oil MAZDA 232 1990 Suplement Service Manual

TROUBLESl-lOOTING GUIDE F2
;TEP 1 INSPECT1ON
ACTION
13 Check if resistance of ignition coil 1s OK*
Yes Go to next step
Resistance (at 20°C iSS*FJ):
Primary coil winding . . . . . . . .
0.81~-0.99Q
Secondary coil winding,,.. 1 O--16 kR
PRIMARY COIL
WINDING SECONDARY COIL
WlNDlNG
NO Replace
14 Check for correct engine compression”
Yes Gc to next step
1 Engine compression (Minimum):
785 kPa (8.0 kg/cm , It4 psi)-300 ipm
NO Check engine condition” l Worn piston, piston rings or cylinder
wall
l Defective cylinder head gasket l Distorted cylinder head l Improper valve seating
*Valve sthing in guide
15 Change fuel and check if acceleration improves
Yes Change fuel to another brand
NO
Go to next step
16 Check if NC cut-off control system is OK’
Yes Go to next step
No Repair or replace
17
I Try known good ECU and check if condition
improves
* Refer to 323 Workshop Manual [1203-IO-89F (Europe) or i204-IO-89F (Australia)].
93GOF2-747
F2-39

F2 TROUBLESHOOT1NG GUIDE
25 HIGH OIL CONSUMPTION [BP TURBO]
DESCRIP- 1
l Oil consumption excessive
TION l Exhaust gas white
TROUBLESHOOTING HINTS1
a PCV system malfunctton *
@ Englne malfunction (Oil
working up, working down, or leakage)
3 Oil leakage from turbocharger
ZEP [ INSPECTION Repair or
replace 1 Check if PCV hose, ventilation hose or their at-
taching nipples are separated, damaged,
ciogged, or restricted 2
Check insrde of air hose, air pipe, and intercool-
er for excesstve oil
3 1 Check white exhaust gas visible when ventilation
1 hose or PCV hose removed
1
4 Remove turbocharger and check at oil seals of
compressor and turbine shafi for oil leakage Yes
NO Yes
NO Yes
No Check hoses for clogged
Yes Replace turbocharger
NO
ACTION
Go to next step
Possibly oil working up
Check PCV valve and PCV hose for
clogged
+ If OK, go to next step
e If not UK, repalr or replace
Go to next step
Go to next step
Engine malfunction (Oil working up,
working down, or leakage)
Check foltowing
. Worn piston or cyiinder
l Worn piston ring groove’ l Stuck piston rings* l Worn vatve seal* l Worn valve stem * l Worn vatve guide’
* Refer to 323 Workshop Manual [1203-IO-89F (Europe) or 1204-IO-89F (Australra)].
93GOF2-74:
FZ-42

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)

TURSUCHARGER CONTROL SYSTEM F2
Removal I InstaIlation
Caution
l Be carefui of following points after turbocharger removal.
l Do not carry the turbocharger by the actuator rod or actuator hose.
l Do not drop the turbocharger.
l Set the turbocharger down with the turbine shaft horizontal.
9 Cover the intake, exhaust, and oil passages to prevent dirt or other materia1 from entering.
l Use the specified new studs when installing the turbocharger.
1. Disconnect the negative battery cable.
2. Lift up the vehicle.
3.
Remove the undercover.
4. Drain
the engine coolant.
5. Remove in
the order shown in the figure.
6. fnstall in the reverse order of removat, referring to Installation Note.
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
G I’
/
43-61 (4.4-6.2, 3245)
36-42 (3.94.3, 28-
7.8-1 1 N-m (80-110 cm-kg, 6
cm-kg, 69-95
indb)
26-31
12.7~g-2. 20-231
w
19-26 (l-9-2.6, 14-19)
7.6-17 N-m (80-7 t d cm-kg, 69-95 in-lb)
N-m (m-kg, Mb]
I 93GOF2-762
F2-47

