engine MAZDA 232 1990 Suplement Manual Online

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

F2 CUNTRULSYSTEM
‘erminal Input Output i Connected to Test condition Correct voltage Remark
2A - - ’ Ground {Injector)
Constant OV -
2B - - I Ground (Output)
Constant OV -
2c , - - 1 Ground (CPU)
Constant OV - 20
-i- Ground (Input) Constant
OV -
2E ’ 0 1 Distributor I
Ignition switch ON Approx. OV
(Ne-signal)
or 5v -
Idle Approx. 2V
2F -j- - - - -
2G 0
Distributor ignition switch ON Approx. OV
(G-stgnal) or 5V
Idle Approx. I.3
2t-I - - -
- - -
21 - - - - - -
2J C
Knock control unit
Idle Approx. 4. OV -
2K 0
Thronle sensor/ Constant . 4.5--5.W
Airflow meter
-
2L
- -
- - - -
I
2M 0 Throttle sensor
Accelerator pedal released Approx. 0.W
-
Accelerator pedal fully depressed Approx. 4.W
2N 0
20 0
2P 0
1
2Q ! 0
2R Oxygen sensor
Airflow meter
Intake air
thermosensor
Water
thermosensor 0
’ Turbocharge
indicator Ignition switch ON
f OV
Idle (Cold engine) ov
Idle (After warm-up) O-l .ov -
Increasing engine speed [After warm-up) 0.5-I .ov
Deceleration o-0.4v
ignition switch ON
’ Idle Approx. 3.8V
-
Approx. 3.OV
Ambient air temperature 20°C (68OF) Approx. 2SV In airflow meter
Engine coolant temperature 20°C (68OF) Approx. 2.5V
-
After warm-up
Below 03
Ignition switch ON
Approx. f2V
-
F2-64

F2 CONTROLSYSTEM
Terminal I Input Output Connected to Test condition Correct voltage Remark
25 0
Overboost warning lgnltion switch ON Approx. 12V
-
buzzer
2T 0 1 Solenoid valve 180 seconds atter engine started when Below 1 SV
(Pressure regulator) engine coolant temperature above 90%
(I 94OF) and Intake air temperature above -
58OC (13WF)
1 Other condition at Idle Approx. 12V
2u 0 Injector (Nos. I 1 3) Ignrtion switch ON Approx. 12V * Engine Signal
Idle Approx. 12V’ Monitor: Green
and red lamps
Engrne speed above 2,000 rpm on de- Approx. f2V
flash
celeratlon (Atter warm-up)
2v 0 Injector (Nos. 2, 4) lgnitlon swrtch ON Approx. 12V
Idle Approx. 12V’
Engine speed above 2,000 rpm on de- Approx. 12V
ceieration (After warm-up)
2W 0
ISC valve Ignition switch ON Approx. 7V
-
Idle Approx. 9V
2x 0 Solenoid valve Ignition switch ON Approx. 12V
(Purge control)
t Idle -
Approx. f2V
t
2Y 0 Cmxit opening Ignition switch UN Approx. 12V
-
relay
Idle Below 1 .OV
22 - - - - - -
-L J
u-
v I U-1 l-
2y 2w 2u 2s 20 20 2M 2K 21 2G 2E 2C
2A 1U 1S IQ 10 1M 1K 11 1G 1E IC 1A
22 2X 2V 2T 2R 2P 2N 2L 2.J i’t-( 2F 2D 2B 1V 1T 1R tP IN IL I..! ItI IF
tD 18
F2-66

F2 CONTROL SYSTEM
93GOF2-79; 2
93GOF2-793
93GOFZ794
1
OXYGEN SENSOR [BP TURBO]
Inspection
Sensor
1. Warm up the engine to normal operating temperature.
2. Disconnect the oxygen sensor connector.
3. Connect a voltmeter to the oxygen sensor terminal @.
4. Run the engine at 4,500 rpm untiI the voltmeter indicates
approx. 0.7V.
5. Increase and decrease the engine speed suddenly and
measure the vottage.
Voltage
Engme speed Voltage (v-)
Decelerating o-0.4
Accelerating 0.5-l .o 6. Connect the
SSTs to the diagnosis connector.
7. Set the system selector select switch to 1 and the test switch
to 02 MONITOR.
8. Increase the engine speed to
between 2,000 and 3,000
rpm, and verify that the monitor lamp flashes for 10 seconds.
Specification:
Monitor lamp flashes more than 8 times/IO sec.
Heater 1. Disconnect the oxygen sensor connector.
2. Check resistance between oxygen sensor connector ter-
minals @ and 0.
Resistance: Approx.-6& [at 20°C (68OF)]
Replacement 1. Disconnect the oxygen connector. ’
2. Remove the oxygen sensor.
3. Install the new oxygen sensor and new washer.
4. Tighten the oxygen sensor to specified torque.
Tightening torque:
29-49 N-m (3-5 m-kg, 22-36 ft-tb)

