1992_GTR_Supp
Nov 19, 2014
Mazda 323 Familia GT GTX GTR GT-R 4WD Workshop Manual
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Mazda 323 o Workshop b Manual SupplementFOREWORD This is a supplement to the workshop manua!(s) shown below. This supplement describes service procedures of. new or modified mechanicat and/or ekctrical systems. For service procedures and important safety notices not contained in this supplement, please refer to the previous workshop manual. Workshop Manual: Form No.1 203-l 1206-1 1229-l 1275-l b O-89F (vol. 1) O-89F (Vol.2) O-89L O-91 c
r
CONTENTS Title Information inspection Maintenance and Pre-Delivery Scheduled Section
IGeneral
I Lubrication j Cooling
System System Carburetor !I
Fuel and Emission Controt System
m EGi
unieaded Fuel BP (DOHC and S
Diesel -Electrica Clutch I-Manual Transaxie 1 Electronically Co Introlled I System
All information in this supplement was the latest available at the time of printing, ail alternations related to modifications will be notified by Service Sulletin. Mazda Motor Corporation HIROSHIMA, JAPAN
I
Automatic Transaxle Shaft System System
Hydraulicaf~yCo~~~rull=;u 1 Transfer
[ Propefier 1 Front ISteerIng
PAPPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN) shown on the following page.
and Rear Axles
Braking IWheels ISusiension 1 Bodv 1 Heater 1 Technical Special Parts / Wiring , DiagramThis manual
and Tires
Electricat Data Toots Index
System System
and Air Conditioner
Refer to the form 5232-l 0-92A -explains onty the secticlns marked
No.with shadows (-1
0 1992 Mazda Motor Corporation PR1NTED tN JAPAN, JAN., 92 @I 1318010192A
VEHlCLE
IDENTlFlCATION
NUMBERS
(VtN)
3MZ BG83J200
50000t-
Gfc
m GENERAL INFORMATIONGIaGlGlGIGIGIGIGIGlGIG1GlGiGIGIGIGIGlGIGI2 2 2 2 2 3 3 3 4 4 4 4 5 5 5 5 5 6 7 7 8 I
>
3
3
1MPORTANT INFORMATION ..................... BASIC ASSUMPTIONS ............................ SAFETY RISK ........................................ POSSIBLE LOSS OF WARRANTY ............. WARNING ON LUBRICANTS AND GREASES HOW TO USE THIS MANUAL.. .................. PREPARATION ...................................... REPAtR PROCEDURE ............................. SYMBOLS ............................................. NOTES, CAUTIONS, AND WARNINGS.. ..... FUNDAMENTAL PROCEDURES ................. PROTECTION OF THE VEHICLE .............. A WORD ABOUT SAFE-T-Y ....................... PREPARATION OF TOOLS AND MEASURING EQUIPMENT ............. SPECIAL TOOLS .................................... REMOVAL OF PARTS ............................. DISASSEMBLY ...................................... REASSEMBLY ....................................... ADJUSTMENTS ..................................... RUBBER PARTS AND TUBtNG ................ JACK AND SAFETY STAND POStTlONS .... VEHICLE LIFT (20SUPPORT TYPE) POSITIONS ............................................ MAINTENANCE NOTE .............................. SPEEDOMETER TESTER CHECK ............. BRAKE TESTER CHECK ......................... CHASSIS DYNAMOMETER CHECK.. ......... WHEEL BALANCE.R ............................... TOWtNG ............................................... IDENTlFiCATlON NUMBER LOCATIONS ..... .UNlTS ..................................................... ABBREVIATIONS ..................................... CAUTION INSTALLATlON OF MOBILE TWO-WAY RADIO SYSTEM ................................... PRECAUTIONS TO TAKE WHEN SERVICING AN ELECTRICAL SYSTEM ..i HANDLING CONNECTORS ..................... USING ELECTRICAL MEASURlNG EQUIPMENT ............................................................................ ................................................
GI- 6 GI- 9 GI- 9 GI- 9 Gl-I 0 GI-I 0 GI-I 0 GI-I 2 GI-I 2 GI-12 GI-13 Gl-13 GI-f4 GI-f 5 GI-1613EGIX-30
1
GIIMPORTANT INFORMATION
tMPORTANT
INFORMATION
BASIC ASSUMPTIONS This workshop manual assumes that you efficient performance of service operations It also assumes that you are familiar with YOU should not attempt to use this manual consequences described below.
have certarn special tools that on Mazda vehicles and that you automobile systems and basic unless these assumpttons are
are necessary for the safe and know how to use them properly. service and repair procedures. correct and you understand the
SAFETY RtSK This manual contains certain notes, warnings, and other precautionary information that fully read and follow to reduce the risk of personal injury to yourself or others and the service that may damage the vehicle or render it unsafe. If there IS no such information specific service method, this does not mean there is no possibility that personal safety wili be jeopardized by the use of incorrect methods or tools. POSStBLE LOSS OF WARRANTY The manufacturers warranty on Mazda vehicles and engines can be voided if improper are performed by persons other than those at an Authorked Mazda Dealer.
you should carerisk of improper in regard to any or vehicle safety
service or repairs REP/ I. Mc pai 2. & illu: 3. Put vir: Exarr
WARNtNG ON LUBRtCANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated during service (e+g., engine sump oils) are more irritating and more likely to cause serious effects, including skin cancer, in the event of gross and prolonged skin contact. Wash skin thoroughly after work involving 011. Protective hand cleaners may be of value provided they can be removed not use gasoline, paraffin, or other solvents to remove oil from the skrn. Lubricants and greases may be slightly irritating to the eyes. from the skin with water Do
Repeated or protonged skin contact shoutd be avoided by wearing protective clothing if necessary. Particular care should be taken with used oils and greases containing lead. Do not allow work clothing .to be contaminated with oil. Dry clean or launder such clothing at regular intervals.9MtlGIX-002
SHOI EXPE PART
SHOW REUl PAGE SEWI
1:
T
*2:
c
Gt-2
HOW TO USE THIS MANUAL
GIoperation that it pro- m
3 3 ,
HOW TO USE THIS
MANUAL
PREPARATION PREPARATION points out the needed Special Service Tool (SST) for the service ceeds. Gather all necessary SST before beginning work. Examde: MANUALPREPARATlON SST490118 Puller, 85oC ball tolnt For removal end
STEERINGSST 1 NUMBER USAGE 149 0118 of he-rod 85oC For removal end of Wrod
S&T
NAME
SS;
ILLUSTRATlON
>
REPAIR PROCEDURE I. Most repair operations begin with an overview illustration. It identifies parts fit together, and visual parts inspections. If a damaged or worn as necessary. 2. Expendable parts, tightening torques, and symbols for oil, grease, and illustration. 3. Pages related to service procedures are shown under the tllustration. vicing the related part Example:
the components, shows how the part is found, repair or replace it sealant are shown in the overview when ser-
Refer to this informatron
1.
3
SHOWS yA;ytDABLE
SHOWS TIGHTENING TORQUE SPECIFICATION 2l
.SHOWS APPLICATION ;vdT OF OlL,
_ SHOWS TORQUE1 Bolt2 3 4 5 6 7 Lock Nate Bearmg cup 16 Beanno Inner race Rem&al page 17 Spacer 18 lhve olnion hspect sphes and teeIh for wear Daoe M-21 ordaqge M-24
TIGHTENING UNIT
> >
SH 3ws RE .ATED 3E FOR . 2 ?VICE
AdtustmgBearing Locknut Washer
screwouter race
SHOWS VISUAL INSPECTION INFORMATION
:9MlJGIX~034
*I l2
The numbering (ex.@> shows service procedure. Unrts shown in N m 1kgf m, ftlbf ] unless otherwlse
speclfted
Gl-3
GI
HOW
TO USE
THIS
MANUAL/FUNDAMENTALand sealant. These symbols
PROCEDURESshow the points of applying such
SYM00LS There are six symbols indicating matertals during service *Symbol
oil, grease,
Meaning
Kind
1 T. i 8 s Q
w- l
Apply
otl
New
engtne
011 or gear
011 as approprkate
Apply
brake
fluid
Only
brake
fluId
I Apply automatic transmtsslon fluid Only ATF
Apply
grease
Appropriate
grease
8
Apply
sealant
Approprrate
sealant
0
Apply
petroleum
Jelly
Appropriate
petroleum
jetty
e05UGIX-005
Note l When special oil or grease
is needed,
this is shown in the illustration.
NOTES, CAUTIONS, AND WARNINGS As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one ISthere fur a specific purpose. NOTES give you added information that wilt help you to complete a particular procedure. CAUTlONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS you should follow when you work on a vehrcle. 9MUGlX.036
FUNDAMENTAL
PROCEDURES
PROTECTION OF THE VEHICLE Always .be sure to cover fenders, seats, and floor areas before starting work.
FUNDAMENTAL
PROCEDURES
GI
A WORD ABOUT SAFETY The following precautions must be followed when jacking up the vehicle. t . Block the wheels. 2. Use only the specfred jacking positions. 3. Support the vehicle with safety stands. Start the engine only after making certain the engine compartment is clear of tools and people. j
9MUGtX-003
PREPARATION OF TOOLS AND MEASURING EQUIPMENT 8e sure that al! necessary toois and measuring are available before starting any work.
equipment
SPECIAL TOOLS Use special tools when
they are required.
47UOGX-CmI 1
>
REMOVAL OF PARTS While correcting a problem, try also to determine its cause Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair.
DISASSEMBLY If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a.way that wiii not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.
I
J
9MUGIX
039
I1
a-5
GI
FUNDAMENTAL
PROCEDURES
I. Inspection of parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems.
2. Arrangement of parts All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
3. Cteaning parts for reuse All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.
REASSEMBtY Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in Section TD for tightening torques not mentioned in the main text. tf removed, these parts should be replaced with new ones: 1. Oil seals 2, Gaskets 3. O-r.ings 4. Lock washers . 5. Cotter pins 6. Nylon nuts Depending on location: 1. Sealant should be applied to gaskets. 2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembty.
9MUGIX-042
Gl-6
FUNDAMENTAL
PROCEDURESgauges and/or testers when making
GIad-
ADJUSTMENTS Use suitable justments.
RUBBER PARTS AND TUBING Prevent gasoline or oil from getting tubing.
on rubber
parts
or
.
_
.
