Mazda : 626 626 Station Wagon RF Turbo Workshop Manual Supplement 4/98 1614-10-98D ame am EuropeMazda 626 626 Station Wagon Workshop Manual Supplement FOREWORD This manual contains the changes and/or additions relating to on-vehicle service and diagnosis procedures for the Mazda 626 and 626 Station Wagon For proper repair and maintenance, a thorough familiarization with this manual is important, and it should always be kept in a handy place for quick and easy reference. All the contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifications affecting repair or maintenance occur, relevant information ‘supplementary to this volume will be made available at Mazda dealers. This manual should be kept up-to-date. Mazda Motor Corporation reserves the right to altar the specifications and contents of this manual without obligation or advance notice. All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical— including photocopying and recording and the use of any kind of information storage and retrieval system—without permission in Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), and related materials shown on the following page. CONTENTS General Information FP, FS, FS (Hii-power) Engine Lubrication System Cooling System Fuel and FP, FS, FS (Hi-power) Emission AF Turk Control Systems | Rr Troe (Hi-powe Engine Electrical System Manual Transaxle Automatic Transaxte Front and Rear Axles Steering System Braking System Suspension Body Body Electrical System Heater and Air Conditioner Systems Technical Data Special Tools ‘There are explanations given only for the sections marked with shadow (Il) © 1998 Mazda Motor Corporation PRINTED IN THE NETHERLANDS, APR.1998 @ 1614-10-98DVEHICLE IDENTIFICATION NUMBERS (VIN) JMZ GF12R20# 100001 — JMZ GF12R2W# 100001 — JMZ GF12T20# 100001 — JMZ GF12T2W# 100001 — JMZ GF14R20# 100001 — JMZ GF14R2W# 100001 — JMZ GF14T20# 100001 — JMZ GF14T2W# 100001 — JMZ GW19R20# 100001 — JMZ GW19R2W#100001 — JMZ GW19T20# 100001 — JMZ GW19T2W# 100001 — JMZ GWESR20# 100001 — JMZ GW69R2W#100001 — JMZ GWe9T20# 100001 — JMZ GWesT2W# 100001 — RELATED MATERIALS 626 Training Manual (Europe) . - 3303-10-97D 626 Workshop Manual (Europe) - 1577-10-97D 626 Station Wagon Workshop Manual Supplement | (Europe) . + 1603-10-97J Engine Workshop Manual RF Turbo . + 1615-10-98D Manual Transaxle Workshop Manual G: + 1441-10-94F 626 626 Station Wagon Wiring (Europe (L.H.D. 5427-10-98D 626 626 Station Wagon Wiring Diagram RF Turbo (UK) .GENERAL INFORMATION HOW TO USE THIS MANUAL . RANGE OF TOPICS... IDENTIFICATION NUMBER LOCATIONS - ENGINE IDENTIFICATION NUMBER . VINCODE . es NEW STANDARD ......-.--26065 + GI-3 ABBREVIATIONS . + Gi-4 SCHEDULED MAINTENANCE : Gk5 ‘SCHEDULED MAINTENANCE TABLE ...... GI-5 HOW TO USE THIS MANUAL RANGE OF TOPICS «This manual indicates only changes/additions, as itis the supplemental forthe related materials. Therefore it may not contain the necessary referential service procedures to operate the services indicated in this manual. Only the referential section, e.g. (Refer to section B), is indicated, so refer to the appropriate section of the related materials for details. GI-1 IDENTIFICATION NUMBER LOCATIONS ENGINE IDENTIFICATION NUMBER RF TurboVIN CODE VIN CODE IZ GF 1 2A 2 0 # 100001 | {serial NUMBER LPUANT HOU NO MEANING. TRANSAXLE, eons 2. SMTX ENGINE CODE +. pF Turbo RE Turbo (ipower BODY STYLE CODE 2 .. 4 DOOR SEDAN — 4.) SD00R HATCH BACK 9. $ DOOR Wagon ‘SPECIFICATION 1... FES passenger 61. FELT passenger MODEL CODE GF 626 uMOeEE ce ——— GW 626 station Wagon MANUFACTURER, IDENTIFICATION MAZDA MOTOR = ‘CORPORATION GI-2NEW STANDARD NEW STANDARD ‘* The following is a comparison of the previous standard and new standard for the parts names of the diese! engine vehicle. ‘New Standar Previous Standard Calibration Resistor Connected Resistance Control Sleeve Position Sensor Control Sleeve Sensor Fuel shut Off Solenoid Fuel Cut Vaive Injection Purp Fuel injection Pump POM Control Relay Main Relay | Pump Speed Sensor | NE Sensor ‘Timer Control Valve. “Timing Control Valve