check engine MAZDA 232 1990 Suplement User Guide

SOLENOID VALVE
CHECK VALVE
r----+ (PURGE CONTROL)
CHiRCOAL
I CANISTER
INTERCOOLER 11 ’ 1 ‘I A-4
II II -
AIR , BYPASS
II ,.-ok----,/ ,CHECK VALVE
(TWO-WAY)
1-1
---II
-d KNO&
II II I I II VALVE
VALVE
THERMOSENSOR
c
I 31c
SENSOR 1 k---k FUEL FILTER
TRANSFER
PUMP
WASTEGATE 7
II t I III TURtiOCHARGERI~
I SOLENOID I II - i 1 WASTFGATF II I
AlOCI fuAl RAlz-rCD
VALVE
le-SIGNAL* -
EJ 0
G-SIGNAL-
DISTRIBUTOR
CATALYTIC CONVERTER ftl”FLLt”” IVIL I =r,
(WITH INTAKE THERMOSENSOR)
*TO ENGINE CONTROL UNIT

F2 TROUBLESt=iUUTlNG GUIDE
SYMPTOM TROUBLESHOOTING
Regarding symptom troubleshooting except LACK OF POWER, POOR XCELERATION, KNOCKING, and
HIGH UIL CONSUMPTION, refer to Workshop Manual [I 203-l O-89F (Europe) or 1204-l O-89F (Australia)].
19 LACK OF POWER [BP TIJR801
DESCRIP- *Performance poor under load when throttle valve wide open
TION *Reduced maximum speed
l Idle condition normal
[TROUBLESHOOTING HINTS1
3 Wastegate always open or opens early
3 Turbocharger damage
@ Factors other than engine malfunction
*Clutch sllpping
l Brake dragging
*Low tire pressure
l Incorrect tire size l Overloaded vehicle
@ Low intake air amount
*Throttle valve not open fully
*Clogged intake air system
TEP INSPECTlON
1
Install pressure gauge in intake air pipe and
check boost pressure at engine speed of
4,000
wm
CT page F2-45
Boost pressure:
More than 2.0 kPa (0.02 kglcm2, 0.3
psi)
@ Air/Fuel mixture lean
l Fuel iine pressure decreases l Fuel injection malfunction
@ Poor ignrtjon
@ Low engine compression
@ Alcohol blended fuel used
@ Knock control system malfunction
ACTION
Yes Go to Step 3
NO Check for air leakage and exhaust gas
leakage
4 If OK, go to next step
4 In not OK, repair
2 Check wastegate
Yes Remove intake air pipe from turbo-
f7 page F2-45 charger and check if compressor wheel
rotates smoothly t7 page F2-46
4 If OK, check air cleaner element
and throttle valve
+ If not OK, replace turbocharger
3 Check factors other than engrne Yes
l Clutch slipping Go to next step
1 8rake dragging
’
l Low tire pressure NO Repair or adjust
l Incorrect tire srze
FZ-32

TROUBLESHUOT1NG GUIDE F2
;TEP
14
15
16 Change fuel and check if condjtjon improves INSPECTION
Check if resistance of rgnrtm
coil IS OK’
Resistance (at 20°C [SS*Fj):
Primary coil winding _....-.. Cl.81 -0.99Q
Secondary coil winding.,.. IO-16 kQ ACTION
Yes Go to next step
PRIMARY COIL
WINDING SECONDARY COIL
WIND tNG
Check fur correct engine compressron”
Yes Go to next step
Engine compression:
785 kPa (8.0 kg/cm2, 1 I4 psi)-300’ rpm L 1
No Check engine condition *
l Worn p&ton, piston rings or cylinder
wall
l Defective cylinder head gasket l Distorted cylinder head l Improper valve seating
l Valve sticking in guide
Yes Change fuel to another brand
No
I I Try known good ECU and check if con-
dition imDroves
* Refer to 323 Workshop Manual [ 1203-lo-89F (Europe) or 1204-l O-89F (Australia)l.
93GOF2-74 6
F2-35

F2 TROUBLESHOOTING GUIDE
20 POOR ACCELERATION [BP TURBO]
IESCRIP- . Performance poor while accelerating
rm
l Idle condition normal
[TROUBLESHOOTING HINTS]
3 Wastegate always open or opens early @ Low intake air amount
3 Turbocharger damage
l Throttle valve not open fully
3 Factors other than engine malfunction *Clogged intake air system l
Ciutch slIpping @ Air/Fuel mixture Iean l Brake draggrng l fuel line pressure decreases
l low tire pressure l Fuel Injection malfunction
l Incorrect tire size @ Poor Ignition
. Overloaded vehicle @ Low engine compression
@ Atcohol blended fuel used
TEP INSPECTION ACTION
-l Install pressure gauge
in intake air pipe and I Yes
1 Go to Step 3
check boost pressure at engine speed of 4,000
rpm
w page F2-45
Boost pressure:
More than 2.0 kPa (0.02 kglcm2, 0.3 psi)
No Check for air leakage and exhaust gas
leakage
4 If OK, go to next step
4 If not OK, repair
2 Check wastegate w page F2-45
Yes Remove Intake air pipe from turbo-
charger and check if compressor wheel
rotates smoothly w page F2-46
c3 If OK, check air cleaner element
and throttle valve
4 If not ok, replace turbocharger
3 Check factors
other than engine
Yes Go to next step l Clutch stipprng l 5rake dragging l Low tire pressure
No l Incorrect ttre size Repair or adjust
FZ-36

