1990 MAZDA 232 ignition

TROUBLESl-lOOTING GUIDE F2
;TEP 1 INSPECT1ON
ACTION
13 Check if resistance of ignition coil 1s OK*
Yes Go to next step
Resistance (at 20°C iSS*FJ):
Primary coil winding . . . . . . . .
0.81~-0.99Q
Secondary coil winding,,.. 1 O--16 kR
PRIMARY COIL
WINDING SECONDARY COIL
WlNDlNG
NO Replace
14 Check for correct engine compression”
Yes Gc to next step
1 Engine compression (Minimum):
785 kPa (8.0 kg/cm , It4 psi)-300 ipm
NO Check engine condition” l Worn piston, piston rings or cylinder
wall
l Defective cylinder head gasket l Distorted cylinder head l Improper valve seating
*Valve sthing in guide
15 Change fuel and check if acceleration improves
Yes Change fuel to another brand
NO
Go to next step
16 Check if NC cut-off control system is OK’
Yes Go to next step
No Repair or replace
17
I Try known good ECU and check if condition
improves
* Refer to 323 Workshop Manual [1203-IO-89F (Europe) or i204-IO-89F (Australia)].
93GOF2-747
F2-39

F2 TROUBLESHOUTING GUIDE
I 22 KNOCKtNG [8P TURBO] I
IESCW-
l Abnormal combustron accompanied by audible “pinging” noise rim
TROUBLESHOOTING HtNTS]
3 incorrect ignition timing (Too advanced) @ Low octan fuel used
2
Knock control system malfunction @ Air/Fuel mixture lean
3 Carbon deposits in cylinder l Fuel injection amount not correct
3 Overheating l Fuel line pressure decreases while accelerating
TEP INSPECTION ACTlON
1
Connect System Selector to diagnosis connector Yes Go to next step
and set Test Switch to “SELF TEST” and check
for correct ignition timing at idle after warm-up’
ignition timing: BTDC 10 f lo
No Adjust
2 Check if “00” is displayed on Self-Diagnosis Yes Go to next step
Checker with igmtlon switch UN*
No Matf unction Code No. displayed
Check for cause (Refer to specified
check sequence) *
“88” flashes
Check ECU terminal 1 F voltage
Vottage: Approx. 12V
(Ignition switch ON) 0 page FZ-60
4 If OK, replace ECU
W: SELF TEST
4 If not OK, check wiring between
ECU and Self-Diagnosis Checker
3 Check for correct fuel line pressure at idle* Yes Check if fuel Iine pressure decreases
when accelerating quickly
Fuel line pressure:
265-314 kPa (2.7-3.2 kg/cm2, 38-46 psi)
(vacuum hose to pressure regulator dis-
connected) 4 If decreases, check for clogging
between fuel pump and pressure
regulator
e If no decrease, go to next step
No tow pressure Check
fuel line pressure while pinching
fuel return hose
3 If fuel line pressure quickly in-
creases, check pressure
regulator*
4 If fuel line pressure gradually in-
creases, check for clogging be-
tween fuel pump and
pressure
regutator
If not clogged, check fuel pump
maximum pressure*
- -
.-
Refer to 323 Workshop Manual [1203-IO-89f (Europe} or t204-IO-89f (Australia)]. F2-40

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.

F2 FUELSYSTEM
Note
l Drain the fuei from the fuel tank before removing the tank.
1. Fuel pump cover
2. FueI pump connector
3. Fuel hoses
Installation Note ..___........_.....__......_...._. below
4. Exhaust pipe
Removal / installation . . . . . . . .__._. . , . . . FZ-57, 58
5. Propeller shaft
Removal ! Installation .._._...._....._.._.. Section L 6. Fuel filier hose, breather hose, and
evaporation hoses
tnstal!ation Note ..m..,* . . . . ...*-. *..,- . . . . m...-e.. below
7. Fuel tank straps
8. Fuel tank
Inspect for cracks and corrosion
93GOF2-772
0 FUEL FILLER HOSE
03UOFX- 13! installation Nate
1. Push the ends of the main fuel hose, fuel return hose, and
evaporative hoses onto the fuel tank fittings at least 25mm
(1 .O in).
2. Push the fuel filler hose onto the fuel tank pipe and filler pipe
at least 35mm (1.4 in).
TRANSFER PUMP CONTROL SYSTEM
System Operation
I. Turn the ignition switch ON and verify that the fuel gauge
indicates more than half and that the transfer pump oper-
ating sound is heard.
Warning
l If the fuel level is less than one half, this inspec-
tion cannot be performed.
2. Ground the transfer pump connector terminai-wire (Y/L) with
a jumper wire and verify that the transfer pump stops.
3. Remove the jumper wire and verify that the transfer pump
begins operation after approx. IO sec.
4. If not as specified, check the following parts.
l Fuel pump control unit. [BP turboJ
(Refer to page F2-53.)
4x4 control unit [BP SOHC] (Refer to page Fl-12.)
l Transfer pump. (Refer to page F2-54.)
. Transfer pump switch. (Refer to page F2-54.)
93GOF2-774
F2-52

