1990 MAZDA 232 fuel pressure

Fl FUEL. SYSTEM
FUEL TANK
Removal / inspection I Installation
Warning
l Before performing the following operation, release the fuel pressure from the fuel system to
reduce the possibiIity of injury or fire. (Refer to page Fl-9.)
l When removing the fuel tank, keep sparks, cigarettes, and open flames away from it.
l Before repairing the fuel tank, clean it throughly with steam to remove all explosive gas.
1. Remove in the order shown in the figure.
2. Inspect the fuel tank components visually and repair or replace as necessary.
3. Install in the reverse order of removal, referring to Installation Note.
FUEL PUMP (MAIN) TRANSFERPU
4341 (4.4-6.2, 3245)
GASKET, REPLACE
ET, REPLACE
4it-55 (4.3 -5.6, 3041)
Nm (m-kg, ft-lb)
a?cnc% .7*7

F2
FUEL AND EMISSION
CONTROL SYSTEMS
(WITH CATALYTIC CONVERTER)
.
INDEX ..*.........**.*.........*..........*...... F2- 2
OUTLINE ...................................... F2- 4
OUTLINE OF CONSTRUCTION.. .... F2- 4
SYSTEM DIAGRAM ...................... F2- 5
VACUUM HOSE ROUTING
DIAGRAM [BP TURBO] ............... F2- 7
WIRING DlAGRAM.. ..................... FZ- 8
ECU REtATlONSHIP DIAGRAM
[BP TURBO] .............................. F2-10
SPEClFtCATlONS. ........................ F2-11
TURBOCHARGER CONTROL
[BP TURBO] ................................ F2-I 2
OUTLINE .................................... F2-I 2
SYSTEM DIAGRAM ................. .; ... F2-12
WASTEGATE CONTROL ...............
F2-13
FUEL,SYSTEM
.............................. F2-15
OUTLINE
.................................... F2-15
CONSTRUCTlON ......................... F2-15
FUEL VAPOR VALVE ................... F2-16
FUEL PUMP CONTROL SYSTEM.. . F2-16
FUEL PUMP RESISTOR/RELAY ...... F2-18
TRANSFER PUMP CONTROL. ....... F2-I 8
CONTROL SYSTEM ....................... F2-20
STRUCTURAL VIEW.. ................... F2-20
OVERBOOST WARN!NG BUZZER
[BP TURBO] .............................. F2-21
TURBOCI-IARGE INDICATOR
[BP TURBO] .............................. F2-21
KNOCK CONTROL SYSTEM
[BP TURBO] .............................. F2-22
OXYGEN SENSOR [BP TURBO]. .... F2-23
PRESSURE REGULATOR CONTROL
SYSTEM [BP TURBO] ................. F2-23
A/C CUT-OFF SYSTEM (ATX) .........
F2-24 SUPPLEMENTAL SERVICE
INFORMATION ............................. F2-25
SELF-DIAGNOSIS FUNCTION .......... F2-26
OUTLINE
.................................... F2-26
MALFUNCTION CODE NUMBERS . . F2-26
TROUBLESHOOTtNG GUIDE
[BP TURBO1
................................ F2-31
RELATlONSHlP CHART ................ F2-31
SYMPTOM TRUUBLESH0OTlNG .... F2-32
tNTAKE AIR SYSTEM ..................... F2-43
COMPONENTS ............................ F2-43
TURBOCHARGERCONTROL
SYSTEM ...................................... F2-45
PREPARATION ............................ F2-45
SYSTEM OPERATION ................... F2-45
WASTEGATE ............................... F2-45
WASTEGATE SOLENOID VALVE.. .. F2-46
TURBOCHARGER ........................ F2-46
AIR BYPASS VALVE ..................... F2-48
INTERCOOLER ............................ F2-49
FUEL SYSTEM .............................. F2-50
PREPARATION ............................ F2-50
PRECAUTION ............................. F2-50
FUEL TANK
................................ F2-51
TRANSFER PUMP CONTROL
SYSTEM ................................... F2-52
FUEL PUMP CONTROL UNIT ........ F2-53
TRANSFER PUMP SWITCH ........... F2-54
TRANSFER PUMP.. ...................... F2-54
FUEL PUMP RESISTOR/RELAY ...... F2-56
INJECTOR
.................................. F2-56
EXHAUST SYSTEM
COMPONENTS .................................................... ;ff;
CONTROL SYSTEM ....................... F2-59
PREPARATION
............................ F2-59
ENGINE CONTROL UNIT (ECU) ..... F2-59
OXYGEN SENSOR ....................... F2-68
KNOCK SENSOR ......................... F2-69
93GOF2.701

