relay MAZDA 626 1987 Owner's Manual

FUEL SYSTEM 4B
INJECTOR
On-vehicle Inspection
If engine runs
1. Warm up the engine and run it at idle.
2. Listen for operational sound of the injector with a
screwdriver or a sound scope.
3. If no operational sound is heard, check the main
relay and injector resistance.
76G04B-066
4. Disconnect the connector from each injector
respectively.
5. Check that the engine speed decreases about
100—200 rpm each time.
6. If not correct, check the injector resistance and in-
jection volume of the injector.
76G04B-067
Inspection
There are 3 inspections which must be performed for
the injectors.
Resistance
1. Remove the injectors from the engine. (Refer to
page 4B—58.)
2. Check the resistance of each injector with an
ohmmeter.
3. If not correct, replace the injector.
Resistance: 12—16 ft
76G04B-068
' Grommet Delivery pipe
76G04B-069
Fuel leakage test and volume test
1. Lift the dynamic chamber upward.
2. Remove the injectors and delivery pipe. (Refer to
pages 4B—58 and 59.)
3. Affix the injectors, pressure regulator, and pulsa-
tion damper to the delivery pipe with wire.
Caution
Affix the injectors firmly to the delivery pipe
so that no movement of the injectors is
possible.
Warning
Be extremely careful when working with fuel.
Always work away from sparks or open
flames.
4B—51

CONTROL SYSTEM 4B
CONTROL SYSTEM
Atmospheric
pressue sensor
Engine control unit
Brake light switch
Clutch switch
Circuti opening
relay
E/L control unit
Air flow meter
Neutral switch
76G04B-129
The control system consists of the input devices and the engine control unit. The engine control unit
controls the fuel injection amount (EGI), fuel injection pressure, bypass air amount, switch monitor func-
tion, and fail-safe function.
4B—83

4B CONTROL SYSTEM
69G04A-161
86U04A-169
76G04B-130
EGI MAIN FUSE
Inspection
Check the continuity of EGI main fuse.
MAIN RELAY
1. Check that a "clicking" sound is heard at the main
relay when turning the ignition switch ON and OFF.
2. Apply 12V and a ground to (A) and (B) terminals
of the main relay.
3. Check continuity at terminals using an ohmmeter.
-Operation
Terminals 12V Not applied 12V Applied
©- ® No continuity Continuity
CIRCUIT OPENING RELAY
Relay Circuit
1. Remove the circuit opening relay.
2. Check the circuit as described.
Terminal Checkina item Correct result
FD Resistance 0.2-300
Fc Continuity (crankinnl oo
B Voltaae (Ian: ON) Batterv voltaae
STA Voltaae (Crankincri Approx. 9V
Ei Continuity oo
Circuit Opening Relay
Apply 12V and a ground to the terminals below and
check the circuit opening relay as described.
12V Grounded Correct result
STA Ei B FP: Continuity
B Fc Fp: Battery voltage
Resistance
Check the resistance between the terminals using an
ohmmeter.
69G04A-164
Between terminals Resistance (Q)
STA <- E1 15-30
B
<-<•
Fc 80-150
B « Fp 00
4B—86

4B CONTROL SYSTEM
Terminal Voltage
If the input and output devices and related wiring are normal, but the engine control unit terminal volt-
age is incorrect, replace the engine control unit.
Terminal Input Output Connection to Voltage (After warming-up) Remarks Terminal Input Output Connection to IGN: ON Idle Remarks
1A — — — — —
1B o Self-Diagnosis Checker (Code number)
For 3sec. after ignition switch OFF ->• ON: below 6.2V (Buzzer sounds) After 3sec.: Battery voltage (Buzzer does not sound)
• Using Self-Diagnosis Check-er and test con-nector grounded • Buzzer sounds: below 6.2V • Buzzer does not sound: Battery voltage
1C — — — — —
1D o Self-Diagnosis Checker (Monitor lamp)
Test connector grounded
For 3sec. after igni-tion switch OFF ON:
below 6.2V (light il-luminates) After 3sec.: Battery voltage (light does not illuminate)
(Test connector grounded) approx. 10V (Test connector not grounded) Monitor lamp ON: below 6.2V Monitor lamp OFF: Battery voltage
With Self-Diagnosis
Checker
1E O Idle switch Accelerator pedal released: below 1.5V
Accelerator pedal depressed: Battery voltage
1F o A/C relay A/C switch ON: below 2.5V A/C switch OFF: Battery voltage
Blower motor ON
1G — — — — —
1H o Water thermo switch Below 1,5V Radiator temp.:
above 17°C (63°F)
11 o Electrical load con-trol unit Electrical load ON: below 1.5V Electrical load OFF: Battery voltage Electrical load: Rear defroster Headlight Blower motor (3rd & 4th position) Electrical fan
1J o Brake light switch Brake pedal released: below 1.5V
Brake pedal depressed: battery voltage
1K — — — — — —
1L o A/C switch A/C switch ON: below 1.5V
A/C switch OFF: battery voltage
Blower motor: ON
1M o Ignition coil © terminal Battery voltage *1 Battery voltage *1 Engine Signal Monitor: green and red lights flash
1N — — — — —
10 — — — —
4B-88

