Mazda 323 1989 Workshop Manual

IV - - . - . . - - -

I

- .

.

Mazda 323

4-Wheel Drive

Workshop

Manual

Supplement

CONTENTS

FOREWORD

This is a supplement to the workshop manu- al(s) shown below. This supplement describes service procedures of new or modified me- chanical and/or electrical systems. For service procedures and important safety notices not contained in this supplement, the previous workshop manual. please refer to

Workshop Manual:

Form No. 1203-I O-89F (Vol. I> Europe

1204-I O-89F (vol. I > Australia

I ZM-1 o-89F (vol.2)

Ali information in this supplement was the latest available at the time of printing, all alter- nations related to modifications wili be notified by Service Bulletin.

Mazda Motor Corporation

HIROSHlMA, JAPAN

APPLlCATlON:

This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (UN) shown on the following page.

Title

Electronically Controlled

Section

Current ) NeH

Wiring

Diagram

Refer to the form No.

5161-l O-89L

5162-t O-89L

Thrs manual explarns only the sectIons marked with shadows ( )

0 1989 Mazda Motor Corporation

PRlNTED IN JAPAN, Dec., ‘88 @$

1229-l O-891

VEHICLE IDENTlFlCATlUN NUMBERS (VIN)

Europe

JMZ BG8262 00 1000Uf-

JMZ BG8362 00 IUOOOl -

JMZ BG82F2 00 lOOOOl-

JMZ BG83F2 00 IOU001 -

JMZ

BG83H2 00 100001-

Australia

JMO BGI WI 00 IO0001 -

GENERAL INFORMATION

IMPORTANT INFORMATION ..................... GI- 2

BASIC ASSUMPTtONS ............................ a- 2

SAFETY RlSK

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GI- 2

POSSBLE LOSS OF WARRANTY ............. GI- 2

WARNiNF ON LUBRICANTS

HOW

AND GREASES

TO USE THIS

....................................

MANUAL.. ..................

PREPARATION ......................................

REPAIR PROCEDURE .............................

GI- 2

Gl- 3

Gl- 3

Gl- 3

SYMBOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a- 4

NOTES, CAUTIONS, AND WARNINGS ....... Gl- 4

FUNDAMENTAL

PROTECTION

PROCEDURES

OF THE VEHICLE

.................

..............

A WORD ABOUT SAFETY .......................

Gl- 4

Gi- 4

Gl- 5

PREPARATION

AND MEASURING

OF TOOLS

EQUIPMENT

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNITS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABBREVIATIONS .....................................

CAUTION ................................................

1NSTALLATtON OF A MOBlLE

............. GI-

Gt-

REMOVAL OF PARTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLY

REASSEMBLY .......................................

ADJUSTMENTS

RUBBER PARTS

......................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AND TUBING ................

G I - 5

Gi- 5

Gl- 6

GC- 7

Gl- 7

.... Gl- 8 JACK AN5 SAFETY STAN5 POSITDNS

VEHICLE LIFT (Z-SUPPORT TYPE)

POSITIONS ............................................

TOWING ..................................................

IDENTIFICATION

GI-

GL

NUMBER LOCATIONS ..... GI-10

8

9

G I - I

Gl-I

Gl-I

0

5

5

0

1

TWO-WAY RADIO SYSTEM ....................

REMOVAL OF tGNIT1ON KEY ON

AUTOMATIC TRANSAXLE

GI-II

MODEL .......... Gl-11

ELECTRICAL TROUBLESHOOTlNG

CAUTION WITH ELECTRICAL

TOOLS

PARTS ........

GI-12

Gl-13

03UGIX-001

GI

IMPORTANT tNFORMATlUN

IMPORTANT INFORMATION

BASIC

ASSUMPTIONS

This workshop manual assumes that you have certain special tools that are necessary for the safe and effi- cient performance of service operations on Mazda vehicles and that you know how to use

them

properly.

It also assumes that you are familiar with automobile should

systems

and basic service and repair procedures. You

not

attempt to use this manual unless these assumptions are correct and you understand the conse- quences described below.

SAFETY RlSK

This manual contains certain notes, warnings, and other precautionary information that you should carefully

read

and follow to reduce the risk of personal injury to yourself or others and the risk of improper service that may damage the vehicle

or

render it unsafe. If there is no such information in regard to any specific service method, this does not mean there is no possibility that personal safety or vehicle safety will be jeopardized by the use of incorrect methods or toots.

POSSIBLE LOSS OF WARRANTY

The manufacturer’s warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Authorized Mazda Dealer.

WARNING ON LUBRICANTS AND GREASES ’

Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used 08s contaminated during service (e.g., engine sump oils) are more irritating and more likely to cause serious effects, including skin cancer, in the event of gross and prolonged skin contact.

Wash skin thoroughly after work involving oil.

Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not use gasoline, paraffin, or other solvents to remove oil from the skin.

Lubricants and greases may be slightly irritating to the eyes.

Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particu- lar care should be taken with used oils and greases containing lead. Do not allow work clothing to be con- taminated with oil. Dry clean or launder such clothing at regular intervafs.

9MUGiX-502

1

.ftl 1

HOW TO USE TtiIS MANUAL

GI

HOW TO USE THIS MANUAL

PREPARATION

PREPARATON points out the needed SpeciaI Service Tool (SST) for the service operation that it pro- ceeds. Gather all necessary SST before beginning work.

Example:

MANUAL STEERING

PREPARATION remova! of W-rod

REPAIR PROCEDURE

I. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and visual parts inspections. If a damaged or worn part is found, repair or replace it as necessary.

2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview iItustration.

3. Pages related to service procedures are shown under the illustration. Refer to this information when ser- vicing the related part.

Example:

--__ __-

EXPENDABLE iI -

SHOWS

REiAT&

PAGE

Zh

FOR

SERVICE x

-

I

I

1 8oit

2. Lock plate

3. Bearrng cup

A

- _ ‘.v,--..s ----.

5. Bearing outer race

V. LVYR*IY.

7Washer

- -0mpanlon f&we r..r...~r.--~.~r....e.-..c~~...~.,~.-*

Q

16 Bearing lnne

Removal . .

,.

I!.~ fnstallatbon f%

._ . . . ._. . . . . .

:7 Spacer

.” I.~.1 mninn

Rerr&l'~ .._. . . . . ..__ . . . . . . . ..__......... page M---21 inspect spllnes and teeth for wear or damage

Adlustment of heloht ._._..... . . . . . DaPe k&Z? I

SHOWS TlGHTENlNG

TORQUE UNIT

9MUGlx-034

‘I : The numbering (ex.@)) shows service procedure.

‘2: Units shown in N-m (m-kg, Wb) unless otherwise specified.

GI

HOW TO USE -MS lVlANUAL/FUNDAMENTAL PROCEDURES

SYMBOLS

There are six symbols indicating oil, grease, and sealant. materials during service.

These

symbols show the points of applying such

Kind

Symbol Meaning

I

Apply oil

It

New engine oil or gear oil as appropriate

Only brake fluid Apply brake fluid

Only ATF Apply automatic transmission fluid

Appropriate grease Apply grease

Appropriate sealant Appty sealant

0 m

Apply petroleum jelty Appropriate petroleum jelly l

Note

When special oil or grease is needed, this is shown in the illustration.

NOTES, CAUTIONS,

As you read through

AND WARNINGS the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information particular procedure. CAUTlUNS are given to prevent you from making that will help you to complete an error that could damage the a vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause per- sona! injury. The foliowing list contains some general WARNINGS you should follow when you work on

a

vehicle.

9MUGlX-036

FUNDAMENTAL PROCEDURES

PROTECTON OF THE VEHICLE

Always be sure to cover fenders, seats, and floor areas be- fore starting work.

FUNDAMENTAL PROCEDURES

GI

A WORD ABOUT SAFETY

The following precautions must be followed when jacking up the vehicle,

3. Block the wheels.

2. Use only the specified jacking positions.

3. Support the vehicle with safety stands.

Start the engine only after making certain the engine compart- ment is clear of tools and people.

9MUGIX-003

I

PREPARATION OF TOOLS AND MEASURING

EQUIPMENT

Be sure that

all necessary

tools and measuring

equipment are

available before starting any

work.

SMUGIX-038

I

SPECIAL TOOLS

Use special toots when they are required.

REMOVAL OF PARTS

White correcting a problem, try also to determine its cause.

Begin work only after first learning which parts and subassem- blies must be removed and disassembled for replacement or repair.

47ilOGX-006

1

1

DISASSEMBLY

If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.

9MlJGIX439 t

GI

FUNDAMENTAL PROCEDURES

1. Inspection of parts

When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems.

9MUGtX-040

2. Arrangement of parts

All disassembled parts should be carefully arranged for re- assembly.

Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

SMLIGIX-041

3. Cleaning parts for reuse

All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.

SMUGIX-004

REASSEMBLY

Standard values, such as torques and certain adjustments must be strictly observed in the reassembly of all parts.

Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in Section TD for tightening torques not mentioned in the main text.

If

removed,

these parts should be replaced with new

ones:

1. Oil seals

3. O-rings

2. Gaskets

4.

Lock washers

5. Cotter pins 6. Nylon nuts

Depending on location:

1. Sealant should be applied to gaskets.

2. Oil should be applied to the moving components of parts.

3. Specified oil or grease should

be

applied at the prescribed locations (such as oil seals) before reassembly.

‘31-6

I

5

FUNDAMENTAL PROCEDURES

67UOGX-002

I ADJUSTMENTS

Use suitable gauges and/or testers when making adjustments.

RUBBER PARTS AND TUBING

Prevent gasoline or oil from getting on rubber parts or tubing.

GI’

Gl-7

GI

JACK AND SAFETY STAND PUSITIONSNEHICLE LIFT (2-SUPPORT TYPE) POSITIONS

JACK AND SAFETY STAND POSITIONS

FRONT END

Jack position:

At the front crossmember

Safety stand positions:

On both sides of the body frame

REAR END

Jack position:

At the center of the rear crossmember

At the rear dtierential (4WD)

Safety stand positions:

On both sides of the body frame

L

03UGlX-801

VEHICLE LIFT (Z-SUPPORT TYPE) POSITIONS

FRONT END

Frame

Side sills

REAR END

Frame

Side sills

I-

03UGtX-010 j

SMUGIX-011 SMUGIX-Cl0

Gl-8

i e

I

I

: -

1

I t

I

WHEEL tiOLLtES

03UGIX-002

I

GI

TOWING TOWING

Proper towing equipment is necessary to prevent damage to the vehicle.

Laws and regulations applicable to vehicles in tow must al- ways be observed.

As a general rule, towed vehicles should be pulled with the driving wheels off the ground. If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies.

With either automatic or manual transaxle:

1, Set the ignition switch in the ACC position;

2. Place the selector lever or shift lever in N (Neutral);

3. Release the parking brake. l l

Caution

50 not tow the vehicle backward with driving wheels on the ground. This may cause internal damage to the transaxles.

50 not use the hook loops under the front and rear of the vehicle for towing purposes These hook loops are designed ONLY for transport tie-down. If tie-down hook loops are used fur towing, the front/rear bumper wiIl be damaged.

TIE-DOWN HOOKS - FRONT

TIE-DOWN HOOKS - REAR

GI

IDENTIFICATION NUMBER LOCATIONSIUNITSIABBREVlATlONS

I

IDENTIFICATCON

VEHKZLE IDENTIFICATION

NUMBER

LOCATIONS

NUMBER @‘IN)

AUTOMATIC TRANSAXLE MODEL AND NUM8ER

ENGINE MODEL AND NUMBER

UNlTS

N-m (m-kg or cm-kg, ft-lb or in-lb) . . . . . .._.......... Torque rpm ._._..._.. . . . . . . .._.._.._. . .._. Revolutions per minute v .._.... .* .*... ..__.._...*. ..*. .*. ,. Volt(s)

0 I.._._............**..-.-*..-....... Ohm(s) (resistance)

Wa (kg/cm2, psi) . . . . . . . . . . Pressure

(usually positive) mmlig (inHg) . . . . . . .._.._... Pressure

(usually negative) w . . . ..*.....e*.-..-..-.....*.e..... Watt liters (US qt, imp qt) .._. Volume

89UOGX-006

ABBREVIATIONS

AB.DC ........................... After bottom dead center

A/C _ Air conditioner

ACC ............................. Accessories

ATX ............................. Automatic transaxte

ATDC ......................... Afier top dead center

ATF .............................. Automatic transmission ftuid

BAC ........................... Bypass air control

BBDC.. ......................... Before bottom dead center

BTDC ........................... Before top dead center

CPU ............................. Central processing unit t

EC-AT ........................... Ekctronically-controlled automatic transmission

ECU ............................. Engine control unit

EGI ............................... Electronic gasotine injection

EL ................................ Electricaf toad

EX ................................ Exhaust

IC ................................. Integrated circuit

IGN ............................... Ignition

IN ................................. Intake tNT ............................... Intermittent

ISC ............................. Idle speed control

LH ................................ Left hand

M .................................. Motor

MIL ............................... Malfunction indicator lamp tb4TX. ............................. Manual transaxle

OD. ............................... Overdrive

OFF .............................. Switch off

ON ................................ Switch on

PCV .............................. Positive crankcase ventilation

PRC.. ............................ Pressure regulator control

P/S ................................ Power steering

P/W .............................. Power wtndow

RH.. .............................. Right hand

SST ............................... Special service tool

ST ................................. Start

SW . . Switch

TDC. ............................. Top dead center

4VVD ............................. 4-wheel drive

CAUTION

GI

INSTALLATION OF MUBlLE TWO-WAY RADIO SYSTEM

If a mobile two-way radio system is installed improperly or if a high-powered type is used, the EGl system and other systems may be affected.

When the vehicle is to be equipped with a mobile two-way radio, observe the fotlowing precautions:

I. Install the antenna at the farthest point from control units.

2. Install the antenna feeder as far as possible from the control unit harnesses (at Ieast 30 cm Ill.8 in]).

3. Ensure that the antenna and feeder are properly adjusted.

4. Do not install a high-powered mobile two-way radio system r i

CRUISE CONTROL UNIT

FEEDER WIRE

CONTROt/UNlT

\

HARNESS

MOBILE TWO-WAY

/

RADlO

AT . LEAST 30 cm

(f1.3 in)

ENGINE C0NiROL UNIT

/

FAR&T POlNT

REMOVAL OF IGNITION KEY ON AUTOMATIC

TRANSAXLE MODEL

The seiector iever must be in P (PARK) to turn the ignition key to the OFF position. If the switch seems to be off but the key cannot be removed, the switch may stilt be in the ACC posi- tion, or the selector lever may not be in P (PARK). Shitt the selector lever to P (PARK), and turn the ignition key to the

LOCK position. The key should now be free for removal.

GI

I

VOLTMETER

POWER SOURC

SMUGIX-a21

CAUTKN

ELECTRICAL

Test Light

TROUBLESHOOTING TOOLS

The test light, as shown in the figure, uses a f2V bulb. The two lead wires should be connected to probes.

The test light is used for simple voltage checks and for check- ing for short circuits. l

Caution

When checking the control unit, never use a butt, over 3.4w.

Jumper Wire

The jumper wire is used for testing by shorting across switch terminals and ground connections. l

Caution

Do not connect a jumper wire from the power source

, line to a body ground; this may cause burning or other damage to harnesses or electronic com- ponents. -

Voltmeter

The DC voltmeter is used to measure of circuit voltage. A volt- meter with a range of 15V or more is used by connecting the positive ( + ) probe (red lead wire) to the point where voltage is to be measured and the negative (-1 probe (black lead wire) to a body ground.

9MUGlX-021

1

Diagnosis Connector

Insert the probe into the service hole when connecting a jum- per wire to the diagnosis connector. l

Caution

Do not insert the jumper wire probe into the diag- nosis terminal. connector terminal, which may damage the

Ohmmeter

The ohmmeter is used to measure the resistance between two points in a circuit and atso to check for continuity and diagno- sis of short circuits. l

Caution

Do not attempt to connect the ohmmeter to any cir- cuit to which voltage is applied; this may burn or otherwise damage the ohmmeter.

i

CAUTION

GI

CAUTlON WITH ELECTRICAL

Battery Cable

PARTS

Before disconnecting connectors or replacing electrical parts, disconne@ the negative battery cable.

9MUGIX-022

I

Connectors

Removal of connector

Never pull on the wiring harness when disconnecting nectars. con-

\

9MUGIX-02:

Connectors can be removed by pressing or pulling the lock lever as shown.

Locking of connector

When locking connectors, make sure to listen for a click that will indicate they are securely locked.

9MUGIX-02

Inspection

1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wire harness side.

Gl-13

GI-i4

2. Check the terminals of waterproof connectors from the con- nector side, as they cannot be accessed from the wire har- ness side. l l

Caution

Use fine wire to prevent damage to the terminal.

Do not damage the terminal when inserting tester lead. the

OWGIX-028

I

Terminals

Inspection

Pull lightly on individual wires to check that they are secured in the terminal.

SMUG IX-027

1

Replacement of terminals

Use the appropriate tools to remove the terminal as shown.

When installing the terminal, be sure to insert it until it locks securely.

Insert a thin piece of metal from the terminal side of the con- nector, and then, with the terminal locking tab pressed down, pull the terminal out from the connector.

< Male >

Same as the female type, gMi)GlX-03

Sensors, Switches, and Relays

Handle sensors, switches, and relays carefully. Do not drop them or strike them against other parts.

I c i

PULLER t

CAUTION

GI

Fuse

Replacement

1. When replacing a fuse, be sure to replace it with one of specified capacity.

If a fuse again fails after it has been reptaced, the circuit probably has a short circuit and the wiring should be checked.

2. Be sure the negative battery terminal i fore replacing a main fuse @A).

; disconnected be-

9MUGIX-031

I

3. When replacing a pullout fuse, use the in the fuse box cover. use puller supplied

9MUGIX-029

1

CODE

B

BR

G

GY t

LB

LG

Wiring Harness

Wiring color codes

Two-color

wires are indicated by

a two-color code symbol.

The first letter indicates the

base

color of the wire and the sec- ond the color of the stripe.

COLOR

Black

Brown

Green

Gray

Blue

Light Blue

Light Green

V

W

-

Y

CODE )

0

P

R

!

COLOR

Orange

Pink

Red

Violet

White

Yellow

-

1

Gl-15

-

I

PRE-DELIVERY INSPECTION

AND

SCHEDULED MAINTENANCE

SERVICES

PRE-DELIVERY INSPECTION TA8LE ..-*...a.. A- 2

SCflEDULED MAiNTENANCE SERVICES

(Australia)

. .. * . . . . . . . l . . . . . . . . . . . . . . . . l .*..* . . . . l . . . . . . .

A- 3

SCHEDULED MAINTENANCE SERVICES

(Europe)

. . . . . . . . . . . . . . . . . l . . . . . . . . . . . . . . . . . . .*..* . . . . . . . .

A- 5

93GOAX-701

1

A

PRE-DELIVERY

PRE-DELIVERY INSPECTION TABLE pieziG-

INSPECT and ADJUST, if necessary, the following Items to specification:

D Glass, exterior bright metal and paint for damage

Cl Wheel tug nuts

9 Trre pressures

LII All weatherstrips for damage or detachment

Z Operation of bonnet release and lock

D Operation of trunk lid, hatch and fuel lid opener

(it equipped)

3 Door operation and alignment

5 Headlight aiming

INSTALL the following parts:

D Wheel caps or rings (if equipped)

D Outside mirror(s)

[ UNDER BONNET-ENGINE OFF )

INSPECT and ADJUST, if necessary, the foIlowIng items to specification:

Cl Fuel, coolant and hydraulrc lines, fittings, connections and components for leaks

Cl Engine oil level

0 Power steering fluid level (if equipped)

D Brake master cylinder fluid levels

0 Clutch master cylinder fluid levels (if equipped) q Windshield washer reservoir fluid level

D Radiator coolant level and specific gravity

Ll Tightness of water hose clamps

I3 Tightness of battery terminals, electrolyte level and specific gravity c) Manual transaxle oit level

D Drive belt(s) tension

C; Carburetor linkage (choke control, wide open throttle posi- tion, etc.) (carburetor model only)

D Accelerator cable and linkage for free movement

D Headlight cleaner and fluid level (if equipped)

BLEED air from fuel line (diesel engine only)

CLEAN the spark plugs (except for diesef engine) piicis-1

INSTALL the foflowing parts:

C Rubber stopper for inside rear view mirror (if equipped) c! Fuse for accessories

CHECK the operation of the following items:

Cl Seat controls (sliding and redining) and head rest ci Seat belts and warnrng system

Z! Ignition swrtch and steering lock

III Power window {if equipped)

0 Door locks including child proof door locks

0 Inhibitor switch (ATX only)

Z All lights including warning and indicator lights

0 Ignrtron key reminder buyer (if equipped)

INSPECTION

Cl Horn, wipers and washers (front and rear, if equipped)

D Antenna (if equipped} q Cigarette lighter and clock (if equipped)

I2 Remote controt outside mirror (if equipped) q Heater, defogger and air conditioner at various mode selec- tions (if equipped) c3 Sunroof (if equipped)

CHECK the fotiowing items: q Presence of spare fuse c3 Upholstery and interior finish

CHECK and ADJUST, if necessary, the following items:

Cl Operation and fit of windows

D Pedal height and free ptay of brake and clutch pedal

Cl Parking brake i UNDER BONNET-ENGtNE

1 OPERATtNG TEMPERATURE

RUNNING AT ]

CHECK the following items:

Cl Operation of idle-up system for air conditioner or power steer- ing (if equipped)

13 Automatic transaxle fluid level

D Initial ignition timing (except disel engine) q Idle speed

El Operation of throttle position sensor (EGI engine)

13 Operation of cold start device and glow plug warning light

(diesel engine only)

D Operation of dash pot [EGI engine) t ON HOtST 1

CHECK the following items:

U Underside fuel, coolant and hydraulic lines, fittings, connec- tions and components for leaks q Tires for cuts or bruises

Cl Steering linkage, suspension, exhaust system and all under- side hardware for looseness or damage

1 ROAD TEST 1

CHECK the foliowing items:

II Brake operation

D Clutch operation

0 Steering control c3 Operation of meters and gauges

0 Squeaks, rattles or unusual noises q Engine general performance c3 Emergency Iocking retractors rAFTER ROAD TEST 1

REMOVE the seat and floor mat protective covers

CHECK for the necessary owner information materials, tools and spare tire in vehicle

93EOAX-002

A-2

i

SCHEDULED MAINTENANCE SERVICES (Australia)

SCHEDULED

MAINTENANCE SERVICES (Australia)

Chart symbols:

I : Inspect: Visual examination or functiona! measurement

A: Adjust

R: Replace or change

T : Tighten of a system’s operation (Performance)

A l

Note

As the result of visual examination formance), correct, clean or replace or functional as required. measurement of a system’s operation (Per-

REMARKS:

After 90,000 km or 72 months, continue to follow

As

“I

the

described maintenance items

and intervals periodically.

for * marked

items

in this maintenance chart please pay attention to the following points.

If the vehicfe is operated under the foltowing conditions, it is suggested that

the engine

oil and oil f&r intervals. be changed more often that at usual recommended a> Driving in dusty condrt,ons. b) Extended periods of idling

or

low speed operation.

*2 c) Driving for a prolonged period iti coid temperatures or driving only short distances regularly.

Replacement of the timing belt is required at every 105,000 km. failure to replace the timing belt may result in damage to the engine.

*3

“4 l 5

If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, than at usual recommended intervals.

Adjust or inspect alternator and water pump drive belt, and power steering and air if equipped.

Replace every two years. repface conditioner more often drive belt

If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the vehicle is operated in extremely humid climates, the brake fluid shotlid be changed annually.

Emission Control and Related Systems

The ignition and fuel systems are vitally important to the proper operation of the emission control and system, as well as for efficient engine operation. It is strongly recommended that all servicing related related to these systems be done by your Authorised Mazda Dealer.

93GOAX-702

-

A-3

A

SCHEDULED MAINTENANCE SERVICES (Australia)

.--- .-- - .-m-w --v-w _ _ -_-- - - _ _ - - _ -- - -

Exhaust manifold bolts and nuts (except turbo)

Engine timlrtg belt”’

Drwe belts * a

--- lumber of months or km, whichever cumes first

_ 48 54 60 1 66 72

T 1

A I

__-

I

_- --

1 I 1

-- i T 1

5 60 67.5 75

Replace every 105,000 km

1 I 1 ! ’ I I

(82.5

1

90

T

1 1

Engine oil * ’

1 r-k:1 c:t+*-* 1

VII IIIIc;I

Except turbo models 1 RIR\R/RIRIRIR

For turbo models

Except turbo models

-

1 For turbo models

R

R

I R 1

1 R 1

R R,R R

Replace every 5,000 km or 6 months

1 R ( ) R ( 1 R ( 1 R 1

ReDlace everv IO.000 km or E

R/R f R

Engine coolant (Wrth Reservoir) Replace e&y 24 months

Fuel system

Idle speed

I

Air cleaner element

Fuet filter

~ Fuel lines and hoses

For F-i. system

(if equipped Idle speed controf)

1

I

1 I 1

1

I

1

R ,

I?

I

I

1 I

1

R

R

I

I

1

I

R

R

1

Ignition system t Initial ignition timing

Spark plugs i I

I

I

I

I

I

-1

I

I

I

I f

Evaporative emission

Evaporative system

Throttle sensor control system

Exhaust emission contra! system

[ Dashpot (Except for ATX) I 1 I 1 1 I 1 1 t 1 1 1 1 1 ! 1 1 I 1

Electrical system

Battery electrolyte level and specific gravity ] I 1 1 I 1 t 1 1 I 1 f I (

Chassis and body

’ C1utcl-1 pedat

Clutch fluid

Brake lines, hoses and connections

Brake fluid * a

Parking brake

Disc brakes

1 Power steering fluid and line Ilf &uiDDedl

Steering operations and gear housing

..‘-~--,

Manual transaxle oil

J-

--

-.-- _.- .-- -..--

I 1 1

I

I I

I \\!‘I

I

I I I

1 t

I

I 1 1

1 I

I 1 rl\jl

I

III

--r--j-

I I

I

II

1 I

I I I

1 I

I ’

I

R oil or 09 transaxle fluid level 1 1 1 111 1 I I 1 I

1 Rear axle oil (Differential)

Front suspension ball joints

1 t I I r . ’ 1 .

I

Bolts and nuts on chassis and body

Drive shaft dust boots

~~

I

I

I . I

I

!

T

,

1 I 1

I

I

I

I

T 1

1 I

I I

I

I

I 1

- -

R

III

1 I 1

I

1 T

I ’

1 I

I

1

I

I

I

1

1

A-4

i i i t- i i

-1

SCHEDULED MAfNTENANCE SERVICES (Europe)

MAINTENANCE

Chart symbols:

TABLE (Leaded Fuel Model)

1 : Inspect: Visual examination and/or functional measurement

A: Adjust: Examination resulting in adjustment or replacement

R: Replace or change

T: Tighten of system’s operation or performance

A

REMARKS

After 80.000 km or 48 months, continue to foltow the described maintenance at the recommended

As

*I for *’ marked items in this’ maintenance chart, note the following points.

Major service interval at 12 months!ZO,OOO km (I 2,000 miles).

*2 intervals.

Lubrication service based on distance only, 10,000 km (6,000 miles), not time.

Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt ii equipped.

“3

*4

Replacement of the timing belt is required every ICQOUO km (60,000 miles). Failure to replace the timing belt may result in damage to the engine.

If the vehicle is operated under any of the following conditions, it is suggested that the engine oil and oil filter be changed more often than the recommended intervals. a) Driving in dusty conditions. b) Extended periods of idling or low speed operation.

*5

*6

*7 c) Driving for prolonged periods in cold temperatures or regularly driving only short distances.

If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often than the recommended intervals.

This is a full function check of all electrical systems, i.e, afl lights, washers (inctuding condition of blades) electric windows sunroof, horn, etc.

Replace every two years. tf there has been continuous hard driving, mountain driving, or it the brakes are used extensively or the vehicle is operated in extremely humid climates, the brake fluid should be changed annually.

