1990 MAZDA 232 engine oil

TROUBLESl-lOOTING GUIDE F2
;TEP 1 INSPECT1ON
ACTION
13 Check if resistance of ignition coil 1s OK*
Yes Go to next step
Resistance (at 20°C iSS*FJ):
Primary coil winding . . . . . . . .
0.81~-0.99Q
Secondary coil winding,,.. 1 O--16 kR
PRIMARY COIL
WINDING SECONDARY COIL
WlNDlNG
NO Replace
14 Check for correct engine compression”
Yes Gc to next step
1 Engine compression (Minimum):
785 kPa (8.0 kg/cm , It4 psi)-300 ipm
NO Check engine condition” l Worn piston, piston rings or cylinder
wall
l Defective cylinder head gasket l Distorted cylinder head l Improper valve seating
*Valve sthing in guide
15 Change fuel and check if acceleration improves
Yes Change fuel to another brand
NO
Go to next step
16 Check if NC cut-off control system is OK’
Yes Go to next step
No Repair or replace
17
I Try known good ECU and check if condition
improves
* Refer to 323 Workshop Manual [1203-IO-89F (Europe) or i204-IO-89F (Australia)].
93GOF2-747
F2-39

F2 TROUBLESHOOT1NG GUIDE
25 HIGH OIL CONSUMPTION [BP TURBO]
DESCRIP- 1
l Oil consumption excessive
TION l Exhaust gas white
TROUBLESHOOTING HINTS1
a PCV system malfunctton *
@ Englne malfunction (Oil
working up, working down, or leakage)
3 Oil leakage from turbocharger
ZEP [ INSPECTION Repair or
replace 1 Check if PCV hose, ventilation hose or their at-
taching nipples are separated, damaged,
ciogged, or restricted 2
Check insrde of air hose, air pipe, and intercool-
er for excesstve oil
3 1 Check white exhaust gas visible when ventilation
1 hose or PCV hose removed
1
4 Remove turbocharger and check at oil seals of
compressor and turbine shafi for oil leakage Yes
NO Yes
NO Yes
No Check hoses for clogged
Yes Replace turbocharger
NO
ACTION
Go to next step
Possibly oil working up
Check PCV valve and PCV hose for
clogged
+ If OK, go to next step
e If not UK, repalr or replace
Go to next step
Go to next step
Engine malfunction (Oil working up,
working down, or leakage)
Check foltowing
. Worn piston or cyiinder
l Worn piston ring groove’ l Stuck piston rings* l Worn vatve seal* l Worn valve stem * l Worn vatve guide’
* Refer to 323 Workshop Manual [1203-IO-89F (Europe) or 1204-IO-89F (Australra)].
93GOF2-74:
FZ-42

TURSUCHARGER CONTROL SYSTEM F2
Removal I InstaIlation
Caution
l Be carefui of following points after turbocharger removal.
l Do not carry the turbocharger by the actuator rod or actuator hose.
l Do not drop the turbocharger.
l Set the turbocharger down with the turbine shaft horizontal.
9 Cover the intake, exhaust, and oil passages to prevent dirt or other materia1 from entering.
l Use the specified new studs when installing the turbocharger.
1. Disconnect the negative battery cable.
2. Lift up the vehicle.
3.
Remove the undercover.
4. Drain
the engine coolant.
5. Remove in
the order shown in the figure.
6. fnstall in the reverse order of removat, referring to Installation Note.
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
G I’
/
43-61 (4.4-6.2, 3245)
36-42 (3.94.3, 28-
7.8-1 1 N-m (80-110 cm-kg, 6
cm-kg, 69-95
indb)
26-31
12.7~g-2. 20-231
w
19-26 (l-9-2.6, 14-19)
7.6-17 N-m (80-7 t d cm-kg, 69-95 in-lb)
N-m (m-kg, Mb]
I 93GOF2-762
F2-47

F2 TURBOCHARGERCONTROLSYSTEM
1. Radiator
2. Insulators
3.
Air hose, and air pipe
4. Oxygen
sensur connector
5. Front exhaust pipe
6. Bracket
1 I 93GOF2-765
93GOF2-761
7. Water hoses
8. Oil pipe
9. Oil return pipe
10. Exhaust
manifold and turbocharger
Removal Note . . . . . . . . . . . . . . . . . . . . . . .._.-........_ below
Installation Note . . . . ..__-.............._...___.._. below
93GOF2-763
Removal Note
Exhaust manifold and turbocharger
1. Remove the exhaust manifold and the turbocharger as an
assembly .
2. Remove the turbocharger from the exhaust
manifold.
InstaIlation Note
Exhaust manifold and turbocharger
1. Remove all gaskets and sealant.
2. Install new gaskets.
3. Supply 25 cc (1.5 cu in) of oil through the oil passage of
the turbocharger.
4. Install the turbocharger to the exhaust manifold.
5. Install the turbocharger and the exhaust manifold assem-
bly to the engine and loosely tighten the nuts.
6. install the bracket and the front exhaust pipe, and tighten
the turbocharger mounting nuts.
AIR BYPASS VALVE
Removal I Installation
1. Remove the vacuum hose and the air hoses from the air
bypass valve.
2. Remove the air bypass valve.
3. Install in the reverse order of removal.
Inspection
1. C_onnect a vacuum pump to air bypass valve port @-
2. Verify that air flows from port @through port @ when 250
f 35 mmHg (9.8 * 1.4 inHg) vacuum
is applied to port
0 a .