GIJACK
JACK
AND
SAFETY
STAND
POSlTiOtWVEHlCLE
LIFT (2-SUPPORT
TYPE) POSlTlONS
AND SAFETY
STAND
POSITIONSSafety stand positions: On both sides of the body frame
FRONT END JacKposition: At the front crossmember
REAR END Jack position: At the center
of the rear crossmember (4WD)
Safety stand positions: On both sides of the body frame
At the rear differential
-03UGW80
VEHICLEFRONT END, Frame Side sills
LIFT
(2-SUPPORT
TYPE)
POSITIONSREAR END Frame Side sills
9MuGIX
010
9MVGtX
01
MAlNTENANCE
NOTE
GINOTECHECK
MAlNTENANCE. SPEEDOMETER
TESTER
Caution l Do not clutch abruptly. l Do not attempt rabbit starts
or accelerate
quickly.13EGIX-302
[Front wheel free-roller method] 1. Set the free roller securely on the floor under the front wheels by matching it to the wheel base and front tread. 2. Place the vehicle softly on the tester and free roller. 3. Start the engine, and engage the clutch softly at a low speed in 2nd gear; then gradually increase the speed. 4. Upon completion of the test, stop the engine by gradually decelerating with soft braking.FREE ROLLER
[Front wheel jack-up method1 1. Place the rear wheels on the roller. 2. Jack up the front wheels and mount on a safety stand. 3. Start the engine, and engage the clutch softly at a low speed in 2nd gear; then gradually increase the speed. Caution l When using either the front wheel free-roller method or front wheel jack-up method, secure the vehicle to prevent forward and lateral movement by attaching towing hardware (chain or wire) to the front and rear tow hook or tie-down hook. BRAKE TESTER CHECK
t 3EGlX-304
I
Caution . To stabilize the drag force of the viscous coupling, conduct the brake test after the speedometer test. 1. Place the wheels to be tested (front or rear) on the roller. 2. Shift itit0 NEUTRAL. 3. Drive the tester roller and check.
a-9
GI
MAINTENANCE
NOTECHECK
CHASSIS DYNAMOMETER
Caution l Do not clutch abruptly. l Do not attempt rabbit starts or accelerate
quickly.
1. Remove the propeller shaft. 2. Lock the center differential (2WD). 3. Place the front wheets on the roller. 4. Lock the rear wheels and apply the parking brake. 5. Drive the tester roller and check. 6. Upon completion of the test, gradually decelerate with soft braking and stop the engine. 7. When the test is done, return the differential lclck rod to the free condition (4WD) and reinstall the propeller shaft.
VIEWED .OM BELOW REE
13EGfX-307 I
WHEEL BALANCER (On-the-car Balance) 1. Jack up all four wheels. Support the wheels to be checked (front or rear) with the wheel balancer sensor stand and the remainrng wheels with safety stands. 2. Set the on-the-car balancer. With the center differential in free condition, drove the tires with the engine; then check.
It3EGIX-308
MAINTENANCETOWlNG Caution g Use methodTowing 0 Rope towing
NOTE
@I to towmethod
vehicles
havingParking brake
problemsitems to confirm Transaxle
in the steeringshtft posttton
system
or drivetrain.Remarks
Released
Neutral
@ Towlng ground
with
front
wheels
off
!Released Neutral Remove propeller shaft
@ Towtng
by wrecker
truck
Released
Neutral
Rempve
propetler
shaft
@Towing or hauling off ground
with
all wheels
Engaged
Any
posItIon
13EGIX.30
TIE-DOWN
HOOKS
-
FRONT
TIE-DOWN
HOOKS
-
REAR
(HATCHBACK)
GIVEHICLE I
IDENTIFICATION
NUMBER
tOCATlONS/UNlTS/ABBREVIATlONSINS7 If a t and Whe 1, II-! 2. II-! 3. E4. Dr
IDENTIFICATIONtDENTtRCATtUN
NUMBERNUM8ER
LOCATIONS(VIM) ENGINE MODEL AND NUMBER
UNITSTorque Revolutions per minute Ampere(s) Volt(s) Ohm(s) (reslstance) Pressure {usually positive) mmHg I inl-lg ] . . . . . . . . . Pressure (usually negatrve) W . . . ._ .._.__.._ . . . . . . ..,......... Watt titers [US qt, Imp qt 1 . V&me mm { rn 1 . . . . . . . . . . . . . . .. . . . . . . . Length89UOGX-006
N.rn f-t&f rpm A.. v $2 kPa
{ kgf m or kgfcm, or tn.lbf 1 . . . . .. . . . . . . . . . . ._ .. . ,_...___.... I... . .._..__......_.....__... { kgflcm*, psr] . . . . . . .
EC-AT ........................... ECU ._ ....................... EG 1 ..................... E/L. ............................ EX .............................. IC ................................ IGN ........................... IN ..... ........................ INT ............................... ISC ............................ U-l ................................ M.. ........................... MIL ........ ...................... MTX. ........................... 00.. .............................. Of F .............................. ON ............................... PCV .............................. PRC ..........................
ABBREWATIONSABDC A/C ACC ATX ATDC ATF BAC BBDC BTDC CPU . . . . . . . After bottom dead center . . . . . . . ._.. _.. . . . . . . . Air conditioner .__ . ... . . . Accessones .._ ._ . . . .. . . . . . . . . . Automate transaxle _.. __ _. . . . . After top dead center ,... ._....__._.. Automatic transmission fluid ._ . . . .. . . . . .. . . . ,. Bypass air control _. . . .. . . . . . . . . .._. Before bottom dead center ., ._._... . . . Before top dead center . . . . . . . . . Central processrng unit _. . . .
P/S ............................. P/W ............................ RH ............................... SST ............................. ST.. ............................... SW.. ............................. TDC. ............................ 4WD .............................
Electronrcally-controlled automatic transmlsslon Engine control unit Electronc gasoll ne injectron Electrrcal load Exhaust Integrated clrcult lgnrtlon Intake Intermittent Idle speed control Left hand Motor MatfunctIon Indicator iamp Manual transaxle Overdnve Swrtch off Switch on Positive crankcase ventilation Pressure regulator control Power steerrng Power window Rlght hand Special service tool Starl Switch Top dead center 4-wheel drive03UGIX-802
W-1 2
CAUTION CAUTlUN
Gl
INSTALLATION OF MOBILE TWO-WAY RADIO SYSTEM If a rkobile two-way radio system is installed improperly or if a high-powered type is used, the EGI system and other systems may be affected. When the vehicle is to be equipped with a mobile two-way radio, observe the following precautions: 1. Install the antenna at the farthest point from control units. 2. lnstatt the antenna feeder as far as possible from the control unit harnesses (at least 30 cm [ If .8 in 1). 3. Ensure that the antenna and feeder are properly adjusted. 4. Do not instali a high-powered mobile two-way radio svstem.
MOBlLE
TWO-WAY
RADIO
AT
FARTHEST
POINT
..,.
. a
._
GIl l
CAUTKN
-* HI the vehicle or cause afire
PRECAUTIONS TO TAKE WHEN SERVICING AN ELECTRICAL SYSTEM Note the following items when servicing the electrical system. Do not alter the wiring or electrical equipment in any way; this may damage from short-circuiting a circuit or overloading it.l
The negatrve rnstalled last.
(-)
battery
cable
must
be removed
first and
l
Do not reptace
with
fuses
exceedrng
specified
capacity
Cautron l 8e sure that the ignitton and other switches are off before disconnectrng or connecting the battery cables. Failure to do so may damage the semrconductor components.
Caution l Repfacing desrgnated
a fuse with one of a larger may damage components
capacrty than or cause a frre.
l l
Secure
harnesses
with
provrded
clamps
to take
up slack.
Tape areas of the harness that may rub or bump against sharp edges to protect rt from damage.
l
When mounting components, be sure harness IS not caught damaged.
the or
Caution l Clamp all harnesses near vibratrng components (for example, the engine) to remove slack and to prevent contact resultrng from vibration.l
Do not handle them.
electrical
components
roughly
or drop
i Drsconnect heatsensitive parts (for example, relays and ECU) when performing maintenance (such as weldrng) where temperatures may exceed 80C [176OFj.
l
Make sure that the connectors are securely connected when installed.
CAUTIONHANDLING Caution *Be sure CONNECTORS to grasp the connectors, not the wires, when disconnecting them.
GI
1. Raise
the rear
2. Lift the tab with a thin piece of metal and remove the
poor
termrnat
contact.
Lift the tab with
a thin
When using a matching male terminal, make sure there IS no
Make sure the termmals are not pushed out of
c Round
connectors
> 1. Raise the cover. 2. Lift the termrnal
to
3. Make sure the terminal is securely mounted in the
Pull lightty on individual wires to check that they are secured rn the
1. Raise the cover. 2. Remove A. 3. Lift the tab with a thin piece of metal and remove the
: .
GIUSING ELECTRICAL MEASURINGUse Test to find open crrcuits or shorted Equpment Test lamp
CAUTIONEQUIPMENTOperationl
Handlingl
precautions or
l
Connect the test lamp between the circuit being measured and a ground. The lamp will lrght if the circurt is energized to the point testedA
Test lamps use 12V t.4W 3.4W bulbs or light-emitting diodes (LEOs). Using a large-capacity bulb may damage :he Ckil.
Jumper
wrre
ctrcult
Used
to create
a temporary
. Connect the jumper wire between the terminals of a cjrcurt to bypass a switch.
l
00 not connect the lumper wrre from the power source line to ground; this may cause burning or other damage to harnesses or electrontc components.
Voltmeter
Used for measuring the voltage of a circutt to find possible opens or shot-k.
l
Connect the positive (+) probe to the point where voltage IS to be. measured and the negatrve (-) probe a ground.
l
l
tol
Connect the voltmeter in parallel wrth the cjrcurt. Set the range to the dewed voltage. Use the service hole when measuring the voltage at the diagnosis connector.
l
Tie a thin wire to the posrtive (+) probe to access narrow terminals. Zero the meter after switching to the measuring range. Before using the ohmmeter, make sure the ignitron switch is off or the megatrve (-) battery cable is disconnected to prevent burning or otherwise damaging the ohmmeter.
Ohmmeter
Used to find opens and shorts In the ctrcurt, to confrrm contrnurty and to measure reststance.
l
Zero
the ohmmeter.&---
l
l l
l
Verify that voltage IS not applied to the circuit Connect the probes between two points in a Circuit., t
I
tl
Ammeter
Used to check alternator output, current supplied to the starter. and dark current wrthrn a circutt. Note Dark current IS the constant of current whrle the ignitron switch is OFF.
flow
+ Connect the ammeter in series with the circuit by touchtng the positive ( +) probe to the power-srde terminal and the negative probe to the ground-srde terminal.
l
(-
Set the range to the desired amperage. Connect the ammeter In series with the circuit. The ammeter may be burned or otherwise damaged if it IS connected in parallel.