Emission Control and Related Systems

The ignition and fuel systems are vitally important to the proper operation of the emission control and related system, as well as for efficient engine operation. It is strongly recommended systems be done by your Authorised Mazda Dealer. that all servicing related to these

93GOAX-704

A-5

SCHEDULED MAlNTENANCE SERVICES (Europe)

Maintenance

Maintenance interval

Months”

Wometers

(Miles)

Engine

Intake and exhaust manifold nuts (Bolts)

Drive belts * 2

Engine ttming belt *’

Engine oi; (Non-Turboj’4

Oil filter * 4

Cooling system (Including coolant level adjustment)

Enaine coolant

Fuel system

Idle speed

Idle mixture

Air cleaner element *’

Fuel filter

Fuel lines and hoses

Ignition system

Initial ignition timing

Spark plugs

Evaporative emission control system

I

Number of months or km (miles), whichever comes first

- 6 1 12 18 24 1 30 36 1 42 48

1,000 10,000 20,000 30,000 40,000 50,000 60,000 1 70,000 80,000

(600) (6,000) (12,000) (18,000) (24,000) (30,000) (36,000)~(42,000) (48,000)

T

A

R R

R

1

[ A I

1 1

A 1

1

A ]

Replace every t 00,000 km (60,000 miles)

R R R R R

R R R R R

I I 1

Reolace everv 2 Years

1 ’

[ A

R 1 R

R R

I

I A I *

A

I

1 I

I t

A

A 1

A

R

R t I

I I

A

A 1

A

I

I

1 [

A

1 I

( A

1

A

R

R

I

I

I

A

Electrical system

Ejattery electrolyte level and specific gravity

Electrical system l

6

Headlight algnment

Chassis and body

Clutch pedal

Clutch fluid

Brake lines, hoses and connections

Brake pedal

Brake flutd *7

Parking brake

Power brake unit and hoses

DGC brakes

Pow& steering fluid

Power steering system and hoses

Steering and front suspension

MTX oil

Rear axle oil

Transfer carrier ui!

Rear suspension bail joint

Bolts, nuts on chassis and body

8ody condltlon (Visual onty)

A

I

A

I

A

I

1 A

I

A

I

T

-

I

1 A iR,i i

I

I

1

A

1

I

1

I

I

I

I

I

I

I 1

I

I

I

I

I

1

I

R

A

1

I

I

I

I

1

I

R

R

A

A

R ’ A . A f

T

R

T

Inspect annually

I

A

A

A

I

I

I

I t

A 1

I 1 I f A 1

I

I

1

A

A

I

I

1

A 1 i 1

I

I

I

A

T

I

A

A

A

I

I

I

I

I R

A

I

I

I

I

I

I

I

I i

R

R

R

T

93GOAX-705

A

I

A

A-6

SCHEDULED MAINTENANCE

Maintenance

Maintenance

Monthso

Kilometers

(Miles)

Chassis and body (Cont’d)

TIES (lnctud~ng spare tires) wrth infiation pressure adjustment

Hinges and catches

U nderslde of vehicle

Seat belt

Roao test

Driveshaft dust boots

‘SERVICES (Europe) A

Number of months or km (miles), whichever comes first

- \ 6 12 18 24 30 36 42 4%

1,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000

(600) (6,000) (12,000) 1(18,000) (24,000) (30,000) (36,000) (42,000) (48,000)

93GOAX-706

A-7

A

SCHEDULED

MAINTENANCE

(Europe)

SCHEDULED MAfNTENANCE SERWCES (Europe)

MAWTENAN CE TABLE (Unlead Fuel Model)

Chati symbols:

I : Inspect: Visual examination and/or functional measurement

A: Adjust: Examination resulting in adjustment or replacement

R: Replace or change

T: Tighten of system’s operation or performance

REMARKS

After 80,000 km or 48 months, continue to follow the described maintenance at the recommended

As for * marked items in this maintenance chart, note the following points.

* 1 Major service interval at 12 months120,OOO km (12,000 miles). intervals.

Lubrication service based on distance only 10,000 km (6,000 miles) not time.

*2 Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt if equipped.

“3 Replacement of the timing belt is required at every 100,000 km (60,000 mile). failure to replace the tim- ing belt may result in damage to the engine.

“4 If the vehicle is operated under any of the following conditions, it is suggested that the engine oil and oil filter be changed more a) Driving in dusty conditions. often than the &commended b) Extended periods of idling or low speed operation. intervals. c> Driving for a prolonged periods in cold temperatures or regularly driving only short distances.

*5 If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more oten than at usual recommended intervals.

*6 This is a full function check of all electrical systems, i.e, all lights, washers (including condition of blades)

“7 electric windows, sunroof, horn etc.

Replace every two years.

If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the vehicle is operated in extremely humid climates, the brake fluid should be changed annually.

Emission Control and Related Systems

The ignition and fuel systems are vitally important to the proper operation of the emission control and related system, as well as for efficient engine operation. It is strongly recommended that all servicing related to these systems be done by your Authorised Mazda Dealer.

93GOAX-707

A-8

SCHEDULED MAtNTENANCE SERVICES (Europe)

A

Maintenance

Maintenance

Months”

Kilometers

(Miles)

Engine

!nrake and exhaust

Owe belts *’ manifold

Engrne timing belt l

3

Engine oil flurbo)‘4

Engine oil (Non-turbo)“4

Oil filter’4

Cooling coolant system level

Engine coolant

(I ncludrng adjustment) nuts (80&j

Fuel system

Idle soeed

Air cleaner elemenf*5

Fuel fitter fuel 11~s and hoses

Ignition system lrritiai ignition timing

Spark plugs

Spark plugs (Only for Sweden)

Number of months or km (miles), whichever comes first

- 6 1 12 18 ‘24 30136 42 48

1,000 10,000 20,000 30,000 40,000 50,000 ( 60,000 70,000 80,000

(600) (6,000) (12,OOO)~(l8,0~0) (24,000) (3O,UOO))(36,000) (42,000) j48,OOU)

T

A

R

1

1

T

R

R

1 A

Reptace

Replace every 100,000

A km {60,000

1 A miles) every 5,000 km (3,000 miles) or 6 months

1 R

R

R

R

R

R

R

R

‘ R

R

I I I

Replace every 2 years

R

R

T

A

R

’ R

I

I t

I

1 f

1

I

R

R

I

A 1

E

I

I

R

R

1 I I

A

I 1 I

1 A

Adjust every 30,000

I km { 18,000

1 I

A mils)

I 1 I

1 A

Evaporative emission control system

Throttle sensor

Throttle sensor (Only for Sweden)

Evaporative system

Evaporatwe system Khlv for Sweden)

Electrical system

Battery electrolyte level and specific gravity

All Electrical

Headlight system alignment

*’

Chassis and body clutch Dedal

Clutch fluid

Brake lines, hoses and connectrons

Brake pedal

Brake fluid”’

Parking brake

Power brake unit and hoses

Disc brakes

Power steering

Power steering fluid system and hoses c

A

1

I

I

I

I

1 Aj

I

1 A ( [ A ]

Adjust every 80,000

1 I

[ lnsoect everv 80.000

I km (48,000 miles) km

1 I

(48.000 miles)

I [

I

1 A

I

A

I

I

I

I

A

I

1

I

I

1

I

1

A

I

A

’

I

1 A

I

A

1 A

1 I

I

; A

I

I

I

I A

I

I

I

I

I

1 1

I

I

I

I

1

R

A

1

I

1

I

I

1

I

I t

I

I

A

I

I

I

1

1

I

!

1 j

I

I

I

1

I

I

I

I

I

R

A

I

1

, \

I

93GOAX-708

*

,

A-9

A

SCHEDULED MAINTENANCE SERVICES (Europe)

Maintenance

Maintenance

Months”

KIlometers

(Miles)

Chassis and body [Cont’d)

Steerrng and front suspension

MTX oil

Rear axle oil

Trabsfercarrter oil

B&s. nuts on chassis and body

Body condition (Visual onfy)

Exhaust system hear shields

Tires (tncluding spare ttres) wtth rnflation pressure adjustment

Hinges and catches

Understde of vehicle

Seat belt

Road test

Driveshafi dust bouts i

Number of months or km (mires), whichever comes first

- 6 12 18 24 30 1 36 42 48

1,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000

(600) 1 (6,000) j(12,OOO) (18,000) (24,000) (30,000) (36,000) (42,000) \(48,000)

A

R

I R I A

T 1 1 T

I

A

A t

A

I

I

1

I

A

A

A

I

R A

R 1 A

R

T

A t nspect annually

I

I bA4

I

I

I

I

1 1 I

A

A

A

T I

A

A

A

,A3

I

I

I

I

I i

1

A

I t

1

1

93GOAX-709

I

R

R

R

T

A-10

ENGINE

(SOHC)

INDEX . ..* ..I.... *...*... . . . . . ..I. . . ..‘.I.. . . . . ..I........

Bl- 2

1 FEATURES 1

OUTLINE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTLINE OF CONSTRUCTION..

SPECIFICATIONS

..............

.................................. lNTERGHANGEABILtP( ..........................

FLYWHEEL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bf- 3

BI- 3

Bf- 3

Bl- 4

Bl- 5

SUPPLEMENTAL SERVICE INFORMATION

REMOVAL

. . . . . . . . . . . . l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I .

Bl- 6

Bf- 6

PROCEDURE . . . . I..... ..,.... .*...*.. . . . . . . . . . . . . . . . Bl- 6

INSTALLATION . . . . . . I... . . . . . I ,... . ..*..... . . . . . . . . . . Bl-14

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . ..I . . . . . . .I . . . . . . . Bl-14

93GOBl-701

91

Bl

INDEX

INDEX

INTAKE MANIFOLD

TIGHTENING TORQUE

19-25 (1.9-2.6, U-19)

EXHAUST

TtGHTIEN!NG

MANIFOLD

TORQUE

,3, 12-w-j

DEFLECTION AT 98 N (30 kg, 22 lb)

DRIVE BELT

AlTERNATOR 8.0-9.0

PIS, P/S + AIC 1 8.0-9-O

NEW

(0.31-0.35)

(0.31-O-35)

ENGINE COMPRESSION

STANDARD

MlNlMUM mm (in)

USED

9.0-l 0.0 (0.35-0.39)

9.0-I 0.0 (0.35-0.39) kPa (kglcm2, psi)-rpm

BP sol-lc

1,197 (12.2, 173)-300

834 (8.5, 121)-300

1. Engine

Removal . . . . . . ..*..*-..............-....... page BY-- 6

Installation . . . . . . ..__. . . . . . . . .._...... . . . . page B1-14

Bl-2

N-m (m-kg, ?t-It cIz!f-mRl-71

OUTLINE

Bl

UUTLlNE OF CONSTRUCTtON

The BP SOHC engine for the 4WD model is the same as for the 2WD model, except that the flywheel is shaped differently.

The 3P SOHC engine for the model, except that

ECE specification (without catatyst) 4WD model is the same as the ECE US83 the fuel and emission control system and the engine electrical system are modified.

(Refer to Sections Ff and G.)

93G08 i -702

SPEClFlCATlONS

Engine/Market

Item

TVDG?

Cyirnder arrangement and number

Combustron chamber

Valve svstem

Dsplacemenr

Bore and stroke

Comoression ratio

Compressron pressure

Valve tlmtng

Valve clearance c

IN

EX cc (cu in) mm (In) kPa (kglcm2, psi)-rpm

Open

Close

BTDC

ABDC

Open

Close

IN

BBDC

ATDC

I

I mm (in)

Idle speed

Ml-x rpm .

ATX

I ignrtton trming

Fi rtng order

*

. ..TEN terminal of diagnosis connector grounded.

I

’

AustraIia

BP soffc us-83

Europe

1 Without catalyst

Gasoline. 4-cvcle

In-line, 4 cylinders

Pentroof

OI-IC, belt-driven

1,839 (112.2)

83.0 x 85.0 (3.27 x 3.35)

8.9

1,197 (12.2, 173)300

2O

5u” so

8’

0: Maintenance-free

0: Maintenance-free

750 f 50’

750 f 50”

I

50 f 10’

1-3-4-2

-

I

850 f 50

93G08 l-704

I

I

Bl-3

BI

INTERCHANGEABILITY

The following chart shows interchangeability and the 2WD model.

OUTIAlE

of the main parts of the I3P SOHC engine for the 4WD model

X . . . . Not Interchangeable Symbols: 9 ._.. Interchangeable

Remark

Cylinder block related

Crankshaft related

Timing belt related

Valve retated

Lubrication system related

Cooling

SyStem related

Part name

[ Cyirnder head i Camshaft oil sea! f Cylinder head bolt

Cyirnaer head gasket

Cylrnder head cover

Cylrnder head cover gasket

Cylinder block

Main bearing cap

Main bearing supper! plate

Oil pan

Trmjng bett cover

’ Front oil seal

Rear oil seal

Crankshaft

Main bearing

Thrust bearing

Connecting rod and cap

1 Connecting rod bearing

Piston

Piston pm

PMon ring

1 Crankshaft pulley

Rear cover

Flywheel

Flywheel bolt

Timing heft

Timing belt crank pulley

Camshaft pulley

Timing belt tenstoner and spring

Camshaft

Rocker arm

Rocker arm shalt

I

HLA

Valve

Valve spring and seat

Valve guide

Valve seat

Oil pump

’ intake

Exhaust

Intake

Exhaust

01

Oil pump gasket strainer

Oil strainer gasket

Oil jet

Oil filter

1

I Water pump

Thermostat

Padi ator

, Cooling fan j lnterchangeabiIity

3 cl

0

0

0

3

G

G

3

0

0

0

1 c

0

0

0 cl

0

0

0

X

0

0

0

0

0

0

0

Cl

0

0

0

0

0

0

0

0

0

9

0

0 r.

0

0

X

X

G

0

0

Shape different

Specification drffereni

1 Speclfrcatlon different

03UOBX-805

BY-4

FLYWHEEL

4WD MODEL

OUTLINE

Bl

2WD MODEL

The flywheel is shaped differently to accommodate the redesigned clutch disc

and

cbtch cover.

Bl-5

Bl

SUPPLEMENTAL

SUPPLEMENTAL SERVICE tNFORMAT1ON, REMOVAL

SERVICE INFORMATION

The following points in this section are changed in comparison with Workshop Manual [Europe (I 203-I U-89F),

Australia (1204- 1 O-89!=)]. l l

Engine

Removal

Installation

93GOF31-705

REMOVAL

Warning w Release the fuel pressure.

PROCEDURE

1. Disconnect the negative battery cable.

2. Drain the engine coolant and transaxle oil.

3. Remove in the order shown in the figure, referring to Removal Note. t

Step 1

*ATX ONLY

1. Undercovers

2. Side covers

3. Resonance chamber and air cleaner assembly

4. Battery bracket, cover and bafiery

5. Battery carrier and battery duct

6. Accelerator cable

7. Radiator hose

8. Coolant reservoir hose

9. Cooling fan connector

IO. Radiator switch connector (ATX)

1 f . A/C cut switch connector (ATX)

61-6

93GOBl-706

12. Oil cooler hoses (ATX)

13. Radiator bracket

14. Radiator and cooling fan assembly

15. P/S and/or A/C drive belt

16. P/S oil pump and bracket

Removal Note .._...._...__......... . . . . . . . page BY -7

17. A/C compressor

Removal Note.. . . . . . . . . . . . . . .._. . . . . . . . ._. page Es1 -7 i 8. Crossmem ber

19. A/C compressor bracket

20. Coolant reservoir

I

1

/

/

REMOVAL

Removal note

P/S oil pump

Bl l

Caution

Do not

damage

the hoses.

I _ Remove the P/S oil pump with the hoses still connected.

2. Position the pump away from the engine and secure it with wire.

93G05? -72t

A/C compressor

l

Caution

Do not damage

the hoses.

1. Remove the

AC

compressor with the hoses still

connected.

2. Position the compressor away from the engine and secure it with wire.

Step 2

1. Disconnect the harness connectors shown in the figure.

OIL PRESSURE SWITCH --- -

DIFFERENTIAL

LUCK SENSOR

GROUND

DIFFERENTIAL r, IDLE SPEED CONTROL

NEUTRAL SWITCH

’ SOLENOID

(ECE WITHOUT

VALVE w

CATALYST)

_--------I

MTX!

BACK-UP LIGHT SWITCH d ---a--

\‘C

Y

INHIBITOR SWITCH

ATX’

Bl

Step 3

1. Disconnect the hoses shown in the figure.

I

REMOVAL

-----a _--w---

/

/ I ti

/

93GOB7 -707

1. Brake vacuum hose

2. Fuel hose

Removal Note . . . . . . . . . .*a . . . . . . . . *.* . . . . . . . . . . a-..

below

3. Vacuum hose (Purge control)

[except ECE without catalyst]

4.

Heater hose

Removal Note *...,.....*............-.I..*.*.*.-*-

Removal note

Fuel hose below l

Warning

Keep sparks and open flame away from the fuel area.

OWOBX-078 l l

Caution

Cover the hose with a rag because fuel will spray out when disconnecting.

Plug the disconnected hoses to avoid fuel leakage.

1. Disconnect the

fuel hoses.

Heater hose l

Caution

Do not lose the heater hose joint O-rings and spacer when removed.

1. Depress the heater hose retainer and remove the heater hose.

REMOVAL

Bl

ATX

0

B

I _ Speedometer cable

2. Select and shift cable (MTX)

3. Shift control cable (ATX)

4. Front exhaust pipe

5. Stabilizer

I

CUTTER PIN.

REPLACE

93GOBl-708

6. Tie-rod end

Removal Note ,,....*......*~.....~...*.,..*...I..-

7. Driveshaft below

Removal Note . . . . . . . . . . . .._............. page 61-l 0

8. Propeller shaft

Removal Note . . . . . . . . . .._...._.._......... page L- 5

1

Removal note

Tie-rod end

1. Remove the cotter pin and loosen the nut until it is flush with the end of the ball joint stud. l

Caution

Do not reuse the cotter pin.

2. Separate the ball joint from the knuckle arm with the SST.

81-9

L

Bl

REMOVAL

Driveshaft

1. Remove the joint shaft

93EOB2-025

I

2. Remove the lower arm ball joint clinch bolt.

_

03UOBX-84 l

Caution

Do not damage the ball joint dust boot.

3. Pry the lower arm downward to separate it from the knuckle.

4

93G031-722 l

Caution

Do nut damage the oil seal.

4. Separate the driveshaft from the transaxle.

d

03UOBX-813

61-10

REMOVAL

81

t

1. Exhaust manifold insulator

2. Exhaust

manifold and

gasket

3. Water inlet pipe and gasket

4, Engine mount member

Removal Note . . . . . . . . . . . . . . .._.................. . . below

5. No.2 engine

mount

rubber and bracket

6. Clutch release cylinder (MTX)

Removal

Note ,...........-.....a........ page BY -12

7. Dynamic damper

8. No.3 engine mount

rubber

9. No.4 engine mount rubber

and bracket

f 0. Engine and transaxle assembly

Removal Note . . . . . . .._....._... . . . . . . . . . page Bl-12

Removal note

Engine mount member

1. Suspend the engine with a chain hoist.

Bl

93GOBl-72:

REMOVAL

2. Remove the No.1 and No.2 engine mount nuts. l

Caution

Be careful that the engine does not fall when remov- ing the member.

3. Remove the engine mount member

bolts and nuts

and the engine mount member.

Clutch release

cylinder (MTX)

f . Remove the release cylinder pipe bracket from the transaxle.

2. Position the release cylinder with the hose connected away from the transaxle for easier removal.

Caution

I

l

Do

nut damage

the

pipe

and hose.

Engine

and

transaxle assembIy l

Caution

Do not damage any components partment. in the engine com-

1. Remove the engine and transaxle assembly.

Bl-12

REMOVAL

Step 6

Separate the engine and transaxle in the order shown in the figure,

MTX

Bl

ATX

1 _ Intake manifold bracket

2. Center differential lock motor

Removal Note . . _. _. . . ._. . . . . . . . . . . . . _. page 33-l 23

3. Starter and bracket

4. Throttle cable (ATX)

5. Air hose [ECE without catalyst only)

6. Torque converter nuts @TX)

7. Transaxle mounting bolts

8. Tramaxle

43GX3i-71

Bl-73

Bl

INSTALLATION

INSTALLATiON

PROCEDURE

I. Tighten all bolts and nuts to the specified torques.

Step I

1. Join the engine and transaxle.

Toraue

-

Snecifications

MTX

37-52 (3.8-5.3, 27-38)

ATX

64-89 (6 S-9 -1, 4746)

37-52 (3.8-5.3, 27-38)

Nm (m-kg, ft-lb)

37-52 (3.8-5.3, 27-38)

55-80 (5.6-8.2, 41-59)

N-m (m-kg, ft-lb

51-14

INSTALLATlON

Step 2

Warning l

Be sure the vehicle is securely suppofied

Torque Specifications on safety stands.

55-80 (5.fG-8.2, 41-59)

67-93 (6.8-9.5,

\

49-69)

43-61 (4.4-6.2,

I

32-45)

ES1

I

74-103 (7.5--10.5, 54-76)

7.8-?I

(80--flO

/

N-m cm-kg, 69-95 in-lb)

7 37-5x

64-89 (6.5-9.1,

I

4746)

27-38)

Engine and transaxle assembly l

Caution

Do not damage any components partment. in the engine

1. Install the engine and transaxle assembly. com-

Bl

INSTALLATION

Engine mount, clutch release cyiinder

mount member

1. Install the No.3

(MTX)

and

engine

engine mount rubber, and loosely tighten the bolt and nuts.

2. Install the No.4 engine mount rubber and bracket assem- bly, and loosely tighten the k~olts and nuts.

I

. - , , . . , .

3. Install the clutch release cylinder and pipe bracket assem-

U-y.

(MTX)

Tightening torque

@: 16-23 Nm (1.6-2.3 m-kg, 12-47 ft-lb)

@: 6.9-9.8

N-m (70-100 cm-kg, 61-87 Mb)

4. Install the No.2 engine mount rubber and bracket assembly.

Tightening torque:

37-52 Nm (3.8-5.3

m-kg, 27-38 ft-lb)

J

93GOBl-72

5. Align the engine mount member to the No.1 and No.2 en- gine mount bolts, and loosely tighten the nuts.

6. Install and tighten the engine mount member bolt and nuts.

Tightening torque:

64-89 N-m (6.5-9.1 m-kg, 47-66

ft-Lb)

7. Tighten the No.7 and No.2 engine mount nuts.

93GOBi-713

I

Tightening torque:

37-52 Mm (3.8-5.3

m-kg, 27-38 ft.lb)

MTX

Step 3

Torque Specifications

1 A-I-X

WUOBX-828

43GOBl-72t

INSTALLATlON

8. Tighten bolts @ in two or three steps in the order shown.

Tightening torque:

43-61 N-m (4.4-6.2

9. Tighten nuts @J.

Tightening torque:

67-93 N-m (6.8-9.5 m-kg, 32-43 ft-lb) m-kg, 49-69 ft-lb)

IO. Tighten the No.3 engine mount nuts 0.

Tightening

74-103 torque:

Nom (7,5--f0,5 m-kg, 54-76 ft-lb)

Ii. Tighten nut @.

Tightening torque:

67-93 N-m (6.8-9.5 m-kg, 49-69 ft-lb)

12. Install the dynamic damper.

Tightening

55-W torque:

N-m (5.6-8.2

13. Remove the chain hoist. m-kg, 41-59 ft-Ib)

6.9-11 N-m (70-l 10 cm-kg, 63-95 in-lb)

-8-3.1, 20-22)

&TX 6.9-11 N-m (70-130 cm-kg,

6% -95 in-lb) b

21-27 (2.1-2.8, 15-20)

16-23 (1.6L2.3,

/

Q-17)

42-57 (4.3~5.8,31142)

COTTER PIN, REPLACE

N-m {m-kg, ft-tb

03UOBX-8:

i

81

INSTALLATION

Propeller shaft

1. Install the propeller shaft. (Refer to page l-5.)

Driveshaft

I. Apply grease to the end of the driveshafi. l l

Caution

When installing the driveshaft, damage the transaxle oil seal. be careful not to

After installation, pult the front hub outward to con- firm that the driveshaft is securely held by the cIip.

2. Install the driveshaft along with a new clip.

3. fnstall the lower arm ball joint to the knuckle and tighten the ciinch bolt.

Tightening torque:

43-59 Nm (4.4-6.0 m-kg, 31-43 ft-lb)

93GOBl-714

4. Install the joint shaft.

5. Tighten the bolts in the order shown.

Tightening torque:

42-62 Nom (4.3-6.3 m-kg, 31-46 f&lb)

93E082-061

I

Tie-rod end

1. InstaIl the tie-rod end to the knuckle.

Tightening torque:

42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)

2. Install a new cotter pin.

03UOBX-848

Stabilizer

I. install and adjust the stabilizer.

Dimension A: i7-19mm (0.67-0.75

Tightening torque:

16-23 Nm (l-6-2.3 m-kg, 12-17 in)

Mb)

I

I

--

D b

D

1

I t

I

03UO8X-835

INSTALLATION

Bl

Exhaust pipe

I. Instail the exhaust pipe along with a new gasket; then loosely tighten locknuts @.

2. Loosely tighten bracket nuts @

3. Tighten locknuts 0.

Tightening

3f-46 torque:

N-m (3.2-4.7 m-kg, 23-34 f&lb)

4. Tighten bracket nuts @.

Tightening

21-27 torque:

Mm (2.1-2.8 m-kg, 15-20 ft-Ib)

Select and shift cables (MTX)

7 _ Install the select cable and the spring pin.

2. Install the shift cable and the spring pin.

Shift control cable (ATX)

1. Install the shift control cable and the spring pin.

Tightening torque:

6.9-l 1 Nom (70-l 10 cm-kg, 61-95 in-lb)

Speedometer cable

1. Connect the speedometer cable.

91

Step 4

1. Connect the hoses shown in the figure.

1NSTALLATION

l

Caution

Position the hose clamp in the original location on the hose, and squeeze it lightly with large pliers to ensure a good fit.

Step 5

1. Connect the harness connectors shown in the figure.

OIL PRESSURE SWITCH THRO77LE

AC. .A--

I -r-h

LOCK SENSOR

/--+I

DIFFERENTIAL

LOCK MOTOR

/ r\ IDLE SPEED CONTROL

E3i -20

Df STRlBUTdR

OXYGEN SENSOR

(EXCEPT ECE

WITHOUT CATALYST)

HEAT

“Rou2ydy __

GAUGE UNIT ’

IDLE-UP

SOLENOID

IECE WlTl-tOUT

‘CATALYST-)

VALVE

BACK-UP LIGHT SWITCH r

/NEUTRAL

INHlBlTdR SWITCH

SWITCH

G3UOBX-837

Step 6

Torque Specifications

7.8-11

N-m (8U---110 cm-kg, 69-95 in-lb)

INSTALLATION

19-25 (1.9-2.6, 14-19)

Bl i

I)

37-S (3.8-5.3, 27-38)

7.8-71

(80-l

N-m

10 cm-k

I)

19-25 (1.9-2.6, 14- -79)

5-1 1.9, 69-79)

-9.3 N-m (65-95 cm-kg, 56-82 h-lb)

7.8-11 N-m (80-1~0 cm-kg, 69-95 in-lb)

Crossmember

1. tnstali the crossmember.

Tightening

93-107 torque:

Nm (9.5-I 1.9 m-kg, 69-79 f+lb) a3uar3x-839

NC compressor

1. Install the A/C compressor.

Tightening

24-35 torque:

N-m (2.4-3.6 m-kg, 17--26 ft-lb)

Bl-21

Bl

.L ‘.. :-.:

L

. .

‘, .

. . ‘?.

,.. ’

93GOE 1-73;

03UOBX-84

Radiator

and cooling

fan assembly f . Install the radiator and cooling fan assembly.

Tightening torque:

7.8-I 1 N-m (80-I 10 cm-kg, 69-95 in-lb)

2.. Connect the cooling fan connector.

3. Connect the radiator switch connector.

4. Connect the A/C cut switch connector.

5. Connect the oil cooler hose. (ATX)

6. Connect the coolant reservoir hose.

7. Connect the upper and lower radiator

@TX)

Pm

hoses. l

Caution

Position the hose clamp in the original location on the hose, and squeeze it tightly with large pliers to ensure a good fit.

