check oil 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

!
i
i
I
i
t-
I
i
i
e
-1
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

INSTALLATION Bl
Air cleaner assembly
1. Install the air cleaner assembly.
Tightening torque
@: 19-25 Nm (I-9-2.6 m-kg, 14-19 Mb)
@: 7.8-11 Nm (80~-110 cm-kg, 69-95 in-lb)
2. Connect the airflow sensor connector.
Resonance chamber
1. lnstail the resonance chamber.
Tightening torque:
7.8-W Nm (SO-11 0 cm-kg, 69-95 in-lb)
Undercover and side cuver
1. install the undercovers and side covers.
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 transaxle with the specified amount and type of transaxle oil. (Refer to pages J3-36, K3-134.)
4. Connect the negative battery cable.
5. Start the engine and check the following:
(1) Engine oil, transaxle oil, and engine coolant 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.
93GOSi-719
al-23

D
D
SUPPLEMENTAL SERVICE iNFORMATION, COMPRESSION 82
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Workshop Manual [Europe (7 203~IO-899,
Australia (I 204-1 U-89F) 1.
Compression
l Inspection
Engine
l Removal
l Engine stand mounting
l Engine stand dismounting
l Ins:attaIion 93GQ32-77 I
COMPRESStON
If the engine exhibits low power, poor fuel economy, or poor idle, check the following:
1. Ignition system (Refer to Section G.)
2. Compression
3. Fuel system (Refer to Section F3.)
93G032-774 93GO32-712
1NSPECTION
1. Verify that the battery is fully charged. Recharge it if
necessary.
2. Warm up the engine to normal operating temperature.
3. Turn the engine OFF.
4. Remove all of the spark plugs.
5. Disconnect the ignition coil connector.
6. Connect a compression gauge to the No.7 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder in the same manner.
Compression:
1,059 kPa (IO.8 kg/cm2, 154 psi)-300 rpm
Minimum:
785 kPa (8-O kg/cm2, 114 psi)-300 t-pm
Allowable difference between cylinders:
196 kPa (2.0 kglcm2, 28 psi) max.
IO. If the compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder waII may be worn.
(2) If the compression stays tow, the valve may be stuck
or seating improperly.
(3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be defective or the cylinder
head distorted.
1 I. Connect the ignition coit connector.
12. Apply antiseize compound or molybdenum-based lubricant
to the spark plug threads.
73. Install the spark plugs.
Tightening torque:
15-23 N-m (1.5-2.3 m-kg, If-17 ft-Ib)
82-11

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

E RADIATOR THERMUSWlTCki
RADIATOR THERMOSWITCH (BP DUHC TURBO)
REMOVAL I INSPECTION I INSTALLATION
I. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
3. Install in the reverse order of removal, referring to InstaHation Note.
7.8-13 H-m
(80-l 10 cm-kg, 69-95 h-lb)
(80-110 cm-kg,
69-95In4b)
REPLACE 1. Resonance chamber
2. Radiator cowling mounting bolts
3. Radiator thermoswitch connector
03WEX-027 4. Radiator thermoswitch
Inspection . . . . . . . . * . . . . . . . . . . . . . ..-. -.*,.a..- . . . . . . .I. below
Installation Note _.,............................._. below
1NSPECTlON 1. Place the switch and a thermometer in engine oil.
Warning
l Do not heat the engine oil above 12O*C (248OF) 2. Heat the engine oil gradually and check continuity of the
switch with
an ohmmeter.
Engine oil temperature “C (*F) Continuity
More than 105 (221) Yes I
t Less than 96 (205) No
1
3. If not as specified, replace the radiator thermoswitch.
Installation Note
Radiator thermoswitch
Caution
l Do not use an impact wrench for installation. 1. Install the radiator thermoswitch along with a new gasket.
Tightening torque: 5.9-12
Nom (60-120 cm-kg, 52-104 in-lb) 93GOEX.721 E-12

TROUBLESHUOT1NG GUIDE F2
;TEP
14
15
16 Change fuel and check if condjtjon improves INSPECTION
Check if resistance of rgnrtm
coil IS OK’
Resistance (at 20°C [SS*Fj):
Primary coil winding _....-.. Cl.81 -0.99Q
Secondary coil winding.,.. IO-16 kQ ACTION
Yes Go to next step
PRIMARY COIL
WINDING SECONDARY COIL
WIND tNG
Check fur correct engine compressron”
Yes Go to next step
Engine compression:
785 kPa (8.0 kg/cm2, 1 I4 psi)-300’ rpm L 1
No Check engine condition *
l Worn p&ton, piston rings or cylinder
wall
l Defective cylinder head gasket l Distorted cylinder head l Improper valve seating
l Valve sticking in guide
Yes Change fuel to another brand
No
I I Try known good ECU and check if con-
dition imDroves
* Refer to 323 Workshop Manual [ 1203-lo-89F (Europe) or 1204-l O-89F (Australia)l.
93GOF2-74 6
F2-35

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