battery MAZDA 232 1990 Suplement Owner's Manual

SELF-DIAGNOSIS FUNCTtON F2
Q3en
or short ci rculi - ON
26
OFF -
ON
34
OFF
ON
42
OFF
Caution
l If there is more than one failure present, the code numbers will be indicated in numerical or-
der, lowest number first.
l After repairing a failure, turn off the ignition switch, disconnect the negative battery cable,
and depress the brake pedai for at least five (5) seconds to erase the malfunction code(s) from
the ECU memory.
f2--27

F2 SELF-DIAGNOSlS FUNCTION
Troubleshooting
If a malfunction code number is shown on the SST (49 l-l01 8 9Ai, 49 B019 9AO), check for the cause
using the chart related to the code number shown, [Regarding code numbers except 05, 24, and 42, refer
to “Troubleshooting” in Workshop Manual [I 203-I O-89F (Europe) or 1204-f 0-89F (Australia)].
r C :ODE No. 05 (KNOCK CONTROL UNIT)-BP TUR80
;TEP
2
3 I INSPECTION
Check knock sensor and knock control unit
circuit for poor connectlon ACTtON
Yes Repalr or replace connector
Check knock control unit terminal voltage with
ignition switch ON
Check that voltage at ECU terminal 2J is
approx. 4V at idle
rs7 page F2-64 Yes Recheck ECU connector for poor
connection
4 If OK, replace ECU
4 If not OK, repair or replace connector
NO Repair wiring harness (R/Y) between
ECU terminal 2J and knock control unit
93GOF2-7:
Circuit Diagram
I
ECU
IGNITION
SWITCH
15A BATTERY
MAIN
RELAY
(FUEL 1N.J)
l W/L Y/i3 G/O W RIB R/L
YIL
jr- -- - - 1 BlLG
-
-
MCK CONTROL
I
. :
MAIN RELAY (FUEL INJ)
W/G BIW
C&=&A
KNOCK CONTROL UNIT
W/R EMLG RN Y/L
1
KNOCK SENSOR

SELF-DIAGNOSIS FUNCTION F2
:UDE No. 24 (FUEL PUMP RESISTOR/RELAY)-BP TURBO
STEP INSPECTION ACTtON
1 1 Disconnect connector from ECU and check if
1 battery voltage exists at connector terminal 1 I (L) Yes Check ECU terminal connector for poor
connection
with ignition switch ON
e If OK. replace ECU
c=> If not OK, repair or replace connector
NO Go to next step
2 In same condltlon as Step 1, check if battery
Yes Repair wiring harness (W/R)
voltage exists at resistor/relay connector terminai- I
wire (W/R)
NO Go to next step
3 Check if there is continuity between fuel pump
Yes Check for short or open circuit
in wiring
res!stor/relay terminals C (‘W/R) and D (L) from main relay (FUEL INJ relay) to
t resistor/relay
NO Replace resistor/relay
93GOF2-74 1 Circuit Diagram
IGNITION
SWITCH DIAGNOSIS
CONNECTOR
rl
F/P TERMINAL *
BATTERY
IGNlTlON
0fP
W/R
FUEL
PUMF
B
c W/R 7
FUEL PUMP
- RESISTOR/RELAY
\I
I/
ECU MAIN RELAY
Of1
W/G . LGrf Grw l v L/O R/Y LGlR YfL B/LG
RIB 1
I GIB J 1 1 [ WR LG ] Y , UW~LGIw/ * 1 W ] 810 WIG BfW
I
I I I
1 I I
I
&J,~&&&l&&c!zr5& &l~&cLa~~c!zch&&&&~
1~ IS 10 10 IM 1K II tC 1E 1C IA 2Y 2w 2u 2s 20 20 28.4 2K 21 2G 2E 2C 2A
IV 17 ?R IP 1N 1~ IJ III IF ro :8
rrrrrT?rrTT
BRff t BIG 1 R/W ! t/B 1 WIB 1 W/R
BIL UY O/B WN
CIRCUIT OPENING RELAY
FUEL PUMP FUEL PUMP RESlSTOR/RE~Y
v WIRBIP
B - LG
93GOF2.74
F2-29

