1990 MAZDA 232 check engine

TURBOCHARGER CONTROL SYSTEM F2
TURBOCHARGER CONTROL SYSTEM
PREPARATION
SST
49 HO80 740
Gauge. pressure
I 93GOF2-754
93GOF2-755
L I 93GOF2-756
93GOF2-757 93GOF2-753
SYSTEM OPERATION
1. Install a pressure gauge 149 kPa (0.5 kg/cm2, 7.1 psi)
min.1.
2. Connect a tachometer to the diagnosis connector lG-
terminal.
3. Start the engine.
4. Verify that the boost pressure when the engine speed is
4,000 rpm is within specification.
Specification: More than 2.0 kPa ( 0.02 kg/cm2, 0.3 psi)
5. If not within the specification, check for air Ieakage, exhaust
gas leakage, and for the wastegate stuck open.
6. if OK, replace the turbocharger.
WASTEGATE
Inspection
1. Remove the air hose from the wastegate actuator.
2 Connect the SST to the actuator.
3. Raise the front of the vehicle and support it on safety stands.
4. Remove the undercover.
F2-45

F2 TURBOCHARGER CONTROL SYSTEM
I 93GOF2-756
93GOF2-75!
93GOF2-761
5. Mark the actuator rod.
Caution
l Do not apply compressed air over 98 kPa (1.0
kg/cm2, 14 psi).
6. Adjust the compressed air pressure to 83 kPa (0.85
kg/cm”, 12 psi).
7. Verify that the rod moves when applying and releasing air
pressure.
WASTEGATE SOLENOID VALVE
Inspection
1, Remove the ,solenoid valve.
2. Verify that air does nut flow from @ through @
3. Apply IN to the solenoid valve and verify that air flows from
@ through @
TURBUCHARGEFI
Inspection
1. Be sure tf7e engine is cool.
2. Remove the air hose.
3. Check that the compressor wheel assembly turns smoothly.
4. If there is excessive drag or noise, replace the turbocharger.
93GOF2-761
FZ-46

F2 FUEL SYSTEM
FUEL
SYSTEM
PREPARATlON
SST
49 LO18 901
Injector checker For
lnsgectlon of
injector
93GOF2.770
9MUOF2-722
03UOFX-7 27
F2-50
PRECAUTION
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 pres-
sure from the fuel system to reduce the possibility of injury
‘or fife,
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 stalts, turn off the ignition switch.
5. Recpnnect the fuel pump connector and install the rear
seat cushion.
b) Use a rag as protection from fuel spray when disconnect-
ing the hoses.
Plug the hoses after
removal.
c) When inspecting the fuel system, use a suitable fuel pres-
sure gauge.
Caution
l Install hose clamps to secure the fuel pressure
gauge to the fuel filter and the fuel main hose to pre-
vent fuet leakage.
Priming Fuel System
After releasing the fuel pressure for repairs or inspection, the
system must be primed to avoid excessive cranking when first
starting the engine. Follow the steps
below.
1. Connect the diagnosis connector terminals F/P and GND
with a jumper wire.
2. Turn the ignition switch
ON for approx. 10 set, and check
for fuel leaks.
3. Turn the ignition switch OFF and remove the jumper wire.

CONTROL SYSTEM F2
CONTROLSYSTEM
PREPARATION
SST
49 HOt8 9A3
Self-dragnosls
checker
Engrne signal
IT-iOFlllO~ 49 GO18 904
Sheet System selector
I 93GUF2-786
For inspection of ECU
93GOF2-787
93GOF2-801
TERMNALS 1
--I”- -
03UOFX
ENGINE CONTROL UNIT (ECU)
Inspection
1. Disconnect the ECU connectors.
2. Connect the SSTs (Engine Signal Monitor and Adapt-
er) to the ECU as shown.
3. Place
the SST (Sheet) 011 the Engine Signal Monitor.
4. Measure the voltage at each terminal.
(Refer to pages FZ-60 to F2-67.)
5. If any ECU terminal voltage is incorrect, check the related
input or output devices and wiring. If no problem is found,
reptace the ECU. (Refer to above.)
Caution l
Never apply voltage to SST terminals A and B.
F2-59

