1990 MAZDA 232 service

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

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

SUPPLEMENTAL SERVICE INFORMATION F2
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison to the Mazda 323 Workshop Manual
[I 203-I U-89F (Europe) or 120410-89F {Australia)].
intake air system components [BP Turbo]
l Removalllnspectionll nstaltation
WASTEGATE [BP Turbo]
l Inspection
WASTEGATE SULENOlD VALVE [BP Turbo]
l Inspection
Turbocharger [BP Turbo]
l Inspection
l Removalllnstaltation
Air bypass valve [BP Turbo]
l Removal/hstallation
l 1 nspection
lntetcoolet [BP Turbo]
l RemovaMnspection/tnstaltation
Fuel tank
l Removal ! Inspection I Installation
Fuel pump control unit [BP Tubto]/4x4 control unit [BP SOHC]
l 1 nspection
l Replacement
Transfer pump switch
l Inspection
l Replacement
Transfer pump
l Inspection
l Replacement
Fuel pump resistor/relay
l System operation
l Inspection
injector [8P Turbo]
l Volume test
Exhaust system components
l Removal / 1 nspection / Installation
Engine control unit (ECU) [BP Turbo]
l Terminal voftage
Oxygen sensor [BP Turbo]
l Inspection
l Replacement
Knock sensor [BP Turbo]
l Replacement 93GOFZ736
F2-25

FUEL SYSTEM F2
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.
6. Install in the reverse order of removal. Caution
l Install a new seat rubber.
03UOFX-826
Disassembly I Assembly
Caution
l Prevent contaminants from entering the transfer pump.
1. 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.
HOSE, REPLACE
@
1. Fuel filter
2. Rubber mount
3. Transfer pump 4. Fuel hose
5. Transter pump switch assembly
93GOF2-77:
FZ-55

G
ENGINE ELECTRICAL SYSTEM
INDEX . ..I 1.. . . . . . . . . . . . . . . . . . . . . . . ..*. . . ..I..... . . . . . ..I...
G- 2
j FEATURES 1
OUTLINE . . . . . . . . . ...*....* .I.............. .I . . . . . . . . . . . . . .
G- 3
OUTLINE. OF CONSTRUCTION ..I... . . . . . . . . . . . G-
3
SPECtFICATiONS . . . . . . . . . . . . ..I............... . . . . . .
G- 3
1 SERVICE 1
SUPPLEMENTAL SERVICE INFORMATION . . G- 4
STARTING SYSTEM
. ..I. . . . . . . . . a.. . . . . . . . . . . . . . . . . . . G- 4
STARTER
l ..I.... . . . . . . . . . . . . . . . . . . l .*.....* .I....... . . . G- 4
CHARGlNG SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G- 5
PREPARATION
. . . . . . . . . . . . ..I..-... . . . . l . . . . . . . . 1. . . . . G- 5
ALTERNATOR (RHD)
. . . . . . . . . . . . . . . . . . . . . . . . . . ...*. G- 5
93GOGX-701

G SUPPLEMENTAL SERVICE INFORMATION, STARTING SYSTEM
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Mazda 323 Workshop Manual
[1203-l O-89F (Europe), ? 204-I O-89F (Australia)].
Starter
l Removal / InstaHation
Atternator (RI-ID)
l Removal I InstatIation 93GOGX-705
STARTING SYSTEM
STARTER
Removal I Installation
I. Remove in the order shown in the figure.
2. Inspect all parts, and repair or replace as necessary.
3. lnstail in the reverse order of removal.
37-52 (3.8-5.3, 27-38)
9.8-t2 N-m
(IOO-120 cm-kg, 87-104 in-lb)
(3.8-5.3, 27-38)
9.8-12.N.m
It t \
I. Battery
(100-120 cm-kg, 87-104 in-lb)
37-52 27-38)
(3.8-5.3, 27-38)
N-m (m-kg, ft-lb)
5. Starter
Remove tram above
6.
Starter bracket 2. intake manifold bracket
3. S terminal wire
4. B terminal wire
G-4

