1992 MAZDA 323 wiring

Mazda 323
o Workshop
b Manual CONTENTS
r Title Section
IG eneral Information
Pre-Delivery inspection and
Scheduled Maintenance
Supplement
I Lubrication System
j Cooling System
FOREWORD
This is a supplement to the workshop manu-
a!(s) shown below. This supplement describes
service procedures of. new or modified me-
chanicat and/or ekctrical systems. For service
procedures and important safety notices not
contained in this supplement, please refer to
the previous workshop manual.
Workshop Manual:
Form No.1 203-l O-89F (vol. 1)
1206-1 O-89F (Vol.2)
1229-l O-89L
1275-l O-91 c
b
All information in this supplement was the
latest available at the time of printing, ail alter-
nations related to modifications will be notified
by Service Sulletin. Carburetor
m !I
Fuel and
Emission
Controt
System EGi unieaded Fuel BP (DOHC
and S
Diesel
-Electrica I System
I-- Clutch
Manual
Transaxie
1 Electronically Co Introlled
I
Automatic
Transaxle Hydraulicaf~y’Co~~~rull=;u
1 Transfer
Mazda Motor Corporation
HIROSHIMA, JAPAN [ Propefier Shaft
1 Front and Rear Axles
P ISteerIng System
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN)
shown on the following page. Braking System
IWheels and Tires
ISusiension
1 Bodv Electricat System
1 Heater and Air Conditioner System
1 Technical Data
Special Toots
Parts Index
/ Wiring Refer to the form No.
, Diagram 5232-l 0-92A
--
This manual explains onty the secticlns marked with shadows (-1
0 1992 Mazda Motor Corporation
PR1NTED tN JAPAN, JAN., ‘92 @I
1318010192A

..,. .
a
._
GI CAUTKN
PRECAUTIONS TO TAKE WHEN SERVICING AN ELECTRICAL SYSTEM l Note the following items when servicing the electrical system.
l Do not alter the wiring or electrical equipment in any way; this may damage the vehicle or cause a fire
from short-circuiting a circuit or overloading it.
l The negatrve (-) battery cable must be removed first and
rnstalled last. l Do not reptace with fuses exceedrng specified capacity
Cautron
l 8e sure that the ignitton and other switches are off
before disconnectrng or connecting the battery cables.
Failure to do so may damage the semrconductor
components. Caution l Repfacing a fuse with one of a larger capacrty than
desrgnated may damage components or cause a frre.
l Secure harnesses with provrded clamps to take up slack. l Tape areas of the harness
that may rub or bump l When mounting
components, be sure the
against sharp edges to
protect rt from damage. harness IS not caught or
damaged.
Caution
l Clamp all harnesses near vibratrng components (for
example, the engine) to remove slack and to prevent
contact resultrng from vibration. i Drsconnect heatsensitive l Make sure that the
parts (for example, relays
and ECU) when performing connectors are securely
connected when installed.
l Do not handle electrical components roughly or drop
them. maintenance (such as
weldrng) where
temperatures may exceed
80°C [176OFj.
-*
HI

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

F3 SELF-DIAGNOSIS FUNCTION
:ODE NO. 25 {SOLENOlD VALVE - PRESSURE REGULATOR CONTROL) (Low temperature opoeration)
INSPECTION ACTION
Disconnect connector from ECU; IS there battery Yes Check ECU termrnal connector for poor
voltage at ECU terminal 2T (G/C) wrth Ignition connection
switch ON?
4 If OK, replace ECU
CT page F3-2
c3 If not OK, repatr or replace connector
NO Go to next step
2 In same condition as rn Step 1. is there battery Yes Repair or replace wlrrng harness (G/O)
voltage at sofenord vatve (PRC low temp.) con-
nector termrnal wrre (G/O)?
NO Go to next step
3 Is solenord valve (PRC low temp ) UK7 Yes Check for a short or open crrcuit in WII-
CT page F343 ing harness (main relay [FUEL INJ re-
lay] - solenoid valve [PRC low temp.])
NO Replace solenord valve (PRC tow temp.)
1
t3EOF3-323
CODE NO. 35 (SOLENOID VALVE - PRESSURE REGULATOR CONTROL) (High temperature opoeration)
STEP lNSPECTlON ACTlON
1 Disconnect connector from ECU: is there battery Yes Check ECU terminal connector for poor
voltage a? ECU terminal 22 (G) with rgnttlon connection
swttch ON7
4 If OK, replace ECU
J page F3-2
e If not OK, repair or replace connector
No Go to next step
2 In same condrtron as In Step 1, is there battery Yes
voltage at solenoid valve (PRC high temp.) con- Repair or replace wiring harness (G)
nector terminal wire (G)?
No Go to next step
3 Is solenoid valve (PRC high temp ) OK7 Yes Check for a short or open circuit In wir-
r;r page F343 ing harness (marn relay [FUEL INJ re-
WI - sofenord valve [PRC high temp.])
No Replace solenoid valve
(PRC high temp.)
f3EOF3-324
Circuit Diagram
ECU
I
2T 22 I
G
TO MAIN RELAY
I SOLENOID
VALVE
(PRC HIGH TEMP.)
F3-18 :3EOf3 32 5
--
TRW
RELAT
c
-..


INPUT
--
KNOCH
--
DIAGM
(TEN T
--
IGNITIi
(STAR1
--
E/L SIC
-a
P/S PR
--
A/c SYI
--
NEUTR
SWITCI
--
STUPb
--
ATMDI
SENSQ
-a
THRUI
-..
INfAk.1
--
AlFlFLC
--
UXYGE
--
WATEF
--
DlSfRl

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

TROUBLESHOOTING GUlDE F3
STEP INSPECTION ACTlON
4
Is there buttery voltage at fuel pump connector Yes
* (G/R) with lgnitron switch ON and F/P terminal Check contmurty of fuel pump
between termrnafs G/R and 8
Check ctrcutt openmg relay
5
Is qector operating sound heard whtle engine IS Yes Go to Step 8
being cranked?
No Go to next step
CcI page F3-45
+ If 0K;check for a short cjrcult rn
wiring harness
(Injector reastor-Injector)
=D If not OK, replace Injector reststor
fuel Line pressure: 265-314 kPa
12.7-3.2 kgflcd, 38-46
psi)
if fuel return hose is clogged or
t, replace pressure
CT psge F3-3
F3-2 3

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

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