13EGIX-31;
Gl-t
6
c
PRE-DELIVERY
INSPECTION
AND SCHEDULED MAINTENANCE SERVICESME-DELIVERY INSPECTION TABLE . . . . . . . . . . SCHEDULED MAINTENANCE SERVICES . . . . . MAINTENANCE TABLE ..*.*.............,....**a,. REMARKS . ..*...*...............**~.*...*.....t...*... AAAA2 3 3 3
13EOAX.301
APRE-DELIVERY [EXTERlORIINSPECT and ADJUST, of necessary. specrfrcatron: 0 Glass, exterior bright metal and 0 Wheel lug nuts 0 Tire pressures 0 All weatherstrips for damage or 0 Operation of bonnet release and 0 Operation of trunk Ild, hatch and (of equipped) 0 Door operation and alignment 0 Headtrght aiming INSTALL the foltowrng parts 0 Wheel caps or rrngs (if equipped) 0 Outsrde mirror(s)
PRE-DELIVERY INSPECTION TABLE
INSPECTION
TABLE
--
the followlng paint for damage
Items
to
0 0 0 0 0
detachment look fuel lbd opener
Horn, wbpers and washers (front and rear, If equipped) Antenna (tf equipped) Cigarette Ibghter and clock (if equipped) Remote control outside mirror (if equrpped) Heater, defogger and air conditioner at various mode selections (if equlppedj 0 Sunroof (If equipped) CHECK the following items 0 Presence of spare fuse 0 Upholstery and Interior finish CHECK and ADJUST, If necessary, the followjng items: IJ Operation and fit of windows 0 Pedal height and free play of brake and clutch pedal 0 Parking brake
MAIN Char3 t: In A: PC R: F!t T: Ti!
1 UNDER
BONNET-ENGINE
OFF
j
INSPECT and ADJUST. If necessary, the following items to specrflcatlon. 0 Fuel, coolant and hydraulic tines, fittings, connectlons and components for leaks 0 Engine 011 level 0 Power steering fluid level (of equipped) 0 Brake master cylinder fluky levels 0 Clutch master cylinder fturcl levels (If equipped) 0 Wtndshreld washer reservojr flurd level 0 Radiator coolant level and specrfic gravity 0 Tightness of water hose clamps 0 Tightness of battery terminals, electrolyte level and specific gravity 0 Manual transaxle oil level 0 Drive belt(s) tension Cl Carburetor lrnkage (choke control, wrde open throttle position. etc ) (carburetor model only) q Accelerator cable and linkage for free movement 0 Headlight cleaner and flurd level (if equipped) BLEED air from fuel line (diesel engrne only) CLEAN the spark plugs (except for diesel engine) piEi6F] INSTALL the following parts 0 Rubber stopper for rnsrde rear view mirror (if equjpped) 0 Fuse for accessories CHECK the operation of the following items. 0 Seat controls (sliding and reclining) and head rest 0 Seat belts and warning system Cl Ign&on switch and steering lock 0 Power window (if equipped) D Door tacks including child proof door locks Cl Inhibitor switch (ATX only) Cl All Ikghts rncluding warning and Indicator lbghts 0 Ignition key reminder buzzer (If equipped)
UNDER BONNET-ENGINE RUNNING AT OPERATING TEMPERATURECHECK the following items: 0 Operation of Idle-up system for air condbtroner or power ing (if equrpped) 0 Automatic transaxle flurd levet 0 tnltial ignrtlon timing (except disel engine) 0 Idle speed 0 Operation of throttle positron. sensor (EGI engrne) 0 Operation of cold start device and glow plug warning (diesel engine only) 0 Operation of dash pbt (EGI.engine) fTiGGJ CHECK the following items. 0 Underside fuel, coolant and hydraulic Irnes, ftttlngs, connections and components for leaks 0 Trres for cuts or brurses 0 Steering Itnkage, suspensron, exhaust system and all underside hardware for .looseness or damage steer-
light
Emis! The ed : to t!
1 ROAD TEST jCHECK the following items 0 8rake operation 0 Clutch operation 0 Steering control !ZI Operation of meters and gauges Cl Squeaks, rattles or unusual noises Cl Engine general performance 0 Emergency locking retractors
1 AFTER ROAD TEST ]REMOVE the seat and floor mat protective CHECK for the necessary owner information and spare tire m vehicle covers materials,took
93EOAX-002
A-Z
SCHEDULED SCHEDULED MAINTENANCE
MAINTENANCE SERVICES
SERVICES
Aor performance n,
MAINTENANCE TABLE Chafi symbols: 1 : Inspect: Visual examination and/or functional measurement of systems A: Adjust: Examination resulting in adjustment or replacement R: Replace or change T: Tighten
operation
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 timing 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. b) Extended periods of idling or low speed operation. 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 ISa 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. 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 related 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
I : i i!
$1 I
-4 I!
A-3
AMaintenance
SCHEDULED
MAtNTENANCENumber 1,000
SERVtCES
(Europe)
Months Kllometers {Miles)
of months or km (miles), whichever comes first 6 12 18 24 30 36 60,000 10,000 20,000 30,000 40,000 50,000
42 70,000
48 80,000
(600)
(6,000) f[t2,000) (18,000) (24,000) (3U,OOO) (36,000) (42,000) {48,000),
Chas EngineSW31Intake and exhaust manrfold Drive belts i Engine trmlng beltW3 Engine oil (Turbo)4 01 filter * Cool!ng system (Includtng coolant level adlustment) Engrne coolantl
nuts (Bolts)
T A
T 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 1 R R I I I I Replace every 2 years
T A
Rear
R
R I Tires Hing
Fuel systemIdle speed Air cleaner element * 5 Fuel falter Fuel Ilnes and hoses A I I R f I f t R
1RI ~
Seat
RI
Ignition systemlnlttal rgnrtloh trmlng Spark plugs Spark plugs (Only for Sweden) 1 I I A Adjust I every 30.000 I A. km (t8.000 I I A mrls) I I A
EvaporativeThrottle sensor
emission control
systemA 1 Adjust every 1 I 1 Inspect every 1 1 A 1 80,000 km (48,000 1 I 1 80,000 km (48,000 1 A miles) 1 I mites) 1 1 ) 1 A I
Throttle sensor (Only for Sweden) Evaporative system Evaporatrve system (Only for Sweden)
Electrical
systemand specific gravity 1 I I f 1 1 I I A I I I A I 1 . 1 A I . 1 I I A.
Battery electrolyte level All Electrical system Headlight alrgnmentl
Chassis and body
t 3EOAX-303
A-4
SCHEDULEDMaintenance Months Kllometers (Miles)
MAINTENANCENumber 1,000 (600)
SERVICES
(Europe)
A48 80,000 (48,000)
of months or km (miles), whichever comes first 6 12 18 1 24 30 36 ] 42 10,000 20,000 30,000 1 40,000 50,000 60,000 1 70,000 (6,000) j(12,000)~(18,000)~(24,000) (30,000) (36,000)~(42,000)
Chassis
and body
(Contd)I I T R R A A T A A Inspect inflation I A I I I I A R R T annually I 1 I A I I I i f 1 1 I I A A , A A T A A 1 I R R R T I I A I I 1 I A I I I13EOAX.304
Steering and front suspension MTX oil Rear axle oil Trabsfercarrier oil Bolts, nuts on chassis and body Body condltlon (Visual only) Exhaust system heat shields Tires (Including spare tjresj with pressure adjustment Hinges and catches Underside of vehicle Seat belt Dnveshafl dust boots
I
1 1
A-5
B2
ENGINE (DOHC)
1 FEATURES
j B2B282B28282B2B2822 2 2 3 4 5 6 7 8
OUTLINE ................................................ OUTLINE OF CONSTRUCTION.. .............. SPEClFICATlONS .................................. INTERCHANGEABILITY .......................... PISTON ............................................... CONNECTING ROD ............................... CRANKSHAFT PULLEY .......................... EXHAUST VALVE .................................. INSTRUCTION FOR HANDLING METALLIC SODllJM~FlLLED EXHAUST VALVE .........
SUPPLEMENTAL
SERVICE
INFORMATION
82013E082-301
9
4
B2OUTLINE
OUTLINE1NTERC The f< and 0 S ym&l -
OUTLINE OF CONSTRUCTION l Theengine is the same as of the previous BP-DOHC are modified for greater reliability and performance. l Metallic sodium-filled exhaust valves are adopted. SPECtFlCATIONSItem TYPe
Turbo engine.
However,
some of the components
13E032-302
Cyhnder arrangementCombustion Valve Bore system Displacement and stroke ratio pressure Compressron Compressron chamber
Gasoline, and number tn-line, DOHC, cm3 tcu mm kPa IN [ kgf/cm2, in] {in) 83.0 1,839 x 85.0 lt1.5, 2O 510 590 8O
4-cycle 4 cyljnders
Pentroof belt-driven { 112.2) 13.27 8.2 psi 1-rpm BTDC ABDC BBDC ATDC 1,127 164)-300 x 3.35)
Cytinder block related
OpenClose Open Close mm (in] IN EX
Valve
tlmlng EX
Valve
clearance *
0. Maintenance-free 0: Maintenance-free rpm BTDC 800 100 l-3-4-2 f f 50 7013EOB2-303
Idle speed Ignltlon Fwng order
Crank&; related
trmrng of dragnosrs connector grounded.
*.. TEN terminal
Timing related
b
Vatve related
Lubricatrc
systemrelated
Coohng .. system related
82-2
The following chart shows interchangeability of the main parts of the previous and the new BP DOHC Turbo engine for 4WD models.S ymiols: 0 _. lnterc hangeable Part name X . . . Not Interchangeable tnterchangeability 0 0 0 0 0 0 0 0 II
BP DOHC
Turbo
engine
Remark
Cyh nder blcck related
Cytlnder head Camshaft 011 seal Cvllnder head bolt Cylrnder head gasket Wnder head cover Cylinder head cover gasket Cylinder block MaEn bearina cao Ma+n bearino suo~oFt elate ,I I
CB
:
0X
II
Oil pan Timrno belt cover Seal elate Front orl seal Rear 011 seal Crankshaft Marn bearina Thrust bearing Connectmg rod Connecting rod beartng Piston Pistonpm
Turbocharger 13mm IO.51 I 1
oil return pipe hole increased in) to 17mm IO.67 in)
from
I II
0 0 0 0 0 0 0 ;JX
Shape Piston
different skirt shortened different gap increased from in ) to 0.35-0.50mm In cylinder)
I
Crankshaft related
clX
Tw Piston rrng Second
Sectional shape Piston ring end
X
~0.006-0.011 in ] (MeasuredShape different
0:?5--0.30mm IO.01 4-0.019
Timing related
belt
Crankshaft pulley Rear cover Flywheel Flywheel bolt Tbmlng belt Timing belt crank pulley Camshaft pulley Timing belt tensioner and Idler Camshaft
I
;5 0 0 0 0 0
spring
00 0
AAValve related Valve Valve spring and seat Vatve wide Valve seal Oil pump Oil pump gasket oil strainer Oil strainer gasket Oil cooler Oil jet Oil filter Water pump 1 Thermostat Radiator Cooling fan Intake Exhaust Intake Exhaust I I
cl0X
Metallic
sodium-filled
valve
0 0 0 0 0 0 0X
Lubrication system related
Heat dissi patlon Shape different
capacity
increased
Coohngsystem related
0 0 0 0 I 3EO32.304
BZ-3.