93GO3 l-73’

INSTALLATION

P/S oil pump and bracket

1. Install the P/S oil pump and bracket.

Tightening

torque:

37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)

Drive belt

I. fnstall the P/S and/or A/C drive belt.

2. Adjust the drive belt deflections. (Refer to page Bl-2.)

-DEFLECTiON CHfiCKIN:

Accelerator cable

I. Install the accelerator cable.

2. Adjust the cable deflection by turning nuts @

Deflection: I-3mm in) g3GOBj-717

Battery duct, battery carrier, and battery

I_ install the battery duct.

2. Install the battery carrier.

Tightening torque:

7.8-I 1 N-m (80-110 cm-kg, 69-95 in-lb)

3. Install the battery, cover and the battery bracket.

Tightening

2.9-5.9 torque:

N-m (30-60 cm-kg, 26-52 in-lb)

4. Connect the positive battery cable.

Bl-22

INSTALLATION

Air cleaner assembly

1. Install the air cleaner assembly.

Tightening

@: 19-25 torque

Nm (I-9-2.6 m-kg, 14-19 Mb)

@: 7.8-11 Nm (80~-110 cm-kg, 69-95 in-lb)

Bl

2. Connect the airflow sensor connector.

Resonance chamber

1. lnstail the resonance chamber.

Tightening

7.8-W torque:

Nm (SO-11 0 cm-kg, 69-95 in-lb)

Undercover and side cuver

1. install the undercovers and side covers.

Steps after installation

1. If the engine oil was drained, refill with the specified amount and type of engine oil.

2. Fill the radiator with the specified amount and type of engine coolant.

3. Fill the transaxle with the specified amount and type of transaxle oil. (Refer to pages J3-36, K3-134.)

4. Connect the negative battery cable.

5. Start the engine and check the following:

(1) Engine oil, transaxle oil, and engine coolant leakage

(2) Ignition timing and idle speed

(3) Operation of emission control system

6. Perform a road test.

7. Recheck the engine oil and engine coolant levels.

93GOSi-719 al-23

INDEX

. . . . . . . . . * * . . . . . . . . .

ENGINE

(DOHC)

. . . . . . . . . . * . . . . . . . . . . . . . . . . . . . l .

BZ- 2

OUTLINE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTLINE OF CONSTRUCTION..

SPEClFlCATlONS

..............

..................................

BZ-

BZ-

BZ-

3

3

4

INTERCHANGEABiLITY

CYLINDER HEAD

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT

. . . . . . . . . . . . . . . . . . . . . . . . . .

..........................................

BZ-

BZ-

5

6

CYLINDER BLOCK AND OIL PAN ........... BZ- 7

PISTON ............................................... BZ- 8

FtYWtiEEL .......................................... BZ- 9

BZ-10

SUPPLEMENTAL

COMPRESSION

SERVICE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INFORMATION

INSPECTION ........................................

REMOVAL ..............................................

PROCEDURE ........................................

ENGINE STAND MOUNTING.. ...................

PROCEDURE ........................................

ENGINE STAND DISMOUNTING..

PROCEDURE ........................................

..............

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROCEDURE ........................................

BZ-11

82-I 1

B2-11

BZ-12

BZ-12

BZ-20

BZ-20

BZ-21

82-21

BZ-23

BZ-23

93GOB2-701

B2

B2

INDEX

TIGHTENING

~IMIY~ULU

TORQUE

19-25 (1.9-2.6, 14-19)

/5--l

INDEX

ENGINE COMPRESSION

STANDARD

MINIMUM

1 kPa (kglcm2, psi)-rpm

BP Turbo

1,059 (10.8, 1543-300 i-85 (8.0, 114)-300

I

DEFLECTION AT 98 N (IO kg, 22 Ib)

DRIVE BELT

ALTERNATOR

P/S, P/S + AIC

1

1 8.0-9.0

( 8.U-9.0

NEW

(0.31-U.35)

[O-31--0.35) mm (in)

USED

9.0-I 0.0 (0.35-U.39)

9.0-10.0 (0.35-0.39)

1. Engine

Removal -*-...-..I-*.* . ..wm._..... * e-e... -. page B2--I 2

Engine stand mounting ._.....__... page B2-20

Engine stand dismounting . . . . . . . page B2-21

Installation _ . . . . . . . . . . . . , . . _. . . . . . _. . . . . . . . , page EQ-23

BZ-2

EXHAUST

TIGHTENING

3826 3.9-A.?,

MANlFOt

TORQUE

-28134)

B2

SPECIFICATlONS

OUTLINE

Item

Type

Cylrnder arrangement

Corn bustlon

I Vaive svstem chamber and number

Displacement

Bore and stroke

Compression ratio cc {cu In) mm (in) kfa (kg/cm’, psi)-rpm Compression pressure

Vatve timing

I

IN

Open

Close

Open

Valve ciearance

EX mm (in)

Close

IN

EX

Idle speed ignition timing

Firing order

* . ..TEN terminal of diagnosis connector grounded i3TDC

ABDC

BBDC

ATDC rPm

BTDC

I

BP DOHC Turbo

Gasoline, kycie

In-tine, 4 cylinders

Pentroof

DOHC. bett-driven

1,839 (112.2)

83.0 x 85.0 (3.27 x 3.35)

8.2

1,059 (10.8, X4)-300

2*

51*

59*

8O

0: Maintenance-free

0: Maintenance-free

800 f 50'

100 f lo* l-3-4-2

93G032-704

J

I

82-4

OUTLINE

B2

INTERCHANGEABILITY

The following chart shows interchangeability of the main park of the BP DOHC Turbo engine for the 4WD model and the BP DOHC Non-Turbo engine for the 2WD model.

Symbols: 5 . Interchangeabie X . . . . Not Interchangeable

Remark interchangeability Part name

Cylinder block related

1 Cylinder head

Camshaft oil sea!

Cylinder head bolt

Cyijnder head gasket

C$rnder head cover

Cylinder head cover gasket

Cylinder block

Man bearing cap

Main bearing support plate

OrI pan

Trming belt cuver

Seal plate

Front oil seal

Rear oil seal

Crankshaft

Main bearing

Thrust bearing

Connecting rod and cap

Connecting rod bearing

Crankshaft related

Timing belt related

Valve related

Lubrication related

Cooling system related system c Oil strainer gasket

Oil cooler

Oil jet

Oil fitter

Water pump

Thermostat

Radiator

Cooling fan

Oil strainer

Oil pump gasket

[ Prston c

Piston pin

Piston ring

Crankshaft pulley

Rear cover

I Flywheel

Flywheel bolt

Timing belt

Timing belt crank pulley

Camshaft pulley f Timing belt tensioner and spring

1, ldter

Camshaft

I-LA

Valve

Vaive sprtng and seat

Valve guide

Valve seal

Oil pump

I Make -

Exhaust

Intake

Exhaust

1

I

I i

0 cl

0

0

3 x cl

:

3 cl

0

0

‘3

0

0

3

3 cl

+--

X

0 cl cl

0

0 cl

0

3

0

0

0

0 cl

0

0

0

;

0 cl

0 cl

0

0

X

X

X

I

I

Shape different

Shape different

-

Shape different

Shape different

Valve timing different

Specificatron drfferent

Specificatron different

Specification different

^^-^-^ m^-

Ix?-5

B2

CYLINDER HEAD

OUTLINE

INTAKE PORT EXHAUST

1

PORT

ENTlFlCATlON MARK

BP TURBO.. .BP26

BP NON-TURBO...BP05

The cylinder head for the BP DOHC Turbo engine is the same as for the BP DO% Non-Turbo engine! ex- cept that the intake ports are shaped differently.

The identification mark is cast at the rear of the cyfinder head.

Identification:

BP DUHC Turbo

BP DOHC

: BP26

Non-Turbo: BP05

W-6

CYLfNDER BLOCK AND OIL PAN

OUTLINE

B2

1

A

CYLINDER BLOCK

I

BP TURBO

I

CONtiECTOR BOLT

BP TURBO

BLIND PLUG

OIL RtiURN PIPE

93GCB2-7C

The cylinder block is no different. But in conjunction with the newly provided turbocharger, the coolant, and

Mxication oil passages on the cylinder block are used.

Tfie oil pan has a provision for oil to return from the turbocharger.

BZ-7

B2

PISTON

BP TURBO

OUTLINE

BP NON-TURBO

,

V

I

J

Because of the addition

of the turbocharger,

the piston crown recess is increased to lower the compression ratio.

B2-8

OUTLfNE

82

BP NON-TURBO

,

The flywheel is shaped differently to accommodate the redesigned clutch disc and clutch cuver.

82-9

82

CAMSHAFT

OUTLINE

IDENTlFlCA~lON

/\

MARK

EXHAUST

INTAKE

IDENTlFlCATlON

IN

EX

MARK

BP TURBO

BP26

8P26

BP NON-TURBO

BP05

BP06

TDC

EXHAUST OPEN

The camshaft valve timing specifications are different to improve engine power.

SUPPLEMENTAL SERVICE iNFORMATION, COMPRESSION

82

SUPPLEMENTAL

SERVICE

INFORMATION

The following points in this section are changed in comparison with Workshop Manual [Europe (7 203~IO-899,

Australia (I 204-1 U-89F) 1.

Compression l Inspection l l l l

Engine

Removal

Engine stand mounting

Engine stand dismounting

Ins:attaIion

93GQ32-77

I

D

COMPRESStON

If the engine exhibits low power, poor fuel economy, or poor idle, check the following:

1. Ignition system (Refer to Section G.)

2. Compression

3. Fuel system (Refer to Section F3.)

93GO32-712

D

93G032-774

1NSPECTION

1. Verify that the battery is fully charged. Recharge it if necessary.

2. Warm up the engine to normal operating temperature.

3. Turn the engine OFF.

4. Remove all of the spark plugs.

5. Disconnect the ignition coil connector.

6. Connect a compression gauge to the No.7 spark plug hole.

7. Fully depress the accelerator pedal and crank the engine.

8. Record the maximum gauge reading.

9. Check each cylinder in the same manner.

Compression:

1,059 kPa (IO.8 kg/cm2, 154 psi)-300 rpm

Minimum:

785 kPa (8-O kg/cm2, 114 psi)-300 t-pm

Allowable difference between cylinders:

196 kPa (2.0 kglcm2, 28 psi) max.

IO. If the compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder and recheck the compression.

(1) If the compression increases, the piston, piston rings, or cylinder waII may be worn.

(2) If the compression stays tow, the valve may be stuck or seating improperly.

(3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be defective or the cylinder head distorted.

1 I. Connect the ignition coit connector.

12. Apply antiseize compound or molybdenum-based to the spark plug threads.

73. Install the spark plugs. lubricant

Tightening

15-23 torque:

N-m (1.5-2.3 m-kg, If-17 ft-Ib)

82-11

B2

REMOVAL

REMOVAL

l

Warning

Release the fuel pressure. (Refer to Section FZ.)

PROCEDURE i. Disconnect the negative battery cable.

2. Drain the engine coolant and transaxle oil.

3. Remove in the order shown in the figure, referring to Removaf Note

Step 1

1. Strut tower bar

2. Undercovers and side covers

3. Air cleaner assembly

4.

Battery bracket

5. Battery cover

6. Battery

7. Battery carrier

8. Accelerator cable

9. Radiator hoses

10. Coolant reservoir hose f I. Cooling fan connector

12. Radiator switch connector

02-12

13. Radiator bracket

14.

Radiator

and coofing fan assembly

15. Battery duct

16. Air pipe and air bypass valve

17. Intercooler and air pipe

Removat Note . . . . . . . . . . . . .._.. m 82-U

18.

Air pipe

and gasket

19. P/S and/or AK drive bett

20. P/S oil pump and bracket

Removal Note . . . . .._.__.....~..~........ page BZ-13

21. A/C compressor

Removal Note . . . . . .._................... page 82-I 3

22. Crossmember

REMOVAL

Removal note intercooler and air pipe

I. Disconnect the hoses shown in the figure.

B2

2. Remove the nuts and the intercooler figure. bracket shown in the

936032-718

3. Loosen hose band @.

4. Remove bolt @and nut 0.

5. Remove the intercooler and air pipe downward.

93GO52-748

RemovaI note

P/S oil pump l

Caution

Do not damage the hoses.

I _ Remove the P/S oil pump with the hoses still connected.

2. Position the pump away from the engine and secure it with wire.

NC compressor l

Caution

Do not damage the hoses.

1. Remove the AC compressor with the hoses still connected.

2. Position the compressor away from the engine and secure it with wire.

93GOB2~749

1

B2-13

B2

REMOVAL

Step 2

1. Disconnect the harness connectors shown in the fiuure.

ALTERNATOR OIL PRESSURE

\.

SWITCH

STARTER

PRESSURE

CObjTROL

REGULATOR

VAVLE

E-SPEED CONTROL

CTOR

KNOCK SENSOR

SWITCH

03 w 08X-80’

Step 3

I. Disconnect the hoses shown in the figure.

-

------a-

93GOB2-720

82-14

_.

SteD 4

OWOBX-07I

REMOVAL

B2

Removal note

Fuel hose l

Warning

Keep sparks and open flame away from the fue! area. l l

Caution

Cover the hose with a rag because fuel will spray out when disconnecting.

Plug the disconnected hoses to avoid fuel leakage-

1. Disconnect the fuel hoses.

Heater hose l

Caution

Do not lose the heater hose joint O-rings and spacer when removed.

1. Depress the heater hose retainer and remove the heater hose.

03UOBX-845

GASKET, REP

1. Speedometer cable

2. Select and

shift cables

3. Front exhaust pipe

4. Stabilizer

5. Tie-rod end

Removal Note . . . . . . . . . . . . . . . . . . . . . . . .._. page BZ-16

OTTER PIN, REPU\CE

IL

J

.

6.

Driveshafts

Removal Note ._.....*., * . . ..- *...- I..... page BZ-16

7. Propeiler shaft

Removal Note . . . . . . . _ . , . . . _. . . . . . . . . _. . . . . page L- 5

B2-15

c

B2

1

Bz-t6

REMOVAL

Removal note

Tie-rod end

1. Remove the cotier pin and loosen the nut until it is flush with the end of the ball joint stud. l

Caution

Do not reuse

the cotter

pin.

2. Separate the ball joint from the knuckle arm with the SST.

Driveshaft

1. Remove the joint shaft.

93ECB2-025

2. Remove the lower arm bali joint clinch bolt.

03tiOBX-81: l

Caution

Do not damage

the

ball joint

dust boot.

3. Pry the lower arm downward to separate it from the knuckle. l

Caution

Do not damage the oil seat.

4. Separate the driveshafi from the Vansaxle.

Step 5

REMOVAL

B2

1. Engine mount member

Removal Note . . . . . . .._.._...._....-.__._.._-_..-.* below

2. No.2 engine mount rubber and bracket

3. Clutch release cylinder

Removal Note _._...._.._.._.....,,....__ page B2-18

4. Dynamic damper

5, No.3 engine mount

rubber

6. No.4 engine mount rubber and bracket

7. Alternator and drive belt

8. I ntercooler brat kets

9. Engine and transaxle assembly

Removal Note . .._.................--.-..

Removal note

Engine mount member

1. Suspend the engine with a chain hoist.

page 62-f 8

82

REMOVAL

2. Remove the No.1 and No.2 engine mount nuts. l caution

Be careful that the engine does not fall when remov- ing the member.

3. Remove the engine mount member bolts and nuts and the engine mount mem her.

03UOSX-81 t

Clutch release cylinder

I. Remove the release cylinder pipe bracket from the transaxle.

2. Position the release cylinder with the hose connected away from the transaxle for easier removal. l

Caution

Do not damage the pipe and hose.

93GOB2-723

Engine and transaxle assembly l

Caution

Do not damage any components partment. in the engine

1, Remove the engine and transaxle assembly. com-

82-l 8

REMOVAL

Step

6

SeDarate

the engine and

transaxle

in the order shown in the

figure.

B2

1. Intake manifold bracket

2. Starter and

bracket

3. Transaxie mounting bolts

4. Transaxle

93GOB2-7;

B2-19

B2

ENGINE

ENGINE

STAND MOUNTING

PROCEDURE

1. Remove in the order shown ir! the figure.

STAND

MOUNTING

1. Exhaust manifold insulator

2. Exhaust manifold and turbocharger assembly

3. Exhaust manifold gasket

82-20

4. Water bypass pipe

5. A/C compressor bracket

6. Water inlet pipe

93GOB2-725

ENGlNE STAND DISMOUNTING

ENGiNE STAND DISMOUNTING

PROCEDURE

1.

Remove the

engine

from the SST (engine

stand).

2. Remove the SST (engine hanger) from the engine.

3. Install the parts shown in the figure.

4. Tighten the parts to the specified torques.

Torque Specifications

B2

93GOB2-753 f&n (m-kg, ft-lb)

93GOB2-75

Water

Inlet Pipe

1. Remove ail foreign material from the water inlet pipe mount- ing surfaces.

2. Install a new gasket and the water inlet pipe.

Tightening torque: f9-25 Nm (1.9-2.6 m-kg, 14-19 ft-lb)

82-21

B2

ENGINE STAND DISMOUNTING

Water Bypass Pipe

1. Apply a small amount of engine coolant to the new O-ring.

2. install the O-ring on the pipe.

3. InstaIi the water bypass pipe.

93GOB2-7%

A/C Compressor Bracket (if equipped)

1. Install the A/C compressor bracket.

Tightening torque

@: 19-25 N&m (1.9-2.6

@: 37-52 Nom (3.8-5.3 m-kg, m-kg,

14-19

27-38 ft-lb) ft-fb)

93AOB2-077

Exhaust Manifold and Turbocharger Assembly

I= Remove all foreign material from the exhaust manifold con- tact surfaces.

2. Install a new gasket.

3. Instatl the exhaust manifold and turbocharger assembly.

Tightening torque:

38-46 N-m (3.9-4.7 m-kg, 28-34 ft-lb)

4. Connect the water hose to the water bypass pipe.

5. Connect the water hose and the oil pipe to the cylinder block.

Tightening torque

@: 12-18 N-m (I -2-l .8 m-kg, 8.7-13 ft-lb)

6. Connect the oil return hose to the oi I pan.

Exhaust Manifold Insulator

1. Install the exhaust manifold insulator.

Tightening torque:

7.8-I 1 Mm (80-I IO cm-kg, 69-95 in-lb)

05WOBX-25

82-22

INSTALLATION

PROCEDURE

1. Tighten a/ b&s and nuts to the specified torques.

Step 1

I. Connect the engine and transaxie.

Torque Specifications

B2

M-89 (6.5L9.l) 47-66)

-38)

B2

Step 2

INSTALLATION l

Warning

Be sure the vehicle is securely supported

Torque Specifications on safety stands.

55-99 (5.6-8.2, 41-59)

19-S (1.9-2.6,

I

14-l 9)

74-2 03

(7,5-10.5, 54-76

6.9-9.8 N-m

B2-24

16-23 (T.6-2.3, 12-17)

19-26 (1.9-2.6, 14-l 9)

64-89 (6.&9.*, 47-56)

9 (6.5-9.1, 4766)

Engine and transaxle assembly l

Caution

Do not damage any camponents partment. in the engine

I. Install the engine and transaxle assembly. com-

93G052-756

-

INSTAlLATION

Alternator and drive belt

1. Monut the alternator to the engine.

Tightening torque

@: 19-25 N-m (1.9-2.6

@J: 37-52 N-m (3.8-5.3 m-kg, 14-19 ft-lb) m-kg, 27-38 ft-lb)

B2

2. Install the drive belt. (Refer to page 82-Z)

Engine mount, clutch release cylinder and engine mount member

1. Install the No.3 engine mount rubber, and loosely tighten the bott and nuts.

93X82-72!

2. Install the No.4 engine mount rubber and bracket assem- bly, and loosely tighten the bolts and nuts.

93G0BZ757

3. lnstalt the clutch release cylinder and pipe bracket assembly.

Tightening torque

@: 16-23 Nm [I .6-2.3 m-kg, 12-17 ft-lb)

0: 6.9-9.8 N-m (70-100 cm-kg, 61-87 in-lb)

93GO32-730

J

4. Install the No.2 engine mount rubber and bracket assembly.

Tightening torque:

37-52 Nrn (3.8-5.3 m-kg, 27-38 R-lb)

B2-25

03UOBX-828

INSTALLATION

5. Align the engine mount member to the No.1 and No.2 en- gine mount boIts, and loosely tighten the nuts.

6. k-&all and tighten the engine mount member bolt and nuts.

Tightening torque:

64-89 N-m (6-509.1 m-kg, 47-66 Mb)

7. Tighten the No.1 and No.2 engine mount nuts.

Tightening torque:

37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)

8. Tighten bolts @ in two or three steps in the order shown.

Tightening

43-61 torque:

Nom (4.4-6.2

9. Tighten nuts @.

Tightening

torque:

67-93 N-m (6.8-9.5 m-kg, 32-43 ft-lb) m-kg, 49-69 f%(b)

IO. Tighten the No.3 engine mount nuts @.

Tightening

74-103 torque:

N-m (7.5-10.5 m-kg, 54-76 ft-Ib)

93G052-731

93GOB2-73;

11. Tighten No.3 engine mount nut @.

Tightening

67-93 torque:

N-m (6.8-9.5 m-kg, 49-69

ftdb)

12. Install the dynarpic damper.

Tightening torque:

55-80 Nom (5.6-8-2

13. Remove the chain hoist. m-kg, 41-59 ft-lb)

Intercooler

1, bracket

Install the intercooler bracket.

Tightening

19-25 torque: him (1.9-2.6 m-kg, 14-I 9 ft-lb)

step 3

Torque Specifications

INSTALLATION

6.9-11 Nn-i (70-110 cm-kg, 6l--95 in-lb)

0 (2.8-3.1, 20-221

59 (4.4-6.0, 3143)

GASKET,REPtiCE

31-46

/

(3.24.7,

/

23-34)

~//<~~z”““‘” PIN REP!JCE

21-2? (2.3-2.8, 15-20) -

- - - ’

N-m (m-kg, fi-tb)

Propeller shaft

I. Install the propeller shaft. (Refer to page L-5.)

93GOB2-734

Drive&aft

I. Apply grease to the end of the driveshaft. l l

Caution

When installing the driveshaft, be careful not to damage the transaxle oil seal.

After installation, pull the front hub outward to con- firm that the driveshaft is securefy held by the clip.

2. Install the driveshaft along with a new clip.

3. tnstall the lower arm ball joint to the knuckle and tighten the clinch bolt.

Tightening torque:

43-59 Nm (4.4-6.0 m-kg, 31-43 ft-lb)

93GOB2.736

82-27

I

E32-28

INSTALLATION

4. Install the joint shaft.

5. Tighten the bolts in the order shown.

Tightening

42-62 torque:

N=m (4.3-6.3 m-kg, 31-46 ft-lb)

93EOB2-061

1

Tie-rod end

1. Install the tie-rod end to the knuckle.

Tightening

42-57 torque:

Nmm (4.3-5.8 m-kg, 31-42 ft-lb)

Z.-Install a new cotter pin.

03 UOBX-848

StabiIiter

I. Install and adjust the stabilizer.

Dimension A: 17.19mm (0.67-0.75 in)

Tightening torque: f 6-23 Nm (I .6-2.3 m-kg, 12-17 ft-lb)

93EOBZ07E

93GOB2-760

Exhaust pipe

I. InstaIl the exhaust pipe along with a new gasket, tighten locknuts @:

2.

3.

Loose1 y tighten brat ket

Tighten locknuts @

nuts @

and loosely

Tightening torque:

31-46 Mm (3.2-4.7

4. Tighten bracket nuts @, m-kg, 23-34 ft.lb)

Tightening

21-27 torque:

Nm (2.1-2.8 m-kg, 15-20 ft-lb)

Select and

shift

cables

1. Install the select cable and the spring pin.

2. Install the shift cable and the spring pin,

93GOB2-737

RIGHT-HAND DRIV

INSTALLATION

Speedometer cable

I_ Connect the speedometer cable.

82

Step 4

1. Connect the hoses shown in the figure. l

Caution

Position the hose clamp in the original location on the hose, and squeeze it lightly with large pliers to ensure a good fit. .

93G082-76

B2-29

‘I

B2

INSTALLATION

Step 5

1. Connect the harness connectors shown in the figure.

ALTERNATOR OIL PF;IESSURE SWITCH

STARTER

PRESSURE REGULATOR

CONTROL VAVLE

GRoYD

O-i-l-tE SENSOR

IDLE-SPEED CONTROL

KNOCK SENSOR

OXYGEhENSO$\

Step 6

Torque Specifications

7.8-11

(80-110

N-m cm-kg, 69-

11 N-m (80--f ’IO cm-kg, 69-95 in-lb)

.

03UO8X-33’

N-m cm-kg, 69-95 in-Ib)

37-52 (3.8-5.3, 27

7.8--fl N-m (80

107 (9.6-T 1.9, 69-79)

N-m (m-kg, ft-lb)

03U03X-83

lNSTAL&ATlON

Crossmember

1. Install the crossmember.

Tightening

93-107 torque:

Nm (9.5-l I .9 m-kg, 69-79 f&lb)

B2

03UOSX-839

A/c compressor

1. Install the A/C compressor.

Tightening torque:

24-35 Nom (2.4-3.6 m-kg, 17-26 ft-lb)

93G032-76:

P/S oil pump and bracket

I. Install the P/S oil pump and bracket.

Tightening torque:

37-52 Nm (3.8-5.3 m-kg, 27-38 ft-lb)

Drive belt

I. Install the P/S and/or A/C drive belt.

2. Adjust the drive belt deflections. (Refer to page 82-2)

Air pipe

1. Install a new gasket and install the air pipe.

Tightening torque:

19-25 N-m (1.9-2.6 m-kg, 14-19 Mb)

/

9313082-738

\\

\

I

Intercooler and air pipe assembty t . Lift the intercooler and air pipe assembly from the bottom of the vehicle, and install hose @ in pipe @ .

2. Install and tighten the mounting bolt and nut.

Tightening torque:

7.8-l 1 Nom (80-l 10 cm-kg, 69-95 in-lb)

3. Tighten hose clamp 0.

B2-31

B2

INSTALLATION

4. Connect the air pipe to the throttle body, and tighten the hose clamp.

5. Connect air hose @ to the wastegate diaphragm,

and se-

curely tighten the hose clamp.

6. Install nut @

Tightening torque:

19-25 Narn (1.9-2.6 m-kg, 14-19 ft-lb)

7. Install the intercooter bracket and tighten nuts @J .

Tightening torque:

7.8-l 1 Narn (80-I IO cm-kg, 69-95 in-lb)

93GOB2-74 1

Air pipe and air bypass valve assembly

1. Connect the air pipe to the turbocharger, and securely tight- en the hose clamp.

2. Install and tighten the bolt @ .

Tightening torque:

7.8-l 1 Nom (80-I 10 cm-kg, 69-95 in-ib)

3. Connect air hose @and Q1 and securely tighten the hose clamps.

Battery duct

1. install the battery duct.

93GOB2-743

Radiator and tooting fan assembly

1. Install the radiator and cooling fan assembly.

Tightening torque:

7.8-l 1 Nm (80-l 10 cm-kg, 69-95 Mb)

2. Connect the tooting fan connector.

3. Connect the radiator switch connector.

4. Connect the oil cooler hose.

5. Connect the coolant reservoir hose.

6. Connect the upper and lower radiator hoses.

82-32

INSTALLATION l

Caution

Position the hose clamp in the original location on the hose, and squeeze it lightly with large pliers to ensure a good fit.

HERE /+Ju

93G082-7ti

7 Accelerator cable

1. Install the accelerator

cable.

Tightening torque

@): 7.8-l

1 N4m (80-l 10 cm-kg, 69-95 in-lb)

2. Adjust the cable deflection by turning nuts @ .

Deflection: I-3mm (U&4--0.12 in)

Battery carrier and battery

1 . Install the battery carrier.

Tightening torque:

7.8-l 1 N4m (80-I IO cm-kg, 69-95 in-lb)

2. Install the battery and the battery cover.

3. Install the battery bracket.

Tightening torque:

2.9-5.9

N.m

(30-60

cm-kg,

26-52

in-lb)

4. Connect the positive battery cable.

Air cleaner assembly

1. Install the air cleaner assembly.

Tightening torque:

19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)

2. Connect the

airflow

sensor connector.

