1992 MAZDA 323 sensor

F3 CONTROL SYSTEM
PRESSURE REGULATOR CONTROL SYSTEM
SOLENOID VALVE TO MAIN RELAY
(PRC HIGH TEYP.)
t ECU
I
PRESSURE REGULATOR
// VACUUM

IJ WATER
THERMOSENSOR
F----------- lNTAKE AIR
THERMOSENSOR
SWITCH SOLEltolD VALVE
(PRC LOW TEMP.)
TO FUEL TANK
13EOF3-31 To prevent vaporlock in the fuel system during hot restart idle, a two-stage pressure regulator is adoped
to the new 323 4WD.
Low temperature operation: The vacuum to the pressure regulator (A and B ports) is cut (solenoid valve
[low temp.] UN), and the fuel injection pressure is increased to 284 kPa (2.90 kgf/cm2, 41 psi ) ,
High temperature operation: The vacuum to the pressure regulator (A port) is cut (solenoid valve [high
temp.] ON), and the fuel injection pressure is increased to 343 kPa [ 3.5 kgf/cm2, 49 psi 1.
Condition and operation
Condition Operation
1
coolant Intake alt Solenoid vrlve Solenoid vatve Opemtlon
I temperature temperature Engine (Idw temp.)
(high temp.) time Operation 40% [fU40f)-
Above 90°C 5U°C (t22OFI ON OFF 180s Low temp.
f f940Fj No load
Above 5O*C
I122OF) OFF ON 210s t-ltgh temp.
3
t3EOF3-319
F3-14 Wast
l Ins fuel
l In:; InJeci
l In:;
l Vol Injecl
l In:;
Presr
l SCI Engir
l InsI

F3 SELF-DIAGNOSIS FUNCTfON
SELF-DIAGNOSIS FUNCTION
OUTLINE
Theself-diagnostic function and diagnosis procedure are the Same as for the previous 4WD model. How-
ever, there is an additional service (malfunction) code (N0.35) for the new modet.
13EOF3-321
SERVICE CODE NUM8ERS
Sensor or
subsystem
NE-signal
G stgnal
Knock sensor I Malfunction display
Cond &ion Fail-safe
Service
code no. Output signal pattern
No NE-signal
ON
-
02
OFF
M
No G srgnal Cancels two-group injection ON
03
OFF
ml
Open or short circuit
pressure sensor
F3-16
--
I

F3 TROUBLESHUOTING GUIDE
TROU8LESHOOTlNG GUIDE
RELATIONSHIP CHART
.

OUTPUT DEVICE
INPUT DEVICE

w
3
s
s
KNOCK SENSOR
0
0 0 0 DtAGNOStS CONNECTOR
(TEN TERMINAL)
0 0 0 IGNITION SWlTCH
(START POSITION) 0 0
0
0
0 0
0 0
0 0
0
0
0
0
0 0 0 0
E/L SIGNAL* 0
P/S PRESSURE SWITCH 0
0
A/C SWtTCH
NEUTRAL AND CLUTCH
SWITCHES
STOPLIGHT SWITCH
ATMOSPHERIC PRESSURE
SENSOR (IN ECU)
THROTTLE SENSOR
0 0 0 0
0
0
0 0’
0
0 0
0
0 0
0
’ 0
0
0 0 0 0 0 0 0
0 I
0 ~ INTAKE AIR THERMOSENSOR 0 0 0 0
0 -~
OXYGEN SENSOR
0 0 0 0 WATER THERMOSENSOR
A
0
* 0 0 0 c 0
13
3F3-32 IN, o . E/L SIGNAL: Blower fan control switch second position or higher, electric cooling fan operating, headlights
rear window defroster ON.
F3-19
i

