fuel MAZDA 323 1992 Suplement Owner's Guide

TROUBLESHOOTING GUiDE F3
15 ENGINE STALLS ON DECELERATION
IESCRIP-
l Engrne unexpectedly stops running dunng or after deceleration
[iON l Idle condition normal.
TROUBLESHOOT1NG HtNTS]
ingrne speed drops too much when releasrng accelerator
3 Idle-speed misadjustment @I Loose connector disconnected by force of deceleration
3 Fuel-cut contrd malfunction
TEP lNSPECTlON ACTION
1 1s idle condition normal? Yes Go to next step
tdle speed: 800 f 50 rpm (in neutral)
NO Adjust or perform Troubleshooting, Nos.
8-I 1 “ROUGH IDLE”
(Refer to Workshop Manual
(1203-I o-89F))
2 Is “00” displayed on Self-Diagnosis Checker Yes Go to next step
with ignition switch ON?
SYSTEM SELECT: 1 NO Service Code No. displayed
Check for cause (Refer to specified
check sequence) ET page F3-16
“88” flashes
Check ECU termrnal 1 F voltage
Voltage: Battery voltage
(ignition switch ON) r;r page F346
W:SELFTEST
e If OK, replace ECU CI page F3-3
4 If not OK, check wirtng
(ECU - Self-Diagnosis Checker)
3 Does Self-Diagnosis Checker Monitor Lamp with Yes Go to next step
lgnttlon switch UN show that switches operate
correctly?
NO Lamp not ON or OFF with specified
switch
Check for cause (Refer to specified
check sequence)
W: SEtF TEST Lamp slways ON
Check wiring between
(ECU terminal 1 D - Self-Diagnosis
Checker)
4 Are ECU ?erminal voltages OK? Yes Go to next step
(especially IV, 20, 20, ZU, 2V.
and 20) v page F346 No
Check for cause
5 Check for poor connection of foltowing parts YC?S Repair or replace
l ignrtion coil l Igniter l Olstribdor l High-tension lead
NO Go to next step l Injector. l Injector resistor l Ctrcuit-opening relay . l ECU
F3-35

F3 TROUBLESHOOTING GUIDE
STEP INSPECTION ACTlON
6 Is dashpot correctly adjusted? Yes Go to next step
c
Dashpot set speed: Approx. 3,500 rpm
No Adjust dashpot
7
Try known good ECU; does condition
Improve?
w page F3-3
13EOF3-336
16 ENGINE STALLS SUDDENLY (INTERMITTENT)
DESCRIP.
l Engine intermittently stops running
TION l Before stalling, engine conditron is OK
TROUBLESHOOTING HINTS]
@ intermittently no spark or no fuel injection caused by ve-
hlcle vibratron, acceleratton, or deceleration
l Poor connectlon in wiring harness
iTEP INSPECTION ACTfON
1 Is “00” displayed on Self-Oiagnoss Checker Yes Go to next step
with lgnltlon swrtch ON?
NO Service Code No. displayed
Check for cause (Refer to speclfled
check sequence).
Note CT page F3-16
l When checking wiring harness and
connectors, tap, move, and wiggle
suspect sensor and/or harness to
recreate problem
“88” flashes ’
Check ECU terminal IF voltage
Voltage: Battery voltage
{ignition swttch ON) w page F3-45
4 If OK, replace ECU
4 If not OK, check wiring
(ECU - Self-Diagnosis Checker)
2 Check for poor connection of foliowrng parts
Yes Reparr or replace
l lgnltfon coil l Igniter l Distributor l t-flgh-tensron lead
No Go to next step l Injector l Injector reststor l Circutt-opening relay l ECU
3 Are ECU terminal voltages OK? Yes Go to Troubleshbotrng No. 2
(especially 16, 2A, 2B, and 2C) .“CRANKS NORMALLY BUT WILL NOT
w page F3-45 START (NO COMBUSTION)”
w page F3-20
Note
. No Check for cause
l When. checking voltages, tap, move, and
wiggle harness and connector to recreate
problem
* lrlrl m-7
F3-36
7.8-l

F3 FUEL SYSTEM
t 3EoF3-344
1
FUEL SYSTEM
FUEL PUMP
inspection
Fuel pump operation
1. Connect the diagnosis connector F/P and GND terminals
by using a jumper wire.
2. Remove the fuel filler cap.
3. Turn ON the ignition switch.
4.
Listen at the filler inlet for the operational sou.nd of the fuel
pump.
5. Install the fuel filler cap.
6. If no sound is heard, measure the voltage between the fuel
pump connector (G/R) to a ground.
Voltage: 8attey vo kage
7. If not as specified, check the circuit opening relay and circuit.
8. ff as specified, check fur continuity between fuel pump con-
nector (G/R) and (B).
9. If there is continuity, reptace the fuel pump.
10. If there is no continuity, repair the ground circuit.
f3EOF3.345
13EOF3-346 FUEL PUMP RESlSTORlRELAY
System Operation
1. Remove the rear seat cushion.
2. Measure the voltage at the fuel pump connector terminal
A (G/R).
Voltage
I
Cranking
1 Battery voltage
Ignition switch ON ov 3. If not as specified, perform the following inspections, and
repair or replace as necessary.
l Fuel pump resistor/relay resistance
(Refer to page F3-41.)
l ECU 11 terminal voltage (Refer to page F3-45.)
l Wiring harness and connector
F3-40
ii e -
*
_~ --
C --
A-'

-,
-,
--
--
-1
E
7
2
I
i 3EAR SE
--

FUEL SYSTEM F3
13EOF3.34
c I 13EOF3-364 FUEL PUMP CONNECTOR
/
!NSTALL CLAMPS
I
l nspection
1, Disconnect the resistor/relay connector.
2. Ground the fuel pump resistor relay terminal D.
3. Apply battery voltage and check for continuity as shown.
Terminal C
Continuity between A and I3
Battery voltage applied NO
ov Yes
4. Measure the resistance between terminals E and F.
Resistance : 0.38--0.42Q (at 2O*C {6S°F 1)
PRESSURE REGULATOR
Inspection
Fuel line pressure
Warning
l Before performing the following operation, release
the fuel pressure from the fuel system to reduce the
possibility of injury or fire. (Refer to page F3-21.)
1. Disconnect the negative battery terminal.
2. Connect a fuel pressure gauge between the fuel filter and
the fuel main hose. (install clamps as shown.) , .
I
3. Connect the negative battery terminal.
/t.
4, Start the engine and run it at idle.
5. Measure the fuel line pressure.
Fuel line pressure:
206-255 kPa [ 2.1-2.6 kgflcml, 30-37 psi )
6. Disconnect the upper vacuum hose from the pressure regu-
lator and measure the fuel line pressure.
Fuel line pressure:
304-392 kPa (3.1-4.0 kgf/cm2, 44-57 psi )
F3-41

F3 FUEL SYSTEM
13EOt=3-349
f3EOF3-350
0
0
ECU
G
0
0 i

13EOF3-35
tNJECTOR
t nspection
injector resistance
1. Disconnect the injector harness,
2. Measure resistance of the injector.
Resistance: l-3Q (at 20°C (68*F])
3. If
not as specified, replace the injector.
Volume Test
1, Remove the injectors and delivery pipe assembly with the
conectors con netted.
2. Affix the injectors to the delivery pipe by using wire.
Warning
l Be extremely careful when working with fuet. Al-
ways work away from sparks and open flames.
Caution
l Affix the injectors firmly to the detivery pipe so that
they do not move.
3. Turn the ignition switch ON and ground the F/P terminal
of the diagnosis connector.
4. Test the individual injectors by following the procedure out-
lined in the chart below.
Test inpctor no.
1
2
3
4 Disconnect injector connector no. Ground ECU terminal
3 2u
4 2v
1 2U
2 2v 5. Check the injection volume by using a graduated container.
Injection v&tie:
105-151 cc [6.40-9.22 cu in)/15 sec.
6. If the injection volume is not as specified, replace the injector.
INJECTOR REStSTOR
Inspection
I. Disconnect the injector harness.
?. Measure resistance of the injector resistor.. .
tnjector
No.1
No.2
No.3
No.4 Measured terminals
Resistance
gg 6 0 (at 2U°C
16PF))
3. If not as specified, replace ihe injector resistor.
F3-42 _
13EOF3-352

F3 CONTROL SYSTEM
Terminal voltage
Reference date
Vs: Battery voltage
‘em&al Input Output Connected to Test condition Correct voltage Remark
1A - - Battery Constant VB
For backup
18 0 Main relay
Ignition switch OFF ov
(FUEL INJ relay) -
ON
V8
1C 0 lgnitlon switch While cranking Approx. 1 OV
(START) -
Ignition switch ON ov
10 0 Self-Diagnosis Test switch at SELF TEST
Wtth Self-
Checker Lamp illuminated for 3 sec. after ignition Approx. 5V
(monitor lamp) switch OFFdON Diagnosis Check-
er and System
lamp not iltuminated after 3 sec. V8 Selector
Test switch at 02 MONITOR with engine
idling Approx. 5V
Monitor lamp illuminated
Test switch at 02 MONITOR with engine
idling Vi3
Monitor lamp not illuminated
IE - - - - - -
IF
0 Self-Diagnosis Buzzer sounded for 3 sec. after ignition
Below 2SV
l With Seif-
Checker switch OFF-+ON
Diagnosis
(service code)
Buzzer not sounded after 3 set V0 ’ Checker and
Buzzer sounded Below 2.5V System Selector
l With System
Buzzer not sounded VB Selector test
switch at SELF
TEST
1G 0 igniter tgnition switch ON
ov
-
Idte
Approx. 0.2V
It-l 0
Solenoid valve Ignition switch ON
VB
(wastegate)
Idle
Approx. 2V ’ -
II
0 Fuel pump While cranking
Approx. 1 OV
resistor/relay -
Idle
8etow 1.5V
IJ 0 NC relay Ignition switch ON
VB
A/C switch UN at idle
Below 2.5V
. NC switch OFF at idle V3
-
IK 0 Diagnosis
connector
(TEN terminal) System Selector test switch at
02 MONITOR
System Selector test switch at
SELF TEST V0
-
8elow l*OV
1L - - - - - -
I
1M - - - - -
I -
lr ‘- l-7
f L.-
r
20 20 2M 2K 21 2G 2E 2c 2A IU 1S 10 10 ltvl tK II Ir; tE 1~ IA
1
22 2x 2v 2T ZR 2P 2N 2L 25 2H 2F 20 2B 1V IT 1R tP 1N IL 1J 1H IF 1~ 1~
1
J=3-46 --
4lways 4
--
AIways 4
--
Atways 1
--
Always 1
-a
Always ’
--
Always i
-e
Always I
2.5v
Always
Always (
-m
Always f
-a
Always 1
Always (
--
Always I
2.5V
Always 1
Always t
Always
--

,,1
CONTROL SYSTEM F3 ‘1
Va: Battew voltage
Incorrect voltage Possible cause
Always OV
l ROOM IOA fuse burned l Open circuit In wiring from ROOM 10A fuse to ECU termina! 1A
Always OV
l Main relay malfunction l Open or short circuit in wiring from main relay to ECU terminal IB
Always OV (starter turns)
l Open or short circuit in wiring from ignition switch to ECU terminal IC
Always OV
Always VB
l Maln relay (FUEL INJ relay) malfunction l Open circuit in wiring from main relay to diagnosis connector terminal +B l Open or short circuit in wiring from diagnosis connector terminal MEN to
ECU terminal 1 D
l Poor connection at ECU connector l ECU malfunction
Always approx. 5V . ECU malfunction
Always below
2.5v
Always Ve -
-
No display on Self- * Main relay (FUEL INJ relay) malfunction
Diagnosis Checker
l Open circuit in wiring from main relay to diagnosis connector terminal + B
“88” displayed and
l Open or short clrcurt in wiring from diagnosis connector terminal FEN to
buzzer sounds con- ECU terminal tF
ti nuousl y
l Poor connection at ECU connector l ECU malfunction
Always QV
l Short circuit in wiring from igniter to ECU terminal 16
Always OV or VB
l Refer to Code No.42 Troubleshooting
(Refer to 323 4-Wheel Drtve Workshop Manual (12?9-IO-89L))
Always VB
Always OV
Always below
2.5V
Atways Ve I ’
l Fuel pump resistor/relay malfunction
l Open or short circurt in wiring from ECU terminal II to fuel pump resis-
tor/relay
A/C does not operate
l A/C reiay malfunction l Open circuit in wiring from ignition switch to A/C relay l Open circuit in wiring from A/C relay to ECU terminal 1J
A/C switch
OFF but l Short circuit in wiring from AIC relay to ECU terminal 1 J
A/C operates . ECU malfunction
l Poor connection at ECU connector l ECU malfunction
Always below 1 .OV a Short circuit in wiring from diagnosis connector terminal TEN to ECU termi-
nal 1K
Always Vs
l Open circuit In wiring from diagnosis connector terminal TEN to ECU terml-
nal IK
-
-
l Open circuit in winrig from diagnosis connector terminal GND to ground’
-
I -
.
. .
-. F3-47

VB: Battery voltage
Incorrect voltage Possible cause
Always OV
l Open or short &curt in wirtng from ECU terminal 25 to buzzer
Always OV or VB
l Refer to Code No.25 Troubleshooting (Refer to page F3-18)
-
Always OV l Main relay (FUEL INJ relay) malfunction l Open or short crrcult rn wlnng from Injector to ECU termtnal 2U or 2V
Always Va
l ECU matfunctlon
Always OV or VB
Always OV or VB
Always OV
Atways OV or VB
l Refer to Code No.34 Troubleshooting
(Refer to 323 Workshop Manual (1203-t O-89F))
l Refer to Code No.26 Troubleshooting
(Refer to 323 Workshop Manual (1203-lO-89F))
l Open or short circuit in wiring from ECU terminal 2Y to relay
l Refer to Code No. 35 Troubleshooting (Refer to page F3-18)
F3-53

R OUTLINE
OUTLINE
OUTLtNE OF CONSTRUCTION
l The%onstruction and operation of the suspension system are basically the same as for previous models.
l The coil spring and shock absorber specifications are changed.
l The stabilizer specifications are changed.
SPECIFICATIONS
13EORX-302
Front suspension
Suspension type
Sprmg type
Shock absorber
Stabrlmr
Specifications
Strut
Coil spring
Oil filled Total toe-rn
Front
wheel
atignment
(‘Unladen)
Rear suspension
Suspensron type
Sprmg type
Shock absorber
Stabrlrzer
Rear wheei
alrgnment
(‘Unladen) Maximum steering 38* f 3*
309 f 30
-0045 f 45’
2035’ f 45’
KIngpin angle degree
12*to’
We Oil fifled
Damprng force N [ kgl Ibf 1 .‘? .@g,$g&;qJ&,$. ‘: ‘., . . ” ‘, : :,
at 0.3 m 112
]ls I Contraction ;. ~ .. . . . . .__. ..:, .. .. ,I. ._ :. . . f: ; _... .:
Type Torsion bar
Diameter mm. f in ]
19.t (0.751
Total toe-in mm fin!
2.h 3 (0.08 f 0.121
degree
O”12’ f 18’
Camber angle degree -0°20’ f 45’
13EORX-303
l Fuel tank full, radrator coolant and engine oil at speclfled levels; and spare tire, jack, and tools in designated positions. Front Coil Spring Specifications
1 Identification mark color Wire diameter Coif .center
M l l
I Free length A a2 mm lin)
diameter mm [in) . mm 1 in) Coil number Rear Coil Spring Speci?ications
ldentlfication mark color M” Wire diameter Coil center
Free length
mm {in) diameter mm 1 in J
mm {in) Coil number
*’ Maln Identlfcatlon mark on second cgil from bottom.
*’ Auxrllary &entificatton mark on thrrd coil from bottom.
Shaded areas tndcate
new specifrcat+ons 13EORXCS05
(I .f

TO TECHNICAL DATA
FUEL AND EMISSION CONTROL SYSTEMS
Item.
Idle speed
tgf-don trrmng-
Fuel pump
MaxImum output pressure
Transfer pump
Maximum output pressure
Fuel filter Engine
rPm
BTDC
kPa [ kgf/cm2, psi 1 1
kPa { kgflcm2, PSI ) 1 BP OUHC turbo
800 f 50
10 l 10
490-736 (5.0-7.5, 71-1 IO]
39 10.4, 5.7 ) or higher
I Type
Low-pressure side Nylon element (in fuel pump)
Hiah-Dressure side PaDer element
Pressure regulator
Regulating low kPa ( kgflcm2, psr 1 265-314 (2.7-3.2, 38-46 1
pressure High kPa { kgflcm2, psr 1 304-392 (3.1-4.0, 44-57 1
lniector
_ Type Low-ohmic
Type of drive
Electromechanical
Resistance q
Approx. 2.11 Q (at 20% ( 68*f )]
lniector reslstor
L - Resistance/injector
Idle-speed control (tSC) valve
TvDe n 1 6 [at 20°C 168OFjj
I Rotarv
Resistance
Solenoid valve (purge control)
Resbstance
Solenoid valve {wastegate)
Resistance n(
R I
i-l I 1 t-13 [at ZO*C {68OF j]
23-27 tat 20°C l68OFll
. r.
33-39 lat 20°C I68OF 11
Solenoid valve (PRC)
Resistance Low temp. q
33-39 [at 2O*C {SS*F]]
High temp. 0 1 33-39 [at 20°C (68OF]]
Water thermosensor
-20°C ( -4OFJ 1 14.6-17.8
Resistance kQ 2o”c I 68OF) 2.21-2.69
40°C ( tO4OF) 1.0-l 3
80°C I176OFJ 0.29-0.35
Airflow meter
Resistance R E244Vs
E2*Vc Fuity closed
Fully open I 20-600
20- 1,000
200-400
EP++THAA
(intake air
thermosensor) -2O*C ( -4OFj 1 13,600-l 8,400
20% 1 68OF) 1 2,210-2,690
6O*C 114OOFl i 493-667
EI ~Fc
I Fully closed 00
0 1
Oxygen sensor (ceramic beater coil)
Resistance
Fuel tank Approx. 6 [at 20°C f68OF)]
I CaDacW L I US oal. ImD aal I I 60 I 15.9, 13.2 I
I
Air cleaner
Element type
Fuel
Specrficatioir Oil permeated
Unteaded premium (RON 95 or higher)
l TEN terminal of diagnosis connector grounded. .
-
ENGINE ELI
3attery
I
Dark current’
Alternator
Starter
Distributor qr
Ignition timin?
ffEN terminal
Ignition coil
Spark plug
l ’ Dark current
r2 Standard pl