3. Connect the hoses shown in the figure.

93GOB2-74!

Strut tower bar

I. Instail the strut tower bar.

Tightening

88-108 torque:

Narn (9.0-11 .U m-kg, 65-80 ft-lb)

Undercover and side cover

1. Install

the undercovers

and

side covers.

93GOB2-746

82-33

82

INSTALLATION

Steps after installation

1. If the engine oil was drained, refill with the specified amount and type of engine oil.

2. Fill the radiator with the specified amount and type of engine coolant.

3. Fill the transaxie with the specified amount and type of transaxle oil. (Refer to page J3-36.)

4. Connect the negative battery cable.

5. Start the engine and check the following:

(I) Engine oiI, transaxle oil, and engine coolant for leakage

(2) Ignition timing and idle speed

(3) Operation of emission control system

6. Perform a road test.

7. Recheck the engine oil and engine coolant levels.

93G032-747

-

BZ-34

LUBRICATION SYSTEM

OUTLiNE ..................................................

OUTUNE OF CONSTRUCTION

LUBRICATION

.................

CIRCUIT ...........................

D- 2

D- 2

D- 2

93GODX-703

D

D

OUTLINE

OUTLINE

BUTLINE OF CONSTRUCTION

The

system

engine is the same as for the 2WD model.

The Bf DOHC turbocharged engine engine oil circulation path is different than that of the BP DOtiC non-turbocharged

because

of the turbocharger lubrication.

93GODX-702

LlJBRICATtON ClRCUlT o-2

93GODX.70:

COOLING SYSTEM

1NDEX . ..*....*~.....*..*~~**~=~~.~~.~...~..**.~.....*...~.. E- 2

OUTLINE ..................................................

OUTLlNE OF CONSTRUCTION.. ................

COOLANT FLOW CHART.. .......................

SPECIFICATKINS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E- 4

E- 4

E- 4

E- 5

TWO-STAGE THERMOSTAT.. ....................

RADIATOR AND COOLING FAN.. ..............

E- 6

E- 7

ELECTRIC COOLING FAN SYSTEM ........... E- 8

SUPPLEMENTAL

THERMOSTAT

INSPECTION

SERVICE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC COOLING

SYSTEM INSPECTlON

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INFORMATION

FAN MOTOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iNSPECTION ..........................................

WATER THERMOSWITCH ..........................

INSPECTION ..........................................

RADIATOR

REMOVAL

THERMOSWITCH

I INSPECTION

.....................

I INSTALLATION..

FAN RELAY ..............................................

REMOVAL I tNSPECTlUN ..........................

E- 9

E- 9

E- 9

FAN SYSTEM ............ E-l 0

E-l 0

E-If

E-l 1

E-l I

E-f 1

E-l 2

E-12

E-l 3

E-l 3

93GOEX-701

E

E

INDEX

tNDEX

-

1. Fan motor

Inspection .._.....,._............._..........

E-Z

page E-1 I

- &ANT RESERVOlR

ENGiNE COOLANT

TOTAL CAPACITY

MTX: 5.0 liters (5.3 US qt, 4.4 Imp qt)

ATX: 6.0 liters (6.3 US qt. 5.3 tmp qt)

BP DOHC TURBO

INDEX

E

III 6

No.2 AND No.3 RELAY

1. Thermostat

Inspection ...................................

2. Electric cooling fan system

System inspection .......................

3. Fan motor

Inspection ................................... page E- 9 page E-l 0

4. Water thermoswitch inspection ...................................

5. Radiator thermoswitch

Removal I Inspection I

Instailation ................................. page E-l 1 6 Fan relay

Removal I Inspection .................. page E-l 1 page E-1 2 page E-1 3

E-3

E

OUTLINE

OUTLINE

OUTttNE OF CONSTRUCTION

The cooling system in the 323 4WD model is basically the same as in the 323 2WD model.

Although there is no fundamental change from the BP DOHC of the 2WD model, the coolant circulation path has been changed to direct coolant to the water-cooied

A two-stage thermostat is used in the BP DUHC turbocharged turbocharger. engine to stabilize the engine coolant tem- peratu re.

The radiator model uses and cooling a two-speed fan specifications are different. The BP DOHC turbocharged electric cooling fan. engine of the 4WD

93GOEX-704

COOLANT FLOW CHART (BP DOHC TURBO)

E-4

SPECIFICATlONS

- km

Cootlng system

- camacltv

Water puma

1 Type

1

I Water seal

: Type

The:mosta! lrters [US Qt. Imo at)

Opening

1

1 Full-open temperature temperature j Full-open lift

EnginelTtansaxte

“C (OF)

OC (OF) mm (in)

Radiator

Coohg

L

“...Except fan

1 Type

Cap vaive opening-pressure kPa (kglcm2,

’ j Tvm? psi) mm (in)

Blade f Outer drameter

Number

A Motor cold area, *2...Cotd

I

/

Current area only

1

I

MTX

8P SOHC

Water-cooled,

ATX forced crrculation

I

] 8P DOW Turbo

MTX

5.0 (5.3, 4.4) I

Centrifugal

Unified mechanical

Wax,single stage”‘,

80.5-83.5

Wax,

(177-182)“1 two-stage*’

Main: 86.5-89.5

Sub : 83.5-86.5

95 (203)*‘,

8.5 (0.335)

(188-l

(182-188)

100 (212)*’ or more’l

93) *’

Main: 8.0 (0.31).mln.‘2

Sub : 1.5 10.061 min

Corrugated

6.0 t&3,5.3) fin seal

1 Wax, two-stage

i

Main: 86.5-89.5 (lSS--193)

Sub 83.G86.5 (182-188)

100 (212)

* Main: 8.0 (0.31) min.

Sub : I.5 (0.06) mm.

74-l 03 (0.75-I .05, 11-l 5)

320 (12.6)

4

6.6 * 1 r

EIectnc

340 (13.4)

5

Hi : 13.3 + 10% max.

Lo: 8.8 + 10% max.

93GOEX-706

1

I

E-5

E

TWO-STAGE THERMOSTAT

OUTlANE

(BP DOHC TURBO)

MAIN VALVE

SINGLE-STAGE

(AMBIENT

100 km/h

(63 mph) ~~~~~

THERMOSTAT fEMP. -20% (4*f))

NTRANCE PORT TEMP

GINE EXIT PORT TEMP.

-

60 kndh

(38 mph)

TWO-STAGE THERMOSTAT

A sub-valve is incorporated cold weather performance, in the thermostat to stabilize the coolant temperature and to reduce heater output temperature fluctuations in the engine, as noted to improve in the diagram.

Operation

Stage 1

During cold weather operation, 83.5*C [182°F]-86.50C engine coolant temperature.

Stage 2

During normal operation, 86.5OC (1 88°F)-89.50C an: flow through the radiator.

[t 88OF] only the sub-valve opens to control the

(I 93OF) the main valve opens to permit increased coul-

E-6

RADIATOR AND COOLING FAN

The radiator and cooling fan specifications are revised.

Specifications r

EnginelTransaxle

Item

1 Radiator

Core size

Width mm (in) H etght

Depth

Fm pnch

Heat dissipaton capacity

Transaxle oil cooler mm (in) kcallh

Type

Heat dissipation capacity kcal/h I

Cooling fan

Number of biades

Outer drameter

Capacity mm (in> w-v

1

Current A

I

MTX

647

390

16

1.3

38,800

-

-

4

320

80-12

6.6 * 1

BP SOHC

ATX

+ t

25 t

43,800

Double tube

1,650

5

340

160-12

Hi : 13.3 + 7 0% max.

Lo: 8.8 + 10% max.

1 BP DOHC Turbo

I

MTX

+

*- e c

C

-

-

+

C c

+

93GOEX-708

I

DEPTH

;ECTION A-A

4WD MODEL

OIL COOLER (ATX

ZWD MODEL

I

E-7

E

ELECTRIC COCUNG

System Circuit

OUTLINE

FAN SYSTEM (BP DOHC TURBO)

WITH A/C r----‘-- -___-

I

---------.--------;

I

II 1

I

ADDITIONAL

FAN

MOTOR

+IIAGNOSlS

CONNECTOR

WATER

THERMOSWlTCH

ABOVE 97% (207OF): ON

RAD1ATdTHERMOSWITCH

ABOVE 105% I221 OF-): ON

Operation

1. When the coolant temperature exceeds 97OC (207*F), the water thermoswitch turns ON to close the No.7 relay, and connects the + I and -1 terminals of the fan motor speed (about 1,660 rpm). connector. The fan motor turns at low

2. When the coolant temperature exceeds 105OC (221 OF), the radiator thermoswitch turns ON, to close the

No.2 and No.3 relays, and connects the +2 and -2 terminals of the fan motor connector. The fan mo- tor turns at high speed (about 2,200 rpm).

3. if the vehicle is equipped with air conditioning, the cooling fan motor operates whenever the NC switch and the blower switch are on, regardless of the coolant temperature.

Also, when the A/C switch and the blower switch are on, the A/C retay closes fan motur. to operate the additional l

Note

The water thermoswitch and the cooling fan reIay are normally-open switches.

Checking cooling fan operation

1. Jump across the TFA and the GND terminals of the diagnosis connector with a jumper wire.

2. Turn the ignition switch to ON and verify that the cooling fan operates smoothly. l

Note

When the water thermoswitch connector is disconnected, the cooling fan wiif not operate.

E-8

SUPPLEMENTAL SERVICE INFORMAT1ON,

SUPPLEMENTAL SERVICE INFURMATtON

The following points in the section are changed in comparison with Workshop

Australia (I 204-I 0-89f)].

Thermostat (BP DUHC Turbo only) l

Inspection

Electric cooling

fan system (BP

DOHC Turbo only)

l

System inspection

Fan motor

l

1 nspection

Water thermoswitch

(BP DOHC Turbo only) l l tnspection

Radiator thermoswitch

(BP DOHC Turbo only) l

Removal I Inspection I Installation

Fan relay

(BP DOHC

Turbo

only)

Removal ! Inspection

THERMOSTAT

Manual [Europe (1203-l 0-89F),

E

93GOEX-710

/

SUB-V ‘A

E

-

THERMOSTAT (BP DOHC TURBO)

INSPECTKM

1. Visually check that the thermostat

2. Place the thermostat valve is airtight. and a thermometer

3.

Heat the water and check the following: in water.

Initial-opening temperature:

Main: 86.5-89.5%

Sub : 83.5-86.5OC

Full-open temperature:

Full-open lift

(188--t93°F)

(f82--f88QF)

100°C (212°F)

Main: 8.Umm CU.31 in) min.

Sub : f.5mm (0.06 in) min.

E-9

E

ELECTRIC COOLING FAN SYSTEM

ELECTRIC COOLING FAN SYSTEM (BP DUHC TURBO)

SYSTEM ClRCUIT r

WITH A/C r-- _______ ------

I

1

ADDITIONAL

FAN

I

I PRESSL

SWITCH

WATER

THERMOSWfTCtl

ABOVE 87OC (207OF): ON

RADlATOjl THERMOSWITCH

ABOVE 105*C (221 “I=): ON

SYSTEM INSPECTION

1. Jump across the test fan (TFA) terminal and the ground

(GN D) terminal of the diagnosis connector.

2. Turn the ignition switch ON and verify that the fan operates.

If the fan does not operate, inspect the cooling fan system components and wiring harness.

8

93GOEX-719

3. Remove the radiator cap and place a thermometer in the radiator filler neck.

4. Start the engine.

5. Verify that the fan operates when the coolant temperature reaches approx. 97*C (207°F).

If it does, check the water thermoswitch.

(Refer to

page

E--i I.)

--

-

% QY-

-THERMOME?ERsi-=i

--------L-

93GOEX-7 i 2

E-10

FAN MOTOR, WATER THERMOSWITCH

E

93GOEX-71:

93GOEX-714 tNSPECTlON

Single-speed

I. Verify

Type (For BP SOW MTX)

that the battery is

fully charged.

2. Disconnect the fan motor connector.

3. Connect the battery and an ammeter to the fan motor nector.

4. Verify that current is as specified.

con-

Current (A): 6.6 k 1

5. If current is not within specification and/or the fan does not turn smoothly, replace the fan motor.

Two-speed Type (Except BP SUHC MTX)

I. Verify that the battery is fully charged.

2. Disconnect the fan motor connector.

3. Connect the battery and an ammeter to the fan motor con- nectors for low-speed inspection.

4. Verify that the fan motor operates smoothly at the standard cu vent.

Current (A): 8.8 + 10% max.

5. Connect the battery, an ammeter, and switch to the fan mo- tor connectors for high-speed inspection.

6. Verify that the fan motor operates smoothly current or less with the switch ON.

at

the standard

Current (A): 13.3 + 10% max.

7. If not as specified, replace the fan motor.

93GOEX-720

93GOEX.715

WATER THERMOSWITCH

(BP DOHC TURBO)

INSPECTlUN

I . Place the switch and a thermometer in water.

2. Heat the water gradually and check continuity of the switch with an ohmmeter.

Coolant temperature OC (OF) 1

More than 97 (207)

Less than 90 (194)

Contrdy

Yes

NO

I

3. If not as specified, replace the water thermoswitch.

E

RADIATOR THERMUSWlTCki

RADIATOR THERMOSWITCH (BP DUHC TURBO)

REMOVAL I INSPECTION I INSTALLATION

I. Disconnect the negative battery cable.

2. Remove in the order shown in the figure.

3. Install in the reverse order of removal, referring to InstaHation Note.

7.8-13

(80-l

H-m

10 cm-kg, 69-95 h-lb)

1. Resonance chamber

2. Radiator cowling mounting bolts

3. Radiator thermoswitch connector

03WEX-027

(80-110

69-95In4b) cm-kg,

REPLACE

4. Radiator thermoswitch

Inspection . . . . . . . . * . . . . . . . . . . . . . ..-. -.*,.a..- . . . . . . .I. below

Installation Note _.,............................._. below

1NSPECTlON

1. Place the switch and a thermometer in engine oil. l

Warning

Do not heat the engine oil above 12O*C (248OF)

2. Heat the engine oil gradually and check continuity of the switch with an ohmmeter.

Engine oil temperature “C (*F) Continuity

I

Yes t

More than 105 (221)

Less than 96 (205)

No

1

3. If not as specified, replace the radiator thermoswitch.

Installation Note

Radiator thermoswitch l

Caution

Do not use an impact wrench for installation.

1. Install the radiator thermoswitch along with a new gasket.

Tightening

5.9-12 torque:

Nom (60-120 cm-kg, 52-104 in-lb)

93GOEX.721

E-12

FAN RELAY(BP DOHCTURBO)

REMOVAL / INSPECTION

1. Disconnect the negative battery cable.

2. Remove the fan relay.

FAN RELAY

E

No.2 FAN REUY w.

@AND

. . . . . .TYPE 1

@ . . . TYPE 2

INSPECTDN f . Check continuity as shown with an ohmmeter.

I

Terminal COMlLJlty

A-C No

B-D Yes

2. Apply 12V between terminals B and D.

Check for continuity between terminals A and C.

3. If not as specified, replace the fan relay.

E-13

Fl

FUEL AND EMISSION

CONTROL SYSTEMS

(WITHOUT CATALYTIC CONVERTER)

INDEX . . . ..*.....*....**..............................~... Fl- 2

1 FEATURES 1

OUTLINE ................................................

OUTLINE OF CONSTRUCTION ................

Fl-

Ff-

3

3

SPECIFICATIONS ...................................

SYSTEM DIAGRAM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTLINE ..............................................

Fl- 3

FI- 4

Fl- 5

Fl-

Fl-

6

6

FUEL TANK AND TRANSFER PUMP.. ...... Fl- 7

1 SERVICE j

SUPPLEMENTAL SERVICE INFORMATION. Fl- 9

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . ..I.... . . . . . . . . . . . . Fl- 9

PRECAUTION . . . . . . . ..,.. . ..*...... . . . . . . . . . . . . . . ..I Fl- 9

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I.. ..I Fl-ICI

TRANSFER

SYSTEM

PUMP CONTROL

OPERATION

SYSTEM ..I... Ff-If

. . . . . . . . . ..I................. Fl-11

4x4 CONTROL UNIT

(FUEL PUMP CONTROL UNIT-j . . . . . . ..I..... FI-12

TRANSFER PUMP SWITCH . . . . . . . . . . . . . . . . . . . . . F1-13

TRANSFER PUMP . . . . . . . . . ..l..................... Fl-13

EXHAUSTSYSTEM

. . . . . . I . . . . . . . l . . . . . . . . . . . . . a. I . . .

Ff-15

COMPONENTS . ..a.. . . . . . . . . . . . . . . . . . I..... . . . . . . . . Fl-15

93GOFf -701

I

Fl

INDEX

1. Fuel tank

Removal I hspection /

I nstalIation 1. . . . . . . . . . . . . . * . . . ..I..... ,*,. page Fl-10

2. 4x4 control unit (Fuel pump control unit)

Inspection .__...._..................__..._. page

Replacement _. . _. _. _. _. . _ _ _. . . _ . _. _. . . . _. page

3. Transfer pump switch

Fl-12

Fl - 12

Removal / lnstaltation . . . . . . . . . . . . . .._ page Fl-13 inspection .._......_.. . . ..-_. . . .._....... page F1 -I 3

Fl-2

93GOFl-702

4. Transfer pump inspection _........._....._................

Installation .**...**..a*..........*..*..__. page Fl-13

Replacement.. . .__.-.. . . . . . . . . . . . . . . , U.-e page FI -13

5. Exhaust system components

Removat I hspection I page fl-15

OUTLINE

Fl

OlJTLlNE OF CONSTRUCTION

The fuel

and

emission control systems of the New 3.23 BP SOHC-engine equipped 4WD model are basically the same as those of the New 323 8P DOHC-engine equipped 2WD model, however, the fuel tank is designed with separate right and

and

left

sections

due to the installation

of the propeller shaft

for the 4-wheel-drive system

a

transfer pump is equipped to pump the fuel from the left to the right (fuei pump side) section of

the

fue! tank. The following chart shows the differences

between

the major parts

of the BP DO%

2WD model and the BP SOHC 4WD model.

33GO”l-703

Difference t

I Part

Transfer pump

Variable Inertra charging system

Two group fuel qectron

G-slgnal (Drstnbutor)

BP DOHC 2WD 1 BP SOHC 4WD

-

0

0

-

-

0

I

-

Remark

Due to installation of propeller shaft

Due to change of engine

Due to abolishment of two group fuel Injection

93GOfl-70s

SPECIFICATIONS

Item

Idle speed

Ignition timing *

Fuel

DUtTlD

Engine vm

BTDC

BP SOHC

850 * 50

5 * to

I

Fuel filter

Type

Low-pressure side

Htgh-pressure side

Pressure regulator

Regulating pressure

In jfXt0r

Type

Resistance

Idbup solenoid vatve

Resistance

Water themosensor

R&stance kPa (kglcm2,

-20% ( -4OF) kQ - .

20°C ( 689=)

40% (104OFj

80°C (176OF) psi) 1 264-314

Nylon element

Paper element

(2.7-3.2, 38.3-45.5)

High-ohmic

12-16

Solenoid A _.._. 17-23, Solenoid 5, C ._... 27-36

14.6-l 7.8

2.2-I -2.69

1.0-l -3

0.29-0.35 l

TEN terminal of dragnosrs connector grounded.

The a (shading) rndrcates newly equipped parts

AIR CLEANER

RESONANCE

CHAMBER

METER

I (WITH INTAKE AIR

THERMOSENSOR)

*

Ne-S’GtiAL * ----El

DlSTRlfjUTOR

IDLE-UP

SOLENOID VALVE

THERMOSENSOR

* TO ENGINE CONTROL UNIT

/

SOLENOID

(PRESSURE

VALVE

REGULATOR CONTROL)

P-“---j

FUEL FILTER

(HIGH-PRESSURE

SIDE)

,CHECKVALVE

(TWO-WAY)

FUEL VAPOR VALVE

I

TRANSFER

\

‘FUEL PUMP

FUEL FILTER

PUMP

t- --

MAIN RELAY r

DliiGNOSlS

CONNECTOR

,

- t

CLUTCH

SWITCH

[/

-I

’ NEUTRAL

SWITCH

Tt

WATE!

THERMOSENSOR

AIRFLOW METER

“-

SQLENOlD VALVE

(PRESSURE

REGULATOR

CONTROL) lNJECTOR

IQNITION

SWITCH

ELECTRICAL

FAN

HEADLIG t IT

SWITCH

AX SWITCH

BLOWER Ivc

SWITCH RELAY

AEAR WINOOW

DEFFIOSTER

SWITCH

I

ECU

4X4 CONTROL UNIT

1

FbEL

PUMP

TRANSFER PUMP TRANSFER

PUMP SWlTCtJ

Fl

FUEL SYSTEM

OUTLlNE

FUEL

SYSTEM

PRESSURE REGULATOR

\

FUEL FILTER

I

1

TRANSFER PUMP i WEL PUMP

1 FILTEF

FUEL TANK

4x4 CONTROL UNIT (FUEL PUMP CONTROL UNIT)

The fuel system consists of the fuel tank, the transfer pump, the fuel pump, the fuel filters, the pressure regu- lator, the delivery pipe, the injectors, and the 4x4 control unit (fuel pump control unit).

Fl-6

FUEL TANK AND TRANSFER PUMP

FUEL SYSTEM

TRANSFER PUMP SWITCH

Fl for the 4-wheel-drive system. ed in the 4x4 control unit).

4x4

CONTkOL UNIT

(FUEL PUMP CONTROL UNIT)

The c with a separate right and left section due to the installation of the propeller shaft

93GOF1-717

A transfer pump is used to pump the fuel from the I& to the right (fuel pump) side. The transfer.pump installed in the fuel tank, and is controlled by the transfer pump switch and the fuel pump contra! unit (Includ-

A fuel vapor valve is instatted on the top of the fuet tank to prevent fuel from flowing out to the charcoal cansiter.

Fl-7 is

Fl

FUEL SYSTEM

Transfer Pump Csntrol

OutIine

The fuel tank is built with separate right and left sections to accommodate the installation of the propeller shaft. As fuel is pulled from the right side of the tank, the transfer pump pumps the fuel from the left to the riuhf (fuel pump) side to balance the fuel level.

FUEL IN 1EFT TANK

4x4 CONTROL UNIT

(FUEL PUMP CONTROL

UNIT)

NO

FUEL IN LEFT

TANK

TRANSFER

/

PUMP SWITCH:

TRANSFER

OFF

PUMP

4x4 CONTROL UNIT

(FUEL PUMP CONTROL

UNIT)

TRANSFER

/ TRAtdFER

PUMP SWITCH: ON

PUMP

Fuel in left tank

The transfer pump switch is OFF, and the transistor within the fuel pump control unit is ON.

As a result, current flows to the coil, the switch is switched ON, and the transfer pump is activated.

No fuel in left tank

The transfer pump switch is ON, and the transistor within the fuel pump control unit is OFF.

As a result, the current to the coil is interrupted, the switch

is

switched OFF, and the transfer pump

is

stopped.

When in this condition, if the vehicle were driven on a rough road surface, the fuel level would vary up and down and fuel pump would switch ON and OFF.

The transfer pump would then operate excessively, shortening the pump life. In order to prevent this, a ten- second delay circuit is provided within the fuel pump control unit.

Fl-8

SUPPLEMENTAL SERVICE INFORMATION, FUEL SYSTEM

Fl

SUPPLEMENTAL SERVICE INFORMATION

The following points in this section are

(I 203-I U-89F, 1204-I O-89F, I2061 O-89F).

changed in comparison

with Mazda 323 Workshop Manuals fuel tank l l

Removal I Inspection I Installation l

4x4 control unit (Fuel pump control unit)

Inspection

procedure added

Replacement procedure added l l

Transfer pump switch

Inspection procedure added

Replacement procedure

added l

Transfer pump

Inspection procedure added l

Replacement procedure added l

Exhaust system components

Removai I Inspection I installation

93GOF? -706

FUELSYSTEM

PRECAUTION

Fuel Pressure Release and Sewicing 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 fire.

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 stalls, turn off the ignition switch.

5. Reconnect 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. l

Caution

Install hose clamps to secure tile fuel pressure gauge to the fuel filter and the fuel main hose to pre- vent fuel 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.

I. Connect the diagnosis connector terminals F/P and GND with a jumper wire.

2. Turn the ignition switch ON for approx. IO sec. and check for fuel leaks.

3. Turn the ignition switch OFF and remove the jumper wire.

Fl-9

Fl

FUEL TANK

Removal / inspection

FUEL. SYSTEM

I Installation l l l

Warning

Before performing reduce the possibiIity the following of injury operation, or fire. release

(Refer the fuel pressure to page

When removing the fuel tank, keep sparks, cigarettes,

Fl-9.) and open from flames the fuel system away from it. to

Before repairing the fuel tank, clean it throughly with steam to remove all explosive gas.

1. Remove in the order shown in the figure.

2. Inspect the fuel tank components visually and repair or replace as necessary.

3. Install in the reverse order of removal, referring to Installation Note.

FUEL PUMP (MAIN) TRANSFERPU

GASKET, REPLACE

4it-55 (4.3 -5.6, 3041)

ET, REPLACE

4341 (4.4-6.2, 3245)

Nm (m-kg, ft-lb) a?cnc% .7*7

FUEL SYSTEM, TRANSFER PUMP CONTROL SYSTEM

Fl l

Note

Drain the fuel from the fuel tank before removing the tank.

I. Fuel pump cover

2.

Fuel pump connector

3.

Fuel hoses

Installation Note . . . . . . . . . . . . , . . . . . . . . . . . . . . _ . . . . . below

4. Exhaust pipe

Removal / lnstaltatjon . . . . . . . . . . . . .._. page Fl -I 5

5. Propeller shaft

Removal / installation ._..._....,_.._..._.. Section L

6. Fuel fiIler hose, breather hose, and evaporation

hoses

Installation Note .

7. Fuel tank straps

8.

Fuel tank inspect for cracks and corrosion below

93m=: -708

I B

FUEL FILLER HOSE

Installation Note

1. Push the ends of the main fuel hose, fuel return evaporative hoses onto the fuel tank fittings

(1.0 in).

hose,

and at least 25mm

2. Push the fuel filler hose onto the fuel tank pipe at ieast 35mm (1.4 in).

and filler

pipe

@,

0

F /

M

E -J

TRANSFER PUMP CONTROL SYSTEM

SYSTEM OPERATION ’

1. 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. l

Warning

If the fuel level is less than one half, this inspec- tion cannot be performed.

03UOFX-Bf 4

2. Ground the transfer pump connector terminal-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. 50 sec.

4.

If not as specified, check the following parts. l

4x4 control unit (Fuel pump control unit). l l

(Refer to page F-I-1 2.)

Transfer pump. (Refer to page FI-I 3.)

Transfer pump switch. (Refer to page Ff -13.)

93GOFl-709

Fl

TRANSFER PUMP CONTROL SYSTEM

4x4 CONTROL UNIT (FUEL PUMP CONTROL

Inspection

I. Remove the 4x4 control unit.

UNIT)

2. Disconnect the 4x4 control unit connector.

3. Check continuity between the 4x4 control unit connector terminal M and a ground.

4. Perform the following inspection according to the measured continuity.

93GOFl-7 10

Continuity exists

1. Turn the ignition switch ON.

2. Ground the 4x4 control unit terminal M with a jumper wire and verify that the voltage at the 4x4 control unit terminal

N is ov.

3. Remove the jumper wire and verify that the voltage at the

4x4 control unit terminal N is approx. WV after approx.

10 sec.

4. If not as specified, replace 4x4 control unit.

93GOF1-717

No continuity exists

1, Turn the ignition switch ON and verify that the voltage at the 4x4 control unit terminal N is OV.

2. Disconnect the transfer pump connector.

3. Turn the ignition switch ON and verify that the voltage at the 4x4 control unit terminal N is approx. WV.

4. If not as specified, replace 4x4 control unit.

Replacement

I. Remove the bolts and remove the 4x4 control unit and the bracket as an assembly.

2. Remove the 4x4 control unit from the bracket.

3. Install in the reverse order of removal.

93GOf t -7 I

Fl-12

TRANSFER PUMP CONTROL SYSTEM

TRANSFER PUMP SWITCH

Removal / Installation .

