Monitor lamp flashes more than 8 times/IO sec.
Heater 1. Disconnect the oxygen sensor connector.
2. Check resistance between oxygen sensor connector ter-
minals @ and 0.
Resistance: Approx.-6& [at 20°C (68OF)]
Replacement 1. Disconnect the oxygen connector. ’
2. Remove the oxygen sensor.
3. Install the new oxygen sensor and new washer.
4. Tighten the oxygen sensor to specified torque.
Tightening torque:
29-49 N-m (3-5 m-kg, 22-36 ft-tb)

CONTROLSYSTEM F2
KNOCK SENSOR
!, -
l The knock sensor and knock control unit cannot be
inspected
individually.
When
a malfunction code number 05 is indicated,
replace.
Replacement
I_ Disconnect the knock sensor connector.
2. Raise the vehicle and support it WI safety stands.
1 93GOF2-797 3. Remove the knock sensor with using the SST
4. Install it in the reverse order of removal.
Tightening torque:
20-34 Nm (2.0-3.5 m-kg, 14-25 ft-lb)
F2-69

H CLUTCH FLUID (WITH ABS)
CLUTCH FLUID (WITH ABS)
PREPARATION
SST
49 0259 770B
For
Wrench, flare nut
m air
bleeding
1
93GOHX-714 93GOHX-712
REPLACEMENT
Note
l A common reservoir is used for the clutch and brake
system fluids.
l The fIuid in the reservoir must be maintained at 314
tevet or higher during replacement.
Caution
l Be careful not to spill the fluid on a painted surface.
If this should happen, wash it off immediately.
l Do not mix different brands of fluid.
l Do not reuse the clutch fluid that was drained.
1. Drain the brake fluid from the master cylinder by pumping
it through a wheel cylinder bleed screw.
2. Remove the bleeder cap from the clutch release cylinder
and attach a vinyl hose to the bleeder plug.
93GOHX-77 3
3. Place the other end of the vinyl hose in a clear container.
4. Fill the reservoir with new fluid to the MAX mark.
5. Slowly pump the clutch pedal several times.
6. With the clutch pedal depressed, loosen the bleeder screw
with the SST to let the fluid escape. Close the bleeder screw
with the SST.
7. Repeat Steps 4 and 5 until only clean fluid is seen.
8. Tighten the bleeder screw.
Tightening torque:
5.9-8.8 Nom (60-90 cm-kg, 52-78 in-lb)
9. Add fluid to the MAX mark.
IO. Slowly pump the clutch pedal several times.
Verify that there is no fluid leakage.
11.
Check operation of the clutch system.
12. Bleed and check operation of the brake system.
(Refer to Section PJ

CLUTCH MASTER CYLINDER (BP DOHC TURBO OR WITH ABS)
‘. I
-K-l
03iJOHX-076 1 ,
93GOHX-720
93GOHX-72’
Removal Note
CIutch pipe
1. Disconnect the clutch pipe with the SST,
Installation Note
Clutch pipe
1. Tighten the clutch pipe with the SST
Tightening torque:
13-22 Mm (1.3-2.2 m-kg, 9.4-l 6 ft-lb)
Air Bleeding
f . After installation, bleed the clutch system. (Refer to betow.)
AIR BLEEDlNG (WITH ABS)
The clutch hydrautic system must be bled to remove air in-
troduced whenever a hydraulic Iine is disconnected.
Note l
The fluid in the reservoir must be maintained at 3/4
level or higher during air bleeding.
Caution l
CMch fluid will damage a painted surface. ff fluid
does get on a painted surface, wipe it off im-
mediately. l
Do not mix different brands of clutch fluid. l
Do not reuse the clutch fluid that was drained.
1. Remove the bleeder cap from the clutch release cylinder
and attach a vinyl hose to the bleeder screw.
2. Inseti the other end of the vinyl hose in a clear container.
3. Slowly pump the clutch pedal several times.
4. While depressing the pedal, loosen the bleeder screw with
the SST to let fluid and air escape.
Close the bleeder screw with the SST.
5. Repeat Steps 3 and 4 until no air bubbles are seen in the
fluid.
6. Tighten the bleeder screw.
Tightening torque:
5-g-8.8 Nm (60-90 cm-kg, 52-78 in-lb)
7. Check for correct clutch operation.
8. Verify that there is no fluid leakage.
H-14

C1UTCf-f UNtT
9MUOHX-032
I
03UOf-lX-028
I
93GOHX-729
I
i
Removal Note
Clutch cover and disc
1. Install the SST.
2. Loosen each bolt one turn at a time in a crisscross pattern
until spring tension is released. Then remove the ciutch cov-
er and disc.
Pilot bearing
1. Remove the pilot bearing with the
SST if necessary.
Flywheel
Note
l After removing the flywheel, inspect for oil leakage
past the crankshaft rear oil seal.
If necessary, replace the oil seal.
1. Hold the flywheel with the SST.
2. Remove the flywheel.
Instalfation Note
Flywheel
1 -Wipe the bolts clean and apply sealant to the bolt threads.
2. Install the flywheel and SST.
3. Tighten the bolts evenly and gradually in the pattern shown.
Tightening torque:
96403 Nmm (9.8-10.5 m-kg, 71-76 ft.lb)
PiIot bearing
Note
l Install the pilot bearing ftush with the flywheeL
I_ Install the new bearing with the SST.
03UOHX-030
H-20

CLUTCW UNIT
Clutch disc
1. Clean the clutch disc splines and main drive gear spIines;
then apply organic molybdenum grease.
2. Hold
the clutch disc in position with the SST.
Clutch cover
1. Install the SST.
2. Align the
dowel holes with the flywheel dowels.
3. Tighten the
botts evenly and gradually in the pattern shown.
Tightening torque:
18-26 N-m (1.8-2.7 m-kg, 13-20 ft-lb)
EWOHX-040
Ii-21