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

SUPPLEMENTAL SERVICE INFORMATION, TROU8LESHOOTlNG GUIDE H
SUPPLEMENTALSERVICE INFORMATION
The following points in this section are changed in comparison with 323 Workshop Manual (1206IO-89F).
Troubleshooting guide
Clutch fluid (with ABS)
l Replacement
Clutch pedal (BP DOHC Turbo) Clutch release cylinder (with ABS) l Air bleeding
Clutch unit
l Removal I Inspection I installation
Clutch master cylinder
(BP DOW Turbo or with ABS) l Removal I Inspection I installation
93GOHX-710
l Removal I Inspection I Installation (BP DUHC Turbo)
l Air bleeding (with ABS)
l Overhaul (BP DUHC Turbo)
TROUBLESHOOTING GUlDE
Problem
Possibte Cause Remedy Page
Slipping
Clutch disc facing worn excessively
Replace U-l 9
Clutch disc facing surface hardened or oifed
Repair or replace H-l 9
Pressure plate damaged Replace H-19
Diaphragm spring damaged or weakened
Replace H-l 9
Insufficient clutch pedal piay
Adjust H-12
Clutch pedal sticking
Repair or replace U-11
Flywheel damaged
Repair or replace H-19
Faulty
Excessive runout or damaged clutch disc
Replace H-19
disengagement
Clutch disc spiines rusted or worn ’
Remove rust or replace H-l 9
Clutch disc facing oiled
Repair or replace H-19
Diaphragm spring weakened
Reptace H-19
Excessive clutch pedal ptay
Adjust -
Insufficient clutch fluid
Add fluid H-10
Leakage of clutch fluid
Locate and repair or -
replace
Clutch vibrates
Clutch disc facing oiled
Repair or replace H-l 9
when accelerating
Torsion rubbers weakened
u-19 Clutch disc facing hardened or damaged Replace
Repair or replace H-19
Clutch disc facing rivets loose
Replace H-l 9
Pressure plate damaged or excessive runout
Replace H-l 9
Flywheel surface hardened or damaged
Repair or replace H-19
Loose or worn engine mount
Tighten or replace -
Clutch pedal
sticking Pedal shaft not properly lubricated
Lubricate or replace H-l 1
Asistireturn spring damaged or poor adjust
Replace or adjust H-11, 12
Abnormal noise
Clutch release bearing damaged
Replace N-1 9
Poor iubrication of release bearing sleeve
Torsion rubbers weakened Lubricate or replace H-19
Replace u-t9 Excessive crankshaft
end play
Repalr -
Pilot bearing worn or damaged
Replace H-79
Worn pivot points of reiease fork
Repair or replace H-19

J3 OUTLtNE
OUTLINE OF CONSTRUCTION
l Full-time 4-wheel drive, incorporating a viscous coupling is used on the BP DUHC Turbo model. BP SUHC
engine equipped models are fitted with an electronically controlled, lockable center differential.
With this system all driving conditions are easily contended with; from good roads to bad roads and
ad-
verse weather conditions.
l The transaxle and transfer unit were developed based on the GSM-R type transaxle.
The transaxle, center differential, viscous coupling, and front differentia! are a single, compact unit.
l The center differential employs a planetary carrier. system and a viscous coupling, and functions to distrib-
ute the driving force to the front and rear differentials as needed.
Through the use of this center differential, tire scuffing common to 4-wheel drive vehicles during tight cor-
nering, is eliminated.
l The speedometer driven gear (for detection of vehicle speed) is installed in the transfer carrier and detects
the speed of the rear wheels.
l Lubrication oil of the transaxle and transfer unit and of the carrier is contained separately.
93GOJ3-704
J3-4

OUTLINE 33
SPECIFICATIONS
TRANSAXLE AND TRANSFER UNIT
Item Engine model
Transaxle control
Forward
Synchromtsh system
Reverse
I St
2nd
3rd
Gear ratlo 4th
5th
Reverse
Final gear ratio
Speedometer gear ratlo
Type
Number of ring Outer
gear teeth
Inner
Center differential
gear teeth
Inner
Number of sun Pinion gear side
gear teeth
Idler gear side
Number of idler gear teeth
Type
011
Capacity BP DOHC turbo BP SOHC
Floor shift
Synchromesh
Selectrve sfiding and synchromesh
3.454 3.307
1.833
I.310 1.233
0.970 Cl.91 4
0.717
3.166 L
4.214 4.388
1 .oo
Planetary carrier
59 79
75 66
14
14
43 33
43
37
ATF: DEXRON-II, M-III Above -18OC (O°F)
API servie GL-4 SAE 75W-90
2.6 liters (2.7 US qt, 2.2 Imp qt)
93GOJ3-305
Transfer Carrier
Number of teeth Ring gear
Pinion gear 37
11
API service GL-5
Oil Type
Capacity Above -18OC tOoF) SAE 90
Below -18OC tOoF) SAE 8OW
0.5 liter (0.53 US qt,
0.44 Imp qt)
93GOLl3-776 -
J3-5