MAZDA 232 1990 Suplement Manual Online

INSTALLATION
I
1 93EOB2-061
03 UOBX-848
93EOBZ07E
93GOB2-760
93GOB2-737
E32-28
4. Install the joint shaft.
5. Tighten the bolts in the order shown.
Tightening torque: 42-62
N=m (4.3-6.3 m-kg, 31-46 ft-lb)
Tie-rod end
1. Install the tie-rod end to the
knuckle.
Tightening torque: 42-57
Nmm (4.3-5.8 m-kg, 31-42 ft-lb)
Z.-Install a new cotter pin.
StabiIiter
I. Install and adjust the stabilizer.
Dimension A: 17.19mm (0.67-0.75 in)
Tightening torque:
f 6-23 Nm (I .6-2.3 m-kg, 12-17 ft-lb)
Exhaust pipe
I. InstaIl the exhaust pipe along with
a new gasket,
tighten locknuts @:
Loose1 y tighten brat ket
Tighten locknuts @
nuts @
and loosely
2.
3.
Tightening torque:
31-46 Mm (3.2-4.7 m-kg, 23-34 ft.lb) 4.
Tighten bracket nuts @,
Tightening torque: 21-27
Nm (2.1-2.8 m-kg, 15-20 ft-lb)
Select and
shift cables
1. Install the select cable and the spring pin.
2. Install the shift cable and the spring pin,

INSTALLATION 82
RIGHT-HAND DRIV
Step 4
1. Connect the hoses shown in the figure. Speedometer cable
I_ Connect the speedometer cable.
Caution
l Position the hose clamp in the original location on the hose, and squeeze it lightly with large
pliers to ensure a good fit. .
93G082-76 ‘I
B2-29

B2 INSTALLATION
Step 5
1. Connect the harness connectors shown in the figure.
ALTERNATOR OIL PF;IESSURE SWITCH PRESSURE REGULATOR
STARTER CONTROL VAVLE
GRoYD O-i-l-tE SENSOR
IDLE-SPEED CONTROL
KNOCK SENSOR
OXYGEhENSO$
Step 6
Torque Specifications
03UO8X-33’
7.8-11 N-m
(80-110 cm-kg, 69- .
11 N-m (80--f ’IO cm-kg, 69-95 in-lb)
N-m
cm-kg, 69-95 in-Ib)
37-52 (3.8-5.3, 27
7.8--fl N-m (80 107 (9.6-T 1.9, 69-79)
N-m (m-kg, ft-lb)
03U03X-83

lNSTAL&ATlON B2
03UOSX-839
93G032-76:
9313082-738
/
\ I
Crossmember
1. Install the crossmember.
Tightening torque:
93-107 Nm (9.5-l I .9 m-kg, 69-79 f&lb)
A/c compressor
1. Install the A/C compressor.
Tightening torque:
24-35 Nom (2.4-3.6 m-kg, 17-26 ft-lb)
P/S oil pump and bracket
I. Install the P/S oil pump and bracket.
Tightening torque:
37-52 Nm (3.8-5.3 m-kg, 27-38 ft-lb)
Drive belt
I. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page 82-2)
Air pipe
1. Install a new gasket and install the air pipe.
Tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 Mb)
Intercooler and air pipe assembty
t . Lift the intercooler and air pipe assembly from the bottom
of the vehicle, and install hose @ in pipe @ .
2. Install and tighten the mounting bolt and nut.
Tightening torque:
7.8-l 1 Nom (80-l 10 cm-kg, 69-95 in-lb)
3. Tighten hose clamp 0.
B2-31

B2 INSTALLATION
93GOB2-74 1
93GOB2-743
82-32
4. Connect the air pipe to the throttle body, and tighten the
hose clamp.
5. Connect air hose @ to the wastegate diaphragm,
and se-
curely tighten the hose clamp.
6. Install nut @
Tightening torque:
19-25 Narn (1.9-2.6 m-kg, 14-19 ft-lb)
7. Install the intercooter bracket and tighten nuts @J .
Tightening torque:
7.8-l 1 Narn (80-I IO cm-kg, 69-95 in-lb)
Air pipe and air bypass valve assembly
1. Connect the air pipe to the turbocharger, and securely tight-
en the hose clamp.
2. Install and tighten the bolt @ .
Tightening torque:
7.8-l 1 Nom (80-I 10 cm-kg, 69-95 in-ib)
3. Connect air hose @and Q1 and securely tighten the hose
clamps.
Battery duct
1. install the battery duct.
Radiator and tooting fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.8-l 1 Nm (80-l 10 cm-kg, 69-95 Mb)
2. Connect the tooting fan connector.
3. Connect the radiator switch connector.
4. Connect the oil cooler hose.
5. Connect the coolant reservoir hose.
6. Connect the upper and lower radiator hoses.

INSTALLATION
93G082-7ti
HERE
/+Ju 7
93GOB2-74!
Caution
l Position the hose clamp in the original location on
the hose, and squeeze it lightly with large pliers to
ensure a good fit.
Accelerator cable
1. Install the accelerator
cable.
Tightening torque
@): 7.8-l 1 N4m (80-l 10 cm-kg, 69-95 in-lb)
2. Adjust the cable deflection by turning nuts @ .
Deflection: I-3mm (U&4--0.12 in)
Battery carrier and battery
1 . Install the battery carrier.
Tightening torque:
7.8-l 1 N4m (80-I IO cm-kg, 69-95 in-lb)
2. Install the battery and the battery cover.
3. Install the battery bracket.
Tightening torque:
2.9-5.9 N.m (30-60 cm-kg, 26-52 in-lb)
4. Connect the positive battery cable.
Air cleaner assembly
1. Install the air cleaner assembly.
Tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
2. Connect the airflow sensor connector.
3. Connect the hoses shown in the figure.
Strut tower bar
I. Instail the strut tower bar.
Tightening torque:
88-108 Narn (9.0-11 .U m-kg, 65-80 ft-lb)
Undercover and side cover
1. Install the undercovers and side covers.
93GOB2-746
82-33

82 INSTALLATION
Steps after installation
1. If the engine oil was drained, refill with the specified amount and type of engine oil.
2. Fill the radiator with the specified amount and type of engine coolant.
3. Fill the transaxie with the specified amount and type of transaxle oil. (Refer to page J3-36.)
4. Connect the negative battery cable.
5. Start the engine and check the following:
(I) Engine oiI, transaxle oil, and engine coolant for leakage
(2) Ignition timing and idle speed
(3) Operation of emission control system
6. Perform a road test.
7. Recheck the engine oil and engine coolant levels.
93G032-747
-
BZ-34

D
LUBRICATION SYSTEM
OUTLiNE .................................................. D- 2
OUTUNE OF CONSTRUCTION ................. D- 2
LUBRICATION CIRCUIT ........................... D- 2
93GODX-703

D OUTLINE
OUTLINE
BUTLINE OF CONSTRUCTION
The
lubrication system of the 323 4WD engine is the same as for the 2WD model.
The Bf DOHC turbocharged engine oil circulation path is different than that of the BP DOtiC non-turbocharged
engine
because of the turbocharger lubrication.
LlJBRICATtON ClRCUlT 93GODX-702
o-2 93GODX.70:

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