1990 MAZDA 232 fuel pump

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
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A-3 i

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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

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

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

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

Fl
FUEL AND EMISSION
CONTROL SYSTEMS
(WITHOUT CATALYTIC CONVERTER)
I
INDEX . . . ..*.....*....**..............................~... Fl- 2
1 FEATURES 1
OUTLINE ................................................ Fl- 3
OUTLINE OF CONSTRUCTION ................ Ff- 3
SPECIFICATIONS ................................... Fl- 3
SYSTEM DIAGRAM
................................ FI- 4
WIRING DIAGRAM
................................. Fl- 5
FUEL SYSTEM
........................................ Fl- 6
OUTLINE .............................................. Fl- 6
FUEL TANK AND TRANSFER PUMP.. ...... Fl- 7
1 SERVICE j
SUPPLEMENTAL SERVICE INFORMATION. Fl- 9
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . ..I.... . . . . . . . . . . . . Fl- 9
PRECAUTION . . . . . . . ..,.. . ..*...... . . . . . . . . . . . . . . ..I Fl- 9
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I.. ..I Fl-ICI
TRANSFER PUMP CONTROL SYSTEM ..I... Ff-If
SYSTEM OPERATION . . . . . . . . . ..I................. Fl-11
4x4 CONTROL UNIT
(FUEL PUMP CONTROL UNIT-j . . . . . . ..I..... FI-12
TRANSFER PUMP SWITCH . . . . . . . . . . . . . . . . . . . . . F1-13
TRANSFER PUMP . . . . . . . . . ..l..................... Fl-13
EXHAUSTSYSTEM
. . . . ..I....... l . . . . . . . . . . . . . a. I... Ff-15
COMPONENTS . ..a.. . . . . . . . . . . . . . . . . . I..... . . . . . . . . Fl-15
93GOFf -701

Fl INDEX
1. Fuel tank
Removal I hspection /
I nstalIation
1. . . . . . . . . . . . . . * . . . ..I..... ,*,.
page Fl-10
2. 4x4 control unit (Fuel pump control unit)
Inspection .__...._..................__..._. page Fl-12
Replacement _. . _. _. _. _. . _ _ _. . . _ . _. _. . . . _.
page
Fl - 12
3. Transfer pump switch
Removal / lnstaltation . . . . . . . . . . . . . .._ page Fl-13
inspection .._......_.. . . ..-_. . . .._....... page F1 -I 3 93GOFl-702
4. Transfer pump
inspection _........._....._................ page Fl-13
Replacement.. . .__.-.. . . . . . . . . . . . . . . , U.-e
page
FI -13
5. Exhaust system components
Removat I hspection I
Installation
.**...**..a*..........*..*..__.
page fl-15
Fl-2

OUTLINE Fl
OlJTLlNE OF CONSTRUCTION
The fuel and emission control systems of the New 3.23 BP SOHC-engine equipped 4WD model are basically
the same as those of the New 323 8P DOHC-engine equipped 2WD model, however, the fuel tank is designed
with separate right
and left sections due to the installation of the propeller shaft for the 4-wheel-drive system
and
a transfer pump is equipped to pump the fuel from the left to the right (fuei pump side) section of the
fue! tank. The following chart shows the differences between the major parts of the BP DO% 2WD model
and the BP SOHC 4WD model.
33GO”l-703
Difference
I t
Part BP DOHC 2WD 1 BP SOHC 4WD Remark Transfer pump -
0 Due to
installation of propeller shaft
Variable Inertra charging system 0 -
Two group fuel qectron Due to change of engine
-
G-slgnal (Drstnbutor) 0
I -
Due to abolishment of two group fuel Injection
93GOfl-70s
SPECIFICATIONS
Item
Idle speed
Ignition timing * Engine
vm
BTDC BP SOHC
850 * 50
5 * to
Fuel DUtTlD I
Fuel filter
Type Low-pressure side
Htgh-pressure side Nylon element
Paper element
Pressure regulator
Regulating pressure kPa (kglcm2, psi) 1 264-314 (2.7-3.2, 38.3-45.5)
In
jfXt0r
Type
Resistance High-ohmic
12-16
Idbup solenoid vatve
Resistance Solenoid A _.._. 17-23, Solenoid 5, C ._... 27-36
Water themosensor
R&stance -20% ( -4OF)
kQ - . 20°C ( 689=)
40% (104OFj
80°C (176OF) 14.6-l 7.8
2.2-I -2.69
1.0-l -3
0.29-0.35
l TEN terminal of dragnosrs connector grounded.
The a (shading) rndrcates newly equipped parts