B2
OUTl1NE
COOUNG
CHANNEL
RtNG
CARRtER
61.5mm
i 2.42
in ] -
56.5mm
(2.22
in
Piston diameter Measured at 90* to pin bore axis and t6.5mm IO.650 in 1 below oil rmg groove. I+
Piston diameter Measured at 90 to pin bore axis and 11 .Omm 10.433 oil ring in 1 below groove.
COOLING
CHANNEL \ *IL YTLET
OIL
t NiET
l l l
The piston skirt is shortened for reduced weight and friction. A cast iron ring carrier is installed in the piston to reduce piston-ring groove wear. A cooling channel is incorporated in the body of the piston. The 011 jet squirts oil into this cootrng channel and the or! absorbs the heat from around the ring lands, reducing piston ring and cylinder wat! wear
Bz-4
OUTLINECONNECTING ROD
B2
18mm
10.17
in!
in t PAINT MARK @VHITE)
27mm
Il.06
ml
CONNECTING
ROD
CAP
PiINT
MARK
(WHITE)
l l
The connecting The connecting
rod beam is windened for increased rod and cap are marked with white
strength. paint for identification.
B2CRANKSHAFT PULLEY
CXJTUNE
ALTERNATOR,
WATER
PUMP
V-RIBBED
BELT
PULLEY
/TORSIONAL
DAMPER
P/S,
A/C
V-RI3BED
BELT
PULLEY
ALTERNATOR
DRIVE
PULLEY
Deflectton
(98
N
( 10
kgf,
22
Ibf f )
Owe Alternator
belt
New 5.5-7.0 {0.22-0.27
)
Used. 6.0-7.5 IO.24-0.29)
mm ftn) Lrmlt 8.0 to.31 ) N I kgf, Ltmit 1 340 135, 771 Ibf]
fension
Owe Alternator
belt
New 460-660 (46-68, llO--140)
Used 400-580 {IO-60, 88-130
l l
The alternator and water pump pulleys are changed to V-ribbed type for improved performance With the adoptjon of the V-ribbed betf. the belt adjustment specifications are changed.
B2-6
EXHAUST
ViitVE
EXHAUST
SIDE
VALVE METALLIC (ABOUT
GUIDE SODIUM VOLUME)
30%
VALVE
STEM ..* :::I :::I
VALVE
HEAD
CYttNDER
HEAD
IDENTlFtCATION
OF METALLIC
SODIUM-FILLED
EXHAUST
VALVE
l
l
Superior he& dissipating .metallic sodium-filled exhaust valves are adopted. During engine operation, the metalic sodium inside the valve stem melts. As the valve moves up and down, the sodium splashes around inside the valve and helps to absorb heat from the cylinder head and to transfer it back to the engine coolant through the valve guide. In this way, the combustion chamber temperature is reduced, reducing knocking and improving fuel efficeincy. Special handling of sodium filled valves is required for personal safety. (See next page.)
B2-7
82
INSTRUCTlUN
FOR HANDLING
METALUC
SODIUM-FltLED
EXHAUST
VALVE
1NSTRUCTION
FOR IiANDLlNG
METALLIC
SODIUM-FILLED
EXHAUST
VALVEof / q i Tht-i tmr Engin l Rer. l Ins;l
improper handling of metallic sodium can cause sever burns, loss of eye sight, and the production htghty ftammabie hydrogen gas. Therefore, handle and dispose of such valves carefully.
First aid l If metallic sodium get into your eyes, quickly fiush it out with large amounts of water. See a physician. l If it gets on your skin, wash it off with plenty of water. See a physician. l If it catches fire, use a dry powder fire extinguisher or dry sand to put it out. Never use water. Note l Do not use the valve as tool. l Do not drain the metaltic sodium from the vatve. l Neutralize the metallic sodium-filled valve before Re!e;,nEel T
The eng proc
its disposal. a metallic sodium-filled exhaust valve.13E082-309
is embossed
on the valve
head to identify
IDENTIFICATION
MARK
0
C8T13.5 in]
Disposal procedure Follow the procedure below to neutralize the valve. (1) Prepare a water-filled bucket (10 Liters [ 11 US qt? 8.8 Imp qtj or more> and a dry powder fire extinguisher in a well ventilated place. (2) Wear safety glasses and gloves. Note l If the valve is broken skip Step (3).
9Omm
(3) Secure the valve in a vice and, using a hacksaw, cut a few 1.5mm [ 0.059 in) deep slits30-90mm 11.2-3.5 in) from the valve stem end. (4) Quickly submerge the valve in the bucket of water. vreat up to eight valve at a time.) :
I1X002-31 1 ,
(5) Leave the valve in the water for about one hour until the bubbles stop. (Stir occasionally with a metat rod for complete reaction.) Caution l Do not reach into the solution or let it get on your skin or clothing; burning may result. (6) Remove the valve with tongs and dtspose of as for a conventional part. (7) Follow local regulations fbr disposal of the solution.
1 t3EOB2-312
SUPPLEMENTAL
SERVICE
HWURMATION
B2Manual [Europe,AUS-
SUPPLEMENTAL
SERVICE
1NFORMATIONin comparison with 323 Workshop
The following points in this section are changed tfilia (I 229-I O-89L)j. Engine l Removal . Installationl
The intercooler installation position is changed because the intercooler is enlarged. With this change, the engine can be removed and installed without removing the intercooler. The engine removal I installation procedure is the same as of the previous BP-DOHC Turbo engine.13E082-313
I I m
82-9
F3c
FUEL AND EMISSION CONTROL SYSTEMSINDEX. . . . . . . . l ..,.... *..,. . . . . . . m...*.*...*.....
i
F3-
2 SUPPLEMENTAL SERVICE tNFOF?MATtON SELF-DtAGNOStS FUNCTtON.. ........ OUTLINE .................................... SERVICE CODE NUMBERS.. ......... TROU8LESHOOTtNG GUtDE ........... RELATIONSHtP CHART.. .............. DIAGNOSTIC JNDEX .................... PRECAUTIONS ............................ SYMPTOM TROUBLESHOOTING .... TURBOCHARGERCONTROL SYSTEM ...................................... TURBOCHARGER ........................ WASTEGATE SOLENOID VALVE.. .. INTERCOOLER ............................ FUELSYSTEM .............................. FUEL PUMP ................................ FUEL PUMP RESISTOR/RELAY ...... PRESSURE REGULATOR .............. INJECTOR .................................. INJECTOR RESISTOR ................... PRESSUR REGULATOR CONTROL SYSTEM ...................................... SOLENOID VALVE (PRESSURE REGULATOR CONTROL) ............. CONTROL SYSTEM ....................... PREPARATION ............................ ENGINE CONTROL UNIT (ECU) ..................................
UUTLtNE OUTLINE OF CONSTRUCTION.. .... SYSTEM DIAGRAM ...................... VACUUM HOSE ROUTING DIAGRAM WIRING DIAGRAM.. ..................... ECU RELATIONSHIP DIAGRAM ...... SPECIFICATIONS.. ....................... TURBOCHARGER CONTROL .......... OUTLINE SYSTEM DIAGRAM ...................... WASTEGATE CONTROL ............... FUEL SYSTEM OUTLINE .................................... CONTROL SYSTEM ....................... STRUCTURAL VIEW ..................... PRESSURE REGULATOR CONTROL SYSTEM .......................................................... ................................. .................................... ..............................
F3F3F3-
4 4 5
F3- 6 F3- 7 F3- 8 F3- 9 F3-IO F3-10 F3-10 F3-11 F3-12 F3-12 F3-13 F3-13 F3-14
F3-I 5 F3-16 F3-16 F3-16 F3-19 F3-19 F3-20 F3-21 F3-22 F3-37 F3-37 F3-38 F3-39 F3-40 F3-40 F3-40 F3-41 F3-42 F3-42 F3-43 F3-43 F3-44 F3-44 F3-45
7 3EOF3-301
F3INDEX I
INDEX
J
D1AGNOSIS CONNECTOR
SELF-DlAGNOSIS
-I. Inject IfI; Vr, 2. Press In3 3. Sole-l Ins
1. Turbocharger Removal I installation . . .. . . .. . .. . .. . . page F3-37 2. Wastegate solenoid valve inspection . .__._. ._. .. . .. . . .. page W-38 3. Injector resistor Inspection __ __,., __ . page F3-42
4, Intercooler Removal / Installation . . . .. . . .._...... page F3-39 5. Engine control unit (ECU) lnspect~on . ... . .._........... .. . .. . . . . . . page F3-45
F3-2
INDEX
F3
t3EOf3.303 1. Injector Inspection ................................. Volume test.; ............................. 2. Pressure regulator Inspection ................................. 3. Solenoid valve (PRC low temp.) Inspection ................................. page F3-42 page F3-42 page F3-4 1 page F3-43 4. Solenoid valve (PRC high temp.) Inspection ;. ............................... 5. Fuel pump resistor/relay System operation ...................... Inspection ....... .......................... 6. Fuel pump (main) Inspection .......... . ...................... page F3-43 page F3-40 page F3-4 1 page F3-40
II
F3OUTLINEOUTLINETheefuel
OUTLINE
OF CONSTRUCTION and emission control system of the new 323 4WD model 1s basically the same as that of the prevrous 323 4WD model; however some parts are changed. The changed parts and interchangable parts are shown betow.13EOF3-304
Changed
parts
1INTAKE SYSTEM AlR
~ componentsl
Contentsl
and
purpose port of
Reference F3-10 F3-37 F3-10 F3-39 F3-1 f F3-38 F3-14
pagl
Turbocharger Intercooler
Size Increased for greater boost pressure Wastegate solenord valve IS lozated on Intake turbocharger to make system more compact increased for Improved
Volumel
t
WastegateI
sojenold
valver
l
Wastegate solenoid valve changed to duty solenoid type for Increased engine power and response Wastegate solenoid valve is located on Intake port turbocharger to make system more compact operattlon changed hot restarting to two-stage operatron
of
Pressure
regulator
LFUEL SYSTEM Fuel Fuel CONTROL SYSTEM qector pump reslstor
One-stage to improve High-ohmic na\ solenoid high-speed Resistance Two-stage Measures Resistance
f3-41F3-12 F3-42 F3-40 F3-t4 F3-43 F39f3EOF3-305
type change to low-ohmrc type with exterreslstor for improved fuel supply during driving reduced operatton for surer fuel supply
Pressure system
regulator control
used to Improve
hot restarting Increased power
Atr flow meter
larger amount of air flow values changed
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 l Check valve (two-way) Evaporative system l Charcoal canister l Check valve (two-way)
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 .
