light MAZDA 232 1990 Suplement User Guide

91 1NSTALLATION
Step 4
1. Connect the hoses shown in the figure.
Caution
l Position the hose clamp in the original location on the hose, and squeeze it lightly with large
pliers to ensure a good fit.
Step 5
1. Connect the harness connectors shown in the figure.
OIL PRESSURE SWITCH
Df STRlBUTdR
OXYGEN SENSOR
(EXCEPT ECE
WITHOUT CATALYST) lVFFFRFh!TIAI
-.I I -4 m-m. I -r-h LOCK SENSOR DIFFERENTIAL
THRO77LE
/--+I / LOCK MOTOR
AC. .A--
r IDLE SPEED CONTROL
r
dz k
/NEUTRAL SWITCH
“Rou2ydy __
HEAT GAUGE UNIT ’
IDLE-UP
SOLENOID VALVE
IECE WlTl-tOUT
‘CATALYST-)
BACK-UP LIGHT SWITCH INHlBlTdR SWITCH
G3UOBX-837
E3i -20

INSTALLATION 82
RIGHT-HAND DRIV
Step 4
1. Connect the hoses shown in the figure. Speedometer cable
I_ Connect the speedometer cable.
Caution
l Position the hose clamp in the original location on the hose, and squeeze it lightly with large
pliers to ensure a good fit. .
93G082-76 ‘I
B2-29

INSTALLATION
93G082-7ti
HERE
/+Ju 7
93GOB2-74!
Caution
l Position the hose clamp in the original location on
the hose, and squeeze it lightly with large pliers to
ensure a good fit.
Accelerator cable
1. Install the accelerator
cable.
Tightening torque
@): 7.8-l 1 N4m (80-l 10 cm-kg, 69-95 in-lb)
2. Adjust the cable deflection by turning nuts @ .
Deflection: I-3mm (U&4--0.12 in)
Battery carrier and battery
1 . Install the battery carrier.
Tightening torque:
7.8-l 1 N4m (80-I IO cm-kg, 69-95 in-lb)
2. Install the battery and the battery cover.
3. Install the battery bracket.
Tightening torque:
2.9-5.9 N.m (30-60 cm-kg, 26-52 in-lb)
4. Connect the positive battery cable.
Air cleaner assembly
1. Install the air cleaner assembly.
Tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
2. Connect the airflow sensor connector.
3. Connect the hoses shown in the figure.
Strut tower bar
I. Instail the strut tower bar.
Tightening torque:
88-108 Narn (9.0-11 .U m-kg, 65-80 ft-lb)
Undercover and side cover
1. Install the undercovers and side covers.
93GOB2-746
82-33

F2 OUTLINE
ECU RELATIONSHIP DlAGRAM [BP TURBO]
INPUT DEVICE KNOCK SENSOR
KNOCK
i( CONTROL
DlSTRlBUTOR ,-, UNIT
NC SWITCH
--k/L SWITCHS
{REAR WINDOW DEFROSTER SWITCH.
HEADLIGHT SWITCH, BLOWER SWITCH,
ELECTRICAL FAN SWITCH)
BATTERY A
THRO77LE
SENSOR
NEUTRAL/ IDENTIFICATION
CLUTCH SWITCH
DIAGNOSIS
CONNECTOR
(TEN TERMINAL) INTAKE AIR
THERMOSENSOR
OUTPUT DEVICE
CIRCUIT
OPENING
SOLENOID VALVE
(PRESSURE REGULATOR
WASTEGATE
SOLENOID VALVE
RESISTOR/RELAY
SOLENOID VALVE
(PURGE CONTROL)
93GOFZ-71
F2-10

F2 CONTROL SYSTEM
CONTROL
SYSTEM
STRUCTURAL VIEW
OXL STOPLIGHT SWITCH CLUTCH SWITCH
INJECTOR
P/S PRESSURE
SWITCH
‘GEN SE877
DtSTRIBUTOR
/ PUMP
CONTROL UNll
CONTROL UNIT
CONNECTOR
P REStSTORlRELAY
FUEL tNJ RELAY (MAIN RELAY)
AIRFLOW METER
SOLENOID VALVE
I NEUTRAL SWITCH
(PRESSURE REGULATOR)
WATER THERMOSENSOR
93GOf2.729

