fuel filter MAZDA 323 1992 Workshop Manual Suplement
[x] Cancel search | Manufacturer: MAZDA, Model Year: 1992, Model line: 323, Model: MAZDA 323 1992Pages: 279, PDF Size: 24.15 MB
Page 22 of 279

SCHEDULED MAINTENANCE SERVICES A
SCHEDULED MAINTENANCE SERVICES
MAINTENANCE TABLE
Chafi symbols:
1 : Inspect: Visual examination and/or functional measurement of system’s operation or
performance , A: Adjust: Examination resulting in adjustment or replacement
n
R: Replace or change
T: Tighten
REMARKS
After 80,000 km or 48 months, continue to follow the described maintenance at the recommended intervals.
As for * marked items in this maintenance chart, note the following points.
+ 1 Major service interval at 12 months/20,000 km (12,000 miles).
Lubrication service based on distance only 10,000 km (6,000 miles) not time.
l 2 Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt
if equipped.
‘3 Replacement of the timing belt is required at every 100,000 km (60,000 mile). Failure to replace the tim-
ing bett may result in damage to the engine.
‘4 tf the vehicle is operated under any of the following conditions, it is suggested that the engine oil and
oil filter be changed more often than the recommended intervals.
a) Driving in dusty conditions. I
:
b) Extended periods of idling or low speed operation. i
i!
c) Driving for a prolonged periods in cold temperatures or regularly driving onty short distances.
*5 If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often
than at usual recommended intervals.
l 6 This IS a full function check of all electrical systems, i.e, atl
ltghts. washers (including condition of blades)
electric windows, sunroof, horn etc.
‘7 Replace every two years. $1
‘I
If there has been continuous hard driving, mountain
drivtng, or if the brakes are used extensively or the
vehicle is operated in extremely humid climates, the brake fluid should be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the-emission control and relat-
ed system, as well as for efficient engine operation. It is strongly recommended that all servicing related
to these systems be done by your Authorised Mazda Dealer.
13EOAX-302 -4
I!
A-3
Page 23 of 279

A SCHEDULED MAtNTENANCE SERVtCES (Europe)
Maintenance Number of months or km (miles), whichever comes first
Months” - 6 12 18 24 30 36 42 48
Kllometers 1,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000
{Miles)
(600) (6,000) f[t2,000) (18,000) (24,000) (3U,OOO) (36,000) (42,000) {48,000), Engine
Intake and exhaust manrfold nuts (Bolts)
Drive belts”
i Engine trmlng beltW3
Engine oil (Turbo)‘4
01 filter
l *
Cool!ng system (Includtng
coolant level adlustment)
Engrne coolant T T T
A A A
A A
Replace every 100,000 km (60,000 miles)
Replace every 5,000 km (3,000 miles) or 6 months
R R R R R 1 R R R
I I I I
I
Replace every 2 years Fuel system
Idle speed
Air cleaner element * 5
Fuel
falter
Fuel Ilnes and hoses Ignition system
A f 1
I R I R
R R
I I f t I ~
lnlttal rgnrtloh trmlng 1 I I I I I I I I
Spark plugs A
A. A A
Spark plugs (Only for Sweden) Adjust every 30.000 km (t8.000 mrls) Evaporative emission control system
Throttle sensor Throttle sensor (Only for Sweden)
Evaporative system
Evaporatrve system (Only for Sweden) 1 A 1 1 A 1 1 A 1 ) A
Adjust every 80,000 km (48,000 miles)
1 I 1 1 I’ 1 1 I 1 1 I
Inspect every 80,000 km (48,000 mites) Electrical system
Battery electrolyte level and specific gravity 1 I f I I I
All Electrical system
l ’ 1 I
I 1 I I I
1 . 1 I I
Headlight alrgnment 1 A A A . A. Chassis and body
t 3EOAX-303
A-4 Chas
SW31 Rear
Tires
Hing
Seat
Page 37 of 279