F3 TROUBLESHOOTING GUIDE
I- STEP lNSPECTlON ACTION
Yes Go to Step 8
5 In same condition as in Step 2, IS fuel ilne pres-
sfire held after Igrxtbon swatch rs turned OFF?
Fuel line pressure: More than 147 kPa
Il.5 kgflcm’, 21 Psi 1 for 5 min.
6 In same condition as in Step 3, IS fuel line pres-
sure held after lgnltron switch IS turned OFF?
Fuel line pressure: More than 147 kPa
{ t.5 kgf/cm*, 21 psi) for 5 min.
No
I Go to next step
Plug both vcuum ports of pressure regulator; IS
fuel lme pressure held after ignltlon switch is
turned OFF? Yes Replace pressure regulator
r~ page F3-3
Fuel line pressure: More than 147 kPa
{ 1.5 kgf/crn*, 21 psi] for 5 min.
NO Check fuel pump hold pressure
e If OK, check InJector for fuel
leakage
e If not OK reptace fuel pump ZF- page F3-42
T page F3-3
8 Dlscofinect water thermosensor connector, does
engtne start? Yes Check water thermosensor
e ff OK. check connectrons of water
thermosensor and ECU 2Q terminal
Q If not OK, replace water thermo-
sensor
ET page F3-13
No 1 Go to next step --~
Is “00” drsplayea on Self-Diagnosis Checker
with ignition switch ON? 9 Yes Go to next step
NO Service Code No. displayed
Check for cause (Refer to specified
check sequence)
c7 page F3-16 SYSTEM SELECT, 1
“88” flashes
Check ECU terminal IF voltage
KIT page F3-45
Voltage: Battery voltage
(ignition switch ON)
e If OK, replace ECU
ET- page F3-2
e If not OK, check wiring
(ECU - Self-Diagnosis Checker)
Y %EtECT SW: A
Yes 1 Go to next step 10 Are rf ECU termrnaf voltages are OK?
(especjaffy 1C. 2D. and 2Q)
CT page F3-45
NO Check for cause
Yes Replace ECU
=T page F3-2
No Change to another brand of fuel
13EOF3 331 Try known good ECU, does condition improve?
CT page F3-2
F3-26

F3 TROUBLESHOOTING GUIDE
3TEI ACTION
Is fuel line pressure correct at Idle?
*
Fuel line pressure: 265-314 kPa
12.7-3.2 kgf/cm’, 38-46 psi]
(Two vacuums hose to pressure regulator
disconnected)
304-392 kPa [ 3.1-4.0 kgf/cm’, 44-57 psi 1
(Upper vacuum hose to pressure regulator
disconnected)
INSTALL CLAMPS Yes Go to next step
No Low pressure
Check fuel line pressure while pinching
fuel return hose
4 If pressure quickly Increases,
check pressure regulator
e If pressure gradually Increases,
check for clogging between fuel
pump and pressure regulator
If hose is not clogged, check fuel
pump maxrmum pressure
Connect System Selector to diagnosis connector
and set Test Switch to SELF TEST; is ignition
tlmlng at idle correct after warm-up?
Ignition timing (BTDC): 10 f lo Yes Go to next step
No Adjust tgnrtkon system
8 Dtsconnect water thermosensor connector; does
engine condrtlon Improve? Yes Replace water thermosensor
No
Try known good ECU. does condltlon
Improve?
w page F3-13
Go to next step
Check if injector resistance is OK
w page F3-42 9 Is jqector operating sound heard at Idle?
Yes
No
Resistance: Approx. 2.11 Q
(at 20°C 168*F])
4 If it is, check wlnng
(ECU - Injector)
c3 If it Is not, replace injector
Go to next step IO
Yes Is engine compressron cprrect?
w Section G
No
Engine compression:
1059 kPa 110.8 kgf/cm2, 152 psi)-300 rDm
is strong blue spark vrslble at each disconnected
hrgh-tension lead?’ Check engine
3 Section B2
17
Yes Go to next step
No Check high-tension lead
w Section G
c3 If UK, check distrrbutor cap and
rotor
3 If not OK, replace htgh-tensron lead
Try known good ‘ECU: does condrtron
Improve7
w page F3-3 12 Are spark plugs.OK?
w Section G
l Wear and carbon butld up l Piug gap l Damage Yes
NO
Clean, adjust
13EOi3.334
F3-32.

TROUBLESHOOTING GUlbE F3 1
14 IDLE MOVES UP AND DOWN/IDLE HUNTS
IESCRLP-
l Engine speeds up and down periodically at idle
UON
TROUBLESHOOTING HINTS]
B Idle switch (En throttle sensor) OFF at idle
3 Air leakage
3 Fuel injection amount Inconstant
. Poor contact point inside airflow meter
9 Poor ignitron
rEP[ INSPECTION
I is “00” displayed on Self-Dragnosis Checker
with ignrtron swatch ON?
SYSTEM SELECT: i I ACTfON
Yes Go to next step
NO Service Code No. displayed
Check for cause (Refer to specified
check sequence) c=;r page F3-16
“86” flashes