4B CONTROL SYSTEM
Terminal Input Output Connection to Voltage (After warming-up) Remarks Terminal Input Output Connection to IGN: ON Idle Remarks
2N o Solenoid valve (EGR) Below 1,5V • Cold engine: be-low 1,5V Radiator coolant temp.—below 17°C (63°F) or Engine coolant temp.—below 70°C (158°F)
• Engine above ap-prox. 1,500 rpm: Battery voltage
20 o Air bypass solenoid valve (Idle-up B) Battery voltage While solenoid ON (Refer to page 4B-35): below 1.5 V
2P o Solenoid valve
(Purge control valve)
Battery voltage • Medium and high
load: below 1,5V
2Q — — — —
2R — — Ground (E02) Below 1,5V
3A — — Ground (E01) Below 1.5V
3B O Ignition switch (Start position) Below 1,5V While cranking: bat-
tery voltage
3C o Injector (No. 4 and No. 2) Battery voltage *1 Battery voltage *1 Engine Signal Monitor green and red lights flash
3D o Inhibitor switch "N" or "P" range: below 2.0V
Other ranges: battery voltage
ATX
3E o Injector (No. 1 and No. 3) Battery voltage *
1
Battery voltage *1 Engine Signal Monitor: green and red lights flash
3F -— — — —
3G — Ground (Ei) Below 1.5V
3H — — — —
31 o — Ma ri relay Battery voltage
3J — — Battery Battery voltage For back-up
76G04B-110
31 3G 3E 3C 3A
3J 3H 3F 3D 3B
2Q 20 2M 2K 21 2G 2E 2C 2A
2R 2P 2N 2L 2J 2H 2F 2D 2B
1W 1U 1S 1Q 10 1M 1K 11 1G 1E 1C 1A
1X 1V 1T 1R 1P 1N 1L 1J 1H 1F 1D 1B
4B—90

4B CONTROL SYSTEM
E/L CONTROL UNIT
Inspection
1. Connect a voltmeter between the E/L control unit
and ground.
2. Start the engine and check the terminal voltages
as described below.
69G04A-174
Terminal Input Output Connection to Voltage (after warm-up) Remarks Terminal Input Output Connection to Ignition switch: ON idle Remarks
A
(BW) — — Ignition switch Battery voltage
B — — — — — —
C
(B) — — Ground OV
D (LY) 0 Electrical fan relay
Battery voltage Coolant temp.: below 97°C (207°F) D (LY) 0 Electrical fan relay
Below 1,5V Coolant temp.:
above 97°C (207°F)
E
(GY) o Engine control unit
(11)
OV E/L: ON E
(GY) o Engine control unit
(11) Battery voltage E/L: OFF
F (RB) 0 Headlight switch
Battery voltage Headlight switch:
ON F (RB) 0 Headlight switch
Below 1,5V Headlight switch:
OFF
G (LB) 0 Blower motor switch
Below 1,5V Blower motor switch: ON (3rd or 4th position) G (LB) 0 Blower motor switch
Approx. 5V Others
H
(BL) 0 Rear defroster switch
Below 1,5V Rear defroster switch: ON H
(BL) 0 Rear defroster switch Battery voltage Rear defroster switch: OFF
76G04B-131
Replacement
1. Remove the engine control unit. (Refer to page
4B-91)
2. Replace the E/L control unit.
3. Install in the reverse order of removal.
4B—93

