sensor MAZDA 323 1992 Suplement User Guide

F3 TROUBLESHUOTING GUIDE
TROU8LESHOOTlNG GUIDE
RELATIONSHIP CHART
.

OUTPUT DEVICE
INPUT DEVICE

w
3
s
s
KNOCK SENSOR
0
0 0 0 DtAGNOStS CONNECTOR
(TEN TERMINAL)
0 0 0 IGNITION SWlTCH
(START POSITION) 0 0
0
0
0 0
0 0
0 0
0
0
0
0
0 0 0 0
E/L SIGNAL* 0
P/S PRESSURE SWITCH 0
0
A/C SWtTCH
NEUTRAL AND CLUTCH
SWITCHES
STOPLIGHT SWITCH
ATMOSPHERIC PRESSURE
SENSOR (IN ECU)
THROTTLE SENSOR
0 0 0 0
0
0
0 0’
0
0 0
0
0 0
0
’ 0
0
0 0 0 0 0 0 0
0 I
0 ~ INTAKE AIR THERMOSENSOR 0 0 0 0
0 -~
OXYGEN SENSOR
0 0 0 0 WATER THERMOSENSOR
A
0
* 0 0 0 c 0
13
3F3-32 IN, o . E/L SIGNAL: Blower fan control switch second position or higher, electric cooling fan operating, headlights
rear window defroster ON.
F3-19
i

F3 TROUBLESHOOTING GUIDE
I- STEP lNSPECTlON ACTION
Yes Go to Step 8
5 In same condition as in Step 2, IS fuel ilne pres-
sfire held after Igrxtbon swatch rs turned OFF?
Fuel line pressure: More than 147 kPa
Il.5 kgflcm’, 21 Psi 1 for 5 min.
6 In same condition as in Step 3, IS fuel line pres-
sure held after lgnltron switch IS turned OFF?
Fuel line pressure: More than 147 kPa
{ t.5 kgf/cm*, 21 psi) for 5 min.
No
I Go to next step
Plug both vcuum ports of pressure regulator; IS
fuel lme pressure held after ignltlon switch is
turned OFF? Yes Replace pressure regulator
r~ page F3-3
Fuel line pressure: More than 147 kPa
{ 1.5 kgf/crn*, 21 psi] for 5 min.
NO Check fuel pump hold pressure
e If OK, check InJector for fuel
leakage
e If not OK reptace fuel pump ZF- page F3-42
T page F3-3
8 Dlscofinect water thermosensor connector, does
engtne start? Yes Check water thermosensor
e ff OK. check connectrons of water
thermosensor and ECU 2Q terminal
Q If not OK, replace water thermo-
sensor
ET page F3-13
No 1 Go to next step --~
Is “00” drsplayea on Self-Diagnosis Checker
with ignition switch ON? 9 Yes Go to next step
NO Service Code No. displayed
Check for cause (Refer to specified
check sequence)
c7 page F3-16 SYSTEM SELECT, 1
“88” flashes
Check ECU terminal IF voltage
KIT page F3-45
Voltage: Battery voltage
(ignition switch ON)
e If OK, replace ECU
ET- page F3-2
e If not OK, check wiring
(ECU - Self-Diagnosis Checker)
Y %EtECT SW: A
Yes 1 Go to next step 10 Are rf ECU termrnaf voltages are OK?
(especjaffy 1C. 2D. and 2Q)
CT page F3-45
NO Check for cause
Yes Replace ECU
=T page F3-2
No Change to another brand of fuel
13EOF3 331 Try known good ECU, does condition improve?
CT page F3-2
F3-26

