alternator MAZDA 232 1990 Workshop Manual Suplement

SCHEDULED MAINTENANCE SERVICES (Australia) A
SCHEDULED MAINTENANCE SERVICES (Australia)
Chart symbols:
I : Inspect: Visual examination or functiona! measurement of a system’s operation (Performance)
A: Adjust
R: Replace or change
T : Tighten
Note
l As the result of visual examination or functional measurement of a system’s operation (Per-
formance), correct, clean or replace as required.
REMARKS:
After 90,000 km or 72 months, continue to follow
the described maintenance items and intervals periodically.
As
“I
*2
*3
“4
l 5 for *
marked items in this maintenance chart please pay attention to the following points.
If the vehicfe is operated under the foltowing conditions, it is suggested that
the engine oil and oil f&r
be changed more often that at usual recommended intervals.
a> Driving in dusty condrt,ons.
b) Extended periods of idling
or low speed operation.
c) Driving for a prolonged period iti coid temperatures or driving only short distances regularly.
Replacement of the timing belt is required at every 105,000 km. failure to replace the timing belt may
result in damage to the engine.
If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, repface more often
than at usual recommended intervals.
Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt
if equipped.
Replace every two years.
If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the
vehicle is operated in extremely humid climates, the brake fluid shotlid be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the emission control and related
system, as well as for efficient engine operation. It is strongly recommended that all servicing related to these
systems be done by your Authorised Mazda Dealer.
93GOAX-702
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A-3 i

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SCHEDULED MAfNTENANCE SERVICES (Europe) A
MAINTENANCE TABLE (Leaded Fuel Model)
Chart symbols:
1 : Inspect: Visual examination and/or functional measurement of system’s operation or performance
A: Adjust: Examination resulting in adjustment or replacement
R: Replace or change
T: Tighten
REMARKS
After 80.000 km or 48 months, continue to foltow the described maintenance at the recommended intervals.
As
*I
*2
“3
*4
*5
*6
*7 for *’
marked items in this’ maintenance chart, note the following points.
Major service interval at 12 months!ZO,OOO km (I 2,000 miles).
Lubrication service based on distance only, 10,000 km (6,000 miles), not time.
Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt
ii equipped.
Replacement of the timing belt is required every ICQOUO km (60,000 miles). Failure to replace the timing
belt may result in damage to the engine.
If the vehicle is operated under any of the following conditions, it is suggested that the engine
oil and
oil filter be changed more often than the recommended intervals.
a) Driving in dusty conditions.
b) Extended periods of idling or low speed operation.
c) Driving for prolonged periods in cold temperatures or regularly driving only short distances.
If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often
than the recommended intervals.
This is a full function check of all electrical systems, i.e, afl lights, washers (inctuding condition of blades)
electric windows sunroof, horn, etc.
Replace every two years.
tf there has been continuous hard driving, mountain driving, or it the brakes are used extensively or the
vehicle is operated in extremely humid climates, the brake fluid should be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the emission control and related
system, as well as for efficient engine operation. It is strongly recommended that all servicing related to these
systems be done by your Authorised Mazda Dealer.
93GOAX-704
A-5

A SCHEDULED MAINTENANCE sERvw3 (Europe)
SCHEDULED MAfNTENANCE SERWCES (Europe)
MAWTENAN CE TABLE (Unlead Fuel Model)
Chati symbols:
I : Inspect: Visual examination and/or functional measurement of system’s operation or performance
A: Adjust: Examination resulting in adjustment or replacement
R: Replace or change
T: Tighten
REMARKS
After 80,000 km or 48 months, continue to follow the described maintenance at the recommended intervals.
As for * marked items in this maintenance chart, note the following points.
* 1 Major service interval at 12 months120,OOO km (12,000 miles).
Lubrication service based on distance only 10,000 km (6,000 miles) not time.
*2 Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt
if equipped.
“3 Replacement of the timing belt is required at every 100,000 km (60,000 mile). failure to replace the tim-
ing belt may result in damage to the engine.
“4 If the vehicle is operated under any of the following conditions, it is suggested that the engine oil and
oil filter be changed more often than the &commended intervals.
a) Driving in dusty conditions.
b) Extended periods of idling or low speed operation.
c> Driving for a prolonged periods in cold temperatures or regularly driving only short distances.
*5 If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more oten
than at usual recommended intervals.
*6 This is a full function check of all electrical systems, i.e, all lights, washers (including condition of blades)
electric windows, sunroof, horn etc.
“7 Replace every two years.
If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the
vehicle is operated in extremely humid climates, the brake fluid should be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the emission control and related
system, as well as for efficient engine operation. It is strongly recommended that all servicing related to these
systems be done by your Authorised Mazda Dealer.
93GOAX-707
A-8

