1992 MAZDA 323 fuel cap

A PRE-DELIVERY INSPECTION TABLE
PRE-DELIVERY INSPECTION TABLE
[EXTERlORI
INSPECT and ADJUST, of necessary. the followlng Items to
specrfrcatron:
0 Glass, exterior bright metal and paint for damage
0 Wheel lug nuts
0 Tire pressures
0 All weatherstrips for damage or detachment
0 Operation of bonnet release and look
0 Operation of trunk Ild, hatch and fuel lbd opener
(of equipped)
0 Door operation and alignment
0 Headtrght aiming
INSTALL the foltowrng parts
0 Wheel caps or rrngs (if equipped)
0 Outsrde mirror(s)
1 UNDER BONNET-ENGINE OFF j
INSPECT and ADJUST. If necessary, the following items to
specrflcatlon.
0 Fuel, coolant and hydraulic tines, fittings, connectlons and
components for leaks
0 Engine 011 level
0 Power steering fluid level (of equipped)
0 Brake master cylinder fluky levels
0 Clutch master cylinder fturcl levels (If equipped)
0 Wtndshreld washer reservojr flurd level
0 Radiator coolant level and specrfic gravity
0 Tightness of water hose clamps
0 Tightness of battery terminals, electrolyte level and specific
gravity
0 Manual transaxle oil level
0 Drive belt(s) tension
Cl Carburetor lrnkage (choke control, wrde open throttle posi-
tion. etc ) (carburetor model only)
q Accelerator cable and linkage for free movement
0 Headlight cleaner and flurd level (if equipped)
BLEED air from fuel line (diesel engrne only)
CLEAN the spark plugs (except for diesel engine)
piEi6F]
INSTALL the following parts
0 Rubber stopper for rnsrde rear view mirror (if equjpped)
0 Fuse for accessories
CHECK the operation of the following items.
0 Seat controls (sliding and reclining) and head rest
0 Seat belts and warning system
Cl Ign&on switch and steering lock
0 Power window (if equipped)
D Door tacks including child proof door locks
Cl Inhibitor switch (ATX only)
Cl All Ikghts rncluding warning and Indicator lbghts
0 Ignition key reminder buzzer (If equipped)
A-Z
0 Horn, wbpers and washers (front and rear, If equipped)
0 Antenna (tf equipped)
0 Cigarette Ibghter and clock (if equipped)
0 Remote control outside mirror (if equrpped)
0 Heater, defogger and air conditioner at various mode selec-
tions (if equlppedj
0 Sunroof (If equipped)
CHECK the following items
0 Presence of spare fuse
0 Upholstery and Interior finish
CHECK and ADJUST, If necessary, the followjng items:
IJ Operation and fit of windows
0 Pedal height and free play of brake and clutch pedal
0 Parking brake UNDER BONNET-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
0 Operation of Idle-up system for air condbtroner or power steer-
ing (if equrpped)
0 Automatic transaxle flurd levet
0 tnltial ignrtlon timing (except disel engine)
0 Idle speed
0 Operation of throttle positron. sensor (EGI engrne)
0 Operation of cold start device and glow plug warning light
(diesel engine only)
0 Operation of dash pbt (EGI.engine)
fTiGGJ
CHECK the following items.
0 Underside fuel, coolant and hydraulic Irnes, ftttlngs, connec-
tions and components for leaks
0 Trres for cuts or brurses
0 Steering Itnkage, suspensron, exhaust system and all under-
side hardware for .looseness or damage 1 ROAD TEST j
CHECK the following items
0 8rake operation
0 Clutch operation
0 Steering control
!ZI Operation of meters and gauges
Cl Squeaks, rattles or unusual noises
Cl Engine general performance
0 Emergency locking retractors 1 AFTER ROAD TEST ]
REMOVE the seat and floor mat protective covers
CHECK for the necessary owner information materials, took
and spare tire
m vehicle
93EOAX-002
-- MAIN Char3 t: In
A: PC R: F!t T: Ti! Emis! The ed : to t!

OUTLINE F3
SPEClFiCATlONS
Iten
Idle speed’
tgnltion trming * Engine
m
BTDC BP TURBO
800 f 50
IO f 10
Fuel pump
Maximum output pressure kPa { kgflcm’, psi 1 1 490-736 {SO-7.5, 7t-110)
Transfer pump
Maximum output pressure
Fuel filter kPa { kgf/cm2, psi ) 1 , 39 10.4, 5.7 1 or higher
Nylon element (in fuel pump)
Idle-speed control (fSC) valve
Type
Resistance I Rotary
nt
11-13 [at 2O*C [68*F)]
Solenoid va tve (purge contra I)
,I
Resistance -2o*c I -4Of 1 14.6-I 7.8
2.21-2.69
.kQ , 2o”c { 68OF)
40% f104*f 1 1.0-l .3
Resistance
Fuel tank
Capacity
Air cleaner
Etement type
Fuel
Specification L {US gal, Imp gal) [ Approx. 6 [at 20°C f 68*FJ]
60 (15.9, 13.2)
01 permeated
Unleaded premium (RON 95 or higher)
11FrlC?.7 11
l TEN terminal of diagnosis connector grounded.
The I; mark indicates newly equipped Parts. l”L”l “VI I
F3-9

