MAZDA 323 1989 Factory Repair Manual

SELF-DIAGNOSIS FUNCTION F
SWITCH MONITOR FUNCTION
Individual switches can be inspected by the SST (Self-Diagnosis checker).
Note
l The TEN terminal of the diagnosis connector must be grounded and the ignition switch ON
(engine stopped).
l If either of the switches remain activated, the monitor lamp will be illuminated.
ECU
NEUTRAL SWITCH (MTX)
CLUTCH SWITCH (MTX)
=d-’ 1
BATTERY
INHIBITOR SWITCH (ATX)
STOPLIGHT SWITCH (MTX)
HEADLIGHT SWITCH MONITER LAMP
REAR WINDOW (SELF-DIAGNOSIS CHECKER)
DEFROSTER SWITCH
AIC SWITCH
BLOWER SWITCH
THROTTLE SENSOR asp-
- _
COOLING FAN SWITCH
03UOFX
Switch
Clutch switch
Neutral switch (MW
(M-W Self-Diagnosis Checker (Monitor lamp)
Light ON Light OFF Pedal released Pedal depressed
In gear Neutral Remark In gear
Clutch pedal released
Inhibitor switch
(ATX) L, S, D or R range
N or P range -
Throttle sensor Pedal depressed (Not fully) Pedal released/fully depressed -
Stoplight switch
Pedal depressed Pedal released -
Headlight switch
ON
OFF Headlights/parking lights: ON
Blower switch
ON
OFF Blower switch at 2nd or
above position
AIC switch
ON OFF Fan speed control at 1st po-
sition
Rear window defroster
switch ON
OFF -
Water thermoswitch Fan operating Fan not operating -
23UOFX-084
F-l 05

SELF-DIAGNOSIS FUNCTION
Inspection Procedure
1. Connect the SST (System Selector) to the diagnosis con-
nector.
2. Set the switch @ to position 1.
3. Set TEST SW to SELF-TEST.
03UOFX.090
MONITOR LAMP
T
03UOFX-091
Procedure
4. Connect the SST (Self-Diagnosis Checker) to the System
Selector and a ground.
5. Set the select switch of the Self-Diagnosis Checker to posi-
tion A.
6. Turn the ignition switch ON.
7. Check if Monitor Lamp illuminates when each switch is made
to function as described below.
Caution
* If either of the switches remain activated, the mon-
itor lamp will be illuminated.
l Do not start the engine.
I
I Set conditions to deactivate each switch l All accessories OFF l Transaxle in neutral l All pedals released NO
-
Verify that monitor lamp does not illuminate
YES
Check each switch as described Check each switch and related wire harness
*Clutch and Neutral CT- pages F-l 72,173
switch
*Throttle sensor w page F-169 l Stoplight switch c7 Section T l Headlight switch c7 Section T l Rear defroster switch T;P Section T l Blower switch [r+ Section T
l Inhibitor switch a Section K l A/C switch 0 Section U l Water thermoswitch c7 Section E
23UOFX-OS!
Neutral and Clutch switch (MTX)
Shift transaxle into gear
Check that monitor lamp illuminates with clutch pedal
released
YES NO PC: l Neutral switch malfunction a page F-173 l Clutch switch malfunction w page F-172
*Open circuit in related wire
harness
l ECU terminal 1 V voltage
incorrect w page F-152
l ECU malfunction
Depress clutch pedal
Check that monitor lamp does not illuminate
Return transmission to neutral PC:
*Clutch switch malfunction w page F-172
23UOFX-088
F-l 06

SELF-DIAGNOSIS FUNCTION
Headlight switch
Turn headlight switch ON
Check that monitor lamp illuminates
YES
Headlight switch OK
Turn headlight switch OFF NO
PC: l Headlight switch malfunction v Section T
*Open circuit in wire harness
from headlight switch to ECU
l ECU terminal 1 U (MTX) 1 H
(ATX) voltage incorrect CT page F-152
l ECU malfunction
23UOFX-087
Rear window defroster switch
Turn rear window defroster switch ON
Check that monitor lamp illuminates
YES
Rear defroster switch OK
Turn rear window defroster switch OFF NO
_ PC: *Rear window defroster switch
malfunction c7 Section T
*Open circuit in wire harness
from rear window defroster
switch to ECU
l ECU terminal 1 T (MTX) 1 J (ATX)
voltage incorrect
u page F-152
l ECU malfunction
23UOFX-088
Inhibitor switch (ATX)
Shift transaxle into L, S, D, or P range
Check that monitor lamp illuminates
YES
Inhibitor switch OK
Shift into P or N range PC: l Inhibitor switch malfunction
*Open or short circuit in related
23UOFX-089
F-l 07