H
CLUTCH
iNDEX ..*..*.............*..*..............................* l-l- 2
OUTLINE .................................................. l-b- 4
OUTLtNE OF CONSTRUCTION
................. H- 4
SPECtFlCATtUNS ....................................
H- 4
CLUTCH CONTROL
.................................... t-i- 5
CLUTCH PEDAL ..................................... H- 5
CLUTCH MASTER CYLINDER ................... H-
7
RELEASE 5EARlNG ................................ H- 8
1 SERVICE /
SUPPLEMENTAL SERVICE INFORMATION.. H- 9
TROUBLESHOOTlNG
GUIDE.. .................... Ii- 9
CLUTCH FLUID (WITH ABS) ......................
H-l 0
PREPARATION ....................................... u-IO
REPLACEMENT ......................................
H-10
CLUTCH PEDAL (BP DOHC TURBO) ........... H-1 1
REMOVAL I INSPECTION / INSTALLATtON . . H-11
CLUTCH MASTER CYLINDER
(BP DOHC TURBO OR WITH ABS)
............ H-f 3
PREPARATION .......................................
u-1 3
REMOVAL I INSPECTION I INSTALLATION
(BP DOHC TURBO) ............................... H-13
AIR BLEEDlNG (-WtTH ABS) ...................... ti-14
OVERHAUL
(BP DOHC TURBO). ............... H-15
CLUTCH RELEASE CYLINDER (WITH ABS). H-l 7
PREPARATION .......................................
H-l 7
AtR
BLEEDING (WITH ABS). ..................... H-17
CLUTCH UNIT
.......................................... u-1 8
PREPARATION
....................................... H-f 8
REMOVAL I INSTALLATION ...................... H-19
93GOHX-701

SUPPLEMENTAL SERVICE INFORMATION, TROU8LESHOOTlNG GUIDE H
SUPPLEMENTALSERVICE INFORMATION
The following points in this section are changed in comparison with 323 Workshop Manual (1206IO-89F).
Troubleshooting guide
Clutch fluid (with ABS)
l Replacement
Clutch pedal (BP DOHC Turbo) Clutch release cylinder (with ABS) l Air bleeding
Clutch unit
l Removal I Inspection I installation
Clutch master cylinder
(BP DOW Turbo or with ABS) l Removal I Inspection I installation
93GOHX-710
l Removal I Inspection I Installation (BP DUHC Turbo)
l Air bleeding (with ABS)
l Overhaul (BP DUHC Turbo)
TROUBLESHOOTING GUlDE
Problem
Possibte Cause Remedy Page
Slipping
Clutch disc facing worn excessively
Replace U-l 9
Clutch disc facing surface hardened or oifed
Repair or replace H-l 9
Pressure plate damaged Replace H-19
Diaphragm spring damaged or weakened
Replace H-l 9
Insufficient clutch pedal piay
Adjust H-12
Clutch pedal sticking
Repair or replace U-11
Flywheel damaged
Repair or replace H-19
Faulty
Excessive runout or damaged clutch disc
Replace H-19
disengagement
Clutch disc spiines rusted or worn ’
Remove rust or replace H-l 9
Clutch disc facing oiled
Repair or replace H-19
Diaphragm spring weakened
Reptace H-19
Excessive clutch pedal ptay
Adjust -
Insufficient clutch fluid
Add fluid H-10
Leakage of clutch fluid
Locate and repair or -
replace
Clutch vibrates
Clutch disc facing oiled
Repair or replace H-l 9
when accelerating
Torsion rubbers weakened
u-19 Clutch disc facing hardened or damaged Replace
Repair or replace H-19
Clutch disc facing rivets loose
Replace H-l 9
Pressure plate damaged or excessive runout
Replace H-l 9
Flywheel surface hardened or damaged
Repair or replace H-19
Loose or worn engine mount
Tighten or replace -
Clutch pedal
sticking Pedal shaft not properly lubricated
Lubricate or replace H-l 1
Asistireturn spring damaged or poor adjust
Replace or adjust H-11, 12
Abnormal noise
Clutch release bearing damaged
Replace N-1 9
Poor iubrication of release bearing sleeve
Torsion rubbers weakened Lubricate or replace H-19
Replace u-t9 Excessive crankshaft
end play
Repalr -
Pilot bearing worn or damaged
Replace H-79
Worn pivot points of reiease fork
Repair or replace H-19