radiator 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

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

Bl INSTALLATION
93GOE 1-73;
03UOBX-84
. .
‘, .
L .G,
. . ‘?.
- -. _ .:
.L ‘.. :-.:
.-_: _. _, _-
.
-_
. :
Cl :- . .
: .._.
. . ._-
;: , ‘. ’
,.. .- -
. ‘L,
93GO3 l-73’
-DEFLECTiON CHfiCKIN:
g3GOBj-717
Bl-22
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
Drive belt
I. fnstall the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page Bl-2.)
Radiator
and cooling fan assembly
f . Install the radiator and cooling fan assembly.
Tightening torque:
7.8-I 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
2.. Connect the cooling fan connector.
3. Connect the radiator switch connector.
4. Connect the A/C cut switch connector.
5. Connect the oil cooler hose. (ATX)
6. Connect the coolant reservoir hose.
7. Connect the upper and lower radiator
@TX)
Pm
hoses.
Caution
l Position the hose clamp in the original location on
the hose, and squeeze it tightly with large pliers to
ensure a good fit.
Accelerator cable
I. Install the accelerator cable.
2. Adjust the cable deflection by turning nuts @
Deflection: I-3mm (0.04--0.12 in)
-
Battery duct, battery carrier, and battery
I_ install the battery duct.
2. Install the battery carrier.
Tightening torque:
7.8-I 1 N-m (80-110 cm-kg, 69-95 in-lb)
3. Install the battery, cover and the battery bracket.
Tightening torque:
2.9-5.9 N-m (30-60 cm-kg, 26-52 in-lb)
4. Connect the positive battery cable.

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

c
OUTLINE B2
INTERCHANGEABILITY
The following chart shows interchangeability of the main park of the BP DOHC Turbo engine for the 4WD
model and the BP DOHC Non-Turbo engine for the 2WD model.
Symbols: 5 . Interchangeabie X . . . . Not Interchangeable
Part name interchangeability Remark
1 Cylinder head Shape different
Camshaft oil sea! :
Cylinder head bolt
3
Cyijnder head gasket cl
C$rnder head cover 0
1
Cylinder Cylinder head cover gasket cl
I
Cylinder block 0
block
related Man bearing cap 0
Main bearing support plate 3
OrI pan x Shape different
Trming belt cuver cl
Seal plate 3
Front oil seal I
3
Rear oil seal cl
Crankshaft ‘3
Main bearing 0
Thrust bearing 0
Connecting rod and cap 0
Connecting rod bearing I
0
Crankshaft [ Prston Shape different
related
Piston pin +-- -
c Piston ring cl
Crankshaft pulley 0
Rear cover 3
I Flywheel X Shape different
Flywheel bolt 0
Timing belt
cl
Timing belt Timing belt crank pulley
cl
Camshaft pulley 0 I
related
f Timing belt tensioner and spring
i 0
1, ldter
Camshaft
; Valve timing different
I-LA
Valve I Make - cl
Valve Exhaust 0
related
Vaive sprtng Intake 0
and seat
Exhaust 0
Valve guide cl
Valve seal 0
Oil pump 0
Oil pump gasket 0
Lubrication Oil strainer
0
system Oil strainer gasket
0
related
Oil cooler
0
Oil jet
0
Oil fitter
0
Water pump cl
Cooling
Thermostat
X system Specificatron drfferent
related Radiator X Specificatron different
Cooling fan
X Specification different
^^-^-^ m^- Ix?-5

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 INSTALLATION
93GOB2-74 1
93GOB2-743
82-32
4. Connect the air pipe to the throttle body, and tighten the
hose clamp.
5. Connect air hose @ to the wastegate diaphragm,
and se-
curely tighten the hose clamp.
6. Install nut @
Tightening torque:
19-25 Narn (1.9-2.6 m-kg, 14-19 ft-lb)
7. Install the intercooter bracket and tighten nuts @J .
Tightening torque:
7.8-l 1 Narn (80-I IO cm-kg, 69-95 in-lb)
Air pipe and air bypass valve assembly
1. Connect the air pipe to the turbocharger, and securely tight-
en the hose clamp.
2. Install and tighten the bolt @ .
Tightening torque:
7.8-l 1 Nom (80-I 10 cm-kg, 69-95 in-ib)
3. Connect air hose @and Q1 and securely tighten the hose
clamps.
Battery duct
1. install the battery duct.
Radiator and tooting fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.8-l 1 Nm (80-l 10 cm-kg, 69-95 Mb)
2. Connect the tooting fan connector.
3. Connect the radiator switch connector.
4. Connect the oil cooler hose.
5. Connect the coolant reservoir hose.
6. Connect the upper and lower radiator hoses.

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
COOLING SYSTEM
1NDEX . ..*....*~.....*..*~~**~=~~.~~.~...~..**.~.....*...~.. E- 2
OUTLINE .................................................. E- 4
OUTLlNE OF CONSTRUCTION.. ................ E- 4
COOLANT FLOW CHART.. ....................... E- 4
SPECIFICATKINS
.................................... E- 5
TWO-STAGE THERMOSTAT.. .................... E- 6
RADIATOR AND COOLING FAN.. .............. E- 7
ELECTRIC COOLING FAN SYSTEM ........... E- 8
SUPPLEMENTAL SERVICE INFORMATION E- 9
THERMOSTAT
.......................................... E- 9
INSPECTION
.......................................... E- 9
ELECTRIC COOLING FAN SYSTEM ............ E-l 0
SYSTEM INSPECTlON
.............................. E-l 0
FAN MOTOR
............................................. E-If
iNSPECTION .......................................... E-l 1
WATER THERMOSWITCH
.......................... E-l I
INSPECTION .......................................... E-f 1
RADIATOR THERMOSWITCH
..................... E-l 2
REMOVAL I INSPECTION I INSTALLATION.. E-12
FAN RELAY .............................................. E-l 3
REMOVAL I tNSPECTlUN .......................... E-l 3
93GOEX-701

INDEX E
BP DOHC TURBO
III 6 No.2 AND No.3 RELAY
1. Thermostat 4. Water thermoswitch
Inspection ...................................
page E- 9 inspection ...................................
page E-l 1
2. Electric cooling fan system 5. Radiator thermoswitch
System
inspection .......................
page E-l 0 Removal I Inspection I
3. Fan motor Instailation .................................
page E-1 2
Inspection ...................................
page E-l 1 6 Fan relay
Removal I Inspection .................. page E-1 3
E-3