F2 CONTROL SYSTEM
Terminal voltage [BP TURBO]
eminal input Output , 1 Connected to Test condition Correct voltage Remark
IA - - Battery Constant Approx. 12V for backup
15 0 Main relay OFF Approx. OV
(FUEL INJ relay) tgnltlon switch
-
ON Approx. 12V
1c 0 1 Ignition switch Wniie cranking Approx. 1 OV
-
(START)
lgnrtron switch ON Approx. OV
ID 0 Self -Diagnosis Test switch at “SELF-TEST” With Self-
Checker Lamp illuminated ior 3 sec. after ignition Approx. 5V Diagnosis Check-
(Monitor lamp) switch OFF* ON er and System
Lamp not illuminated after 3 sec. Approx. 12V Se’ector
Test switch at
“02 MONITOR” at idle
Monitor lamp illuminated Approx. 5V
Test switch at
“02 MONITOR” at idle
Monitor lamp not illumrnated Approx. 12’4
-lE - - - -
- -
1F 0 Self-Diagnosis Buzzer sounded for 3 sec. after ignition
Below 2.5V l With Self-
Checker switch OFF -+ ON Diagnosis
(Code Number)
Buzzer not sounded after 3 sec. Approx. 12V Checker and
Buzzer sounded Below 2.9 System Selector
l With System
Buzzer not sounded Approx. 12V Selector test
switch at
“SELF-TEST’ ’
I I 1G
0 Igniter
7H
0 Solenoid vahe
(Wastegate)
l!
0 Fuel pump
resistor/relay
I
lJ I r-Tcreiay Ignition switch ON
ld!e
Engine speed below 5,300 rpm
Engine speed above 5,300 rpm
While cranking
Idle
Ignition switch ON
AK switch ON at idle 1 Approx. OV
-
Approx. 0.2V
Approx. 12V
-
Below 1.5V
Approx. 1 OV
-
I3elow 15V
Approx. 12V
Below 2.5V
AIC switch OFF at idle Approx. 12V
-
IK 0 Diagnosis System Selector test switch at
connector
(TEN terminal)
1L - - -
- -
-
IM
t 0
1 Ground (Australia) Constant Below 1 .OV Not used
(Except Australia)
F2-60

F2 CONTROL SYSTEM
93GOF2-79; 2
93GOF2-793
93GOFZ794
1
OXYGEN SENSOR [BP TURBO]
Inspection
Sensor
1. Warm up the engine to normal operating temperature.
2. Disconnect the oxygen sensor connector.
3. Connect a voltmeter to the oxygen sensor terminal @.
4. Run the engine at 4,500 rpm untiI the voltmeter indicates
approx. 0.7V.
5. Increase and decrease the engine speed suddenly and
measure the vottage.
Voltage
Engme speed Voltage (v-)
Decelerating o-0.4
Accelerating 0.5-l .o 6. Connect the
SSTs to the diagnosis connector.
7. Set the system selector select switch to 1 and the test switch
to 02 MONITOR.
8. Increase the engine speed to
between 2,000 and 3,000
rpm, and verify that the monitor lamp flashes for 10 seconds.
Specification:
Monitor lamp flashes more than 8 times/IO sec.
Heater 1. Disconnect the oxygen sensor connector.
2. Check resistance between oxygen sensor connector ter-
minals @ and 0.
Resistance: Approx.-6& [at 20°C (68OF)]
Replacement 1. Disconnect the oxygen connector. ’
2. Remove the oxygen sensor.
3. Install the new oxygen sensor and new washer.
4. Tighten the oxygen sensor to specified torque.
Tightening torque:
29-49 N-m (3-5 m-kg, 22-36 ft-tb)

H OUTLINE
OUTLINE
OUTLINE OF CONSTRUCTION
A hydraulic clutch control mechanism is used.
The basic construction is the same as that of 323 2WD model, but there is no interchangeability of parts
except for the release cylinder.
1. An assist/return spring is used on the BP DOHC Turbo model to reduce the required clutch pedal effort..
2. The hydraulic clutch master cylinder for the 8P DOl-lC Turbo model has a built-in check valve.
3. To improve clutch operation feeling and increased parts life, a friction plate and needle roller bearings
are used between the release fork and the release bearing.
93GOHX-704
SPECIFICATIONS
Hem
Clutch control Engine/Transaxle
BP SUHC BP DOHC Turbo
GSMX-R
Hydrautic
Clutch cover
Type
Set load
N (kg, lb) Diaphragm spring
3,846 (392, 862) 5,494 (560, I ,232)
Outer diameter 1
mm (in) 225 (8.858) 230 (9.055)
I 1 nner diameter mm (in)
I 150 (5.906)
I 155 (6.102) I
CI utch disc
Pressure plate side
mm {in) 4.1 (0.161) 3.2 (0.126)
Thickness f
Flywheel side
mm (in) 3.5 (0.138) 3.2 (0. f 26)
I Type I Suspended
I
Clutch pedal LHD 6.55 Pedal
ratio
RHD 6.7
Full stroke mm (in)
I 135 (5.32)
I
Height (With carpet) mm [in)
I I 96-204 (7.72-8.03)
I
Master cylinder Inner diameter
mm {in)
I 15.87 (0.625)
Release cylinder inner diameter
mm (in)
I - 19.05 (0.750)
I
Clutch fluid SAE J1703 or FMVSSI 16 DOT-3
93GOHX-705
H-4