F3 TROUBLESHOOTING GUIDE
3TEI ACTION
Is fuel line pressure correct at Idle?
*
Fuel line pressure: 265-314 kPa
12.7-3.2 kgf/cm’, 38-46 psi]
(Two vacuums hose to pressure regulator
disconnected)
304-392 kPa [ 3.1-4.0 kgf/cm’, 44-57 psi 1
(Upper vacuum hose to pressure regulator
disconnected)
INSTALL CLAMPS Yes Go to next step
No Low pressure
Check fuel line pressure while pinching
fuel return hose
4 If pressure quickly Increases,
check pressure regulator
e If pressure gradually Increases,
check for clogging between fuel
pump and pressure regulator
If hose is not clogged, check fuel
pump maxrmum pressure
Connect System Selector to diagnosis connector
and set Test Switch to SELF TEST; is ignition
tlmlng at idle correct after warm-up?
Ignition timing (BTDC): 10 f lo Yes Go to next step
No Adjust tgnrtkon system
8 Dtsconnect water thermosensor connector; does
engine condrtlon Improve? Yes Replace water thermosensor
No
Try known good ECU. does condltlon
Improve?
w page F3-13
Go to next step
Check if injector resistance is OK
w page F3-42 9 Is jqector operating sound heard at Idle?
Yes
No
Resistance: Approx. 2.11 Q
(at 20°C 168*F])
4 If it is, check wlnng
(ECU - Injector)
c3 If it Is not, replace injector
Go to next step IO
Yes Is engine compressron cprrect?
w Section G
No
Engine compression:
1059 kPa 110.8 kgf/cm2, 152 psi)-300 rDm
is strong blue spark vrslble at each disconnected
hrgh-tension lead?’ Check engine
3 Section B2
17
Yes Go to next step
No Check high-tension lead
w Section G
c3 If UK, check distrrbutor cap and
rotor
3 If not OK, replace htgh-tensron lead
Try known good ‘ECU: does condrtron
Improve7
w page F3-3 12 Are spark plugs.OK?
w Section G
l Wear and carbon butld up l Piug gap l Damage Yes
NO
Clean, adjust
13EOi3.334
F3-32.

TROUBLESHOOTING GUlbE F3 1
14 IDLE MOVES UP AND DOWN/IDLE HUNTS
IESCRLP-
l Engine speeds up and down periodically at idle
UON
TROUBLESHOOTING HINTS]
B Idle switch (En throttle sensor) OFF at idle
3 Air leakage
3 Fuel injection amount Inconstant
. Poor contact point inside airflow meter
9 Poor ignitron
rEP[ INSPECTION
I is “00” displayed on Self-Dragnosis Checker
with ignrtron swatch ON?
SYSTEM SELECT: i I ACTfON
Yes Go to next step
NO Service Code No. displayed
Check for cause (Refer to specified
check sequence) c=;r page F3-16
“86” flashes

Check ECU terminal IF vottage csr page F345
Voltage: Battery voltage
W: SELF TEST (ignition switch ON)
SELECT SW: A
.d P/ e If OK, replace ECU CT page F3-3
c3 If not OK, check wrrjng
(ECU - Self-Dlagnosls Checker)
2 Is intake manrfold vacuum correct at idle? Yes Go to next step
Intake manifold vacuum:
More than 450 mmHg { 17.7 inHg )
No Low vacuum
Check for air leakage at intake air
system
3 Is air cleaner element clean? Yes Go to next step
No Replace abr cleaner element
4 Disconnect each hrgh-tension lead at idie; does Yes Go to next step
engine speed decrease equally at each cylinder?
No Go to Step 8
5 Are ECU terminal voltages OK? Yes Go to next step
(especially 20, 2Q, 20) -
rI7 page F345 No
Check for cause
6 Connect System Selector to diagnosis connector Yes Go to next step
and set Test Switch to SELF TEST; is ignition
timing at idle correct after warm-up?
Ignition timing (BTDC): f 0 f la
No Adjust ignition timing
._
. F3-33