F2 OUTUNE
OUTLINE OF CONSTRUCTION
The fuel and emission control system of the new 323 4WD model is basically the same as that of the new
323 2WD modet; however, a turbocharger and knock control system are added to the BP TURBO model
and the fuel tank is designed
with separate right and left sections due to the installation of the propeller shaft
for the 4-wheel-drive system. A transfer pump is also equipped to pump the fuel from the left
to the right
(fuel pump side) section of the fuel tank.
The major points of difference between the 2WD model and 4WD model are as shown below.
93GOF2-705
Difference
Component 2WD 4WD
BP SUHC BP OOHC BP SOHC BP TURBU Remark
INTAKE AG! 1 Resonance duct 0 0 0 - -
SYSTEM
Resonance chamber 0
0 G -
VICS .-
ui- - -
Turbocharger - - -
0 Refer to page
FZ-12
I ntercooler - - -
0 Refer to page FZ-14
Air bypass valve - - -
0 Refer to page F2-14
FUEL SYSTEM Fuel pump control - - -
0 Refer to page F2-16
Transfer pump - -
0 0 Refer to page F2-18
Operating time for BP
Pressure regulator control 0 0 0 0
TURBO is different
(Refer to page F2-23)
Fuel pump reststorlrelay - - -
0 Refer to page F2-18
EVAPORATIVE
EMISSION
Fuel vapor vatve - -
CONTROL 0 0 Refer to page F2-16
SYSTEM
CONTROL
SYSTEM Point type
0 0
Throttle sensor 0 (MTX) -
-
Variable type - -
0 W-x) 0
Without heater
0 0 0 -
Oxygen sensor F
With heater - -
- 0 Refer to page F2-23
Water thermoswitch (on radiator)
-
Knock control system -
Overboost wami ng buzzer -
Turbocharge Indicator - -
C @TX) - NC cut-off system
- - 0
Refer to page F2-22
- -
0 Refer to page F2-21
- - 0 Refer to page F2-21
93GOF2-706

OUTLINE F2
SPECIFICATIONS
Low-pressure stde
1 High-pressure side
Nylon element (rn fuel pump)
Paper element
-
Pressure regulator
Regutating pressure .
t kPa (kg/cm2, psi) 1 265-3-l 4 (2.7-3.2, 38-46)
-t
Injector
me
Type oi drive
Resrstance
Idle speed cantrol (EC) valve
Type
Resistance
Purge control solenoid valve
Resistance Q
D
s2 [ High-ohmic
Electromechanical
12-76
Rotary
II-13
23-27
Water thermosensor
Resistance
Airflow meter
1 -20% ( -4V) 14.6-I 7.8
kf2
2o”c ( 68OF) 2.21-2.69
4OOC (104OF) 1.0-I .3
8O*C
(176OF) 0.29-0.35
E2++Vs Fully closed 200-600
Fully open 20--l ,200
Resistance Ez-Vc
E?+THAA
(1 ntake air
thermosensor)
200-400
-2o*c ( -4*F) 13,600-I 8,400
20°C ( 68*F) 2,2f O-2,690
60°C (14cPf) 493-667
I
Air cleaner
Element type
Fuel
Specification
* TEN terminal of diagnosis connector grounded.
The t mark indicates newly equipped parts.
Oi! permeated
Europe.....Unhzaded premium
Unleaded reguiar (RON 95 or higher)
(RON 91 or higher) Australia...Unleaded regular
(RON 91 or higher)
93GOF2-7 i 3