13EOF3-306
F3-4
CHECK
VALVE
SOLENOID VALVE (PURGE CONTROL) llll * SOLENOID (PRC LOW VALVE TEMP.)
CHAkCOAL CANISTOR CHECK VALVE
3
~NTERCOOLERII
I
,/
I
II II
f frrmvmlHHt-----lHtIIt
I--M:l,
-1, i -KNmK~[I~
II II
I\ \IFUEL TRANSFER PUMP
FUEL FUEL PUMP
FILTER
FILTER
ISCVALVE
VALVE WATER
AIRkLOW METER (WITH INTAKE AIR THERMOSENSOR)
DISTRIBUTOR CATALYTIC CONVERTERl
TO ENGINE
CONTROL
UNIT
F3VACUUM HOSE ROUTING DIAGRAMPRESSURE
OUTLINE
REGULATOR
IF1 BYPASS
VALVE
.
IIIII
tii
ti
I I
I I
PISSWITCH
Q ; E
.
p
F3ECU RELATtONSHtP1NPUTc
OIJTUNESPE DtAGRAMKNOCK KNOCK DlSTRlBUTOR SENSOR AIRFLOW METER
DEVICE
91c YfTC
THERMOSENSORN EUTRAti CLUTCH
SWITCH
CONNECTOR (TEN TERMINAL,)
OUTPUT
DEVtCE
OXYGENSENSOR INTAKE AIR THERMOSENSOR {AIRFLOW METER) CIRCUIT OPENING TURBOCHARGE
jAGNOSEONNECTOR EN/MEN TERMINA
h
SOLENOID
(PRESSURECONTROL) IGNITER
VALVE REGUL+TOR
* TEN WASTEGATE SOLENOID VALVE (TURBtiHARGER)FUEL PUMP RESlSTORlRELAY SOLENOID VALVE (PURGE CONTROL)13EOF3-311
--
The
@
F3-8
OUTLINESPEClFiCATlONSEngine Iten Idle speed tgnltion trming * Fuel pump Maximum output Transfer pump Maximum output Fuel filter m BTDC pressure pressure kPa kPa { kgflcm, { kgf/cm2, psi 1 1 psi ) 1 , 490-736 BP TURBO 800 f 50 IO f 10 {SO-7.5, 7t-110)
F3
39 10.4, Nylon
5.7 1 or higher (in fuel pump)
element
Idle-speed Type Resistance Solenoid
control
(fSC)
valve I nt 11-13 Rotary [at 2O*C [68*F)]
va tve (purge
contra
I)
,I
Resistance
.kQ
-2o*c 2oc , 40%
I -4Of 1 { 68OF) f104*f 1
14.6-I 7.8 2.21-2.69 1.0-l .3
Resistance Fuel tank Capacity Air cleaner Etement type Fuel Specification TEN terminal The I; markl
Approx. L {US gal, Imp gal) [
6 [at 20C 60 (15.9, 13.2)
f 68*FJ]
01 permeated Unleaded of diagnosis connector grounded. indicates newly equipped Parts. premium (RON 95 or higher) 11FrlC?.7 11 lLl VI I
F3-9
F3TURBOCHARGERCONTROL
TURBOCHARGERCONTROL
OUTLINE l The-capacity of the air-to-air intercooler is increased to reduce the intake air temperature prove engine performance. l With addition of the improved wastegate control system, the engines high rpm torque
and to the tmis increased.
TURBOCHARG
INTERCOOLER
SYSTEM
DIAGRAM
WASTEGATE
SOLENOrD
VALVE
F3-10
TURBOCHARGERCONTROL
F3
WASTEGATE CONTROL The engine control unit controls the wastegate solenoid valve by duty signals to better control the boost pressure, increasing the engines power and response. * 13EOF3.313 Systemr
Diagram
DUTY INTAKE AIR THERMOSENSOR (AIRFLOW METER)
VALVE
F3FUEL
FUEL
SYSTEM
SYSTEM
OUTLINE l Thspressure regulator has two vacuum ports for its two-stage operation. (Refer to page F3-43.) l The injectors are changed from high-ohmic type to low-ohmic type for improvement of the supply of fuel during high-speed engine operation. l To decrease the current in the injectors, an external resistor is equipped and is mounted on the aircleaner housrng .13EOF3315
Pressur regulator
VACUUM
PORTS
13EOF331;
F3-12
: : _, . :. . . . . .1 , ._.s_ , -. _ ._>_ r--A.-
CONTROL CONTROLSTRUCTURAL
SYSTEM
F3
SYSTEMVtEW
SOLENOID
VALVE
PRESSURE
RE
LUTCH
SWlTCH
FUEL
INJ
RELAY
NTAKE AIR THERMOSENSOR AIRFLOW METER)
WATER
THERMOSENSOR
F3-13
F3PRESSURE REGULATOR CONTROL
CONTROLSYSTEM
SYSTEM
SOLENOID (PRC HIGH
VALVE TEYP.)
TO MAIN t
RELAY ECU I
Wast l Ins
fuel l In:;PRESSURE REGULATOR F-----------
THERMOSENSORlNTAKE AIR THERMOSENSOR
IJ
WATER
//
VACUUM \ SOLEltolD (PRC LOW VALVE TEMP.)
InJeci l In:;l Vol
SWITCH
Injecl l In:; Presr l SCI Engir l InsI
TO FUEL
TANK
13EOF3-31
To prevent vaporlock in the fuel system during hot restart idle, a two-stage pressure regulator is adoped to the new 323 4WD. Low temperature operation: The vacuum to the pressure regulator (A and B ports) is cut (solenoid valve [low temp.] UN), and the fuel injection pressure is increased to 284 kPa (2.90 kgf/cm2, 41 psi ) , High temperature operation: The vacuum to the pressure regulator (A port) is cut (solenoid valve [high temp.] ON), and the fuel injection pressure is increased to 343 kPa [ 3.5 kgf/cm2, 49 psi 1. Condition and operationcoolant temperatureAbovef f940Fj
I
Condition Intake alt temperature
Engine
Solenoid
Operation vrlve Solenoid vatve Opemtlon (Idw temp.) (high temp.) time
1 Operation
40% [fU40f)90C 5UC (t22OFI
ONNo
OFF
180s
Low temp. t-ltghtemp.3t3EOF3-319
Above 5O*CI122OF)
loadOFF
ON
210s
F3-14
SUPPLEMENTALThe following shop Manual
SERVICE
INFORMATIONare changed in comparison to the Mazda 323 4-Wheel Drive Work-
. I
points in this section [I 229-l O-89t].
Turbocharger l Removal / Installation Wastegate solenoid l Inspection htercooter l Removal I Installation Fuel pump (main) l Inspection Fuel pump resistor/relay System operation l Inspectionl
valve
Injector Inspection l Volume testl
Injector resistor l Inspection Pressure regulator control system Solenoid valve (pressure regulator unit (ECU)13EOF3.320
l
control}
Engine control l Inspection
F3-I
5
F3SELF-DIAGNOSISOUTLINE Theself-diagnostic function ever, there is an additional SERVICE CODE NUM8ERSCond No NE-signal &ion
SELF-DIAGNOSIS FUNCTION
FUNCTfON
--
and diagnosis procedure are the Same as for the previous 4WD model. Howservice (malfunction) code (N0.35) for the new modet.13EOF3-321
Sensor or subsystem NE-signal
Fail-safe
IService code no.
Malfunction Output ON
display signal pattern
-
02 OFF
G stgnal
No
G srgnal
Cancels injection
two-group03
Mml
ON
OFF Knock sensor Open or short circuit
I
pressure
sensor
F3-16
SELF-DIAGNOSIS
FUNCTION
F3
I
Open
or short
crcuit
13EOFS322
Caution l If there is more than one failure present, the code numbers will be indicated in numerical order, lowest number first. l After repairing a failure, turn off the ignition switch, disconnect the negative battery cable, and depress the brake pedal for at least twenty seconds to erase the service code from the ECU memory.
II
F3-17
F3:ODE NO. 25 {SOLENOlD VALVE INSPECTION Disconnect connector from ECU; voltage at ECU terminal 2T (G/C) switch ON?
SELF-DIAGNOSISPRESSURE REGULATOR
FUNCTIONCONTROL) (Low temperature ACTION opoeration)
-TRWRELAT -.. c
IS there battery wrth Ignition
Yes
Check ECU connection 4 c3
termrnal
connector
for poor
If OK, replace ECU If not OK, repatr or replace step wlrrng harness
CT page connector
F3-2
\
\
NO
Go to next Repair
2
In same condition as rn Step 1. is there battery voltage at sofenord vatve (PRC low temp.) connector termrnal wrre (G/O)? Is solenord valve (PRC low temp ) UK7 CT page
Yes NO Yes
or replace step
(G/O)
Go to next
3
F343 NO
Check for a short or open crrcuit in WIIing harness (main relay [FUEL INJ relay] - solenoid valve [PRC low temp.]) Replace solenord valve (PRC tow temp.) 1t3EOF3-323
INPUT -KNOCH -DIAGM (TEN T -IGNITIi (STAR1 --
CODE STEP 1
NO.
35 (SOLENOID
VALVE
-
PRESSURE
REGULATOR
CONTROL)
(High
temperature ACTlON
opoeration)
lNSPECTlON Disconnect connector from ECU: is there battery voltage a? ECU terminal 22 (G) with rgnttlon swttch ON7 Yes Check ECU connection 4 e No terminal
connector
for poor
If OK, replace ECU If not OK, repair or replace step wiring harness
J connector
page
F3-2
Go to next Repair
E/L SIC -a P/S PR -A/c SYI -NEUTR SWITCI -STUPb -ATMDI SENSQ -a THRUI -..
2
In same condrtron as In Step 1, is there battery voltage at solenoid valve (PRC high temp.) connector terminal wire (G)? Is solenoid valve (PRC high temp ) OK7 r;r page
Yes No Yes
or replace step
(G)
Go to next
3
F343 No
Check for a short or open circuit In wiring harness (marn relay [FUEL INJ reWI - sofenord valve [PRC high temp.]) Replace solenoid (PRC high temp.) valvef3EOF3-324
Circuit
Diagram
IT O MAIN RELAY
ECU
2T
22
ISOLENOID VALVE (PRC HIGH TEMP.):3EOf3 32 5
INfAk.1 -AlFlFLC -UXYGE -WATEF -DlSfRl
G
I
F3-18
TROUBLESHUOTING
GUIDE
F3
TROU8LESHOOTlNGRELATIONSHIP . CHARTOUTPUT DEVICE
GUIDE
\
INPUT KNOCK
DEVICE SENSOR
\
w 3 s s
DtAGNOStS CONNECTOR (TEN TERMINAL) IGNITION (START SWlTCH POSITION)
0
0 0 00
0 0
0
0
E/L SIGNAL* P/S PRESSURE A/C SWtTCH AND CLUTCH SWITCH
0 0 0 0 0 0 0 00
0
0 0 0 0 0
NEUTRAL SWITCHES STOPLIGHT
SWITCH
ATMOSPHERIC PRESSURE SENSOR (IN ECU) THROTTLE SENSOR AIR THERMOSENSOR
0 0 0 0 0 0
0 00
0 0 0 0 0
0 0 0 I 0 0 0 0 0 0
0
0
0
~INTAKE
-~OXYGEN WATER SENSOR THERMOSENSOR
0 0 0 0
0 00 0 0
0
A
0.