Bl INDEX
INDEX
INTAKE MANIFOLD
TIGHTENING TORQUE
19-25 (1.9-2.6, U-19)
EXHAUST MANIFOLD
TtGHTIEN!NG TORQUE
,3, 12-w-j
DEFLECTION AT 98 N (30 kg, 22 lb)
mm (in)
DRIVE BELT NEW USED
AlTERNATOR
8.0-9.0 (0.31-0.35) 9.0-l 0.0 (0.35-0.39)
PIS, P/S + AIC 1 8.0-9-O (0.31-O-35) 9.0-I 0.0 (0.35-0.39)
ENGINE COMPRESSION
STANDARD
MlNlMUM kPa (kglcm2, psi)-rpm
BP sol-lc
1,197 (12.2, 173)-300
834 (8.5, 121)-300
N-m (m-kg, ?t-It
cIz!f-mRl-71
1. Engine
Removal . . . . . . ..*..*-..............-....... page BY-- 6
Installation . . . . . . ..__. . . . . . . . .._...... . . . .
page B1-14
Bl-2

B2 INDEX
INDEX
~IMIY~ULU
TIGHTENING TORQUE
19-25 (1.9-2.6, 14-19)
/5--l ENGINE COMPRESSION
STANDARD
MINIMUM kPa (kglcm2, psi)-rpm
BP Turbo
I
1,059 (10.8, 1543-300
1 i-85 (8.0, 114)-300
EXHAUST MANlFOt
TIGHTENING TORQUE
DEFLECTION AT 98 N (IO kg, 22 Ib)
mm (in)
DRIVE BELT 1 NEW USED
ALTERNATOR 1 8.0-9.0 (0.31-U.35) 9.0-I 0.0 (0.35-U.39)
P/S, P/S + AIC ( 8.U-9.0 [O-31--0.35) 9.0-10.0 (0.35-0.39) 3826 3.9-A.?, -28134)
1. Engine
Removal -*-...-..I-*.* . ..wm._..... * e-e... -. page B2--I 2
Engine stand mounting ._.....__... page B2-20
Engine stand dismounting . . . . . . . page B2-21
Installation _ . . . . . . . . . . . . , . . _. . . . . . _. . . . . . . . , page EQ-23
BZ-2

B2 REMOVAL
Step 2
1. Disconnect the harness connectors shown in the fiuure.
ALTERNATOR OIL PRESSURE SWITCH
\. PRESSURE REGULATOR
STARTER
CObjTROL VAVLE
E-SPEED CONTROL
CTOR
KNOCK SENSOR
SWITCH
03 w 08X-80’
Step 3
I. Disconnect the hoses shown in the figure.
-
------a-
93GOB2-720
82-14

REMOVAL B2
Step 5
1. Engine mount member 5, No.3 engine mount
rubber
Removal Note . . . . . . .._.._...._....-.__._.._-_..-.* below 6. No.4 engine mount rubber and bracket
2. No.2 engine mount rubber and bracket 7. Alternator and drive belt
3. Clutch release cylinder 8. I ntercooler brat kets
Removal Note _._...._.._.._.....,,....__ page B2-18 9. Engine and transaxle assembly
4. Dynamic damper Removal Note . .._.................--.-..
page 62-f 8
Removal note
Engine mount member
1. Suspend the engine with a chain hoist.

INSTAlLATION B2
93X82-72!
93G0BZ757
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J 93GO32-730
Alternator and drive belt
1. Monut the alternator to the engine.
Tightening torque
@: 19-25 N-m (1.9-2.6
m-kg, 14-19 ft-lb)
@J: 37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
2. Install the drive belt. (Refer to page 82-Z)
Engine mount, clutch release cylinder
and engine mount
member
1. Install the No.3 engine mount rubber, and loosely tighten
the bott and nuts.
2. Install the No.4 engine mount rubber and bracket assem-
bly, and loosely tighten the bolts and nuts.
3. lnstalt the clutch release cylinder and pipe bracket assembly.
Tightening torque
@: 16-23 Nm [I .6-2.3 m-kg, 12-17 ft-lb)
0: 6.9-9.8 N-m (70-100 cm-kg, 61-87 in-lb)
4. Install the No.2 engine mount rubber and bracket assembly.
Tightening torque:
37-52 Nrn (3.8-5.3 m-kg, 27-38 R-lb)
B2-25

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

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