F2 TURBOCHARGERCONTROLSYSTEM
1. Radiator
2. Insulators
3.
Air hose, and air pipe
4. Oxygen
sensur connector
5. Front exhaust pipe
6. Bracket
1 I 93GOF2-765
93GOF2-761
7. Water hoses
8. Oil pipe
9. Oil return pipe
10. Exhaust
manifold and turbocharger
Removal Note . . . . . . . . . . . . . . . . . . . . . . .._.-........_ below
Installation Note . . . . ..__-.............._...___.._. below
93GOF2-763
Removal Note
Exhaust manifold and turbocharger
1. Remove the exhaust manifold and the turbocharger as an
assembly .
2. Remove the turbocharger from the exhaust
manifold.
InstaIlation Note
Exhaust manifold and turbocharger
1. Remove all gaskets and sealant.
2. Install new gaskets.
3. Supply 25 cc (1.5 cu in) of oil through the oil passage of
the turbocharger.
4. Install the turbocharger to the exhaust manifold.
5. Install the turbocharger and the exhaust manifold assem-
bly to the engine and loosely tighten the nuts.
6. install the bracket and the front exhaust pipe, and tighten
the turbocharger mounting nuts.
AIR BYPASS VALVE
Removal I Installation
1. Remove the vacuum hose and the air hoses from the air
bypass valve.
2. Remove the air bypass valve.
3. Install in the reverse order of removal.
Inspection
1. C_onnect a vacuum pump to air bypass valve port @-
2. Verify that air flows from port @through port @ when 250
f 35 mmHg (9.8 * 1.4 inHg) vacuum
is applied to port
0 a .

OUTLINE G
L
i i-
OUTLINE
OUTLINE OF CONSTRUCTION
The engine electrical system of the new 323 4WD is as same as that of the new 323 ZWD.
93GOGX-703
SPECIFICATIONS
Item
Battery t
Voltaae EnginelTransaxle
v
Type and capacity
120-hour rate) BP TURBO
MTX BP SOHC
MTX ATX 12
55D23L (60AH)
I
Dark current” mA 1 Max. 20.0
Alternator
Output V-A 12-65
Regulator type Transistorized (built-in iC regulator)
1 I Regulated voltage v
74.1---14.7
Brush length Standard 21.5 (0.846)
mm (in)
Minrmum 8.0 (0.315)
Drive belt deflection
New
98 N (10 kg, 22 lb) 8-9 (0.31-0.35)
mm (in) Used 9-l 0 (0.35-0.39)
Type Direct ] Coaxicat reductron Starter Output V-W
12-U-85 12-0.95 32-l .4
8rush length Standard 17 (0.67) 17.5 (0.69)
mm [in) Minimum 11.5 (0.4531 10.0 (0.39) Distributor
Ignition timing
BTDC
FEN termrnal of diagnosis connector grounded) Electronic spark advance (photo
diode)
10 * I0 5 f lo
Ignition coil Resistance
(at 20°C [68OFj)
I
Primary
coil windinq
I
Spark plug Type I
Secondary 1
f coil windina 1
NGK
Nippon
Denso 10-76 kS-l
8KR5Ell +2 BKR5E”3
BKRGEI 1 l * BKRGE *3
KIGPR-Ull *2 KfGPR-I-Y3
K20PR-Ul l ** K20PR-U
l 3 0.81 ---o-999
pw am
Firrng order
I mm (in) 1.0-I .l (0.039-0.043)“2 0.7-0.8 (0.028-0.03i)*3
l-3-4-2
93GOGX-704
*I Dark current is the constant flow of current while the ignition switch is OFF. (i.e., engine control unit, EC-AT control unit, audro, etc.)
+’ With catalytic converter.
*3 Without catalytic converter.
G-3

