engine MAZDA 323 1992 Suplement Manual PDF

Reading Wiring Diagrams
Loaic symbols I
ypes of logic symbols Operation Expressing output Simple relay circuits
OR
Input to A or 8 will Low electricai potential (L) at A and B +
produce output at C. no output (L) at C
A
6
D- High electrical potential (H) at A or B +
C output (H) at C
AND Input to A and B will High electrical potential (H) at A and B +
produce output at C. output(H) at C
q---J-c
Low electrical potential (L) at A or B + A
no output (L) at C
B a-00-a C
6
INV No input to A will produce Low electrical potential (L) at A -+
an output at B. no ground (H) B
An input to A will not High electrical potential (H) at A +
A- 6 produce an output at B. grounds (L) B A- 6
PROCESS Simplified representation of complex functions within circuit describes
main function. (Examples)
---
--I- 1 1. Igniters
I
-L-l Signal detector for engine control unit, cooling unit, and tachometer.
Ii- 2. r”~“-‘-‘-““‘~~‘.“’
Sbnsl conwflw :
i...-..--.---......-.~~
Signal converter for turn and hazard flasher unit and igniter unit.
Abbreviations used in this booklet
A
AAS
ABS
ACC
ACCEL
ACV
ADD
AE
AIS
ALL
ALT
EP
ANT
EV
EP
ATX
A/C
AIF
AIR
:AC
B/L
CARB
CCT
CIGAR
COMBI
CON
CONT
CPU
CSD
DEF
DOHC
ECPS Ampere
Autoadjusting Suspension
Antilock Brake System
Accessory
Accelerator
Air Control Valve
Additional
Acoustic Equilibration
Air Injection System
Automatic Load Leveling
Alternator
Amplitude Modulation
Amplifier
Antenna
Autostop
Alr Supply Valve
Automatic transmission
Atmospheric Pressure
Automatic Transaxle
Air Conditioner
Air Fuel
Auto Reverse
Battery
Bypass Air Control Valve
Bilevel
$rr$:,tor
Cigarette
Combination
Conditioner
Control
Central Procassino Unit
&Id-Start Device -
Defroster
Double-Overhead Camshaft
Electronically Controlled Power
Steering ECU
EGI
EGR
ELEC
ELR
ETR
EXH
E
FICB
FM
F/S
F/I
GEN
ET
HI
H/D
I;LUMl
INT
ISC
JB
LCD
LF
k!
z Engine Control Unit
Electronic Gasoline Injection
Exhaust Gas Recirculation
Electrio
Emergency Locking Retractor
Electronic Tuner
Exhaust
Front
Fast-Idle Cam Breaker
Frequency Modulation
Feedback
Fuel lniector
Generator
Heater
High-Energy Ignition
High
Heater/Defroster
Ignition
lllumlnation
Idle-Speed Control
Joint Box
Liquid Crystal Display
Left Front
Left Hand
Low
Left Rear
Low Wave
:I, Motor
Middle
MIL
MIN Malfunction Indicator Lamp
Minute
MIX
Mixture
MPX Multiplex
ZR Manual Transmission
MTX Mechanical Tuning Radio
Manual .Transaxie PRG
PTC
P/S ass
kc
FIF
. . .
RH
RPM
!2EL
SQ
ST
SW
TCV
TEMP
TICS
TR
TWS
V
VENT
VOL
VRIS
W Middle Wave
Normally Closed
Normally Open
Overdrive
Switch Off
Switch On
Power
Pressure Regulator Control
Solenoid Valve
Purge Solenoid Valve
Positive Temperature Coefficient
Heater
Power Steering
;im&k-Start System
Recirculation
Right Front
Right Hand
Revolutions Per Minute
Right Rear
Solenoid
Squares Per Milimeter
Start
Switch
Twin Scroll Turbocharger
Solenoid Valve
Temperature
Triple Induction Control System
Transistor
Total Wiring System
Volt
Ventilation
Volume
Variable Resonance Induction
System
Watt(s)
IO

Troubleshooting GI
Precautions to take when servicing an electrical system
l Note the following items when servicing the electrical system.
l Do not alter the wiring or electrical equipment in any way; this may damage the vehicle or cause a fire from
short-circuiting a circuit or overloading it. l
The negative (-) battery cable must be removed first and
installed last. l Do not replace with fuses exceeding specified capacity.
1OA
f5A
Zaution
o Be sure that the ignition and other switches are off
Caution
before disconnecting or connecting the battery
l Replacing a fuse with one of a larger capacity than
cables.
designated may damage components or cause a fire.
Failure to do so may damage the semiconductor
components.