G
ENGINE ELECTRICAL SYSTEM
INDEX . ..I 1.. . . . . . . . . . . . . . . . . . . . . . . ..*. . . ..I..... . . . . . ..I...
G- 2
j FEATURES 1
OUTLINE . . . . . . . . . ...*....* .I.............. .I . . . . . . . . . . . . . .
G- 3
OUTLINE. OF CONSTRUCTION ..I... . . . . . . . . . . . G-
3
SPECtFICATiONS . . . . . . . . . . . . ..I............... . . . . . .
G- 3
1 SERVICE 1
SUPPLEMENTAL SERVICE INFORMATION . . G- 4
STARTING SYSTEM
. ..I. . . . . . . . . a.. . . . . . . . . . . . . . . . . . . G- 4
STARTER
l ..I.... . . . . . . . . . . . . . . . . . . l .*.....* .I....... . . . G- 4
CHARGlNG SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G- 5
PREPARATION
. . . . . . . . . . . . ..I..-... . . . . l . . . . . . . . 1. . . . . G- 5
ALTERNATOR (RHD)
. . . . . . . . . . . . . . . . . . . . . . . . . . ...*. G- 5
93GOGX-701

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

H OUTLINE
OUTLINE
OUTLINE OF CONSTRUCTION
A hydraulic clutch control mechanism is used.
The basic construction is the same as that of 323 2WD model, but there is no interchangeability of parts
except for the release cylinder.
1. An assist/return spring is used on the BP DOHC Turbo model to reduce the required clutch pedal effort..
2. The hydraulic clutch master cylinder for the 8P DOl-lC Turbo model has a built-in check valve.
3. To improve clutch operation feeling and increased parts life, a friction plate and needle roller bearings
are used between the release fork and the release bearing.
93GOHX-704
SPECIFICATIONS
Hem
Clutch control Engine/Transaxle
BP SUHC BP DOHC Turbo
GSMX-R
Hydrautic
Clutch cover
Type
Set load
N (kg, lb) Diaphragm spring
3,846 (392, 862) 5,494 (560, I ,232)
Outer diameter 1
mm (in) 225 (8.858) 230 (9.055)
I 1 nner diameter mm (in)
I 150 (5.906)
I 155 (6.102) I
CI utch disc
Pressure plate side
mm {in) 4.1 (0.161) 3.2 (0.126)
Thickness f
Flywheel side
mm (in) 3.5 (0.138) 3.2 (0. f 26)
I Type I Suspended
I
Clutch pedal LHD 6.55 Pedal
ratio
RHD 6.7
Full stroke mm (in)
I 135 (5.32)
I
Height (With carpet) mm [in)
I I 96-204 (7.72-8.03)
I
Master cylinder Inner diameter
mm {in)
I 15.87 (0.625)
Release cylinder inner diameter
mm (in)
I - 19.05 (0.750)
I
Clutch fluid SAE J1703 or FMVSSI 16 DOT-3
93GOHX-705
H-4

CLUTCH CONTROL H,
CXUTCH CONTROL
CLUTCH PEDAL
l An assistireturn spring is used on BP DO-K Turbo engine-equipped models to reduce the required pedal
effort.
l The assist/return spring is mounted vertical to the pedal for a compact arrangement.
wiNGi B G”3 * RANGE A
RANGE B + + RANGE A
Operation With the clutch pedal fully
released, the assist/return spring is compressed, causing force F to act upon ful-
crum 0,
As a result, force Fy is created, and acts upon fulcrum @ to hold the pedal outward.
1 1 When clutch pedal depressed.
(1) Fukrum @ within range A
When the pedal is depressed, it moves inward, centered upon fulcrum @.
Fy, which is the force opposing pedal movement, acts upon futcrum @ until fulcrum @ crosses the
imaginary line connecting fulcrums
@ and @
As a result, there is a slight feeling of resistance when the clutch pedal is first depressed.
(2) With fulcrum @ within range 8
When fulcrum @ crosses the imaginary line between fulcrums @ and @, Fy now acts in the same
direction as pedal
movement, thus reducing the force required to depress the pedat.
H-5