SELF-DIAGNOSIS FUNCTION
Throttle sensor
Depress accelerator pedal (not fully) and check that
monitor lamp illuminates
YES NO
PC: *Throttle sensor malfunction CT page F-169
*Short circuit in wire harness
from throttle sensor to ECU
*ECU terminal 1 N (MTX) 1T
(ATX) voltage incorrect CT page F-150
l ECU malfunction
Depress acceleration pedal fully and check that monitor
No : PC: *Throttle sensor malfunction w page F-169
lamp does not illuminate *Open circuit in wire harness
from throttle sensor to ECU
YES *ECU terminal 2L (MTX) or 21
(ATX) voltage incorrect a page F-154
Throttle sensor OK
Release accelerator pedal
23UOFX-090
Stoplight switch
Depress brake pedal
Check that monitor lamp illuminates
YES
Stoplight switch OK
Release brake pedal NO
PC: *Stoplight switch malfunction w Section T
*Open circuit in wire harness
1
from stoplight switch to ECU
*ECU terminal 10 (MTX) 1Q
(ATX) voltage incorrect CT page F-l 52
l ECU malfunction
23UOFX-091
Blower switch
---
Turn blower switch to 2nd or higher position
Check that monitor lamp illuminates
YES
Blower switch OK NO
__L PC: *Blower switch malfunction
*Open circuit in wire harness
from blower switch to ECU
l ECU terminal 1 S (MTX) 1 P
(ATX) voltage incorrect
l ECU malfunction p Section T
w page F-152
23UOFX-092
F-l 08

INTAKE AIR SYSTEM F
INTAKE AIR SYSTEM
COMPONENT PARTS
Removal / Inspection / Installation
1, Remove in the order shown in the figure, referring to Removal Note.
2. inspect the intake air system components visually and repair or replace if necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
BP DOHC
19-25 (1 .Q-2.6, 14-19)
A
7.8-11 N.m
7.6-11 N.m
160-l 10 cm-kg, 69-95 i / REPLACE
/ O-RING,
mm
RFPLACE 19-26 (1.9-2
I n
.6, 14-19)
-11 N.m
-110 cm-kg,
-95 in-lb)
(29-41 cm-kg,
25-36 in-lb)
I 7.6-l 1 N.m (60-l 10 cm-kg,
69-95 in-lb)
19-25 (1.91-2.6,
14-19)
N.m (m-kg, ft-lb)
-
23UOFX-093
1. Resonance duct
8. Throttle body
Inspect for damage
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F-l 12
2. Air cleaner
9. Dashpot
Inspect for excessive dirt or damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page F-l 42
3. Air cleaner element
10. ISC valve
Inspection . . . . . . . . . . . . . page F- 79 Inspection . . . . . . . . . . . . . .
page F-l 16
4. Airflow meter
11. Dynamic chamber
Inspection . . . . . . . . . . . . . ,............,...,.. page F-l 68 Removal note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
F-l 12
5. Resonance chamber
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page F-l 12
Inspect for damage 12. Air valve
6. Air hose
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F-l 16
Inspect for damage 13. Intake manifold bracket
7. Accelerator cable 14. intake manifold
Inspection I Adjustment . . . . . . . . . . . . . page F-l 14 Installation
note . . . . . . . . . . . . . . . . . . . . . . . . . page F-l 13
F-l 09

