maintenance MAZDA 232 1990 Workshop Manual Suplement

1
I PRE-DELIVERY INSPECTION
AND
SCHEDULED MAINTENANCE
SERVICES
PRE-DELIVERY INSPECTION TA8LE ..-*...a.. A- 2
SCflEDULED MAiNTENANCE SERVICES
(Australia)
. ..* . . . . . . . l . . . . . . . . . . . . . . . . l .*..* . . . . l . . . . . . . A- 3
SCHEDULED MAINTENANCE SERVICES
(Europe)
. . . . . . . . . . . . . . . . . l . . . . . . . . . . . . . . . . . . .*..* . . . . . . . . A- 5
93GOAX-701

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
-
A-3 i

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

!
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

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 MAINTENANCE ‘SERVICES (Europe) A
Maintenance Number of months or km (miles), whichever comes first
Monthso - 6 12 18 24 30 36 42 4%
Maintenance Kilometers
1,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
(Miles)
(600) (6,000) (12,000) 1(18,000) (24,000) (30,000) (36,000) (42,000) (48,000) Chassis and body (Cont’d)
TIES (lnctud~ng spare tires) wrth infiation
pressure adjustment
Hinges and catches
U nderslde of vehicle
Seat belt
Roao test
Driveshaft dust boots
93GOAX-706
A-7

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

A SCHEDULED MAINTENANCE SERVICES (Europe)
Maintenance Number of months or km (mires), whichever comes first
Months” - 6 12 18 24 30 1 36 42 48
Maintenance KIlometers 1,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
(Miles)
(600) 1 (6,000) j(12,OOO) (18,000) (24,000) (30,000) (36,000) (42,000) \(48,000) Chassis and body [Cont’d)
Steerrng and front suspension I
I
1 1 I I
MTX oil
A A A
R A A A R
Rear axle oil R A A R 1 A A A R
Trabsfercarrter oil
I R I A A R A A A R
B&s. nuts on chassis and body T 1 1 T T
T I T
Body condition (Visual
onfy) t nspect annually
Exhaust system hear shields I i
Tires (tncluding spare ttres) wtth rnflation
pressure adjustment t I I 1
Hinges and catches
A
bA4 ,A3 A
Understde of vehicle
i I I I I
Seat belt
I I I t
Road test
1 I I 1
Driveshafi dust bouts
I I I 1
93GOAX-709
A-10

OUTLINE Bl
UUTLlNE OF CONSTRUCTtON
The BP SOHC engine for the 4WD model is the same as for the 2WD model, except that the flywheel is
shaped differently.
The 3P SOHC engine for the ECE specification (without catatyst) 4WD model is the same as the ECE US83
model, except that the fuel and emission control system and the engine electrical system are modified.
(Refer to Sections Ff and G.)
93G08 i -702
SPEClFlCATlONS
Item
TVDG?
Engine/Market ’
AustraIia BP soffc
Europe us-83
1 Without catalyst Gasoline. 4-cvcle
Cyirnder arrangement and number
Combustron chamber
Valve svstem In-line, 4 cylinders
Pentroof
OI-IC, belt-driven
Fi rtng order *
. ..TEN terminal of diagnosis connector grounded. 1-3-4-2
I 93G08 l-704
IN 0: Maintenance-free
mm (in)
EX
0: Maintenance-free Dsplacemenr cc (cu in) 1,839 (112.2)
Bore and stroke mm (In) 83.0 x 85.0 (3.27 x 3.35)
Comoression ratio
Compressron pressure I 8.9
I I kPa (kglcm2, psi)-rpm 1,197 (12.2, 173)300
Valve tlmtng Open BTDC 2O
IN
Close ABDC 5u”
c
Open BBDC so
EX
Close ATDC 8’
Valve clearance
Idle speed -~
Ml-x 750 f 50’ 850 f 50
rpm . I ATX 750 f 50” - I I I ignrtton trming BTDC 1 50 f 10’
1
Bl-3