1. Refer to “Transfer pump replacement”.

(Refer to below.)

Fl

TRANSFER PUMP SWITCH

93GOF I -7 14

I inspection

1. Check continuity between transfer pump connector termi- nal C and ground terminal.

I

Float position

UD

Down I

Contrnuity

NO

YES

2. If not as specified, replace the transfer pump switch.

I

TRANSFER

Inspection

PUMP f . Remove the rear seat cushion.

2. Disconnect the transfer pump connector.

3. Check for continuity between transfer pump connector terminal-wires (SAW) and (v).

4. If no continuity exists, replace the transfer pump.

OWOFX-824

Replacement l

Warning

When servicing cigarettes, the fuel system, keep sparks, and open flames away from the fuel.

1. Remove the rear seat cushion.

FI-13

TRANSFER PUMP CONTROL

SYSTEM

2. Remove the service hole cover of the transfer pump.

3. Disconnect the transfer pump connectors.

4. Disconnect the fuel hose.

5. Remove the transfer pump. l

Caution

Install a new seal rubber.

6. Install in the reverse order of removal.

03UOFX-626

Disassembly / Assembly l

Caution

Prevent contaminants from entering the transfer pump,

I. Disassemble in the order shown in the figure.

2. Assemble in the reverse order of disassembly.

3. Verify that the transfer pump operates

correctly

it.

1 . Fuel filter

2. Rubber mount

3. Transfer pump

Ft-14

EAL RUBBER, REPLACE

4. Fuel hose

5. Transfer pump switch

EXHAUST SYSTEM

EXHAUST SYSTEM

COMPONENTS

Removal I inspection I installation

1. Remove in the order shown in the figure.

2. Check the exhaust system components

3. /n-stall in the reverse order of removal.

I and repair or replace as necessary.

I GASKET, REPLACE

Fl

7.&l?

(80-l

69-95

N-m

10 cm-kg, in-lb) f’ ’ GASKET, REPLACE

I

{4.1-5.6, 3041)

1. Main silencer

Inspect for deterioration and restriction

2. MiddIe pipe assembly

Inspect for deterioration and restriction

3. Pre-silencer

Inspect for deterioration and restriction

Nm (m-kg, ft-lb

4. Front pipe assembly

Inspect for deterioration

5. Exhaust manifotd insulator

6. Exhaust manifold

Inspect for deterioration and restriction and restriction

F2

FUEL AND EMISSION

CONTROL SYSTEMS

(WITH CATALYTIC CONVERTER)

.

INDEX ..*.........**.*.........*..........*...... F2- 2

OUTLINE ......................................

OUTLINE OF CONSTRUCTION..

SYSTEM DIAGRAM ......................

VACUUM HOSE ROUTING

DIAGRAM [BP TURBO] ...............

WIRING DlAGRAM.. .....................

ECU REtATlONSHIP DIAGRAM

[BP TURBO] ..............................

SPEClFtCATlONS. ........................

F2-

.... F2-

F2-

F2-

FZ-

F2-10

F2-11

4

4

5

7

8

TURBOCHARGER CONTROL

[BP TURBO] ................................

OUTLINE ....................................

SYSTEM DIAGRAM .................

WASTEGATE CONTROL ...............

FUEL,SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTLINE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONSTRUCTlON .........................

FUEL VAPOR VALVE ...................

F2-I

F2-I

.; ... F2-12

F2-13

F2-15

F2-15

F2-15

F2-16

2

2

FUEL PUMP CONTROL SYSTEM.. . F2-16

FUEL PUMP RESISTOR/RELAY ...... F2-18

TRANSFER PUMP CONTROL. ....... F2-I 8

CONTROL SYSTEM .......................

STRUCTURAL VIEW.. ...................

F2-20

F2-20

OVERBOOST WARN!NG BUZZER

[BP TURBO] ..............................

TURBOCI-IARGE INDICATOR

[BP TURBO] ..............................

F2-21

F2-21

KNOCK CONTROL SYSTEM

[BP TURBO] .............................. F2-22

OXYGEN SENSOR [BP TURBO]. .... F2-23

PRESSURE REGULATOR

SYSTEM [BP TURBO]

CONTROL

................. F2-23

A/C CUT-OFF SYSTEM (ATX) ......... F2-24

SUPPLEMENTAL

INFORMATION

SELF-DIAGNOSIS

OUTLINE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MALFUNCTION

SERVICE

............................. F2-25

FUNCTION .......... F2-26

F2-26

CODE NUMBERS . . F2-26

TROUBLESHOOTtNG GUIDE

[BP TURBO1

RELATlONSHlP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHART ................

F2-31

F2-31

SYMPTOM TRUUBLESH0OTlNG tNTAKE AIR SYSTEM .....................

COMPONENTS ............................

TURBOCHARGERCONTROL

.... F2-32

F2-43

F2-43

SYSTEM ......................................

PREPARATION ............................

SYSTEM OPERATION ...................

F2-45

F2-45

F2-45

WASTEGATE ............................... F2-45

WASTEGATE SOLENOID VALVE.. .. F2-46

TURBOCHARGER ........................

AIR BYPASS VALVE .....................

INTERCOOLER ............................

FUEL SYSTEM ..............................

F2-46

F2-48

F2-49

F2-50

F2-50 PREPARATION

PRECAUTION

............................

.............................

FUEL TANK

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F2-50

F2-51

TRANSFER PUMP CONTROL

SYSTEM ................................... F2-52

FUEL PUMP CONTROL UNIT ........ F2-53

TRANSFER PUMP SWITCH ........... F2-54

TRANSFER PUMP.. ...................... F2-54

FUEL PUMP RESISTOR/RELAY

INJECTOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

...... F2-56

F2-56

EXHAUST SYSTEM ;ff;

COMPONENTS

CONTROL SYSTEM

....................................................

....................... F2-59

PREPARATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

F2-59

ENGINE CONTROL UNIT (ECU) ..... F2-59

OXYGEN SENSOR ....................... F2-68

KNOCK SENSOR ......................... F2-69

93GOF2.701

F2

OUTUNE

OUTLINE OF CONSTRUCTION

The fuel and emission control system of the new 323 4WD model is basically the same as that of the new

323 2WD modet; however, a turbocharger and knock control system are added to the BP TURBO model and the fuel tank is designed with separate right and left sections due to the installation of the propeller shaft for the 4-wheel-drive system. A transfer pump is also equipped to pump the fuel from the left to the right

(fuel pump side) section of the fuel tank.

The major points of difference between the 2WD model and 4WD model are as shown below.

93GOF2-705

Difference

Component

INTAKE AG!

SYSTEM

FUEL SYSTEM

1 Resonance duct

Resonance chamber

VICS

Turbocharger

I ntercooler

Air bypass valve

Fuel pump control

Transfer pump

Pressure regulator control

Fuel pump reststorlrelay

EVAPORATIVE

EMISSION

CONTROL

SYSTEM

CONTROL

SYSTEM

Fuel vapor vatve

Throttle sensor

Point type

Variable type

Oxygen sensor F

Without heater

With heater

Water thermoswitch (on radiator)

Knock control system

Overboost wami ng buzzer

Turbocharge Indicator

-

0

-

-

0

-

-

-

-

2WD 4WD

BP SUHC BP OOHC BP SOHC BP TURBU

0 0 0 -

G

.-

0

-

-

-

-

-

0 ui-

-

-

-

-

-

-

-

-

-

0

-

-

0

0

0

0

0

0

-

0

-

0

-

0

0

Remark

-

-

Refer to page FZ-12

Refer to page FZ-14

Refer to page F2-14

Refer to page F2-16

Refer to page F2-18

Operating time for BP

TURBO is different

(Refer to page F2-23)

Refer to page F2-18

-

0

-

-

-

-

-

0

-

0

0 (MTX)

0 W-x)

0

-

C @TX)

-

-

-

0

-

0

-

0

-

0

0

0

Refer to page F2-16

-

Refer to page F2-23

NC cut-off system

Refer to page F2-22

Refer to page

Refer to page

F2-21

F2-21

93GOF2-706

lNDEX

F2

4x4 CONTROL

(FUEL PUMP

CONTROL UNIT)

UNIT

SERVICE, SECTION

1. Fuel tank

Removal / Inspection I lnstailation . . . . .._........._._....... 1 . . . . page F2-51

2. Injector _

Volume test ~..........~..~..,...~..~....~. page F2-56

3. Fuel pump resistor/relay [BP TURBO]

System operation . . ._. . . ._. _ . . . . . . . . . . . page F2-56

Inspection . . . . . . . . . . . . . . . . . . . *. . . . . . . . . . . . . page F2-56

SEAT

4. Fuel pump control unit [BP TURBO]

Inspection *....,...,.........I..... * . . . . . . . page F2-53

Replacement . . . . . . . . . . . . . . . . . . . . . . . . ..-... page F2-53

5. Transfer pump switch

Removal I InstaNation . . . . . . . . . , ..,... page F2-54

Inspection ..a . . . . . . . . . . . . . . . . . . * . . ..I.. e... page F2-54

6. Transfer pump

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F2-54

Replacement ,...,_..... b . .._._......_.... page F2-54

1. Exhaust system

RemovA I Inspection I InstaNation

BP SOHC . . . . __.._......... _........... page F2-57

BP TURBO _.. . . . . . .._.. . . . . . . . . . . . . . . . page FZ-58

F2-3

SOLENOID VALVE

(PURGE CONTROL) r----+

CHECK VALVE

INTERCOOLER 11 ’ 1

I

‘I A-4

CHiRCOAL

CANISTER

AIR

, BYPASS

II II -

II ,.-ok----,/

,CHECK

(TWO-WAY)

VALVE

FUEL FILTER le-SIGNAL*

G-SIGNAL-

-

0

EJ

DISTRIBUTOR c

VALVE

VALVE

---II

THERMOSENSOR

I

31c

1-1

-d KNO&

SENSOR 1 k---k

WASTEGATE

SOLENOID

VALVE

7

I

II

II t

-

TRANSFER

PUMP

II II I I II

I III i 1 WASTFGATF

TURtiOCHARGERI~

II

I

I

AlOCI fuAl RAlz-rCD ftl”FLLt”” IVIL I =r,

(WITH INTAKE THERMOSENSOR)

*TO ENGINE CONTROL UNIT

CATALYTIC CONVERTER

SYSTEM DIAGRAM

BP SOHC

1

OUTLINE

F2

” a

J

I\

U

93GOF2-707 m-5

1

WtRlNG DIAGRAM

BP SOHC

OUTLINE

FZ-8

- r-

93GOF2-71,

F2

ECU RELATIONSHIP

INPUT DEVICE

BATTERY A

DlAGRAM

DlSTRlBUTOR

OUTLINE

[BP TURBO]

KNOCK SENSOR i(

,-,

KNOCK

CONTROL

UNIT

NC SWITCH

--k/L SWITCHS

{REAR WINDOW DEFROSTER

HEADLIGHT SWITCH, BLOWER

SWITCH.

SWITCH,

ELECTRICAL FAN SWITCH)

THRO77LE

SENSOR

NEUTRAL/

CLUTCH SWITCH

DIAGNOSIS

CONNECTOR

(TEN TERMINAL)

OUTPUT DEVICE

INTAKE AIR

THERMOSENSOR

IDENTIFICATION

CIRCUIT

OPENING

F2-10

RESISTOR/RELAY

SOLENOID VALVE

(PURGE CONTROL)

SOLENOID

(PRESSURE

VALVE

REGULATOR

WASTEGATE

SOLENOID VALVE

93GOFZ-71

OUTLINE

F2

SPECIFICATIONS

Low-pressure

1 High-pressure

-

Pressure regulator t

Regutating pressure .

Injector me

Type oi drive

Resrstance

Idle speed cantrol (EC) valve

Type

Resistance

Purge control solenoid valve

Resistance

Water thermosensor stde side

Resistance kPa (kg/cm2, psi) 1 kf2

1 -20% ( -4V)

2o”c ( 68OF)

4OOC (104OF)

8O*C (176OF)

Q

D s2 [

Airflow meter

Fully closed

Fully open

Resistance

E2++Vs

Ez-Vc

E?+THAA

(1 ntake air thermosensor)

-2o*c ( -4*F)

20°C ( 68*F)

60°C (14cPf)

Nylon element (rn fuel pump)

Paper element

265-3-l 4 (2.7-3.2,

High-ohmic

Electromechanical

12-76

38-46)

Rotary

II-13

23-27

14.6-I 7.8

2.21-2.69

1.0-I

0.29-0.35

.3

200-600

20--l ,200

200-400

13,600-I 8,400

2,2f O-2,690

493-667

Air cleaner

Element

Fuel type

Specification

* TEN terminal of diagnosis connector

The t mark indicates newly equipped grounded. parts.

Unleaded reguiar

(RON 91 or higher)

Oi! permeated

Europe.....Unhzaded premium

(RON 95 or higher)

Australia...Unleaded regular

(RON 91 or higher)

-t

93GOF2-7 i 3

I

F2

TURBOCHARGER

TURBOCHARGER CONTROL [BP TURBO]

CONTROL [BP TURBO]

l l

OUTLINE

The air-to-air intercooler is adopted to lower intake air temperature and to improve engine performance.

With addition of the wastegate control system, engine torque at higher rpm is increased.

AIR BYPASS VALVE

WASTEGATE

SOLENOID VALVE

TURBOCHAR

SYSTEM DIAGRAM

ACTUATOR

!NTERCOOLER

-

AIR BYPASS VALVE 1 t

FZ-12 n

Ii Y7rzFes-~ m I

-\

TUREiOCHARGER

WASTEGATE SOLENO1D VALVE

93GOF2-7 7

TURBOCHARGER CONTROL [BP TURBO]

F2

WASTEGATE CONTROL

The engine control unit controls the wastegate

solenoid valve to give higher boost to the engine in the higher rpm range, increasing engine torque

and power.

I

System

Diagram t

1 i i

ECU

AIRFLOW METER r

ACTUATOR

WASTEGATE SOLENOID

: OFF (VALVE CLOSED)

VALVE

ACTUATOR

BOOST

PRESSURE

WASTEGATE SULENOlD

: ON (VALVE OPEN)

VALVE

ACTUATOR

\

WASTEGATE

WASTEGATE

SOLENOID VALVE

Operation

Engine speed below 5,300 rpm

The

wastegate solenoid valve is OFF. Boost pressure is

ap-

plied

directly

to the actuator

and the wastegate opens when the boost pressure exceeds 49 kPa (0.5 kg/cm , 7.1 psi).

Engine speed above 5,300 rpm

The wastegate

solenoid valve is

UN.

Some boost

pressure is

bypassed

to the intake manifold, limiting the opening of the wastegate to increase boost pressure and

improve

engine per- formance.

F2-13

F2

TURBOCHARGER CONTROL [BP

TURBO] lntercooler

The air-to-air intercooler utilizes fresh air flow through the in- tercooler core to reduce the intake air temperature.

If

the

air compressed by the turbocharger was

sent

directly into the combustion chamber without passing through the in- tercooler, the charging air efficiency would be

reduced by

the high temperature of the intake aii-.

The intercooler, by cooling this high temperature air, substan- tially increases the charging air efficiency

and

engine output,

as

well as supressing ignition knocking by reducing the com- bustion gas temperature.

The intercooler is mounted at

the left front of the vehicle.

LARGE

+ FULLY OPEN

BYPASS

AIR

AMOLIN

8EGlNNIp

OF OPEN

SMALIL i

430 VACUUM

(5-l) mmt-lg

OnW

TURBOCHARGER

INLET

93GOF.Z721

Air Bypass Valve

The air bypass valve bypasses intake air from the air funnel to before the turbocharger in order to reduce air vibration noise during deceleration.

When the throttle valve is closed suddenly during high-rpm and heavy-load operation, air vibration occurs between the throttle vatve and the turbocharger as a result of pressuriza- tion

caused

by

inertia

of the intake air. This system prevents such noise.

!=2-14

FUEL SYSTEM

F2

FUEL SYSTEM

Due to the installation of the propeller shaft fur the 4WD, the fuel tank is designed with left and right section.

Therefore, a transfer pump is used to pump the fuet from the left to the right (fuel pump) side. The transfer pump is mounted in the fuel tank, and is controlled by the transfer pump switch and the fuel pump control unit.

The fuel pump control system is adopted for BP turbo model.

CONSTRUCTION

PRESSURE REGULATOR

\

FUEL PUMP

RESISTOR/REU\Y

FUELPUM IP SWI’ TCH

\

TRANSFER

/

PUMP

FUEL VAPOR

FUEL PUMP

FUEL TANK i

4x4 CONTROL UNIT [BP SOHC]

FUEL PUMP CONTROL UNlT [BP TURBO]

F2

FUEL VAPOR VALVE

FUEL SYSTEM

FUEL VAPOR VALVE

93GOF2-722

The fuel vapor valve is installed in the fuel tank to allow fuel vapors within the tank to escape to the charcoal canister.

The fuel vapor valve contains a shut-off valve to prevent raw fuel from escaping during hard cornering 01 at other times when there is significant fuel slosh. l

FUEL PUMP CONTROL SYSTEM [BP TURBO] l

Outline

The fuel pump control system supplies electric power to the fuel pump at ail times while the engine is running. The fuel pump can thus operate even though the fuel pump switch in the airflow meter OFF. rhe fuel pump switch may open (switch OFF) on deceleration due to back-flow of air from the turbocharger.]

To improve fuel pump longevity, the fuel pump is controlled by the engine control unit (ECU). (Refer to next page.)

MAIN RELAY (FUEL 1NJ RELAY)

ECU

FUEL PUMP

RESISTOR/RELAY

I I I

CIRCUIT OPENING

ON

P CPU

TERMINAL F/P

F2-16

FUEL SYSTEM

F2

Two-stage WeI pump operation

Engine running (Except heavy load or cranking)

The ECU 1 I circuit is ON, opening the contact plate in the fuel pump resistor/relay. Current from the circuit opening relay to the fuel pump flows through the resistor in the fuel pump resistor/relay, and the voltage to the fuel pump is reduced to approx. WV, causing the fuel pump to operate at a reduced speed to im- move fuel pump longevity.

MAIN RELAY

L

Engine under heavy load or cranking

The ECU 1 I circuit is OFF and the contact plate in the fuel pump resistor/relay is closed. Unreduced battery current flows to the fuel pump through the contact plate, causing the fuel pump speed and output to be increased to meet the demands of the engine.

I

_:

. :

‘.

. . . . . . . . .

93GW2-725

FZ-17

I

F2

FUEL SYSTEM

FUEL PUMP RESISTOR/RELAY [BP TURBO]

The fuel pump resistorlretay supplies battery voltage to the fuel pump when the ECU 11 circuit is OFF, and approx. 1 OV when the ECU 11 circuit is ON. It is mounted on the firewall.

93GOF2-726

TRANSFER

Outline

PUMP CONTROL

The fuel tank is buitt with separate right and left sections to accommodate shaft. As fuel is puited from the right side of the tank, the right (fuel pumb) side to balance the fuel level. the. installation of the propeller transfer pump pumps the fuel from the left to the

FUEL IN LEFT TANK

I

FUEL PUMP CONTROL. UNIT

NO FUEL IN LEFT TANK

TRANSFER

/

TRANSFER

PUMP SWITCH: OFF

PUMP

FUEL PUMP CONTROL UNIT

TRANSFER

/

TRiNSFER

PUMP SWITCH: UN

PUMP

93GOF2-727

Operation

1. Whenever the ignition switch is ON and fuel is in the left (transfer pump) side of the fuel tank the fuel pump switch is open, the transfer pump circuit in the fuel pump control unit is operates. closed, and the transfer pump

2. When the fuel in the left side of the tank drips betow a specified point, the fuel pump switch is grounded and the transfer pump stops operation.

3. To prevent the transfer pump from

being

turned ON and OFF repeatedly, possibly shorting the life of the pump, when the vehicle is driven on a rough road

and

the fuel level is low, there is a

ten-second

delay circuit in the control unit to delay the turning ON and OFF the pump. f2--I 8

Transfer Pump Switch

FUELSYSTEM

F2

The fuel pump switch is a float-type ON/OFF switch used to operate the transfer pump. It is part of the fuel gauge sender unit. ^_

F2

CONTROL

STRUCTURAL

SYSTEM

VIEW

CONTROL SYSTEM

STOPLIGHT SWITCH CLUTCH SWITCH

INJECTOR

P/S PRESSURE

SWITCH

PUMP

CONTROL UNll

CONTROL UNIT

OXL ‘GEN SE877

DtSTRIBUTOR

SOLENOID

(PRESSURE

/

VALVE

REGULATOR)

I

WATER THERMOSENSOR

NEUTRAL SWITCH

CONNECTOR

P REStSTORlRELAY

FUEL tNJ RELAY (MAIN RELAY)

AIRFLOW METER

93GOf2.729

CONTROL SYSTEM

WE~DOST WARNlNG BUZZER [BP TURBO]

To improve engine reliability, the overboost warning buzzer installed in the instrument cluster sounds during overboost conditions as detected by engine driver is thus warned to reduce engine

speed

and intake air amount caiculations within the ECU. The

speed.

DETECTtON

OVERBOOST

BUZZER

TURBOCHARGE INDICATOR [BP TURBO]

When the turbocharger boost pressure calcul’ated by intake air amount and engine speed reaches the predeter- mined level and the transaxle is in gear, the turbocharge indicator illuminates to inform the driver of turbocharge operation.

1

AIRFLOW METER

ECU

CALCULATION

-, OF

BOOST

PRESSURE

*

TURBOCHARGE

INDICATOR rd”

DISTRI BUTUR i

4 NEUTRAUCLUTCH

SWITCH

F2

CONTROL SYSTEM

KNOCK CONTROL SYSTEM [BP TURBO]

This svstem retards the ignition timina when enaine knocking occurs because of usage of low octane fuel, etc.

1NTAKE

MANIFO

KNOCK SENSOR

(INSTALLED BETWEEN

No.3 CYLINDER)

No.2 AND

IGNITER

KNOCK iX?NTROL

UNIT

Operation

When the engine vibrates, the knock sensor generates a slight voltage signal that is the sent to the knock control unit. The knock control unit determines whether the signal is a knocking signal. If it is a knocking signal, the ignition spark is retarded according to the intensity of the knock to a maximum of 4O.

Inhibition of spark retardation

In order to improve drivability and fuel economy, the ECU inhibits the above spark retardation when the

‘engine load Ls light, the coolant temperature is below O°C (32OF), the engine is cranking during engine test conditions. l

Note

The knock

~ensur

When a matfunction only after inspecting and knock control unit cannot be inspected individually. code number 05 is indicated, replace the knock controt unit or sensor the related wiring and connectors.

F2-22

OXYGEN SENSOR [BP TURBO]

I

CONTROL SYSTEM

CERAMlC HEATER

F2

Because the temperature of the exhaust gas is inherently low in turbocharged uses a rapid heating ceramic heater to detect the air/fuel ratio,

PRESSURE REGULATOR CONTROL SYSTEM [BP TURBO]

93GOF2-733 engines, the BP Turbo model

SOLENOID

(PRESSURE

VALVE

REGULATOR CONTROL) t

PRESSURE

REGULATOR I

II FUEL INJ

RELAY

(MAIN REU\Y)

I

I

FUEL

+ (FROM

II Ir

FUEL c

Ill

(TO FUEL TANK)

PIPE1

-’ VACUUM

CT0 DYNAMIC

CHAMBER)

BATTERY - nme*rn -.-a

To prevent percolation of the fuel during hot restart idle, vacuum to the pressure regulator k cut for 180 sec., and the fuel injection pressure is increased to slightly more than 284 kPa (2.90 kg/cm’, 41.2 psi). l l

Operating condition

Coolant temperature: Above 90°C (194OF)

Intake air temperature: Above 58OC (136OF) g No-load condition

FZ-23

F2

CONTROLSYSTEM

AK CUT-OFF SYSTEM (AI-X)

To improve the retiability of the engine at high temperature condition, the water thermoswitch on the radiator is switched OFF above approx. II I “C (232OF) and stops the A/C operation.

BLOWER FAN

ECU

WATER

THERMOSWITCH

IABOVE

111 OC (232OF): OFF] NC SWITCH

NC OPERATION

IGNITION

T l 1

MAGNET

CLUTCH

BLOWER SWITCH

93GOF2-73

F2-24

SUPPLEMENTAL SERVICE INFORMATION

F2

SUPPLEMENTAL SERVICE INFORMATION

The following points in this section are changed in comparison to the Mazda 323 Workshop Manual

[I 203-I U-89F (Europe) or 120410-89F {Australia)]. l intake air system components

Removalllnspectionll nstaltation

WASTEGATE [BP Turbo] l

Inspection

WASTEGATE SULENOlD VALVE

[BP Turbo]

[BP Turbo] l Inspection l l

Turbocharger [BP Turbo]

Inspection

Removalllnstaltation l

Air bypass valve [BP Turbo]

Removal/hstallation

l

1 nspection lntetcoolet [BP Turbo] l

RemovaMnspection/tnstaltation

Fuel tank l

Removal ! Inspection I Installation

Fuel pump control unit [BP Tubto]/4x4 l l

1 nspection

Replacement

Transfer pump switch l l

Inspection

Replacement

Transfer pump l l

Inspection

Replacement l

Fuel pump resistor/relay

System operation l l

Inspection injector [8P Turbo]

Volume test l

Exhaust system components

Removal / 1 nspection / Installation

Engine control unit (ECU) [BP Turbo] l l

Terminal voftage

Oxygen sensor [BP Turbo]

Inspection l l

Replacement

Knock sensor [BP Turbo]

Replacement control unit [BP SOHC]

93GOFZ736

F2-25

F2

SELF-DIAGNOS1S

SELF-DIAGNOSIS FUNCTION

FUNCTION

OUTLINE

The self-diagnostic function and diagnosis procedure are the same as for the 2WD model. However there are some additional malfunction codes for BP Turbo models.

93GOF2-737

MALFUNCTlON CODE NUMBERS command of throttle

F2-26

SELF-DIAGNOSIS FUNCTtON

F2

Q3en or short ci rculi

-

-

26

34

42

ON

OFF

ON

OFF

ON

OFF l l

Caution

If there is more than one failure present, the code numbers will be indicated in numerical or- der, lowest number first.

After repairing and depress the ECU memory. a failure, turn off the ignition switch, the brake pedai for at least five (5) seconds disconnect the negative battery cable, to erase the malfunction code(s) from f2--27

F2

SELF-DIAGNOSlS FUNCTION

Troubleshooting

If a malfunction code number is shown on the SST (49 l-l01 8 9Ai, 49 B019 9AO), check for the cause using the chart related to the code number shown, [Regarding code numbers except 05, 24, and 42, refer to “Troubleshooting” in Workshop Manual [I 203-I O-89F (Europe) or 1204-f 0-89F (Australia)].

;TEP

I

INSPECTION

Check knock sensor and knock control unit circuit for poor connectlon

05 (KNOCK CONTROL UNIT)-BP TUR80

ACTtON

Yes Repalr or replace connector

2 Check knock control unit terminal voltage with ignition switch ON

3 Check that voltage at ECU terminal 2J is approx. 4V at idle rs7 page F2-64

Yes Recheck ECU connector for connection poor

NO

4 If OK, replace ECU

4 If not OK, repair or replace connector

Repair wiring harness (R/Y) between

ECU terminal 2J and knock control unit

Circuit Diagram

I ECU

IGNITION

SWITCH

15A

BATTERY

93GOF2-7: l

W/L Y/i3 G/O W RIB R/L

:

MAIN RELAY (FUEL INJ)

W/G BIW

C&=&A

KNOCK CONTROL UNIT

W/R EMLG RN Y/L

1

MAIN

RELAY

(FUEL 1N.J) jr-

--

YIL

- - 1

BlLG

MCK CONTROL

KNOCK SENSOR

SELF-DIAGNOSIS FUNCTION

:UDE No. 24 (FUEL PUMP RESISTOR/RELAY)-BP

STEP INSPECTION

1 1 Disconnect connector from ECU and check if

1 battery voltage exists at connector terminal 1 I (L) with ignition switch ON

TURBO

ACTtON

Yes Check ECU terminal connector for connection poor

NO e If OK. replace ECU c=> If not OK, repair or replace connector

Go to next step

2 In same condltlon as Step 1, check if battery voltage exists at resistor/relay connector terminai- wire (W/R)

3 Check if there is continuity between fuel pump res!stor/relay terminals C (‘W/R) and D (L)

Yes Repair wiring harness (W/R)

NO

Go to next step t

Yes Check for short or open circuit in wiring from main relay (FUEL INJ relay) to resistor/relay

NO

Replace resistor/relay

Circuit Diagram

F2

93GOF2-74 1

I

IGNITION

SWITCH rl

BATTERY

DIAGNOSIS

CONNECTOR

F/P TERMINAL *

IGNlTlON

B W/R 7

0fP

-

W/R c

FUEL PUMP

RESISTOR/RELAY

FUEL

PUMF

ECU

I

Of1

RIB 1

W/G

&J,~&&&l&&c!zr5&

1~ IS

GIB \

10 10 IM

.