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

TURBOCHARGER CONTROL SYSTEM F2
TURBOCHARGER CONTROL SYSTEM
PREPARATION
SST
49 HO80 740
Gauge. pressure
I 93GOF2-754
93GOF2-755
L I 93GOF2-756
93GOF2-757 93GOF2-753
SYSTEM OPERATION
1. Install a pressure gauge 149 kPa (0.5 kg/cm2, 7.1 psi)
min.1.
2. Connect a tachometer to the diagnosis connector lG-
terminal.
3. Start the engine.
4. Verify that the boost pressure when the engine speed is
4,000 rpm is within specification.
Specification: More than 2.0 kPa ( 0.02 kg/cm2, 0.3 psi)
5. If not within the specification, check for air Ieakage, exhaust
gas leakage, and for the wastegate stuck open.
6. if OK, replace the turbocharger.
WASTEGATE
Inspection
1. Remove the air hose from the wastegate actuator.
2 Connect the SST to the actuator.
3. Raise the front of the vehicle and support it on safety stands.
4. Remove the undercover.
F2-45

F2 TURBOCHARGER CONTROL SYSTEM
I 93GOF2-756
93GOF2-75!
93GOF2-761
5. Mark the actuator rod.
Caution
l Do not apply compressed air over 98 kPa (1.0
kg/cm2, 14 psi).
6. Adjust the compressed air pressure to 83 kPa (0.85
kg/cm”, 12 psi).
7. Verify that the rod moves when applying and releasing air
pressure.
WASTEGATE SOLENOID VALVE
Inspection
1, Remove the ,solenoid valve.
2. Verify that air does nut flow from @ through @
3. Apply IN to the solenoid valve and verify that air flows from
@ through @
TURBUCHARGEFI
Inspection
1. Be sure tf7e engine is cool.
2. Remove the air hose.
3. Check that the compressor wheel assembly turns smoothly.
4. If there is excessive drag or noise, replace the turbocharger.
93GOF2-761
FZ-46

F2 FUEL SYSTEM
FUEL
SYSTEM
PREPARATlON
SST
49 LO18 901
Injector checker For
lnsgectlon of
injector
93GOF2.770
9MUOF2-722
03UOFX-7 27
F2-50
PRECAUTION
Fuel Pressure
Release and Servicing Fuel System
Fuel in the fuel system remains under high pressure when the
engine is not running.
a) Before disconnecting any fuel line, release the fuel pres-
sure from the fuel system to reduce the possibility of injury
‘or fife,
1. Start the engine.
2. Push the rear seat cushion buttons and remove the
cushion,
3. Disconnect the fuel pump connector.
4. After the engine stalts, turn off the ignition switch.
5. Recpnnect the fuel pump connector and install the rear
seat cushion.
b) Use a rag as protection from fuel spray when disconnect-
ing the hoses.
Plug the hoses after
removal.
c) When inspecting the fuel system, use a suitable fuel pres-
sure gauge.
Caution
l Install hose clamps to secure the fuel pressure
gauge to the fuel filter and the fuel main hose to pre-
vent fuet leakage.
Priming Fuel System
After releasing the fuel pressure for repairs or inspection, the
system must be primed to avoid excessive cranking when first
starting the engine. Follow the steps
below.
1. Connect the diagnosis connector terminals F/P and GND
with a jumper wire.
2. Turn the ignition switch
ON for approx. 10 set, and check
for fuel leaks.
3. Turn the ignition switch OFF and remove the jumper wire.

CONTROL SYSTEM F2
CONTROLSYSTEM
PREPARATION
SST
49 HOt8 9A3
Self-dragnosls
checker
Engrne signal
IT-iOFlllO~ 49 GO18 904
Sheet System selector
I 93GUF2-786
For inspection of ECU
93GOF2-787
93GOF2-801
TERMNALS 1
--I”- -
03UOFX
ENGINE CONTROL UNIT (ECU)
Inspection
1. Disconnect the ECU connectors.
2. Connect the SSTs (Engine Signal Monitor and Adapt-
er) to the ECU as shown.
3. Place
the SST (Sheet) 011 the Engine Signal Monitor.
4. Measure the voltage at each terminal.
(Refer to pages FZ-60 to F2-67.)
5. If any ECU terminal voltage is incorrect, check the related
input or output devices and wiring. If no problem is found,
reptace the ECU. (Refer to above.)
Caution l
Never apply voltage to SST terminals A and B.
F2-59