F2 CONTROL SYSTEM
KNOCK CONTROL SYSTEM [BP TURBO]
This svstem retards the ignition timina when enaine knocking occurs because of usage of low octane fuel, etc.
1NTAKE
MANIFO
KNOCK SENSOR
(INSTALLED BETWEEN No.2 AND
No.3 CYLINDER)
IGNITER
KNOCK iX?NTROL
UNIT
Operation
When the engine vibrates, the knock sensor generates a slight voltage signal that is the sent to the knock
control unit. The knock control unit determines whether the signal is a knocking signal. If it is a knocking
signal, the ignition spark is retarded according to the intensity of the knock to a maximum of 4O.
Inhibition of spark retardation
In order to improve drivability and fuel economy, the ECU inhibits the above spark retardation when the
‘engine load Ls light, the coolant temperature is below O°C (32OF), the engine is cranking during engine test
conditions.
Note
l The knock ~ensur and knock control unit cannot be inspected individually.
When a matfunction code number 05 is indicated, replace the knock controt unit or sensor
only after inspecting the related wiring and connectors.
F2-22

CONTROL SYSTEM F2
t OXYGEN SENSOR [BP TURBO]
I
CERAMlC HEATER
93GOF2-733
Because the temperature of the exhaust gas is inherently low in turbocharged engines, the BP Turbo model
uses a rapid heating ceramic heater to detect the air/fuel ratio,
PRESSURE REGULATOR CONTROL SYSTEM [BP TURBO]
PRESSURE
REGULATOR
I SOLENOID VALVE
(PRESSURE REGULATOR CONTROL)
FUEL
+ (FROM
DELIVERY PIPE1
II
FUEL INJ I
RELAY
(MAIN REU\Y)
I
II Ir
-__. _ - -’ VACUUM
CT0 DYNAMIC
Ill
CHAMBER)
BATTERY -
c
FUEL
(TO FUEL TANK)
nme*rn -.-a
To prevent percolation of the fuel during hot restart idle, vacuum to the pressure regulator k cut for 180
sec., and the fuel injection pressure is increased to slightly more than 284 kPa (2.90 kg/cm’, 41.2 psi).
Operating condition
l Coolant temperature: Above 90°C (194OF)
l Intake air temperature: Above 58OC (136OF)
g No-load condition
FZ-23

TRUUBLESHOOT1NG GUIDE
TROUBLESHOOTING GUIDE [BP TURBO]
RELAT1ONSt-W CHART
,
i OUTPUT DEVICE
INPUT DEVfCE
KNOCK SENSOR
1
I
-
I-
3 DIAGNOSIS CONNECTOR
(TEN TERMfNAL)
IGNITION SWITCH
(START POSITION)
0 0 0 Cl
EIL SIGNAL * ’
0 0
0 0
P/S PRESSURE SWITCH
0
1
0 0 A/C SWITCH
0 0 0 0 NEUTRAt AND CLUTCH
SWfTCHES 0 0
0
STOPLIGHT SWITCH
0
0
0 0 0 ATMOSPHERIC PRESSURE
SENSOR (IN ECU) 0
0
THROTTLE SENSOR 0 0 0 0 0
0 INTAKE AfR THERMOSENSOR 0
AlRFLOW METER 0 0
I------ i
0 OXYGEN SENSOR
WATER THERMOSENSOR 0
0 0
O G-SIGNAL
DISTRIBUTOR
I---- Ne-SIGNAL I-L 0 0 L-
0
0
L.- 0 0
L 0 0
93GOF2-i45
*I E/L SIGNAL: Slower fan control switch Second position or higher, cooSing fan operating? headlights ON, or rear wtn-
dow defroster switch ON