SUPPLEMENTAL SERVICE INFORMATION, TROU8LESHOOTlNG GUIDE H
SUPPLEMENTALSERVICE INFORMATION
The following points in this section are changed in comparison with 323 Workshop Manual (1206IO-89F).
Troubleshooting guide
Clutch fluid (with ABS)
l Replacement
Clutch pedal (BP DOHC Turbo) Clutch release cylinder (with ABS) l Air bleeding
Clutch unit
l Removal I Inspection I installation
Clutch master cylinder
(BP DOW Turbo or with ABS) l Removal I Inspection I installation
93GOHX-710
l Removal I Inspection I Installation (BP DUHC Turbo)
l Air bleeding (with ABS)
l Overhaul (BP DUHC Turbo)
TROUBLESHOOTING GUlDE
Problem
Possibte Cause Remedy Page
Slipping
Clutch disc facing worn excessively
Replace U-l 9
Clutch disc facing surface hardened or oifed
Repair or replace H-l 9
Pressure plate damaged Replace H-19
Diaphragm spring damaged or weakened
Replace H-l 9
Insufficient clutch pedal piay
Adjust H-12
Clutch pedal sticking
Repair or replace U-11
Flywheel damaged
Repair or replace H-19
Faulty
Excessive runout or damaged clutch disc
Replace H-19
disengagement
Clutch disc spiines rusted or worn ’
Remove rust or replace H-l 9
Clutch disc facing oiled
Repair or replace H-19
Diaphragm spring weakened
Reptace H-19
Excessive clutch pedal ptay
Adjust -
Insufficient clutch fluid
Add fluid H-10
Leakage of clutch fluid
Locate and repair or -
replace
Clutch vibrates
Clutch disc facing oiled
Repair or replace H-l 9
when accelerating
Torsion rubbers weakened
u-19 Clutch disc facing hardened or damaged Replace
Repair or replace H-19
Clutch disc facing rivets loose
Replace H-l 9
Pressure plate damaged or excessive runout
Replace H-l 9
Flywheel surface hardened or damaged
Repair or replace H-19
Loose or worn engine mount
Tighten or replace -
Clutch pedal
sticking Pedal shaft not properly lubricated
Lubricate or replace H-l 1
Asistireturn spring damaged or poor adjust
Replace or adjust H-11, 12
Abnormal noise
Clutch release bearing damaged
Replace N-1 9
Poor iubrication of release bearing sleeve
Torsion rubbers weakened Lubricate or replace H-19
Replace u-t9 Excessive crankshaft
end play
Repalr -
Pilot bearing worn or damaged
Replace H-79
Worn pivot points of reiease fork
Repair or replace H-19

J3 OUTLtNE
OUTLINE OF CONSTRUCTION
l Full-time 4-wheel drive, incorporating a viscous coupling is used on the BP DUHC Turbo model. BP SUHC
engine equipped models are fitted with an electronically controlled, lockable center differential.
With this system all driving conditions are easily contended with; from good roads to bad roads and
ad-
verse weather conditions.
l The transaxle and transfer unit were developed based on the GSM-R type transaxle.
The transaxle, center differential, viscous coupling, and front differentia! are a single, compact unit.
l The center differential employs a planetary carrier. system and a viscous coupling, and functions to distrib-
ute the driving force to the front and rear differentials as needed.
Through the use of this center differential, tire scuffing common to 4-wheel drive vehicles during tight cor-
nering, is eliminated.
l The speedometer driven gear (for detection of vehicle speed) is installed in the transfer carrier and detects
the speed of the rear wheels.
l Lubrication oil of the transaxle and transfer unit and of the carrier is contained separately.
93GOJ3-704
J3-4