0
0
0
0
0*
0
ccooling fan operating,headlights
0 133F3-32
E/L SIGNAL: Blowerrear window defroster
fan controlON.
switch
second position
or higher,
electric
IN,
o
i
F3-19
F3IDIAGNOSTiCNo. 1. 2 3 4
TRUUBtESHOOTlNGtNDEXTFtOUBLESHOOTtNG WI/I not crank Cranks normally will not start or cranks but slowly No combustion Partial When corn bustlonengine cold ITEM Refer Engine flrlng to Engine cranks
GUIDE
-..
DESCRIPTtON Electrrcal at normal System speed but shows no sign of par-
PAGE 1 F3-22 1 F3-25 REAR I ---
Engine cranks tial combustion
at normal speed but shows only and will not continue to run
Partial combustronAfter warm-up Cranks normally hard to start but Always When After engine warm-up cold
Engine cranks at normal speed combustion but ~111 not continue hot soaked Engine cranks at normal sive cranktng time before
and shows partial runnrng after being exces-
speed but rqurres starting engine running IS cold and
1 1 hot F3-27
Same condition as No. 5 when Restarts normally after warm-up Same condition soaked Starts normaNy [ Engine r 1 Engine warm-up as No. 5 after when cold
betng
1
tsl
8
1 Rough Engine
idle/ stalls
1 Always at idle Before After When or IX warm-up warm-up A/C, ON P/S, startingI
stalls or vibrates stalls or vibrates
excessively excessively
at idle at idle during but
1 r I
F3-29 1 F3-3 1 1 f
10 11 12I
Engine runs normally at idle stalls or vibrates excessively Engrne stalls or vtbrates NC, P/S, or E/L ON Engine stalts or vibrates tacceleratton from Idle1 I tdle speed excessively up and Engine speeds
during warm-up atter warm-up
excessrvely excessively hrgh down stops after running runnrng
at idle when lust after warm-up at Idle or after durrng startingI
Rough High Engme Engine
rdle/Englne Idle speed stalls statts
stalts after
lus: after
13 14 15 16 17L
warm-up down/idle hunts
1 F3-33 F3-35 F3-36 1t
Idle moves
up and
periodically
on deceleratron suddenly (intermrttent) on accelerattonI
Engine unexpectedly deceleration Engine intermittently
stops
Hesitates/Stumbles 1 Surges tack while of power crulsng
Flat spot occurs just after accelerator is depressed, or m/Id ierkina occurs dunna accelerationI
18 19
1 Unexpected 1 repetrtive
change
In engine load
speed when
that is usually throttle valveIS
1
1 2
Performance poor under wide open Maximum speed reduced Performance deceleration/Backfire poor during durrng
20 21 22 23 24 b 25 26 27l
Poor Runs
acceleration rough
acceleration
2 1 2 +1
Engtne runs rough during deceleratron, and abnormal combustion occurs in exhaust system Abnormal pinging ( Gasoline combust!on noise odor in cabln odor excessive unsatisfactory but magnetic clutch does not accompanied by audible
Knocktng Fuel High Poor A/C odor sulfur smell oil consumption fuel economy does not work Manual (t 203-l Drive Workshop O-89F). Manual
Exhaust
Exhaust
gas has an unusual
1 2 1
Oil consumption Fuel economy Blower (1229-IO-89L).
fan operates,
l113EOFS327
1.. .Refet l 2...Re#er
to 323 Workshop to 323 4-Wheet
F3-20
TRUU8LESH00TlNG
GUIDE
F3
13EOF3-328
PRECAUTIONS Fuel Pressure Release and Servicing Fuel System Fuel in the fuel system remains under high pressure when the engine is not running. a) Before disconnecting any fuel line, release the fuel pressure from the fuel system to reduce the possibility of injury or fire as discribed below. 1. Start the engine. 2. Push the rear seat cushion buttons and remove the cushion. 3. Disconnect the fuel pump connector. 4. After the engine stalls, turn off the ignition switch. 5. Reconnect the fuet pump connector and install the rear seat cushion. b) Use a rag as protection from fuel spray when disconnecting the fuel hoses. Plug the hoses after removal. c) When inspecting the fuel system, use a suitable fuel pressure gauge. Caution l install hose clamps to secure the fuet pressure gauge to the fuei fitter and the fuel main hose to prevent fuel leakage. Pinching Hose When pinching an air hose-or a fuel hose with pliers, wrap the hose with a rag to prevent damage,
13EOF3-329
1
F3-2
t
F3SYMPTOM TROUSLESHOOTING
TROUBLESHOOTING
GUIDEiTEF
2 .l
CRANKS
NORMALLY
BUT
WILL
NOT
START
(NO
COMBUSTION)
LIESCRIPTION
Engine cranks at normal speed but shows no sign of firing l Battery in normal condition *Throttle valve not held fufly open while cranking (dechoke system l Fuel in tank @.I low @I Low malfunction
not operating}
UROOBLESHUOTlNG HINTS] @ No spark l Ignition control malfunction l Ignition system component @ No fuel injection l Fuel pump inoperative l Ihjectors inoperative ;TEP1
fuei tine pressure engine compresslon
INSPECTIONIs strong btue tension lead? spark visible at disconnected highYes
IGo to Step 3
ACTION6
NO
Go to Step
2
2
Is 00 dlsplayed with ignltron switch
on Self-Dlagnosjs ON?
Checker
Yes
Check rgnltion Troubleshooting
system (Refer Misfire)
to c7 Section G
SYSTEM
SELECT:
1
No
Service Code No. displayedCheck check 66 Check for cause sequence) (Refer to specified Gpage
F3-16
\
flashes ECU termrnal
1F voltage
3
page
W-45 8
Voltage:W: SELF TEST
Battery vabage (ignition switch
ON)
C+ If OK, replace ECU 4 If not OK, check wiring (ECU - Self-Diagnosis Yes Does 4 4 engine
CT page F3-2Checker)
3
Connect diagnosis GND with jumper sound heard wjth
connector terminals F/P and wire; IS fuel pump operating ignition switch ON?
start in this condition?
If it does, check circuit-opening relay If it does not, go to Step 5
No
Go to next
step
F3-22
TROUBLESHOOTINGSTEP4
GUlDEACTlON
F3
INSPECTION Is there buttery voltage at fuel pump connector (G/R) with lgnitron switch ON and F/P terminalYes
*
Check contmurty of fuel pump between termrnafs G/R and 8
Check
ctrcutt
openmg
relay
5
Is qector operating being cranked?
sound
heard
whtle
engine
IS
Yes No
Go to Step Go to next
8 step
CcI page
F3-45
+
If 0K;check for a short cjrcult rn wiring harness (Injector reastor-Injector) =D If not OK, replace Injector reststor
fuel Line 12.7-3.2
pressure: kgflcd,
265-314 38-46
kPa
psi)
if fuel
return t, replace
hose
is clogged
or
pressure CT psge F3-3
F3-2 3
__
_
7
_-.
_
,
._
_)
.--.Kze
-
__
F3ZEP 9 Is engine e compression WSPECTION correct? c7
TROU5l.ESHOOTING
GUIDEACTION
Yes Section 82NO
Go to next
step CT Section B2
Engine 1059
compression: kPa 110.8 kgflcm2,
152 psi I-300
rpm
Check engme condrtlon l Worn piston, piston rings or cylinder wall l Damaged cylr nder head gasket *Damaged or warped cylinder head l Improper valve seating *Valve sticking in guide
pc?t.@ Air,1 l F.. etl Irtj
TEP 10 Are all spark plugs OK? c7l l l
Yes Section G
Go to next
step
Wear and Plug gap Damage
carbon
buildup No Clean, adjust
11
Try known
good
ECU;
does
condftlon rmprove CT page F3-2
_-w^r-
^^< 2
F3-24
TROUBLESHOOTING4l Engine
GUIDECOMBUSTION) AFTER running WARM-UP after being
F3hot
CRANKS soaked l Battery *Engine
NORMALLY cranks at nurmal
8UT speed
WILL and
NOT shows
START partial
(PARTfAL combustion
but will not Continue
&RIPFION
in normal condltlon starts normally when
cold @ Vaporlock ssure not held in fuel line after engrne IS
TROUBLESHOOTING 3 Air/Fuel mixture
HINTS]too rich
GND
mth
jumper
wire
tor 3 minutes
with ignition
Fuel line pressure: 265-314 (2.7-3.2 kgflcm2, 38-46
kPspsi 1 c3 4 If pressure quickly increases, check pressure regulator If pressure gradually increases, check fuel line and filter lor clogging If hose is not clogged. check fuel pump maximum pressure hose is clogged or
High pressureCheck if fuel return restricted INSTALL CLAMPS e @
If rt is not, replace pressure regulator It It 6. repalr or replace it
CT page
F3-3
F3-25
F3STEP 5
TROUBLESHOOTINGlNSPECTlON In same condition as in Step 2, IS fuel ilne pressfire held after Igrxtbon swatch rs turned OFF? Fuel line pressure: More than 147 Il.5 kgflcm, 21 Psi 1 for 5 min. kPa Yes
GUIDEACTION Go to Step 8
I-
6
In same condition as in Step sure held after lgnltron switch
3, IS fuel line presIS turned OFF? kPa
Fuel line pressure: More than 147 { t.5 kgf/cm*, 21 psi) for 5 min.