F
BP SOHC
INTAKE AIR SYSTEM
IQ-25 (1.9-2.6, 14-19)
.6-6.5 N.m
6-66 cm-kg,
m IQ-25 (1.9-2.6, 14-19)
IQ-26 (Id--2.v4-19) -Bu 1
.6-11 N.m
O-110 cm-kg, 69-95 in-lb)
N.m (m-kg, ft-lb)
23UOFX-0 94
1. Resonance duct 8. Throttle body
Inspect for damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F-l 12
2. Air cleaner 9. Dashpot
Inspect for excessive dirt or damage Inspection ,.,..,.......,................... page F-l 42
3. Air cleaner element 10. ISC valve
inspection ..,........,..................... page F- 79 inspection ,.,..,.........................I. page F-l 16
4. Airflow meter 11. Dynamic chamber
Inspection ..,..,.....,.......,.......,..... page F-l 68 Removal note ..,.......,................. page F-l 12
5. Resonance chamber 12. Air valve
Inspect for damage Inspection ,..., ,.... ..,..,................. page F-l 16
6. Air hose 13. Intake manifold bracket
Inspect for damage 14. Intake manifold .___
7. Accelerator cable Installation note . . . . . . . . . . . . . . . . . . . . . . . . . page F-l 13
Inspection / Adjustment. . . . . . . . . page F-l 14
F-110

INTAKE AIR SYSTEM F
B6
4.6-6.6 N.m (46-66 cm-kg, 40-67 in-lb)
19-25 (1.9-2.6, 14-19)
GASKET, REPLACE
?.6--ll N.m
IO-110 cm-kg,
19-95 In-lb)
7.6-11 k.m KY
- CASKET, REPLACE (60-I 10 cm-kg,
69-95 in-lb)
\I
I 19-z (1.9-2.6, 14-19) V
N.m (m-kg, ft-It
23UOFX-0
1. Resonance duct 8. Throttle body
Inspect for damage Inspection ,,,.,.,,“,,,.,................... page F-l 12
2. Air cleaner 9. Dashpot
Inspect for excessive dirt or damage Inspection ..,...........,.................. page F-l 42
3. Air cleaner element 10. ISC valve
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F- 79 Inspection . . . . , . . . . . . . . . . . . . . . . . . . . . . . page F-l 16
4. Airflow meter 11. Dynamic chamber
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F-l 68 Removal note. . . . . . . . . . . . . . . . . . . . . . . . . . . . page F-l 12
5. Resonance chamber 12. Air valve
Inspect for damage Inspection . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F-l 16
6. Air hose 13. Intake manifold bracket
Inspect for damage 14. Intake manifold
7. Accelerator cable Installation note . . . . . . . . . . . . . . . . . . . . . . . . . page F-l 13
inspection I Adjustment .,........... page F-l 14
F-III

F INTAKE AIR SYSTEM
1 03UOFX.103
OSUOFX-I 04
1
F-112
I 03UOFX.I 05
OSUOFX-10
OSUOFX-10
THROTTLE BODY
Inspection
1. Check the throttle body for wear and deposits.
2. Check if the throttle valve moves smoothly when the throt-
tle lever is moved from fully closed to fully open.
3. Replace the throttle body if necessary.
Caution
l Do not remove the thin seal coating from the throt-
tle valves or bore.
DYNAMIC CHAMBER
Removal Note
BP DOHC
l Raise the vehicle to remove the four bolts shown in the
figure.
BP SOHC
l Raise the vehicle to remove the five bolts shown in the figure.
B6
l Raise the vehicle to remove the three bolts shown in the
figure.
Inspection (BP DOHC)
1. Check the shutter valve for wear and deposits.
2. Check if the shutter valve is fully open and moves smooth-
ly from fully open to fully closed.

INTAKE AIR SYSTEM F
I 23UOFX-096
INTAKE MANIFOLD
Installation Note
BP
1, Tighten the bolts in the order shown in the figure.
Tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
B6
1. Tighten the bolts in the order shown in the figure.
Tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
2. Refill the radiator with the specified engine coolant.
(Refer to page F-78.)
3. Check for engine coolant leakage.
F-113

F INTAKE AIR SYSTEM
ACCELERATOR PEDAL
Removal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
CLIP, REPLACE
N.m (cm-kg, in-lb)
23UOFX-OF
1. Accelerator cable 3. Clip
Inspection / Adjustment . . . . . . . . . . . . . page F-l 14 4. Return spring
2. Retainer 5. Accelerator pedal
23UOFX-OE
F-114
ACCELERATOR CABLE
Inspection I Adjustment
1. Depress the accelerator pedal fully. Check if the throttle valve
is fully opened.
2. Inspect the play of the accelerator cable.
Play: 1 .O-3.0mm (0.04-0.12 in)
3. Loosen the nuts @to adjust the play if necessary. ._ ,