F2 CONTROLSYSTEM
erminat Input ’ Output Connected to Test condition Correct voltage Remark
1N 0 I Throttle sensor Accelerator pedal released &low l.OV j Ignition switch
(Idle switch)
Accelerator pedal depressed Approx. 12V *N
IO I 0 j [ Stoplight switch Brake pedal released Betow 1 .OV -
1P j 0 1 i P/S pressure lgnitlon switch ON Approx. 12V
I
switch
f/S ON at idle Below 1 .UV
I
P/S OFF at idle Approx. 12V -
I
to 0 A/C switch A/C switch ON
NC switch OFF Beiow 2.W ignition switch
ON and blower
Approx* t2V motor ON
i
1R 0 Electric fan switch Fan operating (Engine coolant tempera- Betow l.OV
ture over 91 *C (t96*F) or diagnosis con-
-
nector terminal TFA grounded)
Fan not operating (Idle) Approx.. f 2V
IS 0 Blower control Blower controf switch OFF or 1st position Approx. 13 Ignition switch
switch
Blower control switch 2nd or higher po- Below 7 .OV ON
sition
IT
Cl Rear window
defroster switch Rear window defroster switch OFF
Rear window defroster switch ON Below 1 .OV Ignition switch
Approx. 12V ON
1u 3 Headlight switch Headlights ON Approx. 12V
-
Headlights OFF Below 1 .OV
-Iv Cl ’ Neutral/Clutch
Neutral position or clutch pedal Below I .OV
switches
depressed
Others Approx. 12V
l-7 I r
f
2V 2W 2U 25 20 20 2M 2K 21 2G IZE 2C 2A IU IS 10 10 IM 1K 11 1G rE tC IA
22 2X (2V 2T 2R 2P 2N 2L 2J 2H’ZF 20 2B fV 1T 1R IP IN 1L 7J III If ItI 1B l F2-62

CONTROL SYSTEM F2
Incorrect voltage
Always below 1 .OV Possible cause
l Throttle sensor misadjustment l Short circuit in wiring from throttle sensor to ECU terminal IN l ECU malfunction
Always approx. f 2V
Atways below 1 .OV (Stopfights OK)
Always below 1 .OV
l Throttle sensor misadjustment l Open circuit in wiring from throttle sensor to ECU terminal IN l Open ctrcuit in wiring from throttle sensor to ECU terminal 20
l Open crrcurt in wiring from stoplight switch to ECU terminal 10
l P/S pressure switch malfunction l Short circuit in wirrng from P/S pressure switch to ECU termrnai 1 P
l ECU malfunction
Always approx. 12V
Atways below 2.5V (Btower fan OK) . P/S pressure switch malfunction
l Open circuit in wiring from P/S pressure switch to ECU terminal I P l Open circuit in wiring from P/S pressure switch to ground
l A/C switch malfunction l Short circuit in wiring from A/C switch to ECU terminal 1 Q l Poor connection at ECU connector l ECU malfunction
Always approx. 12V (Blower fan OK)
l ’ A/C switch malfunction l Open c~rcurt in wiring from NC switch to ECU terminal 1Q l ken circuit H-I winnu from A/C switch to blower control switch
Always below 1.W
l Open or short circuit in wiring from fan relay to ECU terminal IR
(Electrkal cooling fan UK} l ECU malfunctron
Always below 1 .OV (Blower fan OK)
l Short crrcutt in wiring from blower control swrfch to ECU terminal IS l Poor connection at ECU connector l ECU malfunction
Always approx. 12V (Blower fan OK)
Always below Illumination lamp
1.w ON when rear
window defroster
switch ON 1
l Open circurt in wrring from blower control switch to ECU terminat IS
I
l Open or short circuit rn wiring from rear window defroster switch to ECU
terminal 1 T
ftlumination lamp
never ON
l Open circuit in wiring from ignition switch to rear window defroster switch
l Rear window defroster switch malfunction I
Always below 1 .OV (Headlights OK)
l Open or short circurt in wiring from headlight relay to ECU termtnal 1 U
Always below 1 .OV
Always approx. l2V
l Neutral switch malfunction l Clutch switch malfunction l Short circuit in wiring from ECU terminal IV to neutral or clutch switch
l Neutral switch maifunctton l Clutch switch malfunction l Open circuit in wiring from ECU terminal IV to neutral or clutch swttch
l Poor connection at ECU connector
93GOFZ789
F2-63