F3 TROUBLESHOOTING GUIDE
STEP INSPECTION ACTlON
6 Is dashpot correctly adjusted? Yes Go to next step
c
Dashpot set speed: Approx. 3,500 rpm
No Adjust dashpot
7
Try known good ECU; does condition
Improve?
w page F3-3
13EOF3-336
16 ENGINE STALLS SUDDENLY (INTERMITTENT)
DESCRIP.
l Engine intermittently stops running
TION l Before stalling, engine conditron is OK
TROUBLESHOOTING HINTS]
@ intermittently no spark or no fuel injection caused by ve-
hlcle vibratron, acceleratton, or deceleration
l Poor connectlon in wiring harness
iTEP INSPECTION ACTfON
1 Is “00” displayed on Self-Oiagnoss Checker Yes Go to next step
with lgnltlon swrtch ON?
NO Service Code No. displayed
Check for cause (Refer to speclfled
check sequence).
Note CT page F3-16
l When checking wiring harness and
connectors, tap, move, and wiggle
suspect sensor and/or harness to
recreate problem
“88” flashes ’
Check ECU terminal IF voltage
Voltage: Battery voltage
{ignition swttch ON) w page F3-45
4 If OK, replace ECU
4 If not OK, check wiring
(ECU - Self-Diagnosis Checker)
2 Check for poor connection of foliowrng parts
Yes Reparr or replace
l lgnltfon coil l Igniter l Distributor l t-flgh-tensron lead
No Go to next step l Injector l Injector reststor l Circutt-opening relay l ECU
3 Are ECU terminal voltages OK? Yes Go to Troubleshbotrng No. 2
(especially 16, 2A, 2B, and 2C) .“CRANKS NORMALLY BUT WILL NOT
w page F3-45 START (NO COMBUSTION)”
w page F3-20
Note
. No Check for cause
l When. checking voltages, tap, move, and
wiggle harness and connector to recreate
problem
* lrlrl m-7
F3-36
7.8-l

F3 TURBOCHARGERCONTROLSYSTEM
1. Radiator
2. Insulator 3. Air hose, and air pipe
4. Oxygen sensor connector
5. Front exhaust pipe
13EOF534
F3-38 6. Water hose
7. Oil pipe
8. Exhaust manifold and turbocharger
Removal Note ,.........I.....f.~.~l....... II.I.... below
Installation Note . . . . , , l.. . . . . . . , ,.. ,..*, , . . . . . . . . . below
13EOF3-339
Removal Note Exhaust
manifold and turbocharger 1. Remove the exhaust manifold and the turbocharger as an
assembly.
2. Separate the turbocharger assembly from the exhaust
manifold.
Installation Note
Exhaust manifold and turbocharger’ I I Remove .all old 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. Mount the turbocharger assembly 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 nut%
WASTEGATE SOLENOD VALVE
Caution
l The wastegate solenoid valve must be replaced with
the turbocharger, it cannot be replaced by itself.
Inspection 1. Disconnect the connector.
2. Measure the resistance of the solenoid valve.
Resistance: 35-45 !‘l (at 20°C f68OFj) 3. M not as specified, replace the wastegate solenoid valve and
turbocharger as an assembly, if necessary.
(Refer to page F3-37.)
3. Instc

F3 CONTROL SYSTEM
Ve: Battery voltage
Termina
1N ’
10
1P
IQ
IR
IS
1T
tlJ
IV Jnput Outpul
0
0
0
0
0
0
0
0
0 Connected to
Throttle sensor
(idle switch) Test condition
Correct voltage Remark
Accelerator pedal released
Below 1.0V
lgnltlon switch
Accelerator pedal depressed
VI3 ON
Foglrght relay
P/S pressure
switch Fogtight switch ON
Fogfight switch OFF
Ignition switch ON
P/S pressure switch ON at Idle
PIS pressure switch OFF at idle Va
ov
V3
Below 1 .OV
VB -
-
A/C switch A/C switch ON
A/C switch OFF Below 23 Ignition switch
Va ’ ON and blower
motor ON
1 f Ekctrtc cooltng fan Fan operating (coolant temperature over
Below 1 .OV
switch
97OC 1207OF 1 or diagnosis connector
terminal TFA grounded) -
Fan not operating (Idle)
VI3
Blower control Blower control switch OFF or 1st position
.Va
swbtch Ignitton switch
Blower control switch 2nd or hjgher po-
Below 1 .OV ON
sition
Rear window
defroster switch Rear window defroster OFF
Rear window defroster ON Below 1 .OV Ignition switch
V0 ON
Headlight switch
Headfights ON Va
Headlights OFF -
Below 1.OV
Neutral/Clutch
Neutral position or clutch pedal
9eJow I .OV
switches
depressed
Others
Va
7
r u-.
I-I-I
f
2y 2w 2u 2s 20 20 2M 2K 21 2G 2E 2C 2A 1U 1s 10 10 1M 1K 11 rG IE tC ;A
22 2% 2V 2T 2R 2P ZN 2L 25 2H 2F 2D 28 tV 1T ‘IR IF 1N It ;J. IH IF ID 18
i
A
F3-48
-- Alwa@
Always
Always
Always
--
Always
--
Always
--
Always
--
Always
--
Always
(electric
--
Alway<;
--
Always
-e
Afway?;
I .ov
Always
--
Always
--
Alway:;
--

