fuel MAZDA 232 1990 Suplement User Guide

D
D
SUPPLEMENTAL SERVICE iNFORMATION, COMPRESSION 82
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Workshop Manual [Europe (7 203~IO-899,
Australia (I 204-1 U-89F) 1.
Compression
l Inspection
Engine
l Removal
l Engine stand mounting
l Engine stand dismounting
l Ins:attaIion 93GQ32-77 I
COMPRESStON
If the engine exhibits low power, poor fuel economy, or poor idle, check the following:
1. Ignition system (Refer to Section G.)
2. Compression
3. Fuel system (Refer to Section F3.)
93G032-774 93GO32-712
1NSPECTION
1. Verify that the battery is fully charged. Recharge it if
necessary.
2. Warm up the engine to normal operating temperature.
3. Turn the engine OFF.
4. Remove all of the spark plugs.
5. Disconnect the ignition coil connector.
6. Connect a compression gauge to the No.7 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder in the same manner.
Compression:
1,059 kPa (IO.8 kg/cm2, 154 psi)-300 rpm
Minimum:
785 kPa (8-O kg/cm2, 114 psi)-300 t-pm
Allowable difference between cylinders:
196 kPa (2.0 kglcm2, 28 psi) max.
IO. If the compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder waII may be worn.
(2) If the compression stays tow, the valve may be stuck
or seating improperly.
(3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be defective or the cylinder
head distorted.
1 I. Connect the ignition coit connector.
12. Apply antiseize compound or molybdenum-based lubricant
to the spark plug threads.
73. Install the spark plugs.
Tightening torque:
15-23 N-m (1.5-2.3 m-kg, If-17 ft-Ib)
82-11

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

REMOVAL B2
_. OWOBX-07I
03UOBX-845
SteD 4 Removal note
Fuel hose
Warning
l Keep sparks and open flame away from the fue!
area.
Caution
l Cover the hose with a rag because fuel will spray
out when disconnecting.
l Plug the disconnected hoses to avoid fuel leakage-
1. Disconnect the fuel hoses.
Heater hose
Caution
l Do not lose the heater hose joint O-rings and spacer
when removed.
1. Depress the heater hose retainer and remove the heater
hose.
GASKET, REP
OTTER PIN, REPU\CE
91Gr-P7-771 J
-.,-1w- IL .
1. Speedometer cable 6. Driveshafts
2. Select and shift cables Removal Note ._.....*., * . . ..- *...- I..... page BZ-16
3. Front exhaust pipe 7. Propeiler shaft
4. Stabilizer Removal Note . . . . . . . _ . , . . . _. . . . . . . . . _. . . . . page L- 5
5. Tie-rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . .._. page BZ-16
B2-15

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

I
(WITH INTAKE AIR
THERMOSENSOR) AIR CLEANER METER
RESONANCE
CHAMBER /
SOLENOID VALVE
(PRESSURE REGULATOR CONTROL) FUEL FILTER
(HIGH-PRESSURE
SIDE)
P-“---j
Ne-S’GtiAL * ----El
DlSTRlfjUTOR IDLE-UP
SOLENOID VALVE
* TO ENGINE CONTROL UNIT ,CHECKVALVE
(TWO-WAY)
FUEL VAPOR VALVE
*
THERMOSENSOR
‘FUEL PUMP
FUEL FILTER
I TRANSFER PUMP

Fl FUEL SYSTEM
FUEL SYSTEM
OUTLlNE
PRESSURE REGULATOR
1
FUEL FILTER
I TRANSFER PUMP
i WEL PUMP
1 FILTEF
FUEL TANK
4x4 CONTROL UNIT (FUEL PUMP CONTROL UNIT)
The fuel system consists of the fuel tank, the transfer pump, the fuel pump, the fuel filters, the pressure regu-
lator, the delivery pipe, the injectors, and the 4x4 control unit (fuel pump control unit).
Fl-6

c
I
FUEL SYSTEM Fl
FUEL TANK AND TRANSFER PUMP
TRANSFER PUMP SWITCH
4x4 CONTkOL UNIT
(FUEL PUMP CONTROL UNIT)
93GOF1-717
The fuel tank is designed with a separate right and left section due to the installation of the propeller shaft
for the 4-wheel-drive system.
A transfer pump is used to pump the fuel from the I& to the right (fuel pump) side. The transfer.pump is
installed in the fuel tank, and is controlled by the transfer pump switch and the fuel pump contra! unit (Includ-
ed in the 4x4 control unit).
A fuel vapor valve is instatted on the top of the fuet tank to prevent fuel from flowing out to the charcoal cansiter.
Fl-7

Fl FUEL SYSTEM
Transfer Pump Csntrol
OutIine
The fuel tank is built with separate right and left sections to accommodate the installation of the propeller
shaft. As fuel is pulled from the right side of the tank, the transfer pump pumps the fuel from the left to the
riuhf (fuel pump) side to balance the fuel level.
FUEL IN 1EFT TANK
4x4 CONTROL UNIT
(FUEL PUMP CONTROL
UNIT)
TRANSFER / TRANSFER PUMP
PUMP SWITCH: OFF
NO FUEL IN LEFT TANK
4x4 CONTROL UNIT
(FUEL PUMP CONTROL
UNIT) / TRAtdFER PUMP
TRANSFER PUMP SWITCH: ON
Fuel in left tank
The transfer pump switch is OFF, and the transistor within the fuel pump control unit is ON.
As a result, current flows to the coil, the switch is switched ON, and the transfer pump is activated.
No fuel in left tank
The transfer pump switch is ON, and the transistor within the fuel pump control unit is OFF.
As a result, the current to the coil is interrupted, the switch
is switched OFF, and the transfer pump is stopped.
When in this condition, if the vehicle were driven on a rough road surface, the fuel level would vary up and
down and fuel pump would switch ON and OFF.
The transfer pump would then operate excessively, shortening the pump life. In order to prevent this, a ten-
second delay circuit is provided within the fuel pump control unit.
Fl-8