1990 MAZDA 232 Workshop Manual Suplement

I OWGIX-028
1 SMUG IX-027
gMi)GlX-03
GI-i4
2. Check the terminals of waterproof connectors from the con-
nector side, as they cannot be accessed from the wire har-
ness side.
Caution l
Use fine wire to prevent damage to the terminal. l
Do not damage the terminal when inserting the
tester lead.
Terminals
Inspection
Pull lightly on individual wires to check that they are secured
in the terminal.
Replacement of terminals
Use the appropriate tools to remove the terminal as shown.
When installing the terminal, be sure to insert it until it locks
securely.
Insert a thin piece of metal from the terminal side of the con-
nector, and then, with the terminal locking tab pressed down,
pull the terminal out from the connector.
< Male >
Same as the female type,
Sensors, Switches, and Relays
Handle sensors, switches, and relays carefully. Do not drop
them or strike them against other parts.
4 I
i c

CAUTION GI
I 9MUGIX-031
PULLER
t Fuse
Replacement
1. When replacing a fuse, be sure to replace it with one of
specified capacity.
If a fuse again fails after it has been reptaced, the circuit
probably has a short circuit and the wiring should be
checked.
2. Be sure the negative battery terminal i
fore replacing a main fuse @A).
3. When replacing a pullout fuse, use the
in the fuse box cover. ; disconnected be-
use puller supplied
Wiring Harness
Wiring color codes
Two-color wires are indicated by a two-color code symbol.
The first letter indicates the
base color of the wire and the sec-
ond the color of the stripe.
1 9MUGIX-029
LG Light Green - - CODE
B COLOR
Black CODE )
0 COLOR
Orange
BR Brown P Pink
1
G
GY
t
LB Green
Gray
Blue
Light Blue R
! Red
V Violet
W White
Y Yellow
Gl-15

-

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

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
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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