IV rrrrrT?rrTT

17 ?R IP 1N

LGrf

I

Grw

J 1 1

1K

1~

II

IJ tC

III l

1E

IF

I v

[ WR

I

1C ro

IA

:8

BRff t BIG 1 R/W ! t/B 1 WIB 1 W/R

BIL UY O/B WN

CIRCUIT OPENING RELAY

LG

&l~&cLa~~c!zch&&&&~

2Y

L/O

2w

]

FUEL PUMP

Y

2u

1

R/Y

2s 20

I

20

I

LGlR YfL B/LG

* 1 W ] 810

I

28.4 2K 21 2G 2E 2C 2A

MAIN RELAY

WIG BfW

FUEL PUMP RESlSTOR/RE~Y v WIRBIP

B - LG

93GOF2.74

F2-29

F2

SELF-DIAGNOSlS FUNCTION

XIDE No. 1 42 (SOLENOID VALVE - WASTEGATE)-BP

STEP tNSPECTiON

1 Disconnect connector from ECU and check if battery voltage exists at connector terminal f H

(O/B) with Ignition switch ON

TURBO

ACTION

Yes Check ECU terminal connector for poor connection

No e If OK, replace ECU

4 tf not OK, repalr or replace connector

Go to next step

2 in same condition as Step 1, check if battery voltage extsts at solenoid valve connector terminal-wire

Yes Repair wiring harness

3 Check if solenoid valve is OK

.r3 page F2-46

NO Go to next step

Yes Check for short or open circuit in wiring from main relay (FUEL INJ relay) to solenoid valve

NO

Replace solenoid valve

Circuit Diagram

IGNITION SWITCH v

15A

/\:

MAIN RELAY

(FUEL INJ)

B/w

‘L

BA-iTERY k

WIG

./

O/B

WASTEGATE

SOtENOlD VALVE

ECU

RIB 011 GIB WIG

I

1u

10

B&Y

*

1M

I I

B/L B;G UY Rh’

LGIY

1K i

*

L

71

GM, l v L/R

I I

IJB d/B WiB Wff W/R

F2-30

WASTEGATE

SOLENOfD VALVE

A

B

W/R

O/B

MAIN RELAY (FUEL INJ)

WIG %fw

W/R B

TROUBLESHOOTING

RELAT1ONSt-W CHART i

OUTPUT DEVICE

TRUUBLESHOOT1NG

GUIDE

[BP TURBO]

GUIDE

, INPUT DEVfCE

KNOCK SENSOR

DIAGNOSIS CONNECTOR

(TEN TERMfNAL)

IGNITION SWITCH

(START POSITION)

EIL SIGNAL * ’

P/S PRESSURE SWITCH

A/C SWITCH

NEUTRAt AND CLUTCH

SWfTCHES

STOPLIGHT SWITCH

ATMOSPHERIC PRESSURE

SENSOR (IN ECU)

THROTTLE SENSOR

INTAKE AfR THERMOSENSOR

AlRFLOW METER

OXYGEN SENSOR

WATER THERMOSENSOR

DISTRIBUTOR

*I E/L SIGNAL: Slower fan control dow defroster switch ON

0 Cl

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

0

0

0

1

0

0

O switch Second

0

0 position

0

0 or higher,

L

0 cooSing fan operating?

I

-

I-

0 0

I-L

93GOF2-i45

ON, or rear wtn- headlights

0

I------

i

0

0

0

0

3

F2

TROUBLESt=iUUTlNG GUIDE

SYMPTOM TROUBLESHOOTING

Regarding symptom troubleshooting

HIGH UIL CONSUMPTION, except LACK OF POWER, POOR XCELERATION, KNOCKING, and refer to Workshop Manual [I 203-l O-89F (Europe) or 1204-l O-89F (Australia)].

19 LACK OF POWER [BP TIJR801

DESCRIP-

TION l

*Performance poor under load when throttle valve wide open

*Reduced maximum speed

Idle condition normal

[TROUBLESHOOTING HINTS1

3 Wastegate always open or opens early

3 Turbocharger damage

@ Factors other than engine malfunction

*Clutch sllpping l l

Brake dragging

*Low tire pressure

Incorrect tire size l

Overloaded vehicle

@ Low intake air amount

*Throttle valve not open fully

*Clogged intake air system

@ Air/Fuel mixture lean l l

Fuel iine pressure decreases

Fuel injection malfunction

@ Poor ignrtjon

@ Low engine compression

@ Alcohol blended fuel used

@ Knock control system malfunction

ACTION TEP INSPECTlON

1 Install pressure gauge in intake air pipe and check boost pressure at engine speed of 4,000 wm

CT page F2-45

Yes

Go to Step 3

Boost pressure:

More than 2.0 kPa (0.02 kglcm2, 0.3 psi)

NO Check for air leakage and exhaust gas leakage

4 If OK, go to next step

4 In not OK, repair

2 Check wastegate f7 page F2-45

Yes Remove intake air pipe from turbo- charger and check if compressor wheel rotates smoothly t7 page F2-46

4 If OK, check air cleaner element and throttle valve

+ If not OK, replace turbocharger

3 Check factors other than engrne l

Clutch slipping

1 8rake dragging

’ l

Low tire pressure l

Incorrect tire srze

FZ-32

Yes Go to next step

NO Repair or adjust

]sTFP 1

INSPECTION

Aerator depressed ful ty

TROUBLESHOOTING GUIDE

ACTION

F2

I rminal 1F voltage ignition timing: BTDC 10 = I*

: SELF TEST

8 Check for correct fuel line pressure at idle’

Fuel line pressure:

265-314 kPa (2.7-3.2 kg/cm’, 38-46 psi)

(vacuum hose to pressure regulator dis- connected)

Yes Check if fuel line pressure decreases when accelerating quickly

NO

4 If decreases check fuel pump maximum pressure*

If OK, check fuel line and filter for clogging

4 If no decrease, go to next step

Low pressure

Check fuel irne pressure while pinching fuel return hose

4 If fuel line pressure quickly in- creases, check pressure regulator' e If fuel lrne pressure gradually in- creases, check for cloggrng be- tween fuel pump and pressure regulator

If not clogged, check fuel pump maximum pressure*

High pressure

Check of fuel return line is ctogged

4 If OK, replace pressure regulator e If not OK. replace

- _

* Refer to 323 Workshop Manual [I 203-1 O-89F (Europe), or 1204-lU-89F (Australra)].

FZ-33

F2

II. Measure resistance l-O-l.lmm

(0.039-0.043 in)

DAMAGE AND

DETERlORATtON

F2-34

Resistance: 16 kSI per 1 m (3.28 fi)

Manual [I 203-I U-WF (turope) Or 1204-l O-89F (Austraha)].

TROUBLESHUOT1NG GUIDE

;TEP

14

INSPECTION

Check if resistance of rgnrtm coil IS OK’

Resistance (at 20°C [SS*Fj):

Primary coil winding _....-.. Cl.81 -0.99Q

Secondary coil winding.,.. IO-16 kQ

PRIMARY COIL

WINDING

SECONDARY COIL

WIND tNG

Yes

Go

to next step

ACTION

F2

15 Check fur correct engine compressron”

Engine compression:

785 kPa (8.0 kg/cm2, 1 I4 psi)-300’ rpm

L

Yes Go to next step

No

1

Check engine condition *

16 Change fuel and check if condjtjon improves l

Worn p&ton, piston rings or cylinder wall l l

Defective cylinder head gasket

Distorted cylinder head l

Improper valve seating l Valve sticking in guide

Yes Change fuel to another brand

I

No

I Try known good ECU and check if con- dition imDroves

* Refer to 323 Workshop Manual [ 1203-lo-89F (Europe) or 1204-l O-89F (Australia)l. 93GOF2-74 6

F2-35

F2

TROUBLESHOOTING GUIDE

20

IESCRIP- rm l

. Performance poor while accelerating

Idle condition normal

[TROUBLESHOOTING HINTS]

3 Wastegate always open or opens early

3 Turbocharger damage

3 Factors other than engine malfunction l Ciutch slIpping l l

Brake draggrng low tire pressure l

Incorrect tire size

. Overloaded vehicle

TEP INSPECTION

POOR ACCELERATION

-l Install pressure gauge in intake air pipe and check boost pressure at engine speed of 4,000 rpm w page F2-45

[BP TURBO]

I Yes

1

@ Low intake air amount l

Throttle valve not open fully

*Clogged intake air system

@ Air/Fuel mixture Iean l fuel line pressure decreases l

Fuel Injection malfunction

@ Poor Ignition

@ Low engine compression

@ Atcohol blended fuel used

ACTION

Go to Step 3

Boost pressure:

More than 2.0 kPa (0.02 kglcm2, 0.3 psi)

No Check for air leakage and exhaust gas leakage

4 If OK, go to next step

4 If not OK, repair

2 Check wastegate w page F2-45 Yes Remove Intake air pipe from turbo- charger and check if compressor wheel rotates smoothly w page F2-46 c3 If OK, check air cleaner element and throttle valve

4 If not ok, replace turbocharger

3 Check l l factors other than

Clutch stipprng

5rake dragging engine l l

Low tire pressure

Incorrect ttre size

FZ-36

Yes Go to next step

No Repair or adjust

TROUBLESHOOTING GUIDE

F2

;TEP /

4

5

6 i Check if throttle valve fully opens when depress- rng accelerator fully

Check if “00”

Checker

SYSTEM SELECT: 1 t NSPECTION fs dlsptayed with ignition on Self-Diagnosis switch ON* i~sT SW: SELF TEST

ELECT SW: A

Check if continuity between throttle sensor termi- nals IDt and E ts as shown’

ACTION

Yes Go to next step

No Check if accelerator cabte is correctly

Installed *

-a If OK, check throttle body* c=> If not OK, install accelerator cable correctly*

Yes Go to next step

NO Malfunction Code No. displayed

Check for cause (Refer to specified check sequence) *

“88” flashes

Check ECU terminal 1 F voltage

Voltage: Approx. f 2V

(Ignition switch ON) e If OK, replace ECU’ c3 f f not OK, check wiring between

ECU and Self-Diagnosis Checker

Yes Go to next step

CT- page F2-60

7 Connect System Selector to diagnosis connector and set Test Switch to “SELF TEST” and check for correct ignition timing at idle after warm-up’

Ignitian timing: BTDC 10 f 1 D

Yes Check if ignition timing advances when accelerating e If advances, go to next step

=S If no advance, check ECU terminal voltages

No Adjust

8 Check of ECU terminal voltages are OK

CT page F2-60

Yes Go to next step

No Check for cause

9 Check for correct intake manrfold intake manifoId vacuum: vacuum at idle

! More than 450 mmHg (17.7 inHg)

Yes Go to next step

NO

Check ior air leakage 07 intake air sys- tem components

* Refer to 323 Workshop Manual [1203-IO-89F (Europe) or 1204-IO-89F (Australia)].

F2-37

F2

TROUBLESHUOTtNG GUIDE check fuel pump maxi- fuel line and filter for pump and pressure

High pressure

Check if fuel line is clogged

II. Measure resistance r--- ---_--es-,

DAMAGE AND

DETERIORATION

* Refer to 323 Workshop Manual f1203-1 O-89F (Europe) 12041U-89F (Australia)].

F2-38

TROUBLESl-lOOTING

;TEP 1 INSPECT1ON

13 Check if resistance of ignition coil 1s OK*

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

GUIDE

Yes

Go to next step

NO Replace

ACTION

F2

14

15

16

Check for correct engine

1 Engine compression compression”

(Minimum):

785 kPa (8.0 kg/cm , It4 psi)-300 ipm

Change fuel and check if acceleration improves

Check if NC cut-off control system is OK’

Yes Gc to next step

NO l l l

Check engine condition”

Worn piston, piston rings or cylinder wall

Defective cylinder head gasket

Distorted cylinder head l

Improper valve seating

*Valve sthing in guide

Yes Change fuel to another brand

NO Go to next step

Yes Go to next step

No Repair or replace

17 Try known good ECU and check if condition improves

I

* Refer to 323 Workshop Manual [1203-IO-89F (Europe) or i204-IO-89F (Australia)].

93GOF2-747

F2-39

F2

TROUBLESHOUTING GUIDE

22 KNOCKtNG [8P TURBO]

IESCW-

rim

l

Abnormal combustron accompanied

TROUBLESHOOTING HtNTS]

3 incorrect ignition timing (Too advanced)

2 Knock control system malfunction

3 Carbon deposits in cylinder

3 Overheating by audible “pinging” noise

TEP INSPECTION

1 Connect System Selector to diagnosis connector and set Test Switch to “SELF TEST” and check for correct ignition timing at idle after warm-up’

@ Low octan fuel used

@ Air/Fuel mixture lean l l

Fuel injection amount not correct

Fuel line pressure decreases while accelerating

ACTlON

Yes Go to next step ignition timing: BTDC 10 f lo

No Adjust

I

I

2 Check if “00”

Checker is displayed on Self-Diagnosis with igmtlon switch UN*

W: SELF TEST

3 Check for correct fuel line pressure at idle*

Fuel line pressure:

265-314 kPa (2.7-3.2 kg/cm2, 38-46 psi)

(vacuum hose to pressure regulator dis- connected)

Yes Go to next step

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)

4 If OK, replace ECU

4 If not OK, check wiring between

ECU and Self-Diagnosis Checker

Yes Check if fuel Iine pressure decreases when accelerating quickly

4 If decreases, check for clogging between fuel pump and pressure regulator e If no decrease, go to next step

0 page FZ-60

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

I fNSPECTlON

I Check if cootrng system IS OK’

YES

Go to next step

ACTION l

No Repair or reptace l l l

Electric

Radiator* cooling fan *

5 Try known good ECU and check if condltlon rnproves

Yes Replace ECU *

NO Change fuel to another brand or use higher octane fuel

Refer to 323 Workshop Manual [1203-l O-89F (Europe) or It 204-I O-89F (Australia)]. %%‘3OF2-748

-

F2-4 I

F2

TROUBLESHOOT1NG GUIDE

25 HIGH OIL CONSUMPTION [BP TURBO]

DESCRIP- 1 l

Oil consumption excessive

TION l

Exhaust gas white

TROUBLESHOOTING HINTS1 a PCV system malfunctton

@ Englne malfunction

*

(Oil working up, working down, or leakage)

3 Oil leakage from turbocharger

ZEP [ INSPECTION

1 Check if PCV hose, ventilation hose or their at- taching nipples are separated, damaged, ciogged, or restricted

Yes Repair or replace

NO

Go to next step

2 Check insrde of air hose, air pipe, and intercool- er for excesstve oil

ACTION

Yes Possibly oil working up

Check PCV valve and PCV hose for clogged

NO

+ If OK, go to next step e If not UK, repalr or replace

Go to next step

3 1 Check white exhaust gas visible when ventilation hose or PCV hose removed

1

4

1

Remove turbocharger compressor and check at oil seals of and turbine shafi for oil leakage

Yes Go to next step

No Check hoses for clogged

Yes Replace turbocharger

NO l l l l l

Engine malfunction (Oil working up, working down, or leakage)

Check foltowing

. Worn piston or cyiinder

Worn piston ring groove’

Stuck piston rings*

Worn vatve seal*

Worn valve stem *

Worn vatve guide’

* Refer to 323 Workshop Manual [1203-IO-89F (Europe) or 1204-IO-89F (Australra)].

93GOF2-74:

FZ-42

1NTAKE AIR SYSTEM

INTAKE AIR SYSTEM

COMPONENTS

Removaf / Inspection / installation

1. Remove in the order shown in the figure.

2. Inspect all parts and repair or replace as necessary.

3. Install in the reverse order of removal, referring to Installation

I

TURBO

Note.

7.8--f l N-m (SO-1 IO cm-kg,

69-95 in-lb)

@

7.8--11

(80-I

N-m

1 Cl cm-kg, 69-95

/ in-ltr)

F2

N-m {m-kg. ft-

93GOF2-750

F2-43

F2

I. Air cleaner

2. Air cleaner element

Inspect fur dirt, damage, or oil

3. Airflow meter

4. Air hose

5. Air pipe and air hose

6. Accelerator cable lNTAKE AlR SYSTEM

7. Throttle body

8. ISC valve

9. Air valve

IO. Dynamic chamber

I 1. Intake manifold

Installation Note . . . . . . . . ..__..........._._..._._.. below

93GOF2-751 installation Note

Intake manifold

1. Tighten the bolts in steps in the order shown in the figure.

Tightening torque:

19-25 Nm (1.9-2.6 m-kg, 140-f9 ft-lb)

93GOF2-75:

F2-44

L

TURBOCHARGER

PREPARATION

SST

49 HO80 740

Gauge. pressure

TURBOCHARGER

CONTROL SYSTEM

CONTROL SYSTEM

F2

93GOF2-753

SYSTEM OPERATION

1. Install a pressure gauge 149 kPa (0.5 kg/cm2, 7.1 psi) min.1.

93GOF2-754

I

93GOF2-755

2. Connect a tachometer to the diagnosis connector lG- terminal.

3. Start the engine.

4. Verify that the boost pressure when the engine speed is

4,000 rpm is within specification.

Specification: More than 2.0 kPa ( 0.02 kg/cm2, 0.3 psi)

5. If not within the specification, check for air Ieakage, exhaust gas leakage, and for the wastegate stuck open.

6. if OK, replace the turbocharger.

WASTEGATE

Inspection

1. Remove the air hose from the wastegate actuator.

2 Connect the SST to the actuator.

93GOF2-756

I

3. Raise the front of the vehicle and support it on safety stands.

4. Remove the undercover.

93GOF2-757

F2-45

FZ-46

F2

I

TURBOCHARGER CONTROL SYSTEM

5. Mark the actuator rod. l

Caution

Do not apply compressed kg/cm2, 14 psi). air over 98 kPa (1.0

6. Adjust the compressed air pressure to 83 kPa (0.85 kg/cm”, 12 psi).

7. Verify that the rod moves when applying and releasing air pressure.

93GOF2-756

WASTEGATE

Inspection

SOLENOID VALVE

1, Remove the ,solenoid valve.

2. Verify that air does nut flow from @ through @

93GOF2-75!

3. Apply IN to the solenoid valve and verify that air flows from

@ through @

93GOF2-761

TURBUCHARGEFI

Inspection

1. Be sure tf7e engine is cool.

2. Remove the air hose.

3. Check that the compressor wheel assembly turns smoothly.

4. If there is excessive drag or noise, replace the turbocharger.

93GOF2-761

TURSUCHARGER CONTROL SYSTEM

F2

Removal I InstaIlation l

Caution l l l

Be carefui of following points after turbocharger

Do not carry the turbocharger

Do not drop the turbocharger. removal. by the actuator rod or actuator hose.

Set the turbocharger down with the turbine shaft horizontal. l

9 Cover the intake, exhaust, and oil passages to prevent dirt or other materia1 from entering.

Use the specified new studs when installing the turbocharger.

1. Disconnect the negative battery cable.

2. Lift up the vehicle.

3.

Remove the undercover.

4. Drain

the engine

coolant.

5. Remove in

the order shown in the figure.

6. fnstall in the reverse order of removat, referring to Installation Note.

7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)

G I’

/

43-61 (4.4-6.2, 3245)

36-42

7.8-1 1 N-m (80-110

(3.94.3, cm-kg, 6

28- cm-kg, 69-95 indb)

26-31 12.7~g-2. 20-231

w

7.6-17 N-m (80-7 t d cm-kg, 69-95 in-lb)

19-26 (l-9-2.6, 14-19)

N-m (m-kg, Mb]

93GOF2-762

F2-47

I

1

F2

1. Radiator

2. Insulators

3. Air hose, and air pipe

4. Oxygen sensur connector

5. Front exhaust pipe

6. Bracket

TURBOCHARGERCONTROLSYSTEM

7. Water hoses

8. Oil pipe

9. Oil return pipe

10. Exhaust manifold and turbocharger

Removal Note . . . . . . . . . . . . . . . . . . . . . . .._.-........_ below

Installation Note . . . . ..__-.............._...___.._. below

93GOF2-763

Removal Note

Exhaust manifold and turbocharger

1. Remove the exhaust manifold and the turbocharger as an assembly .

2. Remove the turbocharger from the exhaust manifold.

93GOF2-765

I

InstaIlation Note

Exhaust manifold and turbocharger

1. Remove all gaskets and sealant.

2. Install new gaskets.

3. Supply 25 cc (1.5 cu in) of oil through the oil passage of

4. the turbocharger.

Install the turbocharger

5. Install the turbocharger to the exhaust and the exhaust manifold. 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 nuts.

AIR BYPASS VALVE

Removal I Installation

1. Remove the vacuum hose and the air hoses from the air bypass valve.

2. Remove the air bypass valve.

3. Install in the reverse order of removal.

93GOF2-761

Inspection

1. C_onnect a vacuum pump to air bypass valve port @-

2. Verify that air flows from port @through port @ when 250 f 35 mmHg (9.8 * 1.4 inHg) vacuum is applied to port

TURBOCHARGER CONTROL SYSTEM

INTERCOOLER

RemovaI ! Inspection / Installation

1. Remove in the order shown in the figure.

2. Inspect the intercooler for crack or damage. Replace it if necessary.

3. Install in the reverse order of removal

F2

19-25 (1.9-2.6, 14-

(80-l 10 cm-kg, 69-95 in-lb)

1. Air cleaner and airflow meter assembly

2. Battery cooling duct

3. Air hose

4. Bracket

5 Undercover

6. Air hose

7. I ntercooler cm-kg, 69-95 in-lb)

N-m (m-kg, ft-lb)

93GOF2-761

F2-49

F2

FUEL

SYSTEM

PREPARATlON

SST

49 LO18 901

Injector checker

FUEL SYSTEM

For lnsgectlon of injector

93GOF2.770

9MUOF2-722

03UOFX-7 27

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. l

Caution

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 for fuel leaks.

ON

for

approx. 10 set,

and check

3. Turn the ignition switch OFF and remove the jumper wire.

F2-50

FUEL SYSTEM

F2

FUEL TANK

Removal I inspection / Instatlation l l l

Warning

Before performing reduce the possibitity the following operation, release the fue1 pressure from the fuet system to of injury or fire. (Refer to page F2-50.)

When removing

Before repairing the fuel tank, keep sparks, cigarettes, and open flames away from it. the fuel tank, clean it throughly with steam to remove all explosive gas.

1. Remove in the order shown in the figure.

2. Inspect the fuel tank components and repair or replace as necessary.

3. tnstall in the reverse order of removal, referring to Installation Note.

FUEL PUMP TRANSFER PUMP

0 SEAL RUBBER,

A

REPLACE

SSL

7

40-55 (4.1-56, 30-41)

N-m {m-kg, Mb)

93GOF2-771

F2-51

F2

FUELSYSTEM

l

Note

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 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).

03UOFX- 13!

TRANSFER PUMP CONTROL

System Operation

SYSTEM

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. l

Warning

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

I

FUEL PUMP CONTROL UNIT

FUELSYSTEM

FUEL PUMP CONTROL UNIT [BP TURBO] l

Refer to page Fl-12 for BP SOHC model. hspection

1. Remove the fuel pump control unit.

F2

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.

1

93GOF2-775

I

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 ter approx. IO sec. approx. WV af-

93GOF2-799

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.

93GOF2-800

I

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

4. Install in the reverse

unit

from the bracket.

order

of removal.

93GOF2.776

I

F2--53

F2 r

-.

FUELSYSTEM

TRANSFER PUMP SWlTCH

Removal I Installation

1. Refer to replacement of the transfer pump.

(Refer to below.)

93GOF2-777

Inspection

1. Check continuity between transfer pump connector termi- nal C and ground terminal. r

Float Dosition I Comnuity I

I Down I Yes

2. If not as specified, reptace the transfer pump switch.

I

03UOFX-82: 2

TRANSFER PUMP

Inspection

1. Remove the rear seat cushion.

03UOFX-823

2. Disconnect the transfer pump connector.

3. Check for continuity between transfer pump connector terminal-wires (ES) and (t/V).

4. If no continuity exists, replace the transfer pump.

03UOFX-825

Replacement l

Warning

When cigarettes, servicing the and open fuel flames system, keep away from sparks, the fuel.

1. Remove the rear seat cushion.

F2-54

FUEL SYSTEM

2. Remove the service hole cover of the transfer pump.

3. Disconnect the transfer pump connectors.

4. Disconnect the fuel hose,

5. Remove the transfer pump.

F2 l

Caution

Install a new seat rubber.

6. Install in the reverse order of removal.

03UOFX-826

Disassembly I Assembly l

Caution

Prevent contaminants from entering the transfer pump.

1. Disassemble in the order shown in ,the figure.

2. Assemble in the reverse order of disassembly.

3. Verify that the transfer pump operates correctly after assembling it.

HOSE, REPLACE

@

1. Fuel filter

2. Rubber mount

3. Transfer pump

4. Fuel hose

5. Transter pump switch assembly

93GOF2-77:

FZ-55

1

F2

93GOF2-775

93GOF2-78(

FUEL SYSTEM

FUEL PUMP RESISTOR/RELAY

System Operation

I. Remove the rear seat cushion.

2,

Measure

the voltage at the fuel pump connector terminal

A {G/O).

Voltage

r

I-

Crankinq

Others t

Approx. 12V

ACKXOX. I OV

3. If not within specification, perform the following inspection, and repair or replace if necessary. l l l

Fuel pump resistor/relay resistance. (Refer to below.)

ECU II terminal voltage. (Refer to page F2-60.)

Wiring harness and connector.

I i inspection

1.. Disconnect the connector.

2. Ground the fuel pump resister relay terminal D.

3. Apply 12V to terminal C and check for continuity between terminals A and B.

Terminal C

12 applied ov

Continutty between A and B

NO

Yes

4. Measure the resistance between terminals E and F.

Resistance : 0.62-0.66Q [at 20% (68OF)l

93GOF2-78:

1

93GOF2-78;

-

INJECTOR

Volume Test

1. Remove the injectors with the delivery pipe.

2. Affix the injectors to the delivery pipe with wire. l

Caution

Affix the injectors firmly to the delivery pipe so that no movement of the-injectors is possible. l

Warning

Be extremely careful when working with fuel.

Always work away from sparks or open flames.

3. Connect the SST to the battery and injector.

4. Check the injection volume with a graduated container.

Injection

volume:

BP SUHC....44-47

BP Turbo . ...87-105 cc (2.68-2.87 cu in)/15 sec. cc (5.31 -6.41 cu in)/15 sec. l

Caution

When using the SST, make sure of the SST num- ber and use correct one.

5. If nut correct, replace the injector(s).

93GOF2-783

EXHAUST

EXl-iAUSTSYSTEM

COMPONENTS

Removal ! inspection / Installation

I. Remove in the order shown in the figure.

2. Inspect alI

park and repair or replace as necessary.

3. Install in

the

reverse order of removal.

SYSTEM

BP SOHC

KET, REPLACE

7.8-l-i Nm

F2

7.8-11

{8B-110

69-95 in-lb)

N-m cm-kg,

40-55 (4.1-5.6, 3041)

1. Main silencer

Inspect for deterioration

2. Middle pipe assembly

Inspect fur deterioration

3.