F2 SELF-DIAGNOSlS FUNCTION
XIDE No. 1 42 (SOLENOID VALVE - WASTEGATE)-BP TURBO STEP
tNSPECTiON
ACTION
1
Disconnect connector from ECU and check if Yes Check ECU terminal connector for poor
battery voltage exists at connector terminal f H connection
(O/B) with Ignition switch ON
e If OK, replace ECU
4 tf not OK, repalr or replace connector
No Go to next step
2 in same condition as Step 1, check if battery Yes Repair wiring harness voltage extsts at solenoid valve connector
terminal-wire
NO Go to next step
3 Check if solenoid valve is OK
Yes Check for short or open circuit in wiring
.r3 page F2-46 from main relay (FUEL INJ relay) to
solenoid valve
NO Replace solenoid valve
Circuit Diagram
BA-iTERY
15A k
IGNITION SWITCH v /\: ./
WIG
B/w O/B
‘L a,
d
MAIN RELAY
(FUEL INJ)
WASTEGATE
SOtENOlD VALVE
ECU
WASTEGATE MAIN RELAY (FUEL INJ)
SOLENOfD VALVE
RIB 011 GIB WIG * LGIY L GM,
l v L/R
I
A WIG %fw
W/R
1u
10 1M 1K 71 B O/B
I I
i
B&Y B/L B;G UY Rh’ * I
I
IJB d/B WiB Wff W/R W/R B
F2-30

TURSUCHARGER CONTROL SYSTEM F2
Removal I InstaIlation
Caution
l Be carefui of following points after turbocharger removal.
l Do not carry the turbocharger by the actuator rod or actuator hose.
l Do not drop the turbocharger.
l Set the turbocharger down with the turbine shaft horizontal.
9 Cover the intake, exhaust, and oil passages to prevent dirt or other materia1 from entering.
l Use the specified new studs when installing the turbocharger.
1. Disconnect the negative battery cable.
2. Lift up the vehicle.
3.
Remove the undercover.
4. Drain
the engine coolant.
5. Remove in
the order shown in the figure.
6. fnstall in the reverse order of removat, referring to Installation Note.
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
G I’
/
43-61 (4.4-6.2, 3245)
36-42 (3.94.3, 28-
7.8-1 1 N-m (80-110 cm-kg, 6
cm-kg, 69-95
indb)
26-31
12.7~g-2. 20-231
w
19-26 (l-9-2.6, 14-19)
7.6-17 N-m (80-7 t d cm-kg, 69-95 in-lb)
N-m (m-kg, Mb]
I 93GOF2-762
F2-47

TURBOCHARGER CONTROL SYSTEM F2
INTERCOOLER
RemovaI ! Inspection / Installation
1. Remove in the order shown in the figure.
2. Inspect the intercooler for crack or damage. Replace it if necessary.
3. Install in the reverse order of removal
19-25 (1.9-2.6,
(80-l 10 cm-kg, 69-95 in-lb)
cm-kg, 69-95 in-lb) 14-
1. Air cleaner and airflow meter assembly
2. Battery cooling duct
3. Air hose
4. Bracket 5 Undercover
6. Air hose
7. I ntercooler
N-m (m-kg, ft-lb)
93GOF2-761
F2-49

F2 FUEL SYSTEM
93GOF2-775
1 93GOF2-78(
93GOF2-78:
1
93GOF2-78;
-
93GOF2-783
FUEL PUMP RESISTOR/RELAY
System Operation
I. Remove the rear seat cushion.
2,
Measure the voltage at the fuel pump connector terminal
A {G/O).
Voltage
r Crankinq Approx. 12V
I
I- Others t ACKXOX. I OV i
3. If not within specification, perform the following inspection,
and repair or replace if necessary.
l Fuel pump resistor/relay resistance. (Refer to below.)
l ECU II terminal voltage. (Refer to page F2-60.)
l Wiring harness and connector.
inspection
1.. Disconnect the connector.
2. Ground the fuel pump resister relay terminal D.
3. Apply 12V to terminal C and check for continuity between
terminals A and B.
Terminal C
12 applied
ov Continutty between A and B
NO
Yes
4. Measure the resistance between terminals E and F.
Resistance : 0.62-0.66Q [at 20% (68OF)l
INJECTOR
Volume Test
1. Remove the injectors with the delivery pipe.
2. Affix the injectors to the delivery pipe with wire.
Caution
l Affix the injectors firmly to the delivery pipe so that
no movement of the-injectors is possible.
Warning
l Be extremely careful when working with fuel.
Always work away from sparks or open flames.
3. Connect the SST to the battery and injector.
4. Check the injection volume with a graduated container.
Injection volume:
BP SUHC....44-47 cc (2.68-2.87 cu in)/15 sec.
BP Turbo
. ...87-105 cc (5.31 -6.41 cu in)/15 sec.
Caution
l When using the SST, make sure of the SST num-
ber and use correct one.
5. If nut correct, replace the injector(s).