F3 OUTLINE
OUTLINE
OUTLINE OF CONSTRUCTION
Theefuel and emission control system of the new 323 4WD model 1s basically the same as that of the prevr-
ous 323 4WD model; however some parts are changed. The changed parts and interchangable parts
are shown betow.
13EOF3-304
Changed parts
1 ~ components Contents and purpose Reference pagl
INTAKE AlR
SYSTEM Turbocharger
Intercooler
l Size Increased for greater boost pressure l Wastegate solenord valve IS lozated on Intake port of F3-10
turbocharger to make system more compact F3-37
Volume increased for Improved F3-10
t F3-39
Wastegate sojenold valve
l Wastegate solenoid valve changed to duty solenoid
type for Increased engine power and response
l Wastegate solenoid valve is located on Intake port of
turbocharger to make system more compact F3-1 f
F3-38
I r
Pressure regulator One-stage operattlon changed to two-stage operatron F3-14
to improve hot restarting f3-41
L
FUEL SYSTEM High-ohmic type change to low-ohmrc type with exter-
Fuel qector na solenoid reslstor for improved fuel supply during F3-12
high-speed driving F3-42
Fuel pump reslstor Resistance reduced for
surer fuel supply F3-40
CONTROL
SYSTEM Pressure
regulator control system
Atr flow meter Two-stage operatton used to Improve hot restarting
Measures larger amount of air flow Increased power
Resistance values changed F3-t4
F3-43
F3- 9
f3EOF3-305 lnterchangable parts
tntake air system
l
Air valve
l Air bypass valve
l Air cleaner
l Air cleaner element
Fuel system
l Fuel filter assembly
l Fuel pu.mp (transfer
l Fuel vapor valve Control system
. l Throttle sensor
l Water thermosensor
l Knock sensor and control unit
l Oxygen sensor
l Fuel pump control unit
l Main relay
l Circuit opening relay
l Check valve (two-way) .
Evaporative system
l Charcoal canister
l Check valve (two-way)
13EOF3-306
F3-4
Page 38 of 279

CHECK VALVE SOLENOID VALVE
(PURGE CONTROL)
llll
*
SOLENOID VALVE
(PRC LOW TEMP.)
3 ~NTERCOOLERII’ I ,‘/ I
II II
’ f frrmvmlHHt-----lHt I -1 II II
IIt - --M:l, i -KNmK~[I~ ,
’ ISC VALVE
VALVE WATER CHAkCOAL
CANISTOR
CHECK VALVE
I FUEL FUEL FILTER
PUMP
I FUEL FILTER
TRANSFER
PUMP
AIRkLOW METER
(WITH INTAKE AIR THERMOSENSOR)
DISTRIBUTOR
CATALYTIC CONVERTER
l TO ENGINE CONTROL UNIT
Page 42 of 279

OUTLINE F3
SPEClFiCATlONS
Iten
Idle speed’
tgnltion trming * Engine
m
BTDC BP TURBO
800 f 50
IO f 10
Fuel pump
Maximum output pressure kPa { kgflcm’, psi 1 1 490-736 {SO-7.5, 7t-110)
Transfer pump
Maximum output pressure
Fuel filter kPa { kgf/cm2, psi ) 1 , 39 10.4, 5.7 1 or higher
Nylon element (in fuel pump)
Idle-speed control (fSC) valve
Type
Resistance I Rotary
nt
11-13 [at 2O*C [68*F)]
Solenoid va tve (purge contra I)
,I
Resistance -2o*c I -4Of 1 14.6-I 7.8
2.21-2.69
.kQ , 2o”c { 68OF)
40% f104*f 1 1.0-l .3
Resistance
Fuel tank
Capacity
Air cleaner
Etement type
Fuel
Specification L {US gal, Imp gal) [ Approx. 6 [at 20°C f 68*FJ]
60 (15.9, 13.2)
01 permeated
Unleaded premium (RON 95 or higher)
11FrlC?.7 11
l TEN terminal of diagnosis connector grounded.
The I; mark indicates newly equipped Parts. l”L”l “VI I
F3-9
Page 58 of 279

TROUBLESHOOTING GUIDE F3
4 CRANKS NORMALLY 8UT WILL NOT START (PARTfAL COMBUSTION) - AFTER WARM-UP
&RIP-
l Engine cranks at nurmal speed and shows partial combustion but will not Continue running after being hot
soaked
FION
l Battery in normal condltlon
*Engine starts normally when cold
TROUBLESHOOTING
HINTS] 3 Air/Fuel mixture too rich @ Vaporlock
ssure not held in fuel line after engrne IS
GND mth jumper wire tor 3
minutes with ignition
Fuel
line pressure: 265-314 kPs (2.7-3.2 kgflcm2, 38-46 psi 1
c3 If pressure
quickly increases,
check pressure regulator
4 If pressure
gradually increases,
check fuel line and filter lor
clogging
If hose is not clogged. check fuel
pump maximum pressure
High pressure Check if fuel return hose is clogged or
restricted
INSTALL CLAMPS e If rt is not, replace pressure
regulator
@ It It 6. repalr or replace it CT page F3-3
F3-25
Page 74 of 279

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
Page 159 of 279

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