Check ECU terminal IF vottage csr page F345
Voltage: Battery voltage
W: SELF TEST (ignition switch ON)
SELECT SW: A
.d P/ e If OK, replace ECU CT page F3-3
c3 If not OK, check wrrjng
(ECU - Self-Dlagnosls Checker)
2 Is intake manrfold vacuum correct at idle? Yes Go to next step
Intake manifold vacuum:
More than 450 mmHg { 17.7 inHg )
No Low vacuum
Check for air leakage at intake air
system
3 Is air cleaner element clean? Yes Go to next step
No Replace abr cleaner element
4 Disconnect each hrgh-tension lead at idie; does Yes Go to next step
engine speed decrease equally at each cylinder?
No Go to Step 8
5 Are ECU terminal voltages OK? Yes Go to next step
(especially 20, 2Q, 20) -
rI7 page F345 No
Check for cause
6 Connect System Selector to diagnosis connector Yes Go to next step
and set Test Switch to SELF TEST; is ignition
timing at idle correct after warm-up?
Ignition timing (BTDC): f 0 f la
No Adjust ignition timing
._
. F3-33

F3 TROUBLESHOOTING GUIDE
STEP INSPECTION ACTlON
6 Is dashpot correctly adjusted? Yes Go to next step
c
Dashpot set speed: Approx. 3,500 rpm
No Adjust dashpot
7
Try known good ECU; does condition
Improve?
w page F3-3
13EOF3-336
16 ENGINE STALLS SUDDENLY (INTERMITTENT)
DESCRIP.
l Engine intermittently stops running
TION l Before stalling, engine conditron is OK
TROUBLESHOOTING HINTS]
@ intermittently no spark or no fuel injection caused by ve-
hlcle vibratron, acceleratton, or deceleration
l Poor connectlon in wiring harness
iTEP INSPECTION ACTfON
1 Is “00” displayed on Self-Oiagnoss Checker Yes Go to next step
with lgnltlon swrtch ON?
NO Service Code No. displayed
Check for cause (Refer to speclfled
check sequence).
Note CT page F3-16
l When checking wiring harness and
connectors, tap, move, and wiggle
suspect sensor and/or harness to
recreate problem
“88” flashes ’
Check ECU terminal IF voltage
Voltage: Battery voltage
{ignition swttch ON) w page F3-45
4 If OK, replace ECU
4 If not OK, check wiring
(ECU - Self-Diagnosis Checker)
2 Check for poor connection of foliowrng parts
Yes Reparr or replace
l lgnltfon coil l Igniter l Distributor l t-flgh-tensron lead
No Go to next step l Injector l Injector reststor l Circutt-opening relay l ECU
3 Are ECU terminal voltages OK? Yes Go to Troubleshbotrng No. 2
(especially 16, 2A, 2B, and 2C) .“CRANKS NORMALLY BUT WILL NOT
w page F3-45 START (NO COMBUSTION)”
w page F3-20
Note
. No Check for cause
l When. checking voltages, tap, move, and
wiggle harness and connector to recreate
problem
* lrlrl m-7
F3-36
7.8-l

F3 TURBOCHARGERCONTROLSYSTEM
1. Radiator
2. Insulator 3. Air hose, and air pipe
4. Oxygen sensor connector
5. Front exhaust pipe
13EOF534
F3-38 6. Water hose
7. Oil pipe
8. Exhaust manifold and turbocharger
Removal Note ,.........I.....f.~.~l....... II.I.... below
Installation Note . . . . , , l.. . . . . . . , ,.. ,..*, , . . . . . . . . . below
13EOF3-339
Removal Note Exhaust
manifold and turbocharger 1. Remove the exhaust manifold and the turbocharger as an
assembly.
2. Separate the turbocharger assembly from the exhaust
manifold.
Installation Note
Exhaust manifold and turbocharger’ I I Remove .all old gaskets and
sealant. 2. Install new gaskets.
3. Supply 25 cc ( 1.5 cu in ] of oil through the oil passage
of the turbocharger.
4. Mount the turbocharger assembly to the exhaust manifold.
5. Install the turbocharger and the exhaust manifold assem-
bly to the engine and loosely tighten the nuts.
6. Install the bracket and the front exhaust pipe, and tighten
the turbocharger mounting nut%
WASTEGATE SOLENOD VALVE
Caution
l The wastegate solenoid valve must be replaced with
the turbocharger, it cannot be replaced by itself.
Inspection 1. Disconnect the connector.
2. Measure the resistance of the solenoid valve.
Resistance: 35-45 !‘l (at 20°C f68OFj) 3. M not as specified, replace the wastegate solenoid valve and
turbocharger as an assembly, if necessary.
(Refer to page F3-37.)
3. Instc