1992 MAZDA 323 service

SCHEDULED MAINTENANCE SERVICES (Europe) A
Maintenance Number of months or km (miles), whichever comes first
Months’ ’
- 6 12 18 1 24 30 36 ] 42 48
Kllometers 1,000
10,000 20,000 30,000 1 40,000 50,000 60,000 1 70,000
80,000
(Miles) (600)
(6,000) j(12,000)~(18,000)~(24,000) (30,000) (36,000)~(42,000) (48,000)
Chassis and body (Cont’d)
Steering and front suspension
I ’ I
I 1 I
MTX oil A R
Rear axle oil
I R A A R
A A A R I
Trabsfercarrier oil R A 1 A
R A A A R
Bolts, nuts on chassis and body T T 1
T , T T
Body condltlon (Visual only) Inspect annually
Exhaust system heat shields I 1 I
Tires (Including spare tjresj with inflation
pressure adjustment I
I I I
Hinges and catches A A
A 1 A
Underside of vehicle I
I i 1 I I
Seat belt I
I f
I ’ I
Dnveshafl dust boots I I 1 I I
13EOAX.304
A-5

B2
ENGINE
(DOHC)
1 FEATURES j
OUTLINE ................................................
B2- 2
OUTLINE OF CONSTRUCTION..
.............. B2- 2
SPEClFICATlONS
..................................
82- 2
INTERCHANGEABILITY ..........................
B2- 3
PISTON ...............................................
82- 4
CONNECTING ROD ...............................
82- 5
CRANKSHAFT PULLEY ..........................
B2- 6
EXHAUST VALVE ..................................
B2- 7
INSTRUCTION FOR HANDLING METALLIC
SODllJM~FlLLED EXHAUST VALVE .........
82- 8
SUPPLEMENTAL SERVICE INFORMATION 820 9
4
13E082-301

SUPPLEMENTAL SERVICE HWURMATION B2
SUPPLEMENTAL SERVICE 1NFORMATION
The following points in this section are changed in comparison with 323 Workshop Manual [Europe, AUS- tfilia (I 229-I O-89L)j.
Engine
l Removal
. Installation
I
m I
l The intercooler installation position is changed because the intercooler is enlarged. With this change, the
engine can be removed and ‘installed without removing the intercooler. The engine removal I installation
procedure is the same as of the previous BP-DOHC Turbo engine.
13E082-313
82-9

F3
c
FUEL AND EMISSION
CONTROL
SYSTEMS
i
INDEX . . . . . . . . l ..,.... *..,. . . . . . . m...*.*...*..... F3- 2
UUTLtNE
...................................... F3- 4
OUTLINE OF CONSTRUCTION.. ....
F3- 4
SYSTEM DIAGRAM ...................... F3- 5
VACUUM HOSE ROUTING
DIAGRAM
................................. F3- 6
WIRING DIAGRAM.. .....................
F3- 7
ECU RELATIONSHIP DIAGRAM ...... F3- 8
SPECIFICATIONS.. ....................... F3- 9
TURBOCHARGER CONTROL .......... F3-IO
OUTLINE
.................................... F3-10
SYSTEM DIAGRAM ...................... F3-10
WASTEGATE CONTROL ............... F3-11
FUEL SYSTEM
.............................. F3-12
OUTLINE ....................................
F3-12
CONTROL SYSTEM .......................
F3-13
STRUCTURAL VIEW .....................
F3-13
PRESSURE REGULATOR
CONTROL SYSTEM ....................
F3-14 SUPPLEMENTAL SERVICE
tNFOF?MATtON
............................. F3-I 5
SELF-DtAGNOStS FUNCTtON.. ........
F3-16
OUTLINE ....................................
F3-16
SERVICE CODE NUMBERS..
......... F3-16
TROU8LESHOOTtNG GUtDE
........... F3-19
RELATIONSHtP
CHART.. F3-19 ..............
DIAGNOSTIC JNDEX
.................... F3-20
PRECAUTIONS
............................
F3-21
SYMPTOM TROUBLESHOOTING .... F3-22
TURBOCHARGERCONTROL
SYSTEM ......................................
F3-37
TURBOCHARGER F3-37 ........................
WASTEGATE SOLENOID VALVE.. .. F3-38
INTERCOOLER ............................
F3-39
FUELSYSTEM ..............................
F3-40
FUEL PUMP ................................
F3-40
FUEL PUMP RESISTOR/RELAY ......
F3-40
PRESSURE
REGULATOR .............. F3-41
INJECTOR ..................................
F3-42
INJECTOR RESISTOR
................... F3-42
PRESSUR REGULATOR CONTROL
SYSTEM ......................................
F3-43
SOLENOID VALVE (PRESSURE
REGULATOR CONTROL)
............. F3-43
CONTROL SYSTEM
....................... F3-44
PREPARATION ............................ F3-44
ENGINE CONTROL UNIT (ECU) ..... F3-45
7 3EOF3-301

SUPPLEMENTAL SERVICE INFORMATION .
I
The following points in this section are changed in comparison to the Mazda 323 4-Wheel Drive Work-
shop Manual [I 229-l O-89t].
Turbocharger
l Removal / Installation
Wastegate solenoid valve
l Inspection
htercooter
l Removal I Installation
Fuel pump (main)
l Inspection
Fuel pump resistor/relay
l System operation
l Inspection
Injector
l Inspection
l Volume test
Injector resistor
l Inspection
Pressure regulator control system
l Solenoid valve (pressure regulator control}
Engine control unit (ECU)
l Inspection 13EOF3.320
F3-I 5

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

SELF-DIAGNOSIS FUNCTION F3 I
Open or short crcuit
13EOFS322
Caution l If there is more than one failure present, the code numbers will be indicated in numerical or-
der, lowest number first.
l After repairing a failure, turn off the ignition switch, disconnect the negative battery cable,
and depress the brake pedal for at least twenty seconds to erase the service code from the
ECU memory. II
F3-17

F3 TROUBLESHOOTING GUIDE
SYMPTOM TROUSLESHOOTING
2 . CRANKS NORMALLY BUT WILL NOT START (NO COMBUSTION)
LIESCRIP-
l Engine cranks at normal speed but shows no sign of firing l Battery in normal condition
TION *Throttle valve not held fufly open while cranking (dechoke system not operating}
l Fuel in tank
UROOBLESHUOTlNG HINTS]
@ No spark
@.I low fuei tine pressure
l Ignition control malfunction @I Low engine compresslon l Ignition system component malfunction
@ No fuel injection
l Fuel pump inoperative l Ihjectors inoperative
;TEP
INSPECTION
I ACTION
1
Is strong btue spark visible at disconnected high- Yes Go to Step 3
tension lead?
NO Go to Step 2
2 Is “00” dlsplayed on Self-Dlagnosjs Checker
Yes
with ignltron switch ON? Check rgnltion system (Refer to
Troubleshooting “Misfire”)
c7 Section G
SYSTEM SELECT: 1 No
Service Code No. displayed Check for cause (Refer to specified
check sequence)
G- page
F3-16
“66” flashes
Check ECU termrnal 1F voltage
3 page W-45

Voltage: Battery vabage
(ignition switch ON)
W: SELF TEST C+ If OK, replace ECU
4 If not OK, check wiring
CT page F3-2
(ECU
- Self-Diagnosis Checker)
3
Connect diagnosis connector terminals F/P and
Yes
GND with jumper wire; IS fuel pump operating Does engine start in this condition?
sound heard wjth ignition switch ON?
4 If it does, check circuit-opening
relay
4 If it does not, go to Step 5
No Go to next step
F3-22
iTEF
6
8