Pre-silencer

Inspect for deterioration and restriction and restriction and restriction

N-m (m-kg, Mb)

93GOF2-784

4. Catalytic converter

Inspect for deterioration

5. Front

pipe

assembly

Inspect for deterioration

6. Exhaust manifold insutator

7. Exhaust manifold

Inspect for deterioration

and restriction

and restriction and restriction

F2-57

F2

BP DOHC TURBO

38-46

I

(X94.7, 28-34)

EXHAUST SYSTEM

‘\ GASKET, REPLACE

1 , Main silencer

Inspect for deterioration and restriction

2. Middle

pipe

assembly

Inspect for deterioration and restriction

3 _ P re-silencer

Inspect

for

deterioration

and restriction

4. Catalytic converter

Inspect fur deterioration and restriction

40-55 (\s.‘I--5.6, 30-W)

N-m (m-kg, R-B

93GOFZ71

5.

Front pipe assembly

Inspect for deterioration and restriction

6. Oxygen sensur

Inspection . . . . _. . . . . . . . . _ . . . . _. . . . . . _ . . _. . page F2-68

Replac.ement . . . . . . . . . . . . . ..*.--*.-....... page F2-68

7. Exhaust manifold and turbocharger

Removal / Installation . . . . . . . . . . . . . . . . page f2-47

ET’--58

CONTROL SYSTEM

F2

CONTROLSYSTEM

PREPARATION

SST

49 HOt8 9A3

Self-dragnosls checker

Engrne signal

IT-iOFlllO~

49 GO18 904

Sheet

System selector

93GUF2-786

I

For

ECU

ENGINE CONTROL

Inspection

UNIT (ECU)

1. Disconnect the ECU connectors.

2. Connect the SSTs (Engine Signal Monitor and Adapt- er) to the ECU as shown.

93GOF2-787

3. Place

the

SST (Sheet) 011 the Engine Signal Monitor.

4.

Measure the voltage at each terminal.

(Refer to pages FZ-60 to F2-67.)

5. If any ECU terminal voltage is incorrect, check the related input or output devices and wiring. If no problem is found, reptace the ECU. (Refer to above.)

93GOF2-801

TERMNALS 1 l

Caution

Never apply voltage to SST terminals A and B.

--I”- -

03UOFX

F2-59

F2

Terminal voltage [BP TURBO] eminal input

IA -

15

1c

ID

0

0

1

Connected to

Battery -

0

Main relay

(FUEL INJ relay)

1 Ignition switch

(START)

Self -Diagnosis

Checker

(Monitor lamp)

-lE

1F

1G

7H l!

I lJ I

- -

0

-

Self-Diagnosis

Checker

(Code Number)

I

0

I

Igniter

0

0

Solenoid vahe

(Wastegate)

Fuel pump resistor/relay r-Tcreiay

CONTROL SYSTEM

Test condition

Constant

OFF tgnltlon switch

ON

Wniie cranking lgnrtron switch ON

Test switch at “SELF-TEST”

Lamp illuminated ior 3 sec. after ignition switch OFF* ON

Lamp not illuminated after 3 sec.

Test switch at

“02

MONITOR” at idle

Monitor lamp illuminated

Test switch at “02 MONITOR” at idle

Monitor lamp not illumrnated

-

Buzzer sounded for 3 sec. after ignition switch OFF -+ ON

Buzzer not sounded after 3 sec.

Buzzer sounded

Buzzer not sounded

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

AIC switch OFF at idle

Correct voltage Remark

Approx. 12V for backup

Approx. OV

-

Approx. 12V

Approx. 1 OV

-

Approx. OV

With Self-

Approx. 5V Diagnosis Check- er and System

Approx. 12V Se’ector

Approx. 5V

Approx. 12’4

Below

-

Approx.

Below

Approx.

2.5V

12V

2.9

12V

1

Approx. OV

Approx. 0.2V

Approx. 12V

Below 1.5V

Approx. 1 OV

I3elow 15V

Approx. 12V

Below 2.5V

Approx. 12V

- l l

With Self-

Diagnosis

Checker and

System Selector

With System

Selector test switch at

“SELF-TEST’ ’

-

-

-

-

IK 0 Diagnosis connector

(TEN terminal)

System Selector test switch at

1L -

IM t 0

1

- -

Ground (Australia) Constant

- - -

Below 1 .OV Not used

(Except Australia)

F2-60

CONTROL

SYSTEM

F2

Always OV

Incorrect voltage

Always OV

Always OV (Srarrer turns)

I l l l l l

Possible cause

ROOM 10A fuse burned

Open circuit in wiring from ROOM 10A fuse to ECU termrnal IA

Main relay maifunctlon

Open or short crrcu~t in wirrng from main relay to ECU termrnal 1 B

Open or short circuit in wiring from ignition switch to ECU terminal 1C

Always UV

Always approx. 12V

Always approx. 5V l l l

Main relay (FUEL INJ relay} malfunctron

Open circuit in wiring from main relay to diagnosis connector terminal + B

Open or short circuit in wiring from dragnosls connector terminal MEN to

ECU terminal 1D

I l

. Poor connection at ECU connector

ECU matfunction l

ECU malfunction

Always below

2.5V

Always approx. 12V

-

No disptay on Self-

Diagnosis Checker

“88” displayed and buzzer sounds con- tinuously

I -

l l

. Main relay (FUEL INJ retay) malfunction (Refer to page F3-142)

Open circuit in wiring from main relay to diagnosis connector termjnal + B

Open or short circuit in wiring from diagnosis connector terminal FEN to

ECU terminal 1 F

Always OV l l l

Poor connection at ECU connector

ECU malfunction

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

Always below

23

Always approx.

Always below t2V

1 .OV

Always approx. 12V l

Open or short circuit in wiring from ECU terminal 1 I to resistor/retay

A/C does not operate l

AJC relay malfunction 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

AIC operates l l l l

Short circuit in wiring

ECU matfunction from A/C relay to ECU terminal

Poor connection at ECU connector

ECU malfunction

IJ l l l

Short circurt in wiring from diagnosis connector terminal TEN to ECU termi- nal 1K

Open circutt in wiring from diagnosis connector terminal TEN to ECU termi- nal lK

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

1N 0

Connected

I Throttle sensor

(Idle switch) to Test condition

Accelerator pedal released

Accelerator pedal depressed

IO I 0 j

1P j 0 1

I

I

I

[ Stoplight switch i P/S pressure switch to 0 A/C switch

Brake pedal released lgnitlon switch ON f/S ON at idle

P/S OFF at idle

A/C switch ON

NC switch OFF

1R i

0

IS 0

IT Cl

Electric fan switch

Blower switch defroster control

Rear window switch

Correct voltage Remark

&low l.OV j Ignition switch

Approx. 12V *N

Betow 1 .OV

Approx. 12V

Below 1 .UV

Approx. 12V

-

-

Beiow 2.W ignition switch

ON and blower

Approx* t2V motor ON

Fan operating (Engine coolant tempera- ture over 91 *C (t96*F) or diagnosis con- nector terminal TFA grounded)

Fan not operating (Idle)

Blower controf switch OFF or 1st position

Blower control switch 2nd or higher po- sition

Betow l.OV

-

Approx.. f 2V

Approx. 13 Ignition switch

Below 7 .OV ON

Rear window

Rear window defroster defroster switch switch

OFF

ON

Below 1 .OV Ignition switch

Approx. 12V ON

1u

-Iv

3

Cl ’

Headlight switch

Neutral/Clutch switches

Headlights ON

Headlights OFF

Neutral position or clutch pedal depressed

Others

Approx. 12V

Below 1 .OV

Below I .OV

Approx. 12V

- l-7 I 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 r

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

Incorrect

Always below 1 .OV voltage

Always approx. f 2V

Atways below 1 .OV (Stopfights

Always below 1 .OV

OK)

Always approx. 12V

Atways below 2.5V (Btower fan OK)

CONTROL SYSTEM

Possible cause l l l l l l

Throttle sensor misadjustment

Short circuit in wiring from throttle

ECU malfunction

Throttle sensor misadjustment

Open circuit in wiring from throttle

Open ctrcuit in wiring from throttle sensor to ECU terminal sensor to ECU terminal sensor to ECU terminal

IN

IN

20 l l l l

Open crrcurt in wiring from stoplight

P/S pressure switch malfunction

Short circuit in wirrng from P/S pressure

ECU malfunction switch to ECU terminal switch to ECU termrnai

10 l l

. P/S pressure switch malfunction

Open circuit in wiring from P/S pressure

Open circuit in wiring from P/S pressure switch switch to ECU to ground terminal l l l l l l l l

A/C switch malfunction

Short circuit in wiring from A/C switch to ECU terminal

Poor connection at ECU connector

ECU malfunction l

’ A/C switch malfunction

Open ken c~rcurt circuit in wiring

H-I winnu from from

NC

A/C switch switch to ECU to blower terminal control

1 Q

1Q switch

Open or short circuit in wiring from fan relay to ECU terminal

ECU malfunctron

IR

1 P

I P

F2

Always approx. 12V (Blower fan OK)

Always below 1.W

(Electrkal cooling fan UK}

Always below 1 .OV (Blower fan OK)

Always approx.

Always below

1.w

12V (Blower fan OK)

Illumination lamp

ON when rear window defroster switch ON lamp ftlumination never ON

Always below 1 .OV (Headlights OK)

Always below 1 .OV

Always approx. l2V l l l

Short crrcutt in wiring from blower

Poor connection at ECU connector

ECU malfunction control swrfch to ECU terminal IS

1 l

Open circurt in wrring from blower control switch to ECU terminat

I l

Open terminal or short

1 T circuit rn wiring from rear window defroster switch

IS to ECU l l l

Open circuit in wiring from ignition

Rear window defroster switch switch malfunction to rear window

Open or short circurt in wiring from headlight defroster relay to ECU termtnal switch

1 U l l l l l l l

Neutral switch malfunction

Clutch switch malfunction

Short circuit in wiring from ECU terminal

Neutral switch maifunctton

Clutch switch malfunction

Open circuit in wiring from ECU terminal

Poor connection at ECU connector

IV to neutral or clutch switch

IV to neutral or clutch swttch

93GOFZ789

I

F2-63

F2

CUNTRULSYSTEM

‘erminal

2A

2B

Input

-

-

2c , -

20 -i-

2E ’ 0 1

2F

2G

2t-I

21

2J

2K

-

-

-j-

0

C

0

Output i

-

-

Connected

- ’ Ground {Injector)

- I Ground (Output)

- 1 Ground (CPU)

Ground (Input)

Distributor

(Ne-signal)

Distributor

(G-stgnal)

- to

-

-

Knock control unit

Thronle sensor/

Airflow meter

Test condition

Constant

Constant

Constant

I

Constant

Ignition switch ON

Idle ignition switch ON

-

Idle

-

-

Idle

Constant .

Correct voltage

OV

OV

OV

OV

Approx. OV or 5v

Approx. 2V

-

Approx. OV or 5V

Approx. I.3

-

-

Approx. 4. OV

4.5--5.W

Remark

-

-

-

-

-

-

-

-

-

-

2L

- -

2M 0

I

-

Throttle sensor

2N 0

20 0

2P

1

0

2Q ! 0

2R

Airflow meter

Intake air thermosensor

Water thermosensor

0 ’ Turbocharge indicator

- - -

Oxygen sensor

Accelerator pedal released

Accelerator pedal fully depressed

Approx. 0.W

Approx. 4.W

-

Ignition switch ON

Idle (Cold engine)

Idle (After warm-up)

Increasing engine speed [After warm-up)

Deceleration ignition switch ON

’ Idle

Ambient air temperature 20°C (68OF)

Engine coolant temperature 20°C (68OF)

After warm-up

Ignition switch ON f

OV ov

O-l .ov

0.5-I .ov o-0.4v

-

Approx. 3.8V

Approx. 3.OV

-

Approx. 2SV In airflow meter

Approx.

Below

Approx.

2.5V

03 f2V

-

-

F2-64

Above Ok’

Incorrect voltage

Always approx. OV or approx. 2V

-

Always approx. OV or approx. ISV

-

-

Always OV

Always OV

Below 4-W or above 5.5V

Always OV

Always approx. 5V

Always constant

Always above f V

OV after warm-up

Always approx. IV after warm-up

Always OV or approx. 5V

Always OV or approx. 5V

Always OV or approx. 5V

Always OV

CUNTRUL SYSTEM l l

Possible cause

Poor contact at ground terminal

Open crrcurt in wiring from ECU to ground l

Refer to Code No.02 Troubleshooting l

Refer to Code No.03 Troubleshooting

-

-

- l l l l

Refer to Code No.05 Troubleshooting

. Short circutt in wiring from ECU termrnal 2K to throttle sensor, or airflow meter

Poor connection at ECU connector

ECU malfunctron l l l l l l l l

ECU malfunction

Throttle sensor malfunction

Short circurt in wiring from ECU terminal 2L to throttle sensor

Poor connection at ECU connector

ECU malfunction l l l l l

. Throttle sensor m&adjustment

Open circuit in wiring from ECU terminal 2L to throttle sensor

Open circuit in wiring from ECU terminal 2t to ECU terminal 20

Open circuit in wiring from ECU terminal 2M to throttle sensor

Open circuit in wiring from ECU terminal 2K to throttle sensor

Open circuit in wiring from ECU terminal 2D to throttle sensor

Throttle sensor m&adjustment

Refer to Code No.15 Troubleshooting

Refer to Code No.1 7 TroubleshootIng

F2

I l l

Refer to Code No.08 Troubleshooting

-

Refer to Code No.1 0 Troubleshootrng

1 l

Refer to Code No.09 Troubfeshooting l

. Indicator broken

Open or short circuit rn wirinq from ECU 2R to rgnition swatch

F2-65

F2

CONTROLSYSTEM

Terminal I Input Output

25 0

2T 0

Connected

Overboost buzzer

1 Solenoid

(Pressure to warning valve regulator)

2u

2v

2W

2x t 2Y

22 -

0

0

0

0

Injector

Injector

ISC valve

(Nos. I 1 3)

(Nos. 2, 4)

Solenoid valve

(Purge control)

0

Cmxit opening relay

-

-

Test condition lgnltion switch ON

180 seconds atter engine started when engine coolant temperature above 90%

(I 94OF) and

58OC (13WF)

Intake air temperature above

1 Other condition at Idle

Ignrtion switch ON

Idle

Engrne speed above 2,000 rpm on de- celeratlon (Atter warm-up) lgnitlon swrtch ON

Idle

Engine speed above 2,000 rpm on de- ceieration (After warm-up)

Ignition switch ON

Idle

Ignition switch ON t Idle

Ignition switch UN

Idle

-

Correct voltage

Approx. 12V

Below 1 SV

Remark

-

-

Approx.

Approx.

Approx.

Approx.

12V

12V

12V’ f2V

* Engine Signal

Monitor: Green and red lamps flash

Approx.

Approx.

Approx.

12V

12V’

12V

Approx.

Approx.

Approx.

Approx.

Approx. 12V

Below 1 .OV

-

7V

9V

12V f2V

-

-

-

-

-L J u- v

I U-1

2y 2w 2u 2s 20 20 2M 2K 21 2G 2E 2C 2A 1U 1S IQ 10 1M 1K 11 1G 1E IC 1A l-

22 2X 2V 2T 2R 2P 2N 2L 2.J i’t-( 2F 2D 2B 1V 1T 1R tP IN IL I..! ItI IF tD 18

F2-66

Always OV

Incorrect voltage

Always OV or approx. 12V

Always OV

Always approx. 12V

CONTROLSYSTEM

I l

Possible cause

Open or short circuit in wjring from ECU terminal 2s to buzzer

1 l

Refer to Code No.25 Troubieshootlng

F2

7

1 l

Marn relav (FUEL INJ relay) malfunction

/ l

Open or shbrt circuit in wi&g from injector to ECU terminal 2U or 2V l

ECU malfunctron

Always OV or approx. t2V

Always OV or approx. 12V

Always OV l

Refer to Code No.34 TroubleshootIng l

Refer to Code No.26 Troubleshooting l

Open or short circuit KI wiring from ECU terminal 2Y to relay f2-67

F2

CONTROL SYSTEM

OXYGEN SENSOR [BP TURBO]

Inspection

Sensor

1. Warm up the engine to normal operating temperature.

2. Disconnect the oxygen sensor connector.

3. Connect a voltmeter to the oxygen sensor terminal @.

4. Run the engine at 4,500 rpm untiI the voltmeter indicates approx. 0.7V.

93GOF2-79; 2

5. Increase and decrease the engine speed suddenly and measure the vottage.

Voltage

Engme speed

Decelerating

Accelerating

Voltage (v-) o-0.4

0.5-l .o

93GOF2-793

6. Connect the SSTs to the diagnosis connector.

7. Set the system selector select switch to 1 and the test switch to 02 MONITOR.

8. Increase the engine speed to between 2,000 and 3,000 rpm, and verify that the monitor lamp flashes for 10 seconds.

Specification:

Monitor lamp flashes more than 8 times/IO sec.

93GOFZ794

1 Heater

1. Disconnect the oxygen sensor connector.

2. Check resistance between oxygen sensor connector ter- minals @ and 0.

Resistance: Approx.-6& [at 20°C (68OF)]

Replacement

1. Disconnect the oxygen connector. ’

2. Remove the oxygen sensor.

3. Install the new oxygen sensor and new washer.

4. Tighten the oxygen sensor to specified torque.

Tightening torque:

29-49 N-m (3-5 m-kg, 22-36 ft-tb)

!, -

CONTROLSYSTEM

KNOCK SENSOR

F2

93GOF2-797

1 l

The knock sensor and knock control unit cannot be inspected

individually.

When

a malfunction code number

05 is indicated,

replace.

Replacement

I_ Disconnect the knock sensor connector.

2. Raise the vehicle and support it WI safety stands.

3.

Remove the knock sensor with using the SST

4. Install it in the reverse order of removal.

Tightening torque:

20-34 Nm (2.0-3.5 m-kg, 14-25 ft-lb)

F2-69

ENGINE ELECTRICAL SYSTEM

INDEX . ..I 1.. . . . . . . . . . . . . . . . . . . . . . . ..*. . . ..I..... . . . . . ..I... G- 2 j FEATURES 1

OUTLINE

OUTLINE.

. . . . . . . . . ...*....* .I..............

OF CONSTRUCTION

SPECtFICATiONS

.I . . . . . . . . . . . . . . G- 3

..I... . . . . . . . . . . . G- 3

. . . . . . . . . . . . ..I............... . . . . . . G- 3

1 SERVICE 1

SUPPLEMENTAL SERVICE INFORMATION . . G- 4

STARTING

STARTER

CHARGlNG

SYSTEM . ..I. . . . . . . . . a.. . . . . . . . . . . . . . . . . . . G- 4 l . . I . . . . . . . . . . . . . . . . . . . . . . l . * . . . . . * . I . . . . . . . . . .

G- 4

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G- 5

PREPARATION

ALTERNATOR

. . . . . . . . . . . . . . I . . - . . . . . . . l . . . . . . . . 1. . . . .

G- 5

(RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . ...*. G- 5

93GOGX-701

G

G

INDEX

1. Starter

Removal I Instaltation... ._. . . . . . . , . . ._._, page G-4

G-2

93GOGX-702

2. Alternator (RFD)

Removal I Installation. . . .._.. . . . . . . . . . . . . page G-5

L

OUTLINE

OUTLINE

OUTLINE OF CONSTRUCTION

The engine electrical system of the new 323 4WD is as same as that of the new 323 ZWD.

G

93GOGX-703

SPECIFICATIONS

Item

Battery

Dark current”

EnginelTransaxle t Voltaae

Type and capacity

120-hour rate) v mA 1

BP TURBO

MTX

12

55D23L (60AH)

Max. 20.0

MTX

BP SOHC

ATX

Alternator

Starter

Output

Regulator type

1

I Regulated voltage

V-A

Brush length

Standard mm (in) Minrmum

Drive belt deflection

New

98 N (10 kg, 22 lb) mm (in) Used v

Type

Output

8rush length

V-W

Standard mm [in) Minimum

12-65

Transistorized (built-in iC regulator)

74.1---14.7

21.5 (0.846)

8.0 (0.315)

8-9 (0.31-0.35)

12-U-85

9-l 0 (0.35-0.39)

Direct

17 (0.67)

11.5 (0.4531

Electronic spark advance

12-0.95

] Coaxicat reductron

32-l .4

17.5 (0.69)

10.0 (0.39)

(photo diode) Distributor

Ignition timing

FEN termrnal of diagnosis connector grounded)

BTDC

Ignition coil

Resistance

(at 20°C [68OFj)

I Primary

Secondary 1 f coil windina 1

10 * I0

0.81 ---o-999

10-76 kS-l

5 f lo

Spark plug

Type

pw am

Firrng order

NGK

Nippon

I

Denso mm (in)

8KR5Ell +2 BKR5E”3

BKRGEI 1 l

* BKRGE *3

KIGPR-Ull *2 KfGPR-I-Y3

K20PR-Ul l ** K20PR-U l

3

1.0-I .l (0.039-0.043)“2 0.7-0.8 (0.028-0.03i)*3 l-3-4-2

93GOGX-704

*I Dark current is the constant flow of current while the ignition switch is OFF. (i.e., engine control unit, EC-AT control unit, audro, etc.)

+’ With catalytic converter.

*3 Without catalytic converter.

I i i-

G-3

G

SUPPLEMENTAL SERVICE INFORMATION, STARTING SYSTEM

SUPPLEMENTAL SERVICE

INFORMATION

The following points in this section are changed in comparison

[1203-l O-89F (Europe), ? 204-I O-89F (Australia)]. with Mazda 323 Workshop Manual l l

Starter

Removal / InstaHation

Atternator (RI-ID)

Removal I InstatIation

93GOGX-705

STARTING SYSTEM

STARTER

Removal I Installation

I. Remove in the order shown in the figure.

2.

Inspect all parts,

and

repair or replace as necessary.

3. lnstail in the reverse order of removal.

37-52 (3.8-5.3, 27-38)

9.8-t2

(IOO-120

N-m cm-kg, 87-104 in-lb)

27-38)

(3.8-5.3, 27-38)

I. Battery

2. intake manifold bracket

3. S terminal wire

4. B terminal wire

G-4

9.8-12.N.m

(100-120 cm-kg, 87-104 in-lb)

It t \\

37-52

(3.8-5.3, 27-38)

N-m (m-kg, ft-lb)

5. Starter

6.

Remove tram above

Starter

bracket

CHARGWIG SYSTEM

CHARGING

SYSTEM

PREPARATION

SST

49 0118 85OC

Puller, ball joint

For removal joint of ball

93GOGX-707

ALTERNATOR (RHD)

Removal / Installation

I. Remove in the order shown in the figure.

2. Install in the reverse order of removal, referring to Installation Note.

G

72.0, 65-81)

1

I. Negative battery cable

2. Tire and wheel (Right front)

5. Front exhaust pipe

6. Tie-rod end

Removal Note ._....._.........._..._ ._..... page G-6

N-m (m-kg, ft-lb)

7. Stabilizer (Right)

Installation Note . . . . . . . . . . . . . -. . I -. . . . - . . . . page G-6

8. Lower arm (Right)

9. Driveshaft (Right)

IO. Alternator connectors

Remove from below

G

CHARG1NG SYSTEM

Removal Note

Tie-rod end

1. Remove the right side tie-rod end with the SST.

93GOGX-709

1 instailation

Stabilizer

Note

1. Install the stabilizer bolt.

Dimension A: 17-19mm (0.67-0.75 in)

93GOGX-710

G-6

CLUTCH

iNDEX ..*..*.............*..*..............................* l-l- 2

OUTLINE ..................................................

OUTLtNE OF CONSTRUCTION

SPECtFlCATtUNS

.................

....................................

CLUTCH CONTROL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH PEDAL .....................................

CLUTCH MASTER CYLINDER ...................

RELEASE 5EARlNG ................................ l-b- 4

H- 4

H- 4 t-i- 5

H- 5

H- 7

H- 8

1 SERVICE /

SUPPLEMENTAL

TROUBLESHOOTlNG

SERVICE INFORMATION..

GUIDE.. ....................

CLUTCH FLUID (WITH ABS) ......................

PREPARATION

REPLACEMENT

.......................................

......................................

H-

Ii-

9

9

H-l 0 u-IO

H-10

CLUTCH PEDAL (BP DOHC TURBO) ........... H-1 1

REMOVAL I INSPECTION / INSTALLATtON . . H-11

CLUTCH MASTER CYLINDER

(BP DOHC TURBO OR WITH ABS) ............

PREPARATION .......................................

REMOVAL I INSPECTION I INSTALLATION

(BP DOHC TURBO) ...............................

H-f 3 u-1 3

H-13

AIR BLEEDlNG (-WtTH ABS) ...................... ti-14

OVERHAUL (BP DOHC TURBO). ...............

CLUTCH RELEASE CYLINDER (WITH ABS).

H-15

H-l 7

PREPARATION

AtR BLEEDING

.......................................

(WITH ABS). .....................

CLUTCH UNIT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION .......................................

REMOVAL I INSTALLATION ...................... u-1

H-l 7

H-17

H-f 8

H-19

8

93GOHX-701

H

H

I

INDEX

LHD

INDEX

@

\

,a

1,

FLUID SPEClFlCATlON

OR FMVSS116 DOT-3

(WITH ABS) f . Clutch pedal (8P DOHC Turbo)

Removal I Inspection I

Installation . . . . . ..+., ._. . . . . . . -. . . . . . . . . _. . page H-l 1

2. Clutch master cylinder

(BP DOHC Turbo or with ABS)

Removal I Inspection I

Installation (BP DOHC Turbo). . page H-l 3

Air Ueeding (with ABS) . . .._........_ page H-14

Overhaul (BP DOHC Turbo) _...._ page H-15

3. Ctutch release cylinder (with ABS)

Air bleeding .._.,._.......,............._... page H-l 7

H-2

93GOHX-7C

4. Clutch cover

Removal I Installation . . . . . . . . . . . . . . . . . . page H-1 9

5. Clutch disc

Removal I f nstallation .................. page H-l 9

6. Pilot bearing

Removal I I nstallation. ................. page H-f 9

7. Flywheel

Removal / nstallation .................. page H-l 9

INDEX

H

I. Clutch pedal (BP DOHC Turbo)

Removal I inspection / i

1

Installation ................................ page H-l 1

2. Crutch master

cylinder (BP DUHC Turbo)

Overhaul .....................................

3. Clutch cover page H-l 5

Removal I Installation.. ................ page H-t 9

4. Clutch disc

Removal I Installation.. ................ page H-19

5. Pilot bearing

Removal J Installation .................. page H-l 9

6. Flywheel

Removal I installation.. ................ page H-l 9

H-3

H

OUTLINE

OUTLINE

OUTLINE

A hydraulic

The basic

OF CONSTRUCTION clutch construction control mechanism is used. is the same as that of 323 2WD model, but there is no interchangeability of parts except for the release cylinder.

1. An assist/return spring is used on the BP DOHC Turbo model to reduce the required clutch pedal effort..

2. The hydraulic clutch master cylinder for the 8P DOl-lC Turbo model has a built-in check valve.

3. To improve clutch operation feeling and increased parts life, a friction plate and needle roller bearings are used between the release fork and the release bearing.

93GOHX-704

SPECIFICATIONS

Engine/Transaxle

Hem

Clutch control

Clutch cover

CI utch disc

Clutch pedal

Master cylinder

Release cylinder

Clutch fluid

Type

Set load N (kg, lb)

1 mm (in) Outer diameter

I

1 nner diameter mm (in) I

Pressure plate side mm {in)

Thickness

Flywheel side mm (in)

I

Type I

LHD

Pedal ratio

RHD

Full stroke

Height (With carpet)

Inner diameter inner diameter mm (in) I mm [in) I mm {in) I mm (in) I

BP SUHC BP DOHC Turbo

GSMX-R

Hydrautic

Diaphragm spring

3,846 (392, 862) 5,494 (560, I ,232)

225 (8.858) 230 (9.055)

150 (5.906)

I

155 (6.102)

4.1 (0.161) 3.2 (0.126) f

3.5 (0.138) 3.2 (0. f 26)

Suspended

6.55

6.7

135 (5.32)

I 96-204 (7.72-8.03)

15.87 (0.625)

-

19.05 (0.750)

SAE J1703 or FMVSSI 16 DOT-3

93GOHX-705

I

I

I

I

I

H-4

CLUTCH CONTROL

H,

CXUTCH CONTROL

l l

CLUTCH PEDAL

An assistireturn effort.