No I GoYes
to next
step
Plug both vcuum fuel lme pressure turned OFF?
ports of pressure held after ignltlon
regulator; IS switch is
Replace
pressure
regulator
r~
page
F3-3
Fuel line pressure: More than 147 { 1.5 kgf/crn*, 21 psi] for 5 min.
kPa
NO
Check e e
fuel pump
hold
pressure
If OK, check InJector for fuel leakage If not OK reptace fuel pump
ZF- page T page
F3-42 F3-3
8
Dlscofinect water engtne start?
thermosensor
connector,
does
Yes
Check e Q
water
thermosensor of water 2Q terminal thermoET page --~ F3-13
ff OK. check connectrons thermosensor and ECU If not OK, replace water sensor step step
No 9 Is 00 drsplayea on Self-Diagnosis with ignition switch ON? SYSTEM SELECT, 1 Checker YesNO
1 Go to next Go to next
Service Code No. displayed Check for cause (Refer to specified check sequence) 88 Check Voltage: flashes ECU terminal Battery (ignition
c7
page
F3-16
IF voltage voltage switch
KIT page
F3-45
ON) ET- page Checker) F3-2
Y10
e e %EtECT voltages and 2Q) SW: A are OK? CT page F3-45 YesNO
If OK, replace ECU If not OK, check wiring (ECU - Self-Diagnosis step
Are rf ECU termrnaf (especjaffy 1C. 2D.
1 Go to next Check Replace Change
for cause ECU to another brand of fuel13EOF3 331
Try known
good
ECU,
does
condition improve? CT page F3-2
Yes No
=T page
F3-2
F3-26
TROUBLESHOOTING7 * DESCRIPTION CRANKS NORMALLY BUT HARD excessive
GUlDETO START cranking time AFTER before WARM-UP starting after running and
F3being
l Engrne
cranks at normal speed but requkres hot soaked l Battery rn normal condition l Engine starts normatly when cold *Engine runs normally at Idle (If idle condrtron
is not OK,
refer
to Rough
idle
~Nos.
8-l
21)
[ i5
[ ~ROUBLESHOOTLNG HINTS1 ArrlFuel mixture too Rich l Fuel rqection control malfunction l lnpector fuet leakage TEP I tNSPECTlON Is 00 Checker dispiayed on Self-Diagnoses wrth rgnrtron switch ON7 Yes
@ Vaporlock l Fuel pressure not held rn fuel line after engrne stopped l Pressure regulator control system malfunction ACTION I Go to next step
IS
1
SYSTEM?_SELECT.
1
No
Service Code No. displayed Check for cause (Refer to specified check sequence) 88 Check Voltage: flashes ECU terminal Battery (ignition 1F voltage voltage switch
CT oaae w page
F3-16 F3-45
ON) w page F3-2
SELECT
SW. A Yes
Remove vacuum hose from pressure regulator (port A) ancI plug rt. dOt?S engine start normally-,
( cs> It OK. replace ECU / 3 If not OK, check wlrtng ChecKer) (ECU - Self-Dlagnosrs Check pressure regulator control systern (high temperature operation)
w
. page
F3-43
I
NO
Go to next
step
Remove both vacuum hoses from pressure lator (ports A and Bj and plug them; does gine start normally7 @ PtUG / /
reguen-
Check pressure regulator control tem (low temperature operation)
sys-
No
1 Go to next
step
Are ECU (especially
terminal voltages OK 1 C, 20, 20 and 2T)? w page F3-46
YesNO
Go to next Check
step
for cause
F3-27
F3iTEP 5 INSPECTION
TROU8LESliOOTING
GUIDEACTtUN
Run engine at idle; is fuel line pressure ter ignition switch is turned OFF? Fuet Ijne pressure: More than 147 {1,5 kgflcd, 21 pdf for 5 min.
held kPa
af-
Yes No
Go to next
step
Plug both vacuum potts of pressure regulator; and check if fuel line pressure is held after ignition switch is turned OFF 4 c3 If it is, replace pressure regulator If it is not, check fuel pump hold pressure If fuel pump is OK, check injectors for fuet leakage CT page F3-3
NSTAtl
CLAMPS
CT- page
F3-4
6
Warm up engine ture and stop it Connect diagnosis GND with jumper switch ON; does
to normal
operating
tempera-
Yes
Change
to another
brand
of fuel
connector terminals F/P and wire for 3 minutes with rgnitlon engine start easily?
No
Go to next
step
7
Try known
good
ECU;
does
condition improve? CT page F3-3
Yes No
Replace Change
ECU to another brand of fuel
w-
page
F3-3
t3EOF3
F3-28
TROUBLESHOOTING8
GUIDEAT IDLE - ALWAYSat idle in every condition
F3
11l
ROUGH IDLE/ENGINEEngine starts normally but stalls or vibrates
STALLS
DESCRtPTION
excessively
[TROUBLESHOOTiNG
HlNTSJ@ Incorrect idle-speed l ldiespeed misadjustment l Idle-speed control malfunction $I One or more spark plugs not firing 9 Low engine compression B Airflow meter stuck
@ Air/Fuel mixture tw lean l Air leakage l Fuel injection control malfunction *Low fuel line pressure @ One or more injectors clogged or not operating @ Low intake air amount
INSPECTIONIs 00 Checker 1 SYSTEM displayed on Self-Diagnosis with ignition switch ON? SELECT: 1 Go to next step
ACTION
Service Code No. displayedCheck check 88 Check for cause sequence) (Refer to specified
c7 page F3-16IF voltage
\ --. \.
flashes ECU terminal
(17 page
F345
Voltage:4 c3
Battery v&age (Ignition switch ON) IT page F3-2Checker)
YAre ECU (especially
-SELECT terminal voltages OK 20, 20, and ZQ)?
SW: A
If UK, replace ECU If not OK, check wiring (ECU - Self-Diagnosis step
Yes D page F3-45NO
Gu to next CheckGo to
for cause Step 9 step 7 and go to next resistance step is OK
Disconnect each high-tens&on lead at idle: does engine speed decrease equally at each cylindeR
Yes
NOIs injector operating sound heard at idle? [ Yes
Go to next Go to Step Stop Check engine
NO tIs there battery voltage at each injector connector (No.1 (P), No.2 (R), No.3 QV), No.4 (0)) with ignition switch ON? Yes
if injector
CT page F3-41
Resktance:4 c3
Approx. 2.110 (at 20*C [68*F))
if it is, check wiring (ECU - Injector) If it is not, replace itijector step resistor
NOIs there battery v&age at injector with ignition switch ON? resistor (W/R) I .Yes
Go to next Check 4
mjeotor
tf OK, check for short circuit in wiring (Injector resistor-Injector) e3 If not OK, replace injector resistor Check for open circuit in wiring relay (FUEL INJ relay)-Injector Go to next Check 4 c3 step lead (Main resistor) 1
tIs strong blue soark visible at each disconnected
NOYes
high-tension
If UK. check distributor cap and . rotor If not OK, replace high-tension lead
-F3-29
F3TEPI tNSPECTION
TROUBLESHUOTING
GUIDEACflONe 4 If OK, replace injector If not OK, check for cause
710 w Section 82
*
DES& HON -*
ITEP
(Upper vacuum
hose to pressure
regulator
44
If pressure quickly increases, check pressure regulator If pressure gradually increases, check for clogging between fuel pump and pressure regulator if hose is not clogged, check fuel pump maximum pressure
2
3
4
I
12
Is engine
compression
correct?
Yes
Go to next
step
w Sectlon Engine compression: 1059 kPa (10.8 kgf/cm2, 152 psi]-30013
82 rpmNO
Check
for cause
w SectionECU; does condition
B2.
Connect System Selector to diagnosis connector and $et Test Switch to SELF TEST; is ignition timing correct at idle after warm-up?
Yes
Try known improves?
good
w page f3-3
ignition
timing
(BTDC): 10 * toNO
Adjust
ignition
timing
F3-30
TROUSLESHOOTING10 DESCRIPTlO# -Engine runs normalty ROUGH IDLE/ENGINE warm-up STALLS AT IDLE stalls
GUIDEAmER WARM-UP excessively after warm
F3
at idle during
but engine
or vibrates
TROUBLESHOOTING HINTS] 3 Idle-speed control system malfunction 3 Air/Fuel mixture too lean l Air leakage *Low fuel line pressure TEP
@ Air/Fuel mixture too rich l Fuel injection control malfunctlon (correction for coolant tem$eratuie) @ Poor ignition @ Low engine compresslon
INSPECTIONts 00 dlsplayed on Se\-Diagnosis with ignition switch ON? SYSTEM SELECT: 1 Checker YES No Go to next step
ACTION
1
Service Code No. displayed Check for cause (Refer to specified check sequence)
w
page
F3-16
88Check
flashesECU terminal IF voltage
w
page F345
Voltage:e c3
Battery voltage(ignition switch ON)
W: SELF TEST
!f UK, replace ECU ff not OK, check wiring (ECU - Self-Diagnosis step
wChecker)
page F3-3
2
Are ECU (especially
termrnal voltages OK 20, 20, and 2Q)? w page F3-45
Yes No Yes NO
Go to next Check
for cause step 9 step
3
Disconnect each high-tension lead at idle; does engine speed decrease equally at each cylinder?
Go to next Go to Step Go to next
4
Is intake
manifold
vacuum
correct
at idle?
Yes
Vacuum:
More than
450 mmHg f 17.7 InHg )
NO
Check for air leakage tem components
of intake
air sys-
5
Is air cleaner
element
clean?
Yes No
Go to next Replace
step element
air cleaner
F3-3
1
F33TEI Is fuel line pressure * correct
TROUBLESHOOTING
GUIDEACTION
at Idle?
Yes No regulator 44-57 psi 1 regulator
Go to next
step
Fuel line pressure: 265-314 kPa 12.7-3.2 kgf/cm, 38-46 psi] (Two vacuums hose to pressure disconnected) 304-392 kPa [ 3.1-4.0 kgf/cm, (Upper vacuum hose to pressure disconnected)INSTALL CLAMPS
Low pressure Check fuel line pressure fuel return hose 4 e
while
pinching
If pressure quickly Increases, check pressure regulator If pressure gradually Increases, check for clogging between fuel pump and pressure regulator If hose is not clogged, check fuel pump maxrmum pressure
Connect System Selector to diagnosis connector and set Test Switch to SELF TEST; is ignition tlmlng at idle correct after warm-up? Ignition timing (BTDC): 10 f lo
Yes
Go to next
step
No
Adjust
tgnrtkon
system
8
Dtsconnect water engine condrtlon
thermosensor Improve?
connector;
does
Yes No
Replace Try known Improve?
water good step
thermosensor ECU. does condltlon w page F3-13
9
Is jqector
operating
sound
heard
at Idle?
Yes No
Go to next Check
if injector
resistance
is OK
w
page
F3-42
Resistance: (at 20C 4 c3 IO Is engine compressron cprrect? w Engine 105917
Approx. 168*F])
2.11 Q
If it is, check wlnng (ECU - Injector) If it Is not, replace injector step 3 Section B2
Yes Section psi)-300 G No 152 rDm Yes
Go to next Check
compression: kPa 110.8 kgf/cm2, vrslble
engine step
is strong blue spark hrgh-tension lead?
at each
disconnected
Go to next
No
Check
high-tension
lead
w
Section
G
c3 If UK, check distrrbutor cap and rotor 3 If not OK, replace htgh-tensron lead 12 Are sparkl l l
plugs.OK? w Section G carbon butld up
Yes
Try known Improve7 Clean, adjust
good
ECU:
does
condrtron w page F3-3
Wear and Piug gap Damage
NO
13EOi3.334
F3-32.