SUPPLEMENTAL SERVICE INFORMATION, TROU8LESHOOTlNG GUIDE H
SUPPLEMENTALSERVICE INFORMATION
The following points in this section are changed in comparison with 323 Workshop Manual (1206IO-89F).
Troubleshooting guide
Clutch fluid (with ABS)
l Replacement
Clutch pedal (BP DOHC Turbo) Clutch release cylinder (with ABS) l Air bleeding
Clutch unit
l Removal I Inspection I installation
Clutch master cylinder
(BP DOW Turbo or with ABS) l Removal I Inspection I installation
93GOHX-710
l Removal I Inspection I Installation (BP DUHC Turbo)
l Air bleeding (with ABS)
l Overhaul (BP DUHC Turbo)
TROUBLESHOOTING GUlDE
Problem
Possibte Cause Remedy Page
Slipping
Clutch disc facing worn excessively
Replace U-l 9
Clutch disc facing surface hardened or oifed
Repair or replace H-l 9
Pressure plate damaged Replace H-19
Diaphragm spring damaged or weakened
Replace H-l 9
Insufficient clutch pedal piay
Adjust H-12
Clutch pedal sticking
Repair or replace U-11
Flywheel damaged
Repair or replace H-19
Faulty
Excessive runout or damaged clutch disc
Replace H-19
disengagement
Clutch disc spiines rusted or worn ’
Remove rust or replace H-l 9
Clutch disc facing oiled
Repair or replace H-19
Diaphragm spring weakened
Reptace H-19
Excessive clutch pedal ptay
Adjust -
Insufficient clutch fluid
Add fluid H-10
Leakage of clutch fluid
Locate and repair or -
replace
Clutch vibrates
Clutch disc facing oiled
Repair or replace H-l 9
when accelerating
Torsion rubbers weakened
u-19 Clutch disc facing hardened or damaged Replace
Repair or replace H-19
Clutch disc facing rivets loose
Replace H-l 9
Pressure plate damaged or excessive runout
Replace H-l 9
Flywheel surface hardened or damaged
Repair or replace H-19
Loose or worn engine mount
Tighten or replace -
Clutch pedal
sticking Pedal shaft not properly lubricated
Lubricate or replace H-l 1
Asistireturn spring damaged or poor adjust
Replace or adjust H-11, 12
Abnormal noise
Clutch release bearing damaged
Replace N-1 9
Poor iubrication of release bearing sleeve
Torsion rubbers weakened Lubricate or replace H-19
Replace u-t9 Excessive crankshaft
end play
Repalr -
Pilot bearing worn or damaged
Replace H-79
Worn pivot points of reiease fork
Repair or replace H-19