-. _.. . . . . . _ - ._.
-w
CONTROL SYSTEM F3
I .
-.
Ve: Battery voltaae I
Incorrect voltage
Atwafi below 1 .OV
Always VB
Always VS (foglight switch OK)
Always below 1 .OV
Always below 1 .OV
Always Vs
Always
below 23 (blower fan OK)
Always VB (blower fan OK)
Always below 1 .OV
(electric cooling fan OK) -
1-
Possible cause
l Throttle sensor mrsadjustment l Short circuit in wtrrng from throttle sensor to ECU terminal 1 N l ECU malfunction
l Throttle sensor mrsadjustment l Open circuit in wiring from throttle sensor to ECU terminal fN l Open circuit in mnng from throttle sensor to ECU terminal 20
l Foglight relay malfunctron
l Foglrght relay malfunction
l P/S pressure switch maltunctron l Short crrcurt In wrrlng from P/S pressure switch to ECU terminal 1 P l ECU malfunction
l P/S pressure switch malfunction l Open circuit in wlnng from P/S pressure switch to ECU terminal 7 P l Open circuit in wiring from P/S pressure switch to ground
l A/C switch malfunctron l Short circuit tn wiring from A/C switch to ECU terminal 1Q l Poor connection at ECU connector l ECU malfunction
l #C swatch malfunction l Open circuit in wiring from A/C switch to ECU terminal 1Q l Open circuit in wiring from A/C switch to blower control switch
l Open or short circuit in wiring from fan relay to ECU terminal 1R l ECU matfunction
Always below 1 .OV (blower fan OK}
Always Vs (btower fan OK)
Always betow illumination lamp
1 .ov ON when rear
window defroster
switch ON
Illumination lamp
never ON
Atways below 1 .OV (headttghts OK)
l Short circuit in wrrtng from blower control switch to ECU terminal IS l Poor connection at ECU connector l ECU m&function
l Open crrcuit in wrrrng from blower control switch to ECU terminal 1s
l Open or short crrcuit In wiring from rear window defroster switch to ECU
terminal t T
l Open circuit in wiring from ignitron switch to rear window defroster switch l Rear window defroster switch malfunction
l Open or short circuit in wiring from headlight relay to ECU terminal 1 U
Always below 1 .OV
l Neutral switch malfunction l Clutch switch malfunction l Short circuit in wiring from ECU terminal IV to neutral or clutch switch
Always VB
l Neutral switch malfunction l Clutch switch malfunction l Open circuit in wiring from ECU terminal 1V to neutral or clutch swdch l Poor connection at ECU connector
13FOl=3-36 .
F3-49
.:i