FUELSYSTEM F2
FUEL PUMP CONTROL UNIT
I I 93GOF2-775
1
93GOF2-799
I 93GOF2-800
I 93GOF2.776
FUEL PUMP CONTROL UNIT [BP TURBO] l
Refer to page Fl-12 for BP SOHC model.
hspection
1. Remove the fuel pump control unit.
2.
Disconnect the fuet pump controt unit connector.
3. Check ctintinuity between the fuel pump control unit con-
nector terminal B (Y/L) and a ground.
4. Perform the following inspection according to the results of
the continuity check.
Continuity exists
1. Turn the ignition switch ON.
2. Ground the fuel pump control unit terminal B (Y/L) with a
jumper wire and verify that the voltage at the fuel pump con-
trol unit terminal D (in’) is OV.
3. Remove the jumper wire and verify that the voltage at the
fuel pump control unit terminal D (L/Y) is approx. WV af-
ter approx. IO sec.
No continuity exists
1. Turn the ignition switch ON
and verify that the voltage at
the fuel pump control unit terminal D (L/Y) is OV.
2. Disconnect the transfer pump connector.
3. Turn the ignition switch ON and verify that the voltage at
the fuel pump control unit terminat D (LA’) is approx. t2V.
Replacement
1. Move the driver’s seat backward.
2.
Remove the bolts and remove the fuel pump control unit
and bracket as an assembly.
3. Remove the fuel pump control
unit from the bracket.
4. Install in the reverse
order of removal.
F2--53

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

CONTROL SYSTEM F2
Incorrect voltage Possible cause
Always OV
l ROOM 10A fuse burned l Open circuit in wiring from ROOM 10A fuse to ECU termrnal IA
Always OV
I l Main relay maifunctlon l Open or short crrcu~t in wirrng from main relay to ECU termrnal 1 B
Always OV (Srarrer turns)
l Open or short circuit in wiring from ignition switch to ECU terminal 1C
Always UV
l Main relay (FUEL INJ relay} malfunctron l Open circuit in wiring from main relay to diagnosis connector terminal + B l Open or short circuit in wiring from dragnosls connector terminal MEN to
ECU terminal 1D
Always approx. 12V
I . Poor connection at ECU connector
l ECU matfunction
Always approx. 5V
l ECU malfunction
-
I -
Always below No disptay on Self- . Main relay (FUEL INJ retay) malfunction (Refer to page F3-142)
2.5V Diagnosis Checker l Open circuit in wiring from main relay to diagnosis connector termjnal + B
“88” displayed and
l Open or short circuit in wiring from diagnosis connector terminal FEN to
buzzer sounds con- ECU terminal 1 F
tinuously
Always approx. 12V
l Poor connection at ECU connector l ECU malfunction
Always OV
l Short circuit in wiring from igniter to ECU terminal tG
Atways OV or approx. 12V
l Refer to Code No.42 Troubleshooting (Refer to page F2-30)
Always approx. 12V
l Fuel pump resistor/relay malfunction
Always OV
l Open or short circuit in wiring from ECU terminal 1 I to resistor/retay
Always below
A/C does not operate
l AJC relay malfunction
23 l Open circuit in wiring from ignition switch to NC relay l Open circuit in wiring from A/C relay to ECU terminal IJ
A/C switch OFF but
l Short circuit in wiring from A/C relay to ECU terminal IJ
AIC operates
l ECU matfunction
Always approx. t2V
Always below 1 .OV
l Poor connection at ECU connector l ECU malfunction
l Short circurt in wiring from diagnosis connector terminal TEN to ECU termi-
nal 1K
Always approx. 12V
l Open circutt in wiring from diagnosis connector terminal TEN to ECU termi-
nal lK
l Open c~rcud in wiring from diagnosis connector terminal GND to ground
Always above 1 .OV
I
l Open circuit in wiring from ECU terminal 1 M to ground
F2-61

F2 CONTROLSYSTEM
erminat Input ’ Output Connected to Test condition Correct voltage Remark
1N 0 I Throttle sensor Accelerator pedal released &low l.OV j Ignition switch
(Idle switch)
Accelerator pedal depressed Approx. 12V *N
IO I 0 j [ Stoplight switch Brake pedal released Betow 1 .OV -
1P j 0 1 i P/S pressure lgnitlon switch ON Approx. 12V
I
switch
f/S ON at idle Below 1 .UV
I
P/S OFF at idle Approx. 12V -
I
to 0 A/C switch A/C switch ON
NC switch OFF Beiow 2.W ignition switch
ON and blower
Approx* t2V motor ON
i
1R 0 Electric fan switch Fan operating (Engine coolant tempera- Betow l.OV
ture over 91 *C (t96*F) or diagnosis con-
-
nector terminal TFA grounded)
Fan not operating (Idle) Approx.. f 2V
IS 0 Blower control Blower controf switch OFF or 1st position Approx. 13 Ignition switch
switch
Blower control switch 2nd or higher po- Below 7 .OV ON
sition
IT
Cl Rear window
defroster switch Rear window defroster switch OFF
Rear window defroster switch ON Below 1 .OV Ignition switch
Approx. 12V ON
1u 3 Headlight switch Headlights ON Approx. 12V
-
Headlights OFF Below 1 .OV
-Iv Cl ’ Neutral/Clutch
Neutral position or clutch pedal Below I .OV
switches
depressed
Others Approx. 12V
l-7 I r
f
2V 2W 2U 25 20 20 2M 2K 21 2G IZE 2C 2A IU IS 10 10 IM 1K 11 1G rE tC IA
22 2X (2V 2T 2R 2P 2N 2L 2J 2H’ZF 20 2B fV 1T 1R IP IN 1L 7J III If ItI 1B l F2-62