The assist/return spring is used on BP DO-K Turbo engine-equipped models to reduce the required pedal spring is mounted vertical to the pedal for a compact arrangement. wiNGi B G”3

*

RANGE A

RANGE B +

+ RANGE A

Operation

With the clutch pedal fully crum 0,

released, the

assist/return spring is compressed, causing force

As a result, force Fy is created, and acts upon fulcrum @ to hold the pedal outward.

1 1 When clutch pedal depressed.

(1) Fukrum @ within range A

When the pedal is depressed, it moves inward, centered upon fulcrum @.

F to act upon ful-

Fy, which is the force opposing pedal movement, acts upon futcrum @ until fulcrum @ crosses the imaginary line connecting fulcrums

As a

@ and @ result, there is a slight feeling of resistance when the clutch pedal is first depressed.

(2) With fulcrum @ within range 8

When fulcrum @ crosses the imaginary line between fulcrums @ and @, Fy now acts in the same direction as pedal movement, thus reducing the force required to depress the pedat.

H-5

H

CLUTCH CONTROL

RANGE B CT] e

RANGE A

RANGE B ++I

+ RANGE A

93GOHX-70

2. When clutch pedal released.

(1) With fulcrum @ within range B

When the clutch pedal is released, reaction force f (from clutch master cylinder push rod) is applied, and fy force pushing outward overcomes Fy force, with the result that the clutch pedal moves out- ward, centered upon fulcrum @.

(2) With fulcrum @ within range A

When futcrum @ crosses the imaginary iine 4etween fulcrums @ and a, force Fy, which is a result of force F trying to expand the spring, is added to fy and pushes the pedal fully outward. t-l-6

CLUTCH MASTER CYLINDER

C1UTCl-i CONTROL

H

‘CHECK VALVE

RHD

CHECK VALVE

93GOHX-708

A hydraulic clutch master cylinder with a built-in check valve is used on the BP DOHC Turbo model.

This is to provide smooth

engagement

of the clutch disc by controlling (by the check valve) the flow of fluid from the clutch release cylinder back to the master cylinder when the clutch pedal is released, thus cushion- ing the impact “shock”. l-l-7

H

RELEASE BEARING

CLUTCH

CONTROL

CLUTCH PEDAL RELEASED

RELEASE E?EARfNG

RELEASE FORK

ROLLER BEARING

CLUTCH PEDAL DEPRESSED

To improve clutch operation feeling and increased parts life, a newly designed friction plate and needle roller bearings are used between the release fork and the release bearing.

With the kdusion of this friction plate, the force required to depress the clutch pedal is reduced because the usual sliding-contact action between the release bearing and the release fork is changed to a rolling action of the friction plate,

H-8

SUPPLEMENTAL SERVICE INFORMATION,

SUPPLEMENTALSERVICE INFORMATION

TROU8LESHOOTlNG GUIDE

The following points in this section are changed in comparison with 323 Workshop Manual (1206IO-89F).

H

Troubleshooting guide l

Clutch fluid (with ABS)

Replacement

Clutch pedal (BP DOHC Turbo) l

Removal I Inspection I installation

Clutch master cylinder l l l

(BP DOW Turbo or with ABS)

Removal I Inspection I Installation (BP DUHC Turbo)

Air bleeding (with ABS)

Overhaul (BP DUHC Turbo)

Clutch release cylinder (with ABS) l l

Air bleeding

Clutch unit

Removal I Inspection I installation

93GOHX-710

TROUBLESHOOTING GUlDE

Slipping

Problem

Faulty disengagement

Possibte Cause

Clutch disc facing worn excessively

Clutch disc facing surface hardened or oifed

Pressure plate damaged

Diaphragm spring damaged or weakened

Insufficient clutch pedal piay

Clutch pedal sticking

Flywheel damaged

Excessive runout or damaged clutch disc

Clutch disc spiines rusted or worn

Clutch disc facing oiled

’

Diaphragm spring weakened

Excessive clutch pedal ptay

Insufficient clutch fluid

Leakage of clutch fluid

Clutch vibrates when accelerating

Clutch pedal sticking

Abnormal noise

Clutch disc facing oiled

Torsion rubbers weakened

Clutch disc facing hardened or damaged

Clutch disc facing rivets loose

Pressure plate damaged or excessive runout

Flywheel surface hardened or damaged

Loose or worn engine mount

Pedal shaft not properly lubricated

Asistireturn spring damaged or poor adjust

Clutch release bearing damaged

Poor iubrication of release bearing sleeve

Torsion rubbers weakened

Excessive crankshaft end play

Pilot bearing worn or damaged

Worn pivot points of reiease fork

Remedy

Replace

Repair or replace

Replace

Replace

Adjust

Repair or replace

Repair or replace

Replace

Remove rust or replace

Repair or replace

Reptace

Adjust

Add fluid

Locate and repair or replace

Repair or replace

Replace

Repair or replace

Replace

Replace

Repair or replace

Tighten or replace

Lubricate or replace

Replace or adjust

Replace

Lubricate or replace

Replace

Repalr

Replace

Repair or replace

H-l 9 u-19

H-19

H-l 9

H-l 9

H-19

-

H-l 1

H-11, 12

N-1 9

H-19 u-t9

-

H-79

H-19

Page

U-l 9

H-l 9

H-19

H-l 9

H-12

U-11

H-19

H-19

H-l 9

H-19

H-19

-

H-10

-

H

CLUTCH

CLUTCH FLUID (WITH ABS)

PREPARATION

SST

FLUID (WITH ABS)

1

49 0259 770B

Wrench, flare nut m

For air bleeding

93GOHX-712

REPLACEMENT l l

Note

A common reservoir is used for the clutch and brake system fluids.

The fIuid in the reservoir must be maintained tevet or higher during replacement. at 314 l l l

Caution

Be careful not to spill the fluid on a painted surface.

If this should happen, wash it off immediately.

Do not mix different brands of fluid.

Do not reuse the clutch fluid that was drained.

1. Drain the brake fluid from the master cylinder by pumping it through a wheel cylinder bleed screw.

2. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug.

93GOHX-77 3

93GOHX-714

3. Place the other end of the vinyl hose in a clear container.

4. Fill the reservoir with new fluid to the MAX mark.

5. Slowly pump the clutch pedal several times.

6. With the clutch pedal depressed, loosen the bleeder screw with the SST to let the fluid escape. Close the bleeder screw with the SST.

7. Repeat Steps 4 and 5 until only clean fluid is seen.

8. Tighten the bleeder screw.

Tightening

5.9-8.8 torque:

Nom (60-90 cm-kg, 52-78 in-lb)

9. Add fluid to the MAX mark.

IO. Slowly pump the clutch pedal several times.

11.

Verify that there is no fluid leakage.

Check operation of the clutch system.

12. Bleed and check operation of the brake system.

(Refer to Section PJ

CLUTCH PEDAL (BP DOHC TURBO)

CLUTCH PEDAL (BP DOHC TURBO)

REMOVAL I INSPECTION I INSTALLATION

1. Remove in the order shown in the figure, referring to Removal Note.

2.

Inspect alf parts,

and

repair or replace as necessary. l

Note

Apply lithium based grease to the bushings and pins before installation.

.-__.. of removal. p&rrinQ to lnstaI[ation Note.

/

4

@J

H

IS-17

1. Clip

2. Pin

3. Spacer

4. Bushing

5. Clip

6. Assistireturn spring

Adjustment . .._..._.._........_....,......*. page H-12

7. Spring seat

8. Clutch pedal rod

9. Adjusting nut

IO. Busing

Il. Spring seat f 2. Bushing

13. Nut

14. Washer

15. Bolt

16. Spacer

17. Clutch pedal

18. Bushing

19. Bushing

20. Clip

21. Wave washer

22. fin

23. Bushing

24. Nut

25. Push rod

Inspect for damage and bending

26. Clutch fork

27. Pedal pad

Inspect for damage and wear

H

CLUTCH PEDAL (BP DOt-iC TURBO)

1 Adjustment

Assist/return spri rtg

I. Measure the installation length B of the assistlreturn spring.

2. Adjust the installation length B by turning nut A shown in the figure.

Installation length: 35.5-36.5mm (1.398-I .437 in)

93GOHX-716 w-12

CLUTCH MASTER

CYLINDER (BP DOHC TURBO OR WITH ABS)

CLUTCH MASTER

PREPARATDN

SST

CYLINDER (BP DUHC TURBO OR WITH ABS)

49 0259 770B

Wrench, flare ntlt

For dIsconnecti ng and connectmg clutch pipe

H

REMOVAL I INSPECTlON / INSTALLATION

93GOHX-717

(BP DOHC TURBO) l

Caution

Clutch fluid wilt damage painted surfaces. Be sure to use a container or rags to collect it. If ftuid does get on a painted surface, wipe it off immediately with a rag.

I. Remove in the order shown in the figure, referring to Removal Note.

2. Inspect al\ parts, and repair or replace as necessary.

3. Install in the reverse order of removal, referring to InstaIIation Note.

LHD

(1.9-2.6, 14-W)

1. Strut bar

2. Battery

3. Diagnosis connector

4. Clutch pipe

Removal Note . . ..._.-...._..._._....._,.. page H-14

Installation Note. . . . . . . . . . .._....._.... .._ page H-14

5. Clip

19-25 (1 A-2.6, 14--19)

N-m (m-kg, Mb)

Q?CflUY.7,

6. Nut

7. Clutch master cylinder

Check for fluid leakage from cylinder bore

Overtraul .__.

Air bleeding .,._.._,......._._.I...........- page K-14

8. Gasket

H-13

1

CLUTCH

MASTER CYLINDER (BP

DOHC TURBO OR WITH ABS)

Removal Note

CIutch pipe

1. Disconnect the clutch pipe with the SST,

‘. I

-K-l

,

03iJOHX-076

Installation Note

Clutch pipe

1. Tighten the clutch pipe with the SST

Tightening

13-22 torque:

Mm (1.3-2.2 m-kg, 9.4-l 6 ft-lb)

Air Bleeding f . After installation, bleed the clutch system. (Refer to betow.)

93GOHX-720

93GOHX-72’

AIR BLEEDlNG (WITH ABS)

The clutch hydrautic system must be bled to remove air in- troduced whenever a hydraulic Iine is disconnected. l

Note

The fluid in the reservoir must be maintained level or higher during air bleeding. at 3/4 l l l

Caution

CMch fluid will damage a painted surface. ff fluid does get on a painted surface, wipe it off im- mediately.

Do not mix different brands of clutch fluid.

Do not reuse the clutch fluid that was drained.

1. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder screw.

2. Inseti the other end of the vinyl hose in a clear container.

3. Slowly pump the clutch pedal several times.

4. While depressing the pedal, loosen the bleeder screw with the SST to let fluid and air escape.

Close the bleeder screw with the SST.

5. Repeat Steps 3 and 4 until no air bubbles are seen in the fluid.

6. Tighten the bleeder screw.

Tightening

5-g-8.8 torque:

Nm (60-90 cm-kg,

7. Check for correct clutch operation.

8. Verify that there is no fluid leakage.

52-78 in-lb)

H-14

CLUTCH MASTER CYLINDER (BP DOHC TURBO OR WfTH ABS)

H

OVERHAUL (BP DOHC TURBO) l

Caution

Clean the disassembled pressed air. parts in solvent and blow through all ports and passages with com-

I. Disassemble in the order shown in the figure, referring to Disassembly Note.

2. Inspect all parts, and repair or replace as necessary.

3. Assemble

in

the

reverse order

of

disassembly,

referring to Assembly Note.

RHD

83--t 12 (8.5--f1.5, 61.5-83.2)

1. Clip

2. Hose

3. Joint

4. Bushing

5. Snap ring

.

Disassembly Note ._, . . . ._. . . . . ._.. . . . . .

Assembly Note . . . . . . . . . . . . ..__......_.... page H-l 7

6. Piston and secondary cup

Disassembly Note .,....-.............,. page H-l 6

Assembly Note . . . . . . . . . . . . . . . . . . . . .._._.. page H-l 6 inspect for wear, scoring and cracks

7. Spacer page t-i-1 6 assembly

N-m (m-kg, B-lb) n?fznuv

JJ”“r 1*-

7?3 t LC

8. Primary cup

Inspect for wear and cracks

9. Return spring

IO. Joint bolt

1 I. Packing

12. One-way valve piston

Disassembly Note .._......._...I....,.. page H-l 6

13. Return spring . .._.._......_..._..............- page H-l 6

14. Master cylinder body

Inspect cylinder bore for scoring and corrosion

w-f5

H

CLUTCH MASTER CYLINDER (BP DOHC TURBO OR WITH ABS)

Disassembty

Snap ring

Note

l

Caution

Do not damage

the

push

rod

contact

surface of the piston.

1. Press the piston down and remove the snap ring with snap- ring pliers.

Piston and secondary cup assembly l

Caution

Hold a rag over the master cylinder to prevent the piston and secondary cup assembly from jumping out.

1. Remove the piston and secondary cup assembly, spacer, and primary cup by applying compressed air through the clutch pipe installation hole.

One-way vaive piston and return spring l

Caution

Hold a rag over the master cylinder to prevent the piston and spring from jumping out.

1. Remove the piston by applying compressed air through the cylinder bore.

Assembly Note l l l l l

Caution

Before assembly, make sure all parts are completety clean.

Do not mix different brands of clutch ftuid.

Do not reuse the clutch fluid

that

was drained.

Apply the specified clutch fluid to the piston and secondary cup assembty, spacer, primary cup, and cylinder bore before assembly.

Replace parts with new ones whenever specified to do so.

03uot-!x-019

Piston and secondary cup assembty

1. InstaD the spring, primary cup, spacer, and piston and

secondary

cup assembly, noting the proper direction of the parts.

CLUTCH MASTER CYLlNDER (BP DOHC TURBO OR WITH A8S), CLUTCH RELEASE CYLINDER (WITH AN)

H

Snap ring l

Caution

Do not damage the push rod contact surface of the piston. t . While pressing the piston, install the snap ring.

CLUTCH RELEASE CYLINDER (WITH ABS)

PREPARATION

SST

49 0259 770B

Wrench, flare nut

For disconnecting and connecting clutch pipe

93GOHX-724

AIR BLEEDING (WITH ABS)

I_ After installation, bleed the clutch system.

(Refer to page H-16.)

93GOHX-725

H-17

H

PREPARATION

SST

49 E301 060

Brake, ring gear

CLUTCH UNIT

49 E301 062

Collar

(Part of

49 E301 060)

49 1285 071

Puller, bearing Lj , - e

49 0823 U72A

Installer 1 eccentric shaft bearing @@D

For removal and i nstaI\abon of c!utch cover and flywl-leel

49 E3OI 061

Body

(Part of

49 E301 060)

For removal and installation of cIutch cover and flywheel

49 SE01 310

Centering clutch disc tool,

For

I removal bearing of blot

49 1285 073

Chuck

(Part of

49 1285 071)

1 For

I installation bearing of pilot

For removal and installation of dutch cover and flywheel

7

For support and alrgnment of clutch disc

For removal bearing of pilot

93GOHX-726

-

H-18

CLUTCH UNIT

REMOVAL I fNSTALLATION l

Remove the clutch release cylinder with the clutch pipe connected.

- Do not remove the pilot bearing if not necessary. f . Remove in the order shown in the figure, referring

2. Instal! in the reverse order of removal, referring to Removal Note. to Installation Note.

-761 BP SOHC

,E+--l

BP DOHC TURBO

H

-;

B

(MORI Wl-llTE TA No.2 OR

EQUIVALENT ORGANIC

MOLYBDENUM GREASE)

1. Clutch release cylinder

2. Transaxle

Service ~......-...tl.*I.*-......*,,.**..l.......

3. Bout

Section J3

1

4. Release bearing

5. Clutch release fork t .- cover

Removal Note _....._._._.-..._....___.._. page H-20 lnstaflation Note .._.......-..._.. . .._..._. page H-21

7. Clutch disc

Removal Note . . . . . . . .._...

* . . * .

Installation Note.. . . . . . . . . . w . . . .

8. Pilot bearing

. . * . a . * . page H-20

.,..I.._ page H-21

Removal Note . . . . . . . . . .._.

1 nstatlation Note.. . . . . __

*.*..

-....

.**-. ..- page H-20

.,..... - page H-21

9. Flywheel

Removal Note . . . . . . . . . . . . . . . . . .

Installation Note . . . . . . . . . . . . . . .

. ..*.-.- page H-20

_...a-.. page H-20

H-19

I

H-20

C1UTCf-f UNtT

Removal Note

Clutch cover and disc

1. Install the SST.

2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released. Then remove the ciutch cov- er and disc.

9MUOHX-032

I

Pilot bearing

1. Remove the pilot bearing with the

SST

if necessary.

03UOf-lX-028

I Flywheel l

Note

After removing the flywheel, inspect for oil leakage past the crankshaft rear oil seal.

If necessary, replace the oil seal.

1. Hold the flywheel with the SST.

2. Remove the flywheel.

Instalfation

Flywheel

Note

1 -Wipe the bolts clean and apply sealant to the bolt threads.

2. Install the flywheel and SST.

3. Tighten the bolts evenly and gradually in the pattern shown.

Tightening

96403 torque:

Nmm (9.8-10.5 m-kg, 71-76 ft.lb)

93GOHX-729

PiIot bearing l

Note

Install the pilot bearing ftush with the flywheeL

I_ Install the new bearing with the SST.

03UOHX-030 i

CLUTCW UNIT

Clutch disc

1. Clean the clutch disc splines and main drive gear spIines; then apply organic molybdenum

2. Hold grease.

the

clutch disc in position with the SST.

EWOHX-040

Clutch cover

1. Install the SST.

2. Align the

3. Tighten the

dowel

holes with the flywheel dowels.

botts evenly and

gradually in the pattern shown.

Tightening

18-26 torque:

N-m (1.8-2.7 m-kg, 13-20 ft-lb)

Ii-21

I

J3

MANUAL TRANSAXLE AND

TRANSFER UNIT (GSMX-R)

INDEX .........................................

/FEATURES] I

OUTLINE .....................................

OUTLINE OF CONSTRUCTION

J3- 4

..... J3- 4

SPECIFlCATtUNS ....................... J3- 5

TRANSAXLE AND TRANSFER UNIT J3- 5

STRUCTURAL VIEW.. ................. J3- 6

TRANSAXLE ................................

DOUBLE CONE SYNCHRU

J3- 8

MECHANlSM ........................... J3- 8

SHIFT FORKS AND SHIFT RODS . . J3- 10 iNTERLUCK

TRANSFER

CENTER

MECHANISM

UNtT ..........................

......... ., J3- 11

J3- 12

DIFFERENTIAL

VISCOUS COUPLING

............. J3- 14

J3- 20 (BP DOHC TURBO). ..................

CENTER DlFFERENTIAL LUCK

SYSTEM (MANUAL) ..................

CENTER DIFFERENTIAL LOCK

J3- 23

J3- 24 SYSTEM (ELECTRICAL)

CENTER DIFFERENTIAL

.............

LOCK

CONTROL SWITCH ...................

CENTER DIFFERENTIAL LUCK

ASSEMBLY ..............................

CENTER DIFFERENTIAL LOCK

SENSOR SWlTCH.. ...................

IDLER GEAR SHAFI- ...................

POWERFLOW ..............................

J3-

J3-

J3-

J3-

J3-

28

29

31

33

34

TROUBLESHOOTING GUIDE .........

J3- 2

J3- 35

TRANSAXLE

INSPECTlON

REPLACEMENT..

OIL ..........................

.............................

.......................

TRANSFER CARRIER CM .............

INSPECTION

REPLACEMENT.

.............................

........................

J3-

33-

36

36

J3- 36

339 36

J3-

J3-

36

36

TRANSAXLE AND

TRANSFER

PREPARATION

UNIT ........................

..........................

REMOVAL .................................

J3-

J3-

J3-

38

38

42

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION .............................

ASSEMBLY ...............................

J3-

J3-

J3-

48

72

75

INSTALLATION

SHIFT MECHANISM..

. . . . . . . . . . . . . . . . . . . . . . . . . .

....................

OVERHAUL ...............................

CENTER DIFFERENTIAL

J3-I

J3-119

J3-119

I2

LOCK SYSTEM ...........................

SYSTEM DIAGRAM .....................

INSPECTION .............................

CENTER DIFFERENTIAL

LOCK MOTOR ............................

INSPECTDN

REPLACEMENT

.............................

.........................

4x4 CONTROL UNIT.. ...................

J3-121

J3-121

J3-122

J3-123

J3-123

J3-123

INSPECTION

REPLACEMENT..

.............................

.......................

CENTER DIFFERENTIAL

LOCK SWITCH ...........................

INSPECTION .............................

J3-126

53-l

53-l

J3-126

J3-126

REPLACEMENT .........................

CENTER DIFFERENTIAL

J3-127

LUCK SENSOR SWITCH ............. J3-127

INSPECTION ............................. J3-127

REPLACEMENT ......................... J3-127

26

26

93GOJ3-701

J3

JNDEX

LHD

//

INDEX

/

ABOVE -18OC (UOF): 90

BELOW --t8OC (UOF): 8UW

CAPACITY: 0.5 liter

IO.53 US qt, 0.44 Imp qt vIscOsIn:

ALL SEASON DEXRON-II,

ABOVE -18OC @OF): ?5W-90

M-III

CAPACITY:

\_\;/

2.6 liters

(2.7 us qt, 2.2 Imp qt)

1. Transaxle oil

Inspection.. ._._.. . . . . . . . . . . . . . . . . . . . . . . . . page J3- 36

Replacement -.._.......-...............

2. Transfer carrier oi! page J3- 36

Inspection . . . ..-*..-.*a. . . . . * . . . . . . . . . . . . . page J3- 36

Replacement . . ..-...Ir.....*....~...... page J3- 36

3. Transaxle and transfer unit

Removal . . . . . . . ..-.-........-._._._....... page J3- 42

Disassembly, .._. . . .-. ._. .-. . . . . . . . . . . . . page J3- 48

Inspection.. . . . . . . ._. .-. .-. .-. . ._. . . . ._. . . page J3- 72

Assembly _.._..._.__._......._._..._...._ page J3- 75

4. Shift mechanism

Overhaul ,._.._... . . . . . . . . . . . ._..._......_ page J3-1 19

J3-2

5. Center differential lock motor

Inspection . . . . . . . . . . . . . .._......._._......

Replacement .,-.....,..._.............. page page

J3-I

J3-123

23

6.4x4 Control unit

Inspection ,.......... ~ ....._._._........I- page J3-I 26

Replacement ..*...** . . . . *.*...- . . . . . . . - page J3-126

7. Center differential lock switch

Replacement ..~ ..,....._.........._,... page 33-l 26

8. Center differential lock sensor switch

. . . _. . . _. _ . . . _

Replacement ..,.. . . . . . . . . . . . . . .._...... page J3-128

lNDEX

J3

GRADE: API SERVICE GL-5

ABOVE -18OC (OOF): 90

BELOW -18°C (OOf): 80W

CAPACITY: 0.5 liter

(0.53 us qt, 0.44 Imp qt)

SERVICE, SECTiON T

\ t

1

4.

I. Transaxle oil

Inspection . . . . .._........_................ page J3- 36

Reptacement . . . . . . . . . _,. . . . ._. . . . . . . . . . page J3- 36

2. Transfer carrier oil

Inspection.. . .._. . . .._ ._. ._.. . . . . . . . . . . . . . page J3- 36

Replacement . . . . . . . . . . ..l._............ page J3- 36

3. TransaxIe and transfer unit

Removal .I...............~.......~......__ page J3- 42

Disassembly .**.,.--......-.**.....,.._. page J3- 48 t nspection . . .._........*...*I.-..-........ page J3- 72

Assembly . .._....._.....--......-........

page J3- 75 lnstaliation . . . . ._. . . _ .-. . . . . . ..-. . . .._., . _ page J3-I 12

Shift mechanism

Overhaul . . . ..*..-.*._.........-.......... pageJ3-119

GRADE: API SERVICE Gt4

ALL SEASON DEXRON-II,

ABOVE -18OC (OOF): 75W-90

M-D

CAPACITY: 2.6 liters

(2.7 US qt, 2.2 Imp qt)

5. Center differential lock motor

Inspection . . . . . . . . . . . . . . . . . . .._..._....... page J3-123

Replacement . . . _ , . . . . . . *. . . . . _ . _. . . . _ . . page J3- 123

6. 4x4

Control unit

Inspection . . . . . . . . . . . . .._...._......._.... page J3-126

Replacement . . . .._......_........ . . . . . . page J3-126

7. Center differential lock switch

Inspection.. . _ . _ . _. _. . _. . . . . _ . . . _ . . . . . . . . . page J3-f 27

Replacement . . . . . .._...._........_..... page 33-l 27

8. Center differential lock sensor switch

Inspection . . . . . . . . . . . . . . ** .-... 1*..**-.I..

pageJ3-128

Replacement . . ..=......-.... -* . . . . -..-. page J3-I 28

J3-3

J3

OUTLtNE

l l l l l

OUTLINE OF CONSTRUCTION

Full-time 4-wheel drive, incorporating a viscous coupling is used on the BP DUHC Turbo model. BP SUHC engine equipped models are fitted with an electronically controlled, lockable center differential.

With this system all driving conditions verse weather conditions. are easily contended with; from good roads to bad roads and ad-

The transaxle and transfer unit were developed based on the GSM-R type transaxle.

The transaxle, center differential, viscous coupling, and front differentia! are a single, compact unit.

The center differential employs a planetary carrier. system and a viscous coupling, and functions to distrib- ute the driving force to the front and rear differentials as needed.

Through the use of this center differential, tire scuffing common to 4-wheel drive vehicles during tight cor- nering, is eliminated.

The speedometer driven gear (for detection of vehicle speed) is installed in the transfer carrier and detects the speed of the rear wheels.

Lubrication oil of the transaxle and transfer unit and of the carrier is contained separately.

93GOJ3-704

J3-4

OUTLINE

SPECIFICATIONS

TRANSAXLE AND TRANSFER UNIT

Engine model

Item

Transaxle control

Synchromtsh

Gear ratlo system

Forward

Reverse

I St

2nd

3rd

4th

5th

Reverse

Final gear ratio

Speedometer gear ratlo

Type

Number of ring gear teeth

Center differential

011

Outer

Inner gear teeth Inner

Pinion gear side

Number gear teeth of sun

Idler gear side

Number of idler gear teeth

Type

Capacity

33

BP DOHC turbo

Selectrve

BP SOHC

Floor shift

Synchromesh sfiding and synchromesh

3.454 3.307

1.833

I.310 1.233

Cl.91 4 0.970

0.717

3.166 L

4.214 4.388

1 .oo

Planetary carrier

59

75

79

66

14

14

43 33

43

37

ATF: DEXRON-II, M-III Above -18OC (O°F)

API servie GL-4 SAE 75W-90

2.6 liters (2.7 US qt, 2.2 Imp qt)

93GOJ3-305

Transfer Carrier

Number of teeth

Oil

Ring gear

Pinion gear

Type

Capacity

-

37

11

API service GL-5

Above -18OC tOoF) SAE 90

Below -18OC tOoF) SAE 8OW

0.5 liter (0.53 US qt, 0.44 Imp qt)

93GOLl3-776

J3-5

J3

STRUCTURAL

8P DOHC TURBO

VIEW

OUTLINE

/

14

d

‘8

1. Primary I st gear

2. Primary 2nd gear

3. Primary 3rd gear

4. Primary 4th gear

5. Primary 5th gear

6. Primary reverse gear

J3-6

7. Secondary I st gear

8. Secondary 2nd gear

9. 3rd gear

10. Secondary 4th gear

11. Secondary 5th gear

12. Secondary reverse gear

93GOJ3-706

13. Reverse idler gear

14. Viscous

15. Front coupling and center differential assembly

16. Idkr gear assembly

17. Transfer carrier assembly