F3 CONTROL SYSTEM
Vs: Battery voltage
‘erminat Input Output Connected to Test condition
Correct voltage Remark
2A’ - - Ground (i nlector) Constant CIV -
26 - - Ground (output) Constant ov -
2C - - Ground (CPU) Constant ov -
2D - - Ground (input) Constant ov -
2E 0 Distributor Ignition switch ON QV or 5v
{NE-slgnal) -
f
r ldte
Approx. 2V
2F - - - -
- -
2G 0 Dstributor Ignition switch ON
ov or 5v
(G signal)
ldte Approx. 1.5V
a-l -I- - -
- -
21 - - - - - -
23 0 Knock control unit Idle Approx. 4.W -
I
2K 0 Throttle sensor/ Constant 4.5--5SV
Airflow meter
-
2L cl
2M 0 Speedometor
sensor
Throttle sensor Ignition switch UN
Accelerator pedal released
Accelerator pedal fully depressed 0 or 5V
Approx. 0.W
Approx. 4.W
-
2N 0
20 0
2P 0
2Q 0
2R Oxygen sensor Ignition switch ON ov
Idle (cold engine) ov
Idle (after warm-up) o- 1 .ov -
Increasing engine speed (after warm-up) 0.5-l .ov
Deceleration o--0.w
Airflow meter ignition switch ON Approx. 3.W
-
Idle Approx. 3.OV
Intake air Ambient air temperature 2O*C (68*F) Approx. 2.5V In arrflow meter
thermosensor
Water Engine’cooiant temperature 20°C (68OF) Approx. 2.W
thermosensor -
After warm-up Below 0.5V
0 Turbocharge Ignition switch ON VS
indicator -
7
r u-l 7 c Ul I-'
2y ?A’ 2u 25 20 20 2M 2K 21 ?G 2E 2C 2A 1u 1s 10 10 1M ?K 11 1G 1E 1C 1A
22 2x zv 2T 2R 2P 2N 2L 2J 2H 2F 20 28 1V 1T tR tP 1N IL 1.1 1~ qF 10 1~
F3-50
L --
4b&e (
--
Alway:
-a
--
Always
--
--
--
Always
--
Always
--
Below L
-I
--
Always
--
Alway:,
Alway:;
Alway:;
--
Alway:;
--
Always
--
Always
--
Always
Always

CONTROL SYSTEM F3
VS: Battery voltage
Incorrect voltage Possible cause
Ab&e OV
l Poor contact at ground terminal l Open circuit in wiring from ECU to ground
Always approx. OV or approx. 2V
l Refer to Code No. 02 Troubleshooting
(Refer to 323 Workshop Manual (l203-lo-89F))
Always approx. OV or approx. 1.5V
l Refer to Code No, 03 Troubleshooting
(Refer to 323 Workshop Manual (1203-lo-89F))
Always OV
Always OV
- -
l Refer to Code No. 05 Troubleshooting
(Refer to 323 4-Wheel drive Workshop Manual (1229-10-891))
l Short circuit in wiring from ECU terminal 2K to throttle sensor, or airflow
meter
l Poor connection at ECU connector l ECU matfunctlon
Below 4.5V or above 5.5V
-
l ECU matfunction
l Refer to section 1
Always OV
l Throttle sensor malfunction l Short circuit in wlnng from ECU termrnal 2M to throttle sensot l Poor connection at ECU connector
. ECU malfunction
Always approx. 5V . Throttle sensor misadjustment
l Open circuit in wiring from ECU terminal 2D to throttle sensor
Always constant
l Open circuit in wiring from ECU terminal 2M to throttle sensor
. Open circurt in wiring from ECU terminal 2K to throttle sensor
l Open circuit in wiring from ECU terminal 2D to throttle sensor
Always above 1V 1 . Throttle sensor mtsadjustment
Always OV (after warm-up)
Always approx. IV (after warm-up)
l Refer to Code No. 15 Troubleshooting
(Refer to 323 Workshop Manual (1203-I O-89F))
l Refer to Code No.17 Troubleshooting
(Refer to 323 Workshop Manual (1203-lo-89F))
Always OV or approx. 5V
l Refer to Code No. 08 Troubleshooting
(Refer to 323 Workshop Manual (t203-lo-89F))
Always OV or approx. 5V
Always OV or approx. 5V
l Refer to Code No. 10 Troubleshooting
(Refer to 323 Workshop Manual (l203-lo-89F))
l Refer to Code No. 09 Troubleshooting
(Refer to 323 Workshop Manual (1203-10.89F))
Always OV
I
l Indicator broken l Open or short circuit In wiring from ECU 2R to ignition switch
13EOF3-36;
F3