timing belt 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

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

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

BI OUTIAlE
INTERCHANGEABILITY
The following chart shows interchangeability of the main parts of the I3P SOHC engine for the 4WD model
and the 2WD model.
Symbols: 9 ._.. Interchangeable X . . . . Not Interchangeable
Part name
j lnterchangeabiIity Remark
[ Cyirnder head 3
i Camshaft oil sea! cl
f Cylinder head bolt 0
Cyirnaer head gasket 0
Cylrnder head cover 0
Cylinder Cylrnder head cover gasket 3
block Cylinder block 0
related
Main bearing cap 0
Main bearing supper!
plate 0
Oil pan G
Trmjng bett cover
’ Front oil seal G
3
Rear oil seal 0
Crankshaft
0
Main bearing 0
Thrust bearing c
Connecting rod and cap 0
1 Connecting rod bearing 0
Crankshaft Piston
0
related
Piston pm cl
PMon ring
0
1 Crankshaft pulley 0
Rear cover 0
Flywheel X Shape different
Flywheel bolt 0
Timing heft
0
Timing belt Timing belt crank pulley
0
related
Camshaft pulley 0
Timing belt tenstoner and spring Cl
Camshaft
0
Rocker arm 0
Rocker arm shalt 0
HLA 0 I
Valve
retated
Lubrication
system
related Valve ’ intake
Exhaust 0
1
0
Valve spring Intake 0
and seat
Exhaust 0
Valve guide
0
Valve seat 9
Oil pump
0
01 gasket pump
0
Oil strainer r.
Oil strainer gasket G
Oil jet
0
Oil filter 0
Cooling
SyStem related
1 I Water pump
Thermostat
Padi ator
, Cooling fan 0
0
X
X Specification drffereni
1 Speclfrcatlon different
03UOBX-805
BY-4

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

OUTLINE G
L
i i-
OUTLINE
OUTLINE OF CONSTRUCTION
The engine electrical system of the new 323 4WD is as same as that of the new 323 ZWD.
93GOGX-703
SPECIFICATIONS
Item
Battery t
Voltaae EnginelTransaxle
v
Type and capacity
120-hour rate) BP TURBO
MTX BP SOHC
MTX ATX 12
55D23L (60AH)
I
Dark current” mA 1 Max. 20.0
Alternator
Output V-A 12-65
Regulator type Transistorized (built-in iC regulator)
1 I Regulated voltage v
74.1---14.7
Brush length Standard 21.5 (0.846)
mm (in)
Minrmum 8.0 (0.315)
Drive belt deflection
New
98 N (10 kg, 22 lb) 8-9 (0.31-0.35)
mm (in) Used 9-l 0 (0.35-0.39)
Type Direct ] Coaxicat reductron Starter Output V-W
12-U-85 12-0.95 32-l .4
8rush length Standard 17 (0.67) 17.5 (0.69)
mm [in) Minimum 11.5 (0.4531 10.0 (0.39) Distributor
Ignition timing
BTDC
FEN termrnal of diagnosis connector grounded) Electronic spark advance (photo
diode)
10 * I0 5 f lo
Ignition coil Resistance
(at 20°C [68OFj)
I
Primary
coil windinq
I
Spark plug Type I
Secondary 1
f coil windina 1
NGK
Nippon
Denso 10-76 kS-l
8KR5Ell +2 BKR5E”3
BKRGEI 1 l * BKRGE *3
KIGPR-Ull *2 KfGPR-I-Y3
K20PR-Ul l ** K20PR-U
l 3 0.81 ---o-999
pw am
Firrng order
I mm (in) 1.0-I .l (0.039-0.043)“2 0.7-0.8 (0.028-0.03i)*3
l-3-4-2
93GOGX-704
*I Dark current is the constant flow of current while the ignition switch is OFF. (i.e., engine control unit, EC-AT control unit, audro, etc.)
+’ With catalytic converter.
*3 Without catalytic converter.
G-3