4C
FUEL AND EMISSION
CONTROL SYSTEMS
(FUEL INJECTION FE DOHC)
OUTLINE 4C— 2
COMPONENT APPLICATION 4C— 2
SYSTEM DIAGRAM 4C— 3
COMPONENT LOCATION 4C— 4
VACUUM HOSE ROUTING
DIAGRAM 4C— 7
SPECIFICATIONS 4C— 8
TROUBLESHOOTING GUIDE 4C— 9
TROUBLESHOOTING WITH SST.. 4C— 11
INSPECTION PROCEDURE 4C— 12
PRINCIPLE OF CODE CYCLE 4C— 13
CODE NUMBER 4C— 14
SWITCH MONITOR FUNCTION 4C— 25
INSPECTION PROCEDURE 4C— 26
IDLE ADJUSTMENT 4C— 29
IDLE SPEED 4C— 29
IDLE MIXTURE 4C— 30
INTAKE AIR SYSTEM 4C— 31
COMPONENT DESCRIPTION 4C— 31
REMOVAL 4C— 32
PARTS INSPECTION 4C— 33
REPLACEMENT 4C— 36
INSTALLATION 4C— 37
VARIABLE INERTIA CONTROL
(VIC) SYSTEM 4C— 39
COMPONENT DESCRIPTION 4C— 40
TROUBLESHOOTING 4C— 40
IDLE SPEED CONTROL
(ISC) SYSTEM 4C— 44
COMPONENT DESCRIPTION 4C— 45
TROUBLESHOOTING 4C— 46
REMOVAL 4C— 48
FUEL SYSTEM 4C— 49
COMPONENT DESCRIPTION 4C— 50
TROUBLESHOOTING 4C— 51
FUEL PRESSURE RELEASE AND
SERVICING FUEL SYSTEM 4C— 52
MULTI-PRESSURE TESTER 4C— 53
FUEL PUMP 4C— 56
PULSATION DAMPER 4C— 57
INJECTOR 4C— 57
TRANSFER PUMP CONTROL
SYSTEM 4C— 59
REPLACEMENT 4C— 60
FUEL TANK 4C— 65
PRESSURE REGULATOR
CONTROL (PRC) SYSTEM 4C— 68
COMPONENT DESCRIPTION 4C— 69
TROUBLESHOOTING 4C— 69
DECELERATION CONTROL
SYSTEM 4C— 72
COMPONENT DESCRIPTION 4C— 73
TROUBLESHOOTING 4C— 73
ELECTRONIC SPARK ADVANCE
(ESA) CONTROL SYSTEM 4C— 75
COMPONENT DESCRIPTION 4C— 76
TROUBLESHOOTING 4C— 76
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM 4C- 77
COMPONENT DESCRIPTION 4C— 77
TROUBLESHOOTING 4C— 78
EVAPORATIVE EMISSION
CONTROL (EEC) SYSTEM 4C— 80
COMPONENT DESCRIPTION 4C— 80
TROUBLESHOOTING 4C— 81
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM.... 4C— 86
COMPONENT DESCRIPTION 4C— 86
PCV VALVE 4C— 86
EXHAUST SYSTEM
(UNLEADED FUEL) 4C— 87
REMOVAL AND INSTALLATION.. 4C— 88
INSPECTION 4C— 88
EXHAUST SYSTEM
(LEADED FUEL) 4C— 89
REMOVAL AND INSTALLATION.. 4C— 90
CONTROL SYSTEM 4C— 91
RELATIONSHIP CHART 4C— 92
EGI MAIN FUSE 4C— 96
CONTROL RELAY 4C— 96
NEUTRAL SWITCH 4C— 97
CLUTCH SWITCH 4C— 97
P/S PRESSURE SWITCH 4C— 97
ENGINE CONTROL UNIT 4C— 98
E/L CONTROL UNIT 4C—102
AIR FLOW SENSOR 4C—103
THROTTLE SENSOR 4C—104
IDLE SWITCH 4C—106
WATER THERMO SWITCH 4C—106
WATER THERMO SENSOR 4C—107
OXYGEN SENSOR 4C—107
DISTRIBUTOR 4C—108
OXYGEN SENSOR HEATER 4C—109
KNOCK SENSOR 4C—109
INTAKE AIR THERMO SENSOR .. 4C—110
76G04C-001