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

J3
MANUAL TRANSAXLE AND
TRANSFER UNIT (GSMX-R)
INDEX .........................................
J3- 2
/FEATURES] I
OUTLINE .....................................
J3- 4
OUTLINE OF CONSTRUCTION ..... J3- 4
SPECIFlCATtUNS ....................... J3- 5
TRANSAXLE AND TRANSFER UNIT J3- 5
STRUCTURAL VIEW.. ................. J3- 6
TRANSAXLE ................................ J3- 8
DOUBLE CONE SYNCHRU
MECHANlSM ........................... J3- 8
SHIFT FORKS AND SHIFT RODS . . J3- 10
iNTERLUCK MECHANISM ......... ., J3- 11
TRANSFER UNtT
.......................... J3- 12
CENTER DIFFERENTIAL ............. J3- 14
VISCOUS COUPLING
(BP DOHC TURBO). .................. J3- 20
CENTER DlFFERENTIAL LUCK
SYSTEM (MANUAL) .................. J3- 23
CENTER DIFFERENTIAL LOCK
SYSTEM (ELECTRICAL) ............. J3- 24
CENTER DIFFERENTIAL LOCK
CONTROL SWITCH ................... J3- 28
CENTER DIFFERENTIAL LUCK
ASSEMBLY
.............................. J3- 29
CENTER DIFFERENTIAL LOCK
SENSOR SWlTCH.. ................... J3- 31
IDLER GEAR SHAFI- ................... J3- 33
POWERFLOW .............................. J3- 34
TROUBLESHOOTING GUIDE ......... J3- 35 TRANSAXLE OIL .......................... J3- 36
INSPECTlON ............................. 33- 36
REPLACEMENT.. ....................... J3- 36
TRANSFER CARRIER CM .............
339 36
INSPECTION ............................. J3- 36
REPLACEMENT. ........................ J3- 36
TRANSAXLE AND
TRANSFER UNIT ........................ J3- 38
PREPARATION .......................... J3- 38
REMOVAL ................................. J3- 42
DISASSEMBLY
........................... J3- 48
INSPECTION ............................. J3- 72
ASSEMBLY ............................... J3- 75
INSTALLATION
.......................... J3-I I2
SHIFT MECHANISM.. .................... J3-119
OVERHAUL ............................... J3-119
CENTER DIFFERENTIAL
LOCK SYSTEM ........................... J3-121
SYSTEM DIAGRAM ..................... J3-121
INSPECTION ............................. J3-122
CENTER DIFFERENTIAL
LOCK MOTOR ............................ J3-123
INSPECTDN ............................. J3-123
REPLACEMENT ......................... J3-123
4x4 CONTROL UNIT.. ................... J3-126
INSPECTION ............................. 53-l 26
REPLACEMENT.. ....................... 53-l 26
CENTER DIFFERENTIAL
LOCK SWITCH ........................... J3-126
INSPECTION ............................. J3-126
REPLACEMENT ......................... J3-127
CENTER DIFFERENTIAL
LUCK SENSOR SWITCH ............. J3-127
INSPECTION ............................. J3-127
REPLACEMENT ......................... J3-127
93GOJ3-701

J3 INDEX
JNDEX
LHD
// /
vIscOsIn:
ALL SEASON DEXRON-II, \_\;/ M-III
ABOVE -18OC @OF): ?5W-90
CAPACITY: 2.6 liters
(2.7 us qt, 2.2 Imp qt) ABOVE -18OC (UOF): 90
BELOW --t8OC (UOF): 8UW
CAPACITY: 0.5 liter
IO.53 US qt, 0.44 Imp qt 1. Transaxle oil
Inspection.. ._._.. . . . . . . . . . . . . . . . . . . . . . . . . page J3- 36
Replacement -.._.......-............... page J3- 36
2. Transfer carrier oi!
Inspection
. . . ..-*..-.*a. . . . . * . . . . . . . . . . . . . page J3- 36
Replacement . . ..-...Ir.....*....~......
page J3- 36 3. Transaxle and transfer unit
Removal . . . . . . . ..-.-........-._._._....... page J3- 42
Disassembly, .._. . . .-. ._. .-. . . . . . . . . . . . . page J3- 48
Inspection.. . . . . . . ._. .-. .-. .-. . ._. . . . ._. . . page J3- 72
Assembly _.._..._.__._......._._..._...._ page J3- 75
Installation _.._.._.._._..._. . . . . . . . . .._.._ page J3-1 I 2
4. Shift mechanism
Overhaul ,._.._... . . . . . . . . . . . ._..._......_ page
J3-1 19 J3-2 Inspection . . . . . . . . . . . . . .._......._._...... 5. Center differential lock motor
page J3-I 23 Replacement .,-.....,..._..............
page J3-123 6.4x4 Control unit
Inspection ,.......... ~ ....._._._........I- page J3-I 26
Replacement ..*...** . . . . *.*...- . . . . . . . - page J3-126 7. Center differential lock switch
1 nspection ..,....*.....*.. *.*.* . . . . -.- . . . . page J3-126
Replacement ..~ ..,....._.........._,... page 33-l 26
8.
Center differential lock sensor switch
Inspection.. . . . . . . _ _ _ . . . _. . . _. _ _ _. __. . . . _ _ page J 3- 128
Replacement ..,.. . . . . . . . . . . . . . .._...... page J3-128