0 Tape areas of the
l When mounting l Secure harnesses with provided clamps to take up slack.
harness that may rub or
components, be sure the
bump against sharp
harness is not caught or
edges to protect it from
damaged.
damage.
Zaution
B Clamp all harnesses near vibrating components
(for example, the engine) to remove slack and to
prevent contact resulting from vibration.
D Do not handle electrical components roughly or drop
them.
l Disconnect heat-
sensitive parts (for
example, relays and
ECU) when performing
maintenance (such as
welding) where
temperatures may exceed
80°C (176°F). l Make sure that the
connectors are securely
connected when
installed.
11

d-II __ EXCEPT F.R.GERMANY -CURRENT FROM BATTERY
-----CURRENT FROM IGl. IG2
-I 1--~-l-l-a-r-~ A, ,.,TiTl-TLITr r-.-a ar.1. ?I,-% ----CIJARENT FROM ACC
“-‘e 30A
I -mILLUMINATION LAMPS I-4
HiZP
r--- “f E-l
MAIN 00A FUSE l5A
q
-GA- I’LIE iHTS
---mm_
n POSITION LIGHTS E-l
TAIL 15A
-W/B
I
+-.
i-. I
i REAR WIPER
15A
-0J‘o ---- L/G _--- ;-.-&+v ---.
WIPER 20A .---$- ---. l REAR WIPER E WASHER o-2
m--c____ L _____ ;--:-; ____. l ;:E;H;E:;SHm
O-l
HEATER 30A
-- _-__ ,,,-j __-__; --me., HEATER
G
t
METER 15A : - - l COURTESY LAMPS I-3
-------B/y ---- + I
ZiUNROOF 15A : --•INTERIOR 6 SPOT LAMPS I-2
t
-oJy)--
G/O---:--- -t----.mSLIOING SUNROOF M
~~~~ .--- __ ___ n SOUN0 WARNING SYSTEM I-2
48s VALV
30A I
i
AES 60A +--t-
I mSTOF’LIGHTS F-3
ABS iOA
--- ’ ‘I ---
GNITION ! ;
iWITCH 1 I
TRUNK COMPARTMENT
‘LAMP I-3
‘mPOWER DOOR LOCK A
K-2
FUSE 30A
y-------t- --~--G/!---j--& .--- - l HEADLIGHT CLEANER O-l
I
’ . ---B/R---+-* ----
K-l
I PowE~~om!,IJ,+~~ -..---- -...;PO,.,ER WI,.,,,OWS
! I ENGINE 15A
’ I (’ I :
:.
.--
1 ----L ---- l -* ---- OJY) ---- FJ,w----l-q -..--
FUEL INJ ’ .-------------------:-L.---
’ I UENGINE CONTROL SYSTEM B-l
FUSE 20A
l REAR WINOOW DEFROSTER I-l
-- mCIGARETTE LIGHTER I-l
mAUOI0 SYSTEM J
aSTARTING SYSTEM A-l

SYSTEM CIRCUIT DIAGRAM/
CONNECTOR LOCATIONS
ENGINE-RELATED SYSTEMS EXTEFlIOFl LIGHTING SYSTEMS STARTING SYSTEM...............24 HEADLIGHTS
CHARGING SYSTEM...............26 EXCEPT F.R.GERMANY...........44
ENGINE CONTROL SYSTEM.........28 F.R.GERMANY..................46
COOLING FAN SYSTEM............36 HEADLIGHT LEVELING SYSTEM.....46
TAILLIGHTS
CHASSIS-RELATED SYSTEMS EXCEPT F.R.GERMANY...........48
ANTI-LOCK BRAKE SYSTEM........82 F.R.GERMANY.a................50
LICENSE PLATE LIGHTS
INSTFUMENT CLUSTEA-FiELATED SYSTEMS EXCEPT F.R.GERMANY...........48
INSTRUMENT CLUSTER 6 WARNING
I LAMPS........................38
BOOY-ELATED SYSTEMS WINDSHIELD WIPER 6 WASHER.....40
HEADLIGHT CLEANER.............40
REAR WIPER 6; WASHER...........42
HORNS.........................6 0
REAR WINDOW DEFROSTER.........6 4
SOUND WARNING SYSTEM..........6 6
POWER WINDOWS.................7 4
POWER DOOR LOCK...............7 6
POWER OUTSIDE MIRRORS.........7 8
SLIDING SUNROOF...............8 0
SEAT WARMERS..................8 4 F.R.GERMANY..............u.i5 ii
POSITION LIGHTS
EXCEPT F.R.GERMANY...........4 4
F.R.GERMANY..................5 0
FRONT 6 REAR FOG LIGHTS.......5 2
T;l%&HAZARD FLASHER
sTopLIGHi ..... ...............