TROUBLESHOOTING GUIDE F3
8
1 ROUGH IDLE/ENGINE STALLS AT IDLE - ALWAYS
DESCRtP- 1 l Engine starts normally but stalls or vibrates excessively at idle in every condition
TION
[TROUBLESHOOTiNG HlNTSJ @ Air/Fuel mixture tw lean @ Incorrect idle-speed l ldiespeed misadjustment l Idle-speed control malfunction
$I One or more spark plugs not firing
9 Low engine compression
B Airflow meter stuck l Air leakage l Fuel injection control malfunction
*Low fuel line pressure
@ One or more injectors clogged or not
@ Low intake air amount operating
INSPECTION
Is “00” displayed on Self-Diagnosis
Checker with ignition switch ON?
1
SYSTEM SELECT: 1
ACTION
Go to next step
Service Code No. displayed Check for cause (Refer to specified
check sequence) c7 page F3-16
“88” flashes
Check ECU terminal IF voltage
(17 page F345
--.
‘\.
Voltage: Battery v&age
(Ignition switch ON)
4 If UK, replace ECU IT page F3-2 c3 If not OK, check wiring
(ECU - Self-Diagnosis Checker) Y -SELECT SW: A
Are ECU terminal voltages OK
(especially 20, 20, and ZQ)?
D page F3-45 Yes
Gu to next step
NO Check for cause
Disconnect each high-tens&on lead at idle: does
engine speed decrease equally at each cylindeR Yes Go to Step 9
NO Go to next step
Is injector operating sound heard at idle? [ Yes Go to Step 7
t- NO Stop engine and go to next step
Yes Check if injector resistance is OK
CT page F3-41 Is there battery voltage at each injector connec-
tor (No.1 (P), No.2 (R), No.3 QV), No.4 (0)) with
ignition switch ON?
Resktance: Approx. 2.110
(at 20*C [68*F))
4 if it is, check wiring
(ECU - Injector)
c3 If it is not, replace itijector
Go to next step
NO
Is there battery v&age at injector resistor (W/R)
I .Yes
with ignition switch ON? Check mjeotor resistor
4 tf OK, check for short circuit in wir-
ing (Injector resistor-Injector)
e3 If not OK,’ replace injector resistor
Check for open circuit in wiring (Main
relay (FUEL INJ relay)-Injector resistor)
Go to next step
t NO 1
Is strong blue soark visible at each disconnected Yes
‘Check ‘high-tension lead
4 If UK. check distributor cap and
rotor .
c3 If not OK, replace high-tension lead
‘-F3-29

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 GUIDE
(at 20% [SS*F])
If It is, check wiring
e If OK, check distributor cap and
rotor
e If not OK, replace high-tensjon lead
12 Are spark plugs UK? Yes Is engine compresston correct? w Section 82
w Section G
. Wear and carbon burld up Engine compression: l Plug gap 1059 kPa 110.8 kgf/cm*, 352 psi I-300 rpm l Damage
4 If OK, go to next step
4 If not OK, check for cause
w Section 82
c
NO Clean, adjust
13 Check for injector leakage Yes
Replace injector
No Go to next step
14 Try known good ECU: does condition improve?
w page F3-45
----- Am.*
F3-34
~ROlJ8L Engine so:
3 Idle-sp.
T> fuel-cL

F3 FUEL SYSTEM
t 3EoF3-344
1
FUEL SYSTEM
FUEL PUMP
inspection
Fuel pump operation
1. Connect the diagnosis connector F/P and GND terminals
by using a jumper wire.
2. Remove the fuel filler cap.
3. Turn ON the ignition switch.
4.
Listen at the filler inlet for the operational sou.nd of the fuel
pump.
5. Install the fuel filler cap.
6. If no sound is heard, measure the voltage between the fuel
pump connector (G/R) to a ground.
Voltage: 8attey vo kage
7. If not as specified, check the circuit opening relay and circuit.
8. ff as specified, check fur continuity between fuel pump con-
nector (G/R) and (B).
9. If there is continuity, reptace the fuel pump.
10. If there is no continuity, repair the ground circuit.
f3EOF3.345
13EOF3-346 FUEL PUMP RESlSTORlRELAY
System Operation
1. Remove the rear seat cushion.
2. Measure the voltage at the fuel pump connector terminal
A (G/R).
Voltage
I
Cranking
1 Battery voltage
Ignition switch ON ov 3. If not as specified, perform the following inspections, and
repair or replace as necessary.
l Fuel pump resistor/relay resistance
(Refer to page F3-41.)
l ECU 11 terminal voltage (Refer to page F3-45.)
l Wiring harness and connector
F3-40
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