4C OUTLINE
COMPONENT LOCATION
Input and Output Devices
Solenoid Solenoid Idle valve valve switch /nnA
Solenoid
valve*1 Solenoid valve*1
'(No.1 purge control)
E/L control unit
Engine control unit
Control relay
Knock sensor*2
Water thermo
switch*1
Oxygen Distributor
sensor*1
Clutch switch
\ Oxygen sensor
\ relay*1
Solenoid valve*1 (EGR)
Solenoid valve (ISC)
Air flow sensor
Neutral switch
Water thermo sensor
*1...Unleade fuel only
*2...Leaded fuel only
76G04C-004
4C—4

4C TROUBLESHOOTING WITH SST
Check connector: (Green, 6 pin)
49 H018 9A1
86U04A-011
Test connector: (Green, 1 pin)'
INSPECTION PROCEDURE
1. Connect the SST to the check connector. (Green,
6-pin) and the negative battery terminal.
2. Set the select switch to position A.
Note
The check connector is located at the rear of
the left side wheel housing.
3. Ground the test connector (Green, 1-pin) with a
jumper wire.
Note
The test connector is located near the Self-
Diagnosis Checker check connector.
86U04A-012
OO
uu
SELF-DIAGNOSIS CHECKER
MONITOR LAMP SELECT SW «

o o o
o
76G04C-012
4. Turn the ignition switch ON.
5. Verify that 88 flashes on the digital display and that
the buzzer sounds for three seconds after turn-
ing the ignition switch ON.
6. If 88 does not flash, check the control relay (refer
to page 4C—96), power supply circuit, and check
connector wiring.
7. If 88 flashes and the buzzer sounds continuously
for more than 20 seconds check the check con-
nector wiring, then replace the engine control unit
and perform steps 3 and 4 again.
8. Note the code numbers and check for the causes
by referring to the check sequences shown on
pages 4C—16 to 4C—24. Repair as necessary.
Note
Cancel the code numbers by performing the
after-repair procedure after repairing.
AFTER-REPAIR PROCEDURE
1. Cancel the memory of malfunctions by disconnect-
ing the negative battery cable and depress the
brake pedal for at least five seconds.
76G04C-013
4C-12

TROUBLESHOOTING WITH SST 4C
Malfunction display
Sensor or subsystem Self-diagnosis Fail-safe Malfunction
code no. Malfunction code output signal pattern
Sensor or subsystem Self-diagnosis Fail-safe
08
Air flow sensor Open or short circuit Maintains basic sig-nal at preset value
09 o°pNp II IIL •
Water thermo sensor Open or short circuit Maintains constant 35°C (95°F) command
11 0°FNFJUUL
Intake air thermo sensor (dynamic chamber)
Short circuit Maintains constant 20°C (68°F) command
12
Throttle sensor Open or short circuit Maintains constant command of throttle valve fully open
15 ON n
OFF •L 01
Oxygen sensor Sensor output con-tinues less than 0.55V 120 sec. after engine starts (1,500 rpm or over)
Cancels
EG I
feed-
back operation
17 ON n
OFF L HI il
Feedback system Sensor output not changed 20 sec. af-ter engine starts (1,500 rpm or over)
Cancels
EG I
feed-
back operation
25 0°nfJU1LJIL
Solenoid valve (pres-sure regulator control)
Open or short circuit
26 2LMJIL
Solenoid valve (No.1 purge control)
Open or short circuit
27 ON nn
OFF | _ •111
-ii-Solenoid valve (No.2
purge control)
Open or short circuit
28 ON nn
OFF L Hi nr
Solenoid valve (EGR)
Open or short circuit
34 ^jmiHum
Solenoid valve (Idle speed control)
Open or short circuit
36 °FFJMI«U
Oxygen sensor relay
Open or short circuit
41 <£jimjiuM
Solenoid valve (Vari-able inertia control)
Open or short circuit
76G04C-018
Caution
a) If there is more than one failure present, the lowest number malfunction code is dis-
played first, the remaining codes are displayed sequentially.
b) After repairing a failure, turn off the ignition switch and disconnect the negative battery
cable and depress the brake pedal for at least 5 seconds to erase the memory of a mal-
function code.
4C—15