TROUBLESHOOTING14 IESCRLPUONl
GUlbEDOWN/IDLE HUNTS
F3
1
IDLE Engine speeds up and down
MOVES
UP AND at idle
periodically
TROUBLESHOOTING HINTS] B Idle switch (En throttle sensor) OFF at idle 3 Air leakage 3 Fuel injection amount Inconstant . Poor contact point inside airflow meter 9 Poor ignitron rEP[ I INSPECTION is 00 displayed on Self-Dragnosis with ignrtron swatch ON? Checker Yes NO SYSTEM SELECT: i I Go to next step ACTfON
Service Code No. displayed Check for cause (Refer to specified check sequence)
c=;r page
F3-16
\
86 Check Voltage: W: SELF SELECT SW: A TEST P/ .d Yes e c3
flashes ECU terminal Battery (ignition
IF vottage voltage switch
csr page
F345
ON) CT page Checker) F3-3
If OK, replace ECU If not OK, check wrrjng (ECU - Self-Dlagnosls step
2
Is intake Intake More
manrfold
vacuum
correct
at idle?
Go to next
manifold vacuum: than 450 mmHg
{ 17.7
inHg
) No Low vacuum Check for air leakage system at intake air
3
Is air cleaner
element
clean?
Yes No
Go to next Replace
step element
abr cleaner step 8 step
4
Disconnect each hrgh-tension lead at idie; does engine speed decrease equally at each cylinder?
Yes No
Go to next Go to Step Go to next Check
5
Are ECU (especially
terminal voltages 20, 2Q, 20)
OK? rI7 page F345
Yes No Yes
for cause step
6
Connect System Selector to diagnosis connector and set Test Switch to SELF TEST; is ignition timing at idle correct after warm-up? Ignition timing (BTDC): f0 f la
Go to next
No
Adjust ._
ignition
timing
.
F3-33
TROUBLESHOOTING
GUIDE
~ROlJ8LEngine so: 3 Idle-sp. T> fuel-cL
(at 20%
[SS*F])wiring
If It is, check
e e
If OK, check distributor cap and rotor If not OK, replace high-tensjon lead
12
Are spark . Wear and l Plug gap l Damage
plugs
UK?
Yes
Is engine
compresston
correct?
w Sectioncarbon burld up
G
w Section
82
Engine compression: 1059 kPa 110.8 kgf/cm*, 352 psi I-300 rpm4 4 If OK, go to next step If not OK, check for cause
w Section
82
cNO
Clean, Replace
adjust injector step
13
Check
for injector
leakage
YesNo
Go to next
14
Try known
good
ECU:
does
condition improve? w page F3-45
-----
Am.*
F3-34
TROUBLESHOOTING15 IESCRIP[iONl l
GUiDE
F3
ENGINE Engrne unexpectedly Idle condition normal. when stops running dunng
STALLS or after
ON DECELERATION deceleration
TROUBLESHOOT1NG HtNTS] ingrne speed drops too much 3 Idle-speed misadjustment 3 Fuel-cut contrd malfunction TEP 1 1s idle condition tdle speed: 800 normal? f
releasrng
accelerator @I Loose connector disconnected ACTION Yes Go to next Adjust 8-I 1 (Refer (1203-I step Nos. by force of deceleration
lNSPECTlON
50 rpm
(in neutral)
NO
or perform Troubleshooting, ROUGH IDLE to Workshop Manual o-89F)) step No. displayed (Refer to specified
2
Is 00 displayed on Self-Diagnosis with ignition switch ON? SYSTEM SELECT:1
Checker
YesNO
Go to next Service check 88 Check Voltage:
Code sequence)
Check for cause
ET page
F3-16
flashes ECU termrnal Battery (ignition
1 F voltage voltage switch
r;r
page
F346
ON) CI Checker) page F3-3
W:SELFTEST
e 4 YesNO
If OK, replace ECU If not OK, check wirtng (ECU - Self-Diagnosis step ON or OFF (Refer with
3
Does Self-Diagnosis lgnttlon switch UN correctly?
Checker Monitor show that switches
Lamp with operate
Go to next Lamp switch Check check not
specified
for cause sequence)
to specified
Lamp slways Check wiring (ECU terminal Checker)W:
ON between 1 D - Self-Diagnosis
SEtF
TEST
4
Are ECU (especially
?erminal voltages OK? IV, 20, 20, ZU, 2V. and 20) v page F346 of foltowing parts
Yes NoYC?S
Go to next Check Repair
step
for cause or replace
5
Check for poor connection l ignrtion coil l Igniter l Olstribdor l High-tension lead l Injector. l Injector resistor l Ctrcuit-opening relay l ECU
NO
Go to next step
.
F3-35
F3STEP 6 c Is dashpot Dashpot correctly set speed: INSPECTION adjusted? Approx.
TROUBLESHOOTING
GUIDEACTlON
Yes 3,500 rpm No
Go to next
step
Adjust
dashpot
7
Try known Improve?
good
ECU;
does
condition w page F3-313EOF3-336
16 DESCRIP. TIONl l
ENGINE Engine Before
STALLS
SUDDENLY
(INTERMITTENT)
intermittently stops running stalling, engine conditron is OK caused by ve-
TROUBLESHOOTING HINTS] @ intermittently no spark or no fuel injection hlcle vibratron, acceleratton, or deceleration l Poor connectlon in wiring harness iTEP 1 INSPECTION Is 00 displayed on Self-Oiagnoss with lgnltlon swrtch ON?
ACTfON Checker Yes NO Go to next step
Service Code No. displayed Check for cause (Refer to speclfled check sequence). Note l When checking wiring connectors, tap, move, suspect sensor and/or recreate problem 88 Check Voltage: flashes ECU terminal Battery {ignition
CT page
F3-16
harness and and wiggle harness to
IF voltage voltage swttch
w
page
F3-45
ON)
4 4 2 Check for poor connection l lgnltfon coil l Igniter l Distributor l t-flgh-tensron lead l Injector l Injector reststor l Circutt-opening relay l ECU Are ECU (especially of foliowrng parts Yes
If OK, If not (ECU Reparr or
replace ECU OK, check wiring - Self-Diagnosis replace
7.8-l
Checker)
No
Go to next
step
3
terminal voltages OK? 16, 2A, 2B, and 2C) w page F3-45 .
Yes
Go to Troubleshbotrng No. 2 .CRANKS NORMALLY BUT WILL START (NO COMBUSTION) Check for cause
NOT w page F3-20
Note l When. checking wiggle harness problem
voltages, tap, and connector
move, and to recreate
No
* lrlrl
m-7
F3-36
TURBOCHARGER TURBOCHARGERTURBOCHARGER Reinovaf / Installation
CONTROL
SYSTEM
F3
II 11 :j
CONTROL
SYSTEM
Caution l Be careful of the following points after turbocharger removal. l Do not carry the turbocharger by the actuator rod or actuator hose. l Do not drop the turbocharger. l Set the turbocharger down with the turbine shaft horizontat. l Cover the intake, exhaust, and oil passages to prevent dirt or other material the turbocharger. l Use the specified new studs when installing the turbocharger. 1, 2. 3. 4. 5. 6.I--
from
entering
Disconnect the negative battery cable. Raise the vehicle and support it on safety stands. Remove the undercover. Orain the engine coolant. Remove in the order shown in the figure, referring to Removal Install in the reverse order of removal, referring to Installation7.8-1 1 N-m ~80-110 kgfcm. 69-96 idbf j
Note. Note.
3842
13.94.3,
28-
31--46
13.2-4.7,
23-341
T, REPLACE
.
12-18
1 f-2-1.8,
8.7-13
I
GASKET,
REPLACE
3946
13.94.7,
2%
19-26
1 t .9-2.6,
14-19
1
7.6-11
Mm
t80-?lO
kgfcm,
69-95
hlbfl ~-t-n 1 kgf-m, Wlbt] 13EOF3 3.31
F3-3i
F31. Radiator
TURBOCHARGERCONTROLSYSTEM6. Water hose 7. Oil pipe8. Exhaust manifold and turbocharger Removal Note ,.........I.....f.~.~l....... II.I.... below Installation Note ....,,l.. ......,,.. ,..*, ,......... below13EOF3-339
2. Insulator3. Air hose, and air pipe 4. Oxygen sensor connector 5. Front exhaust pipe
3. Instc
Removal
Note
Exhaust manifold and turbocharger 1. Remove the exhaust manifold and the turbocharger as an assembly. 2. Separate the turbocharger assembly from the exhaust manifold.
Installation
Exhaust manifold
Note and turbocharger
I I Remove .all old gaskets and sealant. 2. Install new gaskets. 3. Supply 25 cc ( 1.5 cu in ] of oil through the oil passage of the turbocharger. 4. Mount the turbocharger assembly to the exhaust manifold. 5. Install the turbocharger and the exhaust manifold assembly to the engine and loosely tighten the nuts. 6. Install the bracket and the front exhaust pipe, and tighten the turbocharger mounting nut%
WASTEGATE
SOLENOD
VALVE
Caution l The wastegate solenoid valve must be replaced with the turbocharger, it cannot be replaced by itself. Inspection1. Disconnect the connector. 2. Measure the resistance of the solenoid valve.
Resistance:13EOF534
35-45
!l (at 20C
f68OFj)
3. Mnot as specified, replace the wastegate solenoid valve and turbocharger as an assembly, if necessary. (Refer to page F3-37.)
F3-38
TURBOCHARGERINTERCOOLER Removal / Installation 1 I Remove the front bumper. (Refer to Section S.) 2. Remove in the order shown in the figure. 3. Install in the reverse order of removal.
CONTROL
SYSTEM
F3
7-i-11
N-h
l80-110
kgfem,
69-95
In-lbf 1
wrn
1 kgf-m, ft-lbf I 13EOF3-34:
1.
Air hose
2. Intercooler
F3
FUEL SYSTEM
FUEL SYSTEMFUEL 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 kagee ii -C-A-' _~ -, \ -, --*
t 3EoF3-344 1
7. If not as specified, check the circuit opening relay and circuit. 8. ff as specified, check fur continuity between fuel pump connector (G/R) and (B). 9. If there is continuity, reptace the fuel pump. 10. If there is no continuity, repair the ground circuit.-1f3EOF3.345
E 7 2
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
I13EOF3-346
Cranking Ignition switch ON
1
Battery voltage ov
I3EAR i --
SE
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
FUEL SYSTEM
F3
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.Battery Terminal voltage ov C applied Continuity betweenNO
A and
I3
Yes
4. Measure13EOF3.34
the resist