FUEL SYSTEM F2
FUEL SYSTEM
Due to the installation of the propeller shaft fur the 4WD, the fuel tank is designed with left and right section.
Therefore, a transfer pump is used to pump the fuet from the left to the right (fuel pump) side. The transfer
pump is mounted in the fuel tank, and is controlled by the transfer pump switch and the fuel pump control unit.
The fuel pump control system is adopted for BP turbo model.
CONSTRUCTION
PRESSURE REGULATOR
FUEL PUMP
FUEL PUMP
RESISTOR/REU\Y
TRANSFER PUMP
/
FUELPUM IP SWI’
TCH
FUEL VAPOR
FUEL TANK
i
4x4 CONTROL UNIT [BP SOHC]
FUEL PUMP CONTROL UNlT [BP TURBO]

F2 CONTROL SYSTEM
CONTROL
SYSTEM
STRUCTURAL VIEW
OXL STOPLIGHT SWITCH CLUTCH SWITCH
INJECTOR
P/S PRESSURE
SWITCH
‘GEN SE877
DtSTRIBUTOR
/ PUMP
CONTROL UNll
CONTROL UNIT
CONNECTOR
P REStSTORlRELAY
FUEL tNJ RELAY (MAIN RELAY)
AIRFLOW METER
SOLENOID VALVE
I NEUTRAL SWITCH
(PRESSURE REGULATOR)
WATER THERMOSENSOR
93GOf2.729

CONTROL SYSTEM F2
t OXYGEN SENSOR [BP TURBO]
I
CERAMlC HEATER
93GOF2-733
Because the temperature of the exhaust gas is inherently low in turbocharged engines, the BP Turbo model
uses a rapid heating ceramic heater to detect the air/fuel ratio,
PRESSURE REGULATOR CONTROL SYSTEM [BP TURBO]
PRESSURE
REGULATOR
I SOLENOID VALVE
(PRESSURE REGULATOR CONTROL)
FUEL
+ (FROM
DELIVERY PIPE1
II
FUEL INJ I
RELAY
(MAIN REU\Y)
I
II Ir
-__. _ - -’ VACUUM
CT0 DYNAMIC
Ill
CHAMBER)
BATTERY -
c
FUEL
(TO FUEL TANK)
nme*rn -.-a
To prevent percolation of the fuel during hot restart idle, vacuum to the pressure regulator k cut for 180
sec., and the fuel injection pressure is increased to slightly more than 284 kPa (2.90 kg/cm’, 41.2 psi).
Operating condition
l Coolant temperature: Above 90°C (194OF)
l Intake air temperature: Above 58OC (136OF)
g No-load condition
FZ-23

F2 TROUBLESt=iUUTlNG GUIDE
SYMPTOM TROUBLESHOOTING
Regarding symptom troubleshooting except LACK OF POWER, POOR XCELERATION, KNOCKING, and
HIGH UIL CONSUMPTION, refer to Workshop Manual [I 203-l O-89F (Europe) or 1204-l O-89F (Australia)].
19 LACK OF POWER [BP TIJR801
DESCRIP- *Performance poor under load when throttle valve wide open
TION *Reduced maximum speed
l Idle condition normal
[TROUBLESHOOTING HINTS1
3 Wastegate always open or opens early
3 Turbocharger damage
@ Factors other than engine malfunction
*Clutch sllpping
l Brake dragging
*Low tire pressure
l Incorrect tire size l Overloaded vehicle
@ Low intake air amount
*Throttle valve not open fully
*Clogged intake air system
TEP INSPECTlON
1
Install pressure gauge in intake air pipe and
check boost pressure at engine speed of
4,000
wm
CT page F2-45
Boost pressure:
More than 2.0 kPa (0.02 kglcm2, 0.3
psi)
@ Air/Fuel mixture lean
l Fuel iine pressure decreases l Fuel injection malfunction
@ Poor ignrtjon
@ Low engine compression
@ Alcohol blended fuel used
@ Knock control system malfunction
ACTION
Yes Go to Step 3
NO Check for air leakage and exhaust gas
leakage
4 If OK, go to next step
4 In not OK, repair
2 Check wastegate
Yes Remove intake air pipe from turbo-
f7 page F2-45 charger and check if compressor wheel
rotates smoothly t7 page F2-46
4 If OK, check air cleaner element
and throttle valve
+ If not OK, replace turbocharger
3 Check factors other than engrne Yes
l Clutch slipping Go to next step
1 8rake dragging
’
l Low tire pressure NO Repair or adjust
l Incorrect tire srze
FZ-32