GI-3ABBREVIATIONS ABBREVIATIONS ‘Antilock brake system (ATP. 000000000022 Automatic transanie fig FSO. Fuel shut off LHD, Left hand drive RHO. Se Right hand drive SAS .0000011111121 Sophisticated air bag sensor SST 6000000.2.21 Special service tool rovers ELT Timer control valve TINS 2010LIIILIIT Tall number side lights GlSCHEDULED MAINTENANCE SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE Chart symbols: + Inspect Inspect and clean, repair, or replace if necessary. (As forthe air cleaner element wet type, inspect, and itnec- essary repiace,) Replace T: Tighten Lubricate Remarks: To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. Its strongly recommended that all servicing related to these systems be done by an authorized Mazda Dealer. ‘After 160,000 km (96,000 miles) or 96 months, continue to follow the described maintenance at the recommended intervals. ‘+ Refer below for a description of items marked” in the maintenance chart. 1: Also adjust and inspect the power steering and air conditioner drive belts, if equipped. *2: Replacement of the timing belt is required at every 100,000 km (60,000 miles). Failure to replace the timing belt may resutt in damage to the engine. *3: Ifthe vehicle is operated under any of the following conditions, change the engine oil and oil fiter more often than recommended intervals. ‘a) Driving in dusty conditions. b) Extended periods of idling or low speed operation. ) Driving for long period in cold temperatures or driving regularly at short distance(less than 8 kn/5 miles) only. *4 Ifthe vehicle is operated in very dusty or sandy areas, inspect and replace, itnecessary, the air cleaner element more offen than the recommended intervals. *5 This is a full function check of electrical systems such as lights, wiper and washer systems (including wiper biades), and power windows. %6 Ifthe brakes are used extensively(for example, continuous hard driving or mountain driving) or if the vehicle is operated in extremely humid climates, change the brake fluid annually, GI-5SCHEDULED MAINTENANCE ‘OqOS TONGT AUD | | i v T v T 1 T ‘eyera bupied “oBey29) 10} joadsu pue Jona) piny yoRUD | | 1 1 1 1 1 1 1 Ping yomig ing xe19 soeIdeus ebeyeoopnodupuewrrpnproe || /'{ fel fal fat fal fay jap fo Ping oyeig “oBexe9| piny pue Buyjoms "sie0s " “uoyson00 ‘Buyerp ‘eBewep ‘sypeno.ojpodsu| | |! } ft] fel fe \ 1 ' suoqoeuueo @ s2s0y 's0uy e618 [Heid sou pve nBrou roped wou |r ft ati titi sitesi fittest tito Syeped yn 8 AEE ‘Ad08 8 SISSVHO 1 1 1 1 1 WOUIUBYE TUB PEOH ue soysem 9 (Uonpu 294mm pjoryspum ‘woyshs Bun Jo wonoL “Aynei6 oyoods pur | teotofotefetapebepatapapepepap aps. ‘wsorshs yeauoe}@ Ny U ‘ 1 t 1 1 i t ‘Tuneib oypads 9 ona] evkonneye Kaneg WALSAS TWOIHLOS13 ‘UopSeUUGD 9500] PUB SEER] "S}PEI9 105 eds) [1 r T T T v 1 T ‘Ses0u % Sou jon [- vows jong coeidew | u a 8 seuy 16ng ee iea Gee 4 u 1 u 1 8 1 % wouwsre soue9p sy WALSAS 73nd 3 reaN Kind Tein OVE eoomeentars (s9p 000'09) 14 000'00t 40 s1e8K > yS1y 7 eoeIdOY soem | 1 ' ! 1 1 1 1 Geese 410) eedsut pue ‘Ayrenb ue Jono} We|Oo AUD, [x9] 3ue}009 Burpriouy) wHeisks Bu}ood WALSAS ONTI009 ‘ebeyeoi 1 podsu pub eyHOeedU [Ue] e [eel el| el ulelelylel|e|elele|e WO ut ulelelelelelelelelelelefelfelelele yooubug, (Sen 000'68) ur 000'001 Krone aoedats & ¥0q Bun eu6ug camantmemowwomoaven TTT Ti fifi fi fififef efi fi [i | cao SUBIEOD e1nseaN 120A 2 10 (S9nu1 000°81) wi 000'0E Avene woodsul ‘eauere6 een ouibua aNIDNA (6) (oad 2) | 229 (0s)|vs)| Carr] Cevy] GE) | (Oe) 2) (@v)[~2)] (6) | (seu oo0% x) | fagaiet ca egeste 201 0s+|orsloer|ozi{ort oot| os | 08 |oz | 09 [05 |or |oc [oz for |” woi0001* | wy goueuonmay os{ [ve] [ez{ [oa| |e] |ee| |e] |e suo ‘Gesu sowoo senauorym “(eas) wy J0 s4qUOU 70 HoqUINN) LeAIeIU] EOUEUETUIEN. GI-6SCHEDULED MAINTENANCE oY ‘SSBuRIBN VOq JOUBUE OOD PUT THOR ue S180 ‘saypteios 04 Burggam wed wees wodsuy 1 1 1 1 1 syeq eg paoy [- pue py muna ‘sio0p jo soyoreo pue sobunj ovary | 71 J) (7) |] fat fat fay fa soyoteo @ $96u1H “wojsoue0 (wwounsnipe e:nssoxd voneyur uy) ewe eBeurp Hook peullcy euiEomen Fea einen aera | y ' ' ