brake light MAZDA 232 1990 Workshop Manual Suplement

A PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
pieziG-
INSPECT and ADJUST, if necessary, the following Items to
specification:
D Glass, exterior bright metal and paint for damage
Cl Wheel tug nuts
9 Trre pressures
LII All weatherstrips for damage or detachment
Z Operation of bonnet release and lock
D Operation of trunk lid, hatch and fuel lid opener
(it equipped)
3 Door operation and alignment
5 Headlight aiming
INSTALL the following parts:
D Wheel caps or rings (if equipped)
D Outside mirror(s)
[ UNDER BONNET-ENGINE OFF )
INSPECT and ADJUST, if necessary, the foIlowIng items to
specification:
Cl Fuel, coolant and hydraulrc lines, fittings, connections and
components for leaks
Cl Engine oil level
0 Power steering fluid level (if equipped)
D Brake master cylinder fluid levels
0 Clutch master cylinder fluid levels (if equipped) q
Windshield washer reservoir fluid level
D Radiator coolant level and specific gravity
Ll Tightness of water hose clamps
I3 Tightness of battery terminals, electrolyte level and specific
gravity
c) Manual transaxle oit level
D Drive belt(s) tension
C; Carburetor linkage (choke control, wide open throttle posi-
tion, etc.) (carburetor model only)
D Accelerator cable and linkage for free movement
D Headlight cleaner and fluid level (if equipped)
BLEED air from fuel line (diesel engine only)
CLEAN the spark plugs (except for diesef engine)
piicis-1
INSTALL the foflowing parts:
C Rubber stopper for inside rear view mirror (if equipped)
c! Fuse for accessories
CHECK the operation of the following items:
Cl Seat controls (sliding and redining) and head rest
ci Seat belts and warnrng system
Z! Ignition swrtch and steering lock
III Power window {if equipped)
0 Door locks including child proof door locks
0 Inhibitor switch
(ATX only)
Z All lights including warning and indicator lights
0 Ignrtron key reminder buyer (if equipped) Cl Horn, wipers and washers (front and rear, if equipped)
D Antenna (if equipped} q
Cigarette lighter and clock (if equipped)
I2 Remote controt outside mirror
(if equipped) q
Heater, defogger and air conditioner at various mode selec-
tions (if equipped)
c3 Sunroof (if equipped)
CHECK
the fotiowing items: q
Presence of spare fuse
c3 Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
Cl Operation and fit of windows
D Pedal height and free ptay of brake and clutch pedal
Cl Parking brake
i UNDER BONNET-ENGtNE RUNNING AT ]
1 OPERATtNG TEMPERATURE
CHECK the following items:
Cl Operation of idle-up system for air conditioner or power steer-
ing (if equipped)
13 Automatic transaxle fluid level
D Initial ignition timing
(except disel engine) q
Idle speed
El Operation of throttle position sensor (EGI engine)
13 Operation of cold start device and glow plug warning light
(diesel engine only)
D Operation of dash pot [EGI engine)
t
ON HOtST 1
CHECK the following items:
U Underside fuel, coolant and hydraulic lines, fittings, connec-
tions and components for leaks q
Tires for cuts or bruises
Cl Steering linkage, suspension, exhaust system and all under-
side hardware for
looseness or damage
1 ROAD TEST 1
CHECK the foliowing items:
II Brake operation
D Clutch operation
0 Steering control
c3 Operation of meters and gauges
0 Squeaks, rattles or unusual noises q
Engine general performance
c3 Emergency Iocking retractors
rAFTER ROAD TEST 1
REMOVE the seat and floor mat protective covers
CHECK for the necessary
owner information materials, tools
and spare tire in vehicle
93EOAX-002
A-2

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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

SCHEDULED MAlNTENANCE SERVICES (Europe)
Maintenance Number of months or km (miles), whichever comes first
Months” - 6 1 12 18 24 1 30
36 1 42 48
Maintenance Wometers 1,000 10,000 20,000 30,000 40,000 50,000 60,000 1 70,000 80,000
interval
(Miles) (600) (6,000) (12,000) (18,000) (24,000) (30,000) (36,000)~(42,000) (48,000)
Engine Intake
and exhaust manifold nuts (Bolts) Drive belts * 2
Engine ttming belt *’
Engine oi; (Non-Turboj’4
Oil filter * 4
Cooling system (Including coolant
level adjustment)
Enaine coolant T
1 1 1
1 1 ’
A
[ A I A 1 A ] [ A
Replace every t 00,000 km (60,000 miles)
R
R R R R R R R 1 R
R R R R R R R R
I I 1 I
Reolace everv 2 Years
Fuel system
Idle speed
Idle mixture
Air cleaner element *’ Fuel
filter
Fuel lines and hoses
I A I * A 1 A 1 A
I
A A A A
I R I R
R
I R I
1 I
t I 1 [ I
Ignition system
Initial ignition timing
Spark plugs I t I I 1 I 1 I
A A ( A A
Evaporative emission control system
Electrical system
Ejattery electrolyte level and specific gravity A
A 1 A A 1 A
Electrical system
l 6
I I I
I t I 1 I I
Headlight algnment
A A f A 1 A
Chassis and body
Clutch pedal
Clutch fluid
Brake lines, hoses and connections
Brake pedal
Brake flutd *7
Parking brake
Power brake unit and hoses
DGC brakes
Pow& steering fluid
Power steering system and hoses
Steering and front suspension
MTX oil
Rear axle oil
Transfer carrier
ui!
Rear suspension bail joint
Bolts, nuts on chassis and body
8ody condltlon (Visual onty)
-
I I I I I I I I
1 I I I I I I I
I
1 I I
i
1 I I I I I I
I I I
R I 1 I R
A A A 1 A
1
1 i 1 I
I
I I
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I
I I I I I I I
I 1 I I
I 1 I 1 i
1 A
A R A A A R
iR,i A R A A A R
R ’
A . A R A A A R
f I
T
T T T
T
I Inspect annually
93GOAX-705
A-6

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

SCHEDULED MAtNTENANCE SERVICES (Europe) A
Maintenance Number of months or km (miles), whichever comes first
Months” - 6 1 12 18 ‘24 30136 42 48
Maintenance Kilometers 1,000 10,000 20,000 30,000 40,000 50,000 ( 60,000 70,000 80,000
(Miles) (600) (6,000) (12,OOO)~(l8,0~0) (24,000) (3O,UOO))(36,000) (42,000) j48,OOU)
Engine
!nrake and exhaust manifold nuts (80&j
Owe belts *’
Engrne timing belt l 3
Engine oil flurbo)‘4
Engine oil (Non-turbo)“4
Oil filter’4
Cooling system (I ncludrng
coolant level adjustment)
Engine coolant T 1 T T
A 1 1 A A 1 A A
Reptace every 100,000 km
{60,000 miles)
Replace every 5,000 km (3,000 miles) or 6 months
R R 1 R R R R ‘ R R R
R R R R R R R ’ R
I I I I
Replace every 2 years
Fuel system
Idle soeed
I A 1
Air cleaner elemenf*5 I f R E
R
Fuel fitter
R R
fuel 11~s and hoses 1
t 1 I I I I
Ignition system
lrritiai ignition timing
Spark plugs
Spark plugs (Only for Sweden) 1 I I I 1 I I 1 I I 1 I
A 1 A A 1 A
Adjust every 30,000 km {
18,000 mils)
Evaporative emission control system
Throttle sensor
Throttle sensor (Only for
Sweden)
Evaporative system Evaporatwe system Khlv
for Sweden) 1 1 Aj 1 A ( [ A ] 1 A
Adjust every 80,000 km (48,000 miles)
I 1 I [ I 1
I I [ 1 I
lnsoect everv 80.000 km (48.000 miles)
Electrical system
Battery electrolyte level and specific gravity
A 1 A A ’ 1 A ; A *
All Electrical system *’ I I 1 I I I I I I
Headlight alignment A A A I
c I A ,
Chassis and body
clutch Dedal
Clutch fluid
Brake lines, hoses and connectrons
Brake pedal
Brake fluid”’
Parking brake
Power brake unit and hoses
Disc brakes
Power steering fluid
Power steering system and hoses I
I I 1 1 1 I I
I I
I
I I I I 1 1 I
1
1 I I
I I I I t ! I I
I I I R I 1 I R
A A A A
I I I I
I 1 I 1
I 1 I I I I j I ,
I
I 1 I 1
I
93GOAX-708
A-9

F2 CONTROLSYSTEM
erminat Input ’ Output Connected to Test condition Correct voltage Remark
1N 0 I Throttle sensor Accelerator pedal released &low l.OV j Ignition switch
(Idle switch)
Accelerator pedal depressed Approx. 12V *N
IO I 0 j [ Stoplight switch Brake pedal released Betow 1 .OV -
1P j 0 1 i P/S pressure lgnitlon switch ON Approx. 12V
I
switch
f/S ON at idle Below 1 .UV
I
P/S OFF at idle Approx. 12V -
I
to 0 A/C switch A/C switch ON
NC switch OFF Beiow 2.W ignition switch
ON and blower
Approx* t2V motor ON
i
1R 0 Electric fan switch Fan operating (Engine coolant tempera- Betow l.OV
ture over 91 *C (t96*F) or diagnosis con-
-
nector terminal TFA grounded)
Fan not operating (Idle) Approx.. f 2V
IS 0 Blower control Blower controf switch OFF or 1st position Approx. 13 Ignition switch
switch
Blower control switch 2nd or higher po- Below 7 .OV ON
sition
IT
Cl Rear window
defroster switch Rear window defroster switch OFF
Rear window defroster switch ON Below 1 .OV Ignition switch
Approx. 12V ON
1u 3 Headlight switch Headlights ON Approx. 12V
-
Headlights OFF Below 1 .OV
-Iv Cl ’ Neutral/Clutch
Neutral position or clutch pedal Below I .OV
switches
depressed
Others Approx. 12V
l-7 I r
f
2V 2W 2U 25 20 20 2M 2K 21 2G IZE 2C 2A IU IS 10 10 IM 1K 11 1G rE tC IA
22 2X (2V 2T 2R 2P 2N 2L 2J 2H’ZF 20 2B fV 1T 1R IP IN 1L 7J III If ItI 1B l F2-62