engine coolant 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

A SCHEDULED MAINTENANCE SERVICES (Australia)
lumber of months or km, whichever cumes first
P
_ 48 54 60 1 66 72
5
60 67.5 75 90 .--- .-- -
.-m-w --v-w _ _ -_-- - - _ _ - -
_ -- - - --- __-
_-
-- -- (82.5
Exhaust manifold bolts and nuts (except turbo) T 1
I i T 1
1 T
Engine timlrtg belt”’ Replace every 105,000 km
Drwe belts * a
A I 1 I 1 1 I 1
! ’ I I 1 1
Engine oil * ’ Except turbo models 1 RIR\R/RIRIRIR R R,R R R/R
For turbo models R
Replace every 5,000 km or 6 months
r-k:1 c:t+*-* 1 Except turbo models
R 1 R 1 1 R ( ) R ( 1 R ( 1
R 1 f R
-
1 VII IIIIc;I 1 For turbo models I R 1 ReDlace everv IO.000 km or E
Engine coolant (Wrth Reservoir)
Fuel
system
Replace e&y 24 months
For F-i. system
Idle speed (if equipped Idle 1 1 1 I
I speed controf)
Air cleaner element 1
R , I R I R
Fuet filter
I I? R R
~ Fuel lines and hoses
1 I 1 I I 1 I I 1 1
Ignition system
t Initial ignition timing
Spark plugs i I I I -1 I I
I I I I I
f
Evaporative emission control system
Evaporative system
Throttle sensor
Exhaust emission contra! system
[ Dashpot
(Except for ATX) I 1 I
1 1 I 1 1 t 1 1 1 1 1 ! 1 1 I 1
Electrical system
Battery electrolyte level and specific gravity ]
I 1 1 I 1 t I ’ 1 1 I 1 f I ( 1
I 1
Chassis and body
Brake lines, hoses and connections
Brake fluid * a
Parking brake
Disc brakes
1 Power steering fluid and line Ilf &uiDDedl
I 1 1 I I I
I 1 1 III II
I ’
I I
Steering operations and gear housing
I
1 1 I --r--j- 1 I
I
Steerino linkanes. rack auide and tie rod pnds .-- --
----.“.a ..‘-~--, J- -.-- _.- .-- -..-- I I I t I 1 1 I I I I I I I 1
Manual transaxle oil I \\!‘I rl\jl I 1 I R III
1 Transfer Automatic carrier oil or 09 automatic transaxle fluid level
1 1 I 1 111 I 1 I l 1 I 1 I 1[11i t I 1 I 1 I I 1 I
R 1 Iii 1 I
1 Rear axle oil (Differential) 1 t I I I I I I I I
t ’ I r . ’ 1 . I I I I I R I 1
I
I I
i T
1 T T T 1 T [ T I 1 T
Front suspension ball joints
Bolts and nuts on chassis and body
I I I . I ! ,
I 1 I . I 1 ’ I I ’
Drive shaft dust boots
I
I 1 I 1
I 1 1 I
~~
- - ’ C1utcl-1 pedat
Clutch fluid
1
A-4

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
I
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

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

Bl SUPPLEMENTAL SERVICE tNFORMAT1ON, REMOVAL
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Workshop Manual [Europe (I 203-I U-89F),
Australia (1204- 1 O-89!=)].
Engine
l Removal
l Installation 93GOF31-705
REMOVAL
Warning
w Release the fuel pressure.
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil.
3. Remove in the order shown in the figure, referring to Removal Note.
Step 1
t
I
*ATX ONLY 1
93GOBl-706
1. Undercovers
2. Side covers
3. Resonance chamber and air cleaner assembly
4. Battery bracket, cover and bafiery
5. Battery carrier and battery duct
6. Accelerator cable
7. Radiator hose
8. Coolant reservoir hose
9. Cooling fan connector
IO. Radiator switch connector (ATX)
1 f . A/C cut switch connector (ATX) 12. Oil cooler hoses (ATX)
13. Radiator bracket
14. Radiator and cooling fan assembly
15. P/S and/or A/C drive belt
16. P/S oil pump and bracket
Removal Note .._...._...__......... . . . . . . . page BY -7
17. A/C compressor
Removal Note.. . . . . . . . . . . . . . .._. . . . . . . . ._. page Es1 -7
i 8. Crossmem ber
19. A/C compressor bracket
20. Coolant reservoir
61-6

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

B2 REMOVAL
REMOVAL
Warning
l Release the fuel pressure. (Refer to Section FZ.)
PROCEDURE
i. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil.
3. Remove in the order shown in the figure, referring to Removaf Note
Step 1
1. Strut tower bar
2. Undercovers and side covers
3. Air cleaner assembly
4.
Battery bracket
5. Battery cover
6. Battery
7. Battery carrier
8. Accelerator cable
9. Radiator hoses
10. Coolant reservoir hose
f I. Cooling fan connector
12. Radiator switch connector
13. Radiator bracket
14. Radiator and coofing fan assembly
15. Battery duct
16. Air pipe and air bypass valve
17. Intercooler and air pipe
Removat Note . . . . . . . . . . . . .._.. m _._._..., page 82-U
18. Air pipe and gasket
19. P/S and/or AK drive bett
20. P/S oil pump and bracket
Removal Note . . . . .._.__.....~..~........ page BZ-13
21. A/C compressor
Removal Note . . . . . .._................... page 82-I 3
22. Crossmember
02-12

B2 ENGINE STAND DISMOUNTING
93GOB2-7%
93AOB2-077
05WOBX-25
82-22 Water Bypass Pipe
1. Apply a small amount of engine coolant to the new O-ring.
2. install the O-ring on the pipe.
3. InstaIi the water bypass pipe.
A/C Compressor Bracket (if equipped)
1. Install the A/C compressor bracket.
Tightening torque
@: 19-25 N&m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 37-52 Nom (3.8-5.3 m-kg, 27-38 ft-fb)
Exhaust Manifold and Turbocharger Assembly
I= Remove all foreign material from the exhaust manifold con-
tact surfaces.
2. Install a new gasket.
3. Instatl the exhaust manifold and turbocharger assembly.
Tightening torque:
38-46 N-m (3.9-4.7 m-kg, 28-34 ft-lb)
4. Connect the water hose to the water bypass pipe.
5. Connect the water hose and the oil pipe to the cylinder
block.
Tightening torque
@: 12-18 N-m (I -2-l .8 m-kg,
6. Connect the oil return hose to the oi 8.7-13 ft-lb)
I pan.
Exhaust Manifold Insulator
1. Install the exhaust manifold insulator.
Tightening torque:
7.8-I 1 Mm (80-I IO cm-kg, 69-95 in-lb)

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 tNDEX
INDEX
-
- &ANT RESERVOlR
ENGiNE COOLANT
TOTAL CAPACITY
MTX: 5.0 liters (5.3 US qt, 4.4 Imp qt)
ATX: 6.0 liters (6.3 US qt. 5.3
tmp qt)
1. Fan motor
Inspection .._.....,._............._..........
page E-1 I
E-Z