1990 MAZDA 232 fuel

TRANSFER PUMP CONTROL SYSTEM Fl
TRANSFER PUMP SWITCH
I
93GOF I -7 14
OWOFX-824
TRANSFER PUMP SWITCH
Removal / Installation
.
1. Refer to “Transfer pump replacement”.
(Refer to below.)
inspection
1. Check continuity between transfer pump connector termi-
nal C and ground terminal.
Float position Contrnuity
UD
NO
I Down
I YES I
2. If not as specified, replace the transfer pump switch.
TRANSFER PUMP
Inspection
f . Remove the rear seat cushion.
2. Disconnect the transfer pump connector.
3. Check for continuity between transfer pump connector
terminal-wires (SAW) and (v).
4. If no continuity exists, replace the transfer pump.
Replacement
Warning
l When servicing the fuel system, keep sparks,
cigarettes, and open flames away from the fuel.
1. Remove the rear seat cushion.
FI-13

TRANSFER PUMP CONTROL SYSTEM
2. Remove the service hole cover of the transfer pump.
3. Disconnect the transfer pump connectors.
4. Disconnect the fuel hose.
5. Remove the transfer pump.
Caution
l Install a new seal rubber.
6. Install in the reverse order of removal.
03UOFX-626
Disassembly / Assembly
Caution
l Prevent contaminants from entering the transfer pump,
I. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
3. Verify that the transfer pump operates
correctly after assembling it.
EAL RUBBER, REPLACE
1 . Fuel filter
2. Rubber mount
3. Transfer pump 4. Fuel hose
5. Transfer pump
switch
Ft-14

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

lNDEX F2
4x4 CONTROL UNIT
(FUEL PUMP
CONTROL UNIT)
SERVICE, SECTION SEAT
1. Fuel tank
Removal / Inspection I
lnstailation . . . . .._........._._....... 1 . . . . page F2-51
2. Injector _
Volume test ~..........~..~..,...~..~....~. page F2-56
3. Fuel pump resistor/relay [BP TURBO]
System operation . . ._. . . ._. _ . . . . . . . . . . . page F2-56
Inspection . . . . . . . . . . . . . . . . . . . *. . . . . . . . . . . . . page F2-56 4. Fuel pump control unit [BP TURBO]
Inspection *....,...,.........I..... * . . . . . . . page F2-53
Replacement . . . . . . . . . . . . . . . . . . . . . . . . ..-... page F2-53
5. Transfer pump switch
Removal I InstaNation . . . . . . . . . , ..,... page F2-54
Inspection ..a . . . . . . . . . . . . . . . . . . * . . ..I.. e... page F2-54
6. Transfer pump
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F2-54
Replacement ,...,_..... b . .._._......_.... page F2-54
1. Exhaust system
RemovA I Inspection I InstaNation
BP SOHC . . . . __.._......... _........... page F2-57
BP TURBO _.. . . . . . .._.. . . . . . . . . . . . . . . . page FZ-58
F2-3

SOLENOID VALVE
CHECK VALVE
r----+ (PURGE CONTROL)
CHiRCOAL
I CANISTER
INTERCOOLER 11 ’ 1 ‘I A-4
II II -
AIR , BYPASS
II ,.-ok----,/ ,CHECK VALVE
(TWO-WAY)
1-1
---II
-d KNO&
II II I I II VALVE
VALVE
THERMOSENSOR
c
I 31c
SENSOR 1 k---k FUEL FILTER
TRANSFER
PUMP
WASTEGATE 7
II t I III TURtiOCHARGERI~
I SOLENOID I II - i 1 WASTFGATF II I
AlOCI fuAl RAlz-rCD
VALVE
le-SIGNAL* -
EJ 0
G-SIGNAL-
DISTRIBUTOR
CATALYTIC CONVERTER ftl”FLLt”” IVIL I =r,
(WITH INTAKE THERMOSENSOR)
*TO ENGINE CONTROL UNIT

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]