F2 CONTROL SYSTEM
Terminal voltage [BP TURBO]
eminal input Output , 1 Connected to Test condition Correct voltage Remark
IA - - Battery Constant Approx. 12V for backup
15 0 Main relay OFF Approx. OV
(FUEL INJ relay) tgnltlon switch
-
ON Approx. 12V
1c 0 1 Ignition switch Wniie cranking Approx. 1 OV
-
(START)
lgnrtron switch ON Approx. OV
ID 0 Self -Diagnosis Test switch at “SELF-TEST” With Self-
Checker Lamp illuminated ior 3 sec. after ignition Approx. 5V Diagnosis Check-
(Monitor lamp) switch OFF* ON er and System
Lamp not illuminated after 3 sec. Approx. 12V Se’ector
Test switch at
“02 MONITOR” at idle
Monitor lamp illuminated Approx. 5V
Test switch at
“02 MONITOR” at idle
Monitor lamp not illumrnated Approx. 12’4
-lE - - - -
- -
1F 0 Self-Diagnosis Buzzer sounded for 3 sec. after ignition
Below 2.5V l With Self-
Checker switch OFF -+ ON Diagnosis
(Code Number)
Buzzer not sounded after 3 sec. Approx. 12V Checker and
Buzzer sounded Below 2.9 System Selector
l With System
Buzzer not sounded Approx. 12V Selector test
switch at
“SELF-TEST’ ’
I I 1G
0 Igniter
7H
0 Solenoid vahe
(Wastegate)
l!
0 Fuel pump
resistor/relay
I
lJ I r-Tcreiay Ignition switch ON
ld!e
Engine speed below 5,300 rpm
Engine speed above 5,300 rpm
While cranking
Idle
Ignition switch ON
AK switch ON at idle 1 Approx. OV
-
Approx. 0.2V
Approx. 12V
-
Below 1.5V
Approx. 1 OV
-
I3elow 15V
Approx. 12V
Below 2.5V
AIC switch OFF at idle Approx. 12V
-
IK 0 Diagnosis System Selector test switch at
connector
(TEN terminal)
1L - - -
- -
-
IM
t 0
1 Ground (Australia) Constant Below 1 .OV Not used
(Except Australia)
F2-60

OUTLINE G
L
i i-
OUTLINE
OUTLINE OF CONSTRUCTION
The engine electrical system of the new 323 4WD is as same as that of the new 323 ZWD.
93GOGX-703
SPECIFICATIONS
Item
Battery t
Voltaae EnginelTransaxle
v
Type and capacity
120-hour rate) BP TURBO
MTX BP SOHC
MTX ATX 12
55D23L (60AH)
I
Dark current” mA 1 Max. 20.0
Alternator
Output V-A 12-65
Regulator type Transistorized (built-in iC regulator)
1 I Regulated voltage v
74.1---14.7
Brush length Standard 21.5 (0.846)
mm (in)
Minrmum 8.0 (0.315)
Drive belt deflection
New
98 N (10 kg, 22 lb) 8-9 (0.31-0.35)
mm (in) Used 9-l 0 (0.35-0.39)
Type Direct ] Coaxicat reductron Starter Output V-W
12-U-85 12-0.95 32-l .4
8rush length Standard 17 (0.67) 17.5 (0.69)
mm [in) Minimum 11.5 (0.4531 10.0 (0.39) Distributor
Ignition timing
BTDC
FEN termrnal of diagnosis connector grounded) Electronic spark advance (photo
diode)
10 * I0 5 f lo
Ignition coil Resistance
(at 20°C [68OFj)
I
Primary
coil windinq
I
Spark plug Type I
Secondary 1
f coil windina 1
NGK
Nippon
Denso 10-76 kS-l
8KR5Ell +2 BKR5E”3
BKRGEI 1 l * BKRGE *3
KIGPR-Ull *2 KfGPR-I-Y3
K20PR-Ul l ** K20PR-U
l 3 0.81 ---o-999
pw am
Firrng order
I mm (in) 1.0-I .l (0.039-0.043)“2 0.7-0.8 (0.028-0.03i)*3
l-3-4-2
93GOGX-704
*I Dark current is the constant flow of current while the ignition switch is OFF. (i.e., engine control unit, EC-AT control unit, audro, etc.)
+’ With catalytic converter.
*3 Without catalytic converter.
G-3

G SUPPLEMENTAL SERVICE INFORMATION, STARTING SYSTEM
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Mazda 323 Workshop Manual
[1203-l O-89F (Europe), ? 204-I O-89F (Australia)].
Starter
l Removal / InstaHation
Atternator (RI-ID)
l Removal I InstatIation 93GOGX-705
STARTING SYSTEM
STARTER
Removal I Installation
I. Remove in the order shown in the figure.
2. Inspect all parts, and repair or replace as necessary.
3. lnstail in the reverse order of removal.
37-52 (3.8-5.3, 27-38)
9.8-t2 N-m
(IOO-120 cm-kg, 87-104 in-lb)
(3.8-5.3, 27-38)
9.8-12.N.m
It t \
I. Battery
(100-120 cm-kg, 87-104 in-lb)
37-52 27-38)
(3.8-5.3, 27-38)
N-m (m-kg, ft-lb)
5. Starter
Remove tram above
6.
Starter bracket 2. intake manifold bracket
3. S terminal wire
4. B terminal wire
G-4