.54
F.R.GERMANY..................5 6
EXCEPT F.R.GERMANY...........5 8
BACK-UP LIGHTS................6 0
INTERIDFI LIGHTING SYSTEMS IG KEY CYLINDER LAMP..........6 6
INTERIOR 6; SPOT LAMPS.........6 6
COURTESY LAMPS................6 8
TRUNK COMPARTMENT LAMP........6 8
ILLUMINATION LAMPS............7 0
A;~ATOEOS;DITIONING~LATED SYSTE
........................
ACCESSORIES
CIGARETTE LIGHTER.............64
DIGITAL CLOCK.................6 4
AUDIO SYSTEM..................7 2
OTHER
DIAGNOSIS CONNECTOR...........86

I-la1 = ENGINE CONTROL SYSTEM (l/3)
MAIN W/R (F) 0 ocrg\
m BOA JEJJS ROOM “27
rnn L’H(F-=-l ^T.^..^^-^
GNITION
I w
I I C (Fl
JB-04
I W/Y LG/Y W/B
0 (EM) (EM) (EM) (EM)
IA ID 1K lF
(SECTION n-1)
ENGINE CONTROL UNIT
7:: 81-03
IA
64) L .L (EM)
I I
I ’ W/R (EM)
B/W (RI
(EM1
I I B/R EM)
ThiCT”, l.lCIlT
II”.J / ““l~lL,Y I Ii
CLUSTER
(SECTEN cl -G/R +z::
t I I - ,- I
CONTROL SYSTEM
(SECTION B-lb)
I FUEL
B PUMP
(R)
I PUMP RELAY
~-_-, _-.. -, l-01 ENGINE CONTROL UNITtEM)
1” IS 10 10 1M 1K II IG 1E IC i&
R/B O/L G/B G * Xi/ L G/W x V L/R
BR/Y B/L B/G L/Y R/W * L/B O/B W/B W/y W/R
IV lT ,R !P fN IL 1J fH 1F 10 113
L-04 FUEL PUMP(R)
181-05 IGNITER (EM) 2H 2F 2D 28
91-06 CONDENSER (EM)
181-07 IGNITION COIL (EM)
I 8
I
-27 TRANSFER PUMP (Rl 161-28 FUEL PUMP RELAY (EM)
I
Y/L L/Y
B XL I i1-02 MAIN RELAY(E)
81-03 CIRCUIT OPENING
(FUEL INJ) RELAY (EM)
28

MAIN FUSE
Bl-26 FUEL PUMP
UNIT
JB-02 JOINT BOX
JBT
B: -04 FUEL PUMP
HAFINESS SYMSOL : z (I=) m (It) a (I) m (R) +++ (OH) E (IN) *f’ WI)= (EM) ?fi!! (IW)
I
B
i
ENGINE coNTRoL

3-lb l ENGINE CONTROL SYSTEM (z/3)
KNOCK CONTROL UNIT
INJECTOR RESISTOR
DISTRIBUTOR
~I-01 ENGINE CONTROL UNIT (EM)
El-09 DISTRIBUTOR IEM) B l-l 1 ISC VALVE (EM)
2Y 2w 2u 2s 20 20 2M 2K 21 26 2E 2C 2A
R/B O/L G/B G f -G/Y L G/W * R/Y L/W R -G/h-G/R * Y/L Q/B 3/LGB/O
G W/L Y/B G/O W R/B R/L G/R R/Y Y x 3/BRB/#
22 2X 2V 2T 2R 2P 2N 2L 2J 2H 2F 20 28
I-12 SOLENOID VALVE
(PURGE CONTROL) (EM) 81-14 SOLENOID VALVECPRC LOW TEMP) (EM) 81-15 INJECTOR NO.1 (INJ) 81-16 INJECTOR ~0.3 (INJ) 81-17 INJECTOR N~.~(INJ) El-18 INJECTOR No.4 (IN,
1-19 WATER THERMOSENSOEBl-24 KNOCK CONTROL LJNIfBl-25 KNOCK SENSOR00 81-29 SOLENOID VALVE
Bl-30 INJECTOR RESISTOR 81-31 SOLENOID VALVE
30

-” ‘ENGINE CONTROL SYSTEM (3/3)
FRM\IT FOG LIGHT RELAY REAR WINDOW
INsTF%+ffNT CLUSTER BLOWER
SWITCH
(SECTION G1
B/O B/O E/LG B/BA L/Y t
(EM) (EM) (EMI (EM)
I
%P
:;~~~=====~::~~~~=~~=~~
POWER STEERING
PRESSURE SWITCH
8
2-01 ENGINE CONTROL UNIT (EM) El-10 POWER STEERING PRESSURE SWITCH(F)
I” IS 10 ID 1M IK iI IG IE 1C ,A 2Y 2W 2U 25 20 20 2H 2K 21 26 2E
2C 2A
R/B O/L G/B G * -G/Y L G/W * v L/R LG L/O Y R/Y L/W R -G/d-G/F * Y/L P/B 3/LG B/O
BR/ B/L B/G L/Y R/W * L/B O/B W/B W/Y W/R G W/L Y/B G/O W R/B R/L G/R R/Y * x B/BqE/O
1” ,T
IR II’ 1N IL 1.J 1H 1F 10 16 2X 2V 2T 2R 2P 2N 2L 2J 2H 2F 2D 28
1-20 AIRFLOW METER (EM) 81-21 THROTTLE SE%;; 81-22 CLUTCH SWITCH (F) 81-23 NEUTRAL SWITCH (EM)
ii
32

ENGINE CONTROL --
HARwEss SYYBOL : a (F) m (E) a (I) m (R) +++(DR) z (IN) ^t (FFi)c (EM)= (INJ)
_ :-e*_l-,
-bGi”
B-l

Ve:BenyVdhfp
Test condttton
-roliqc lblwk
lgnhn switch ON
VI3
- bmtm
2A
28
x
2D
2E
2F
26
2H
21
2J
2K
21
2M
2N
20
2P
20
2R Test condtthw
ranabla
2s
2T
2u
2v
2W
2x
2Y
arm-up)
P
P
8°F) P
ov
ov
ov
ov
ov of sv
Approx. 2v
-
ov or 5v
tpplox. 1.5
- connected to
oveftmost warning
tluzz.af
I
I
i”e started wilh cootanl 1 Below 1.5V 1 No&ad engine 1Bo sec. alter eng
temperature is above 90% 1194°F ) and
CondilkJn
iniake air temperature is between 40%
I l@i°F) and So% (122OFj
Other condition at idle
VB
lgrition switch ON
L VE ‘Engine Signd
Idle
VFJ’ Monitor: Green
Engine speed above 2.ooO rpm during
VE and red lamps
Nash Sde”&d valve
m kw tap.)
deceteralion (alter warm-up) -
-
0 -
lanition switch ON -
-
-
-
0 lnjedor (Nos. 1. 3) -
Ignition switch ON
Idle
injector (Nos 2. 4) IgrMon switch ON
I -3 Va
I
ISC valve -
-
0
0
-
0
0
0
0
-
0
0
-
- Idle -
Lpprox. 4.01
4.!--5sv
0 of 5v Knock control unit
Engine speed above 2,GOD rf
Thio#e sensor/
Airllow mder Constant -
0 Solenoid valve
(purge conlro4) Ignition switch ON
II
-
I* I “la I
lgnitlon switch ON .-.- ._
lgnitiin swilch ON VB
-
Idle Below 1.w
210 sec. alter engine started with coolant Below 1.5V No&d engine
temperature above 90% ( 194OF) and
cofditlon
intake air temperature above 50°C
/122OF)
Other condition al idle Va - 0
0 Qrcuit-oparing
relay
sdenoid valve
(PRC high temp.) Accelerator pedal released
Accelerator pedal lully depfesw ,pprox. 0.5L
.pprox. 4.oi 22 -
1 J
Is- r,
L-7 r
2Y Zw 2U 2s 20 20 ZM 2K 21 2G 2E 2C ZA 1U IS 10 10 1M tK I, tG 1E ,C ,A
22 2X ZV 2T ZR 2P 2N 2L 2J 2H ZF 20 28 1V IT IF! ,P IN 1L 1J t” 1F 10 19 lamlion switch ON
Idle (cold engine)
Idle (alter warm-up) ov
o-l.OV
0.5-l.OV
o-0.4v
xpprox. 3.8
tipprox. 3.0
tpprox 2.5
bpprox. 2.5
Bdow 0.5v
V8 -
lncreasmg engine speed (after w
Deceleralion
lgnltro” switch ON Airllow meter -
n airflow meter intake aa
Ambient air temperalure 20°C (6
ErlQl”l? codant temperature 200(
Alter warm-up
Ignition switch ON Water
thermosensor
To&charge
rndlcator
1 I
UI “I
u-1 r
-
2Y ZW ZU ZS 20 20 2M ZK 21 2G 2E 2C ZA lU IS 10 10 1f.I 1K 11 1G 1E tC 1A
22 2X 2V 27 2P 2P 2N 2L 2J 2H ZF 2D 28 IV IT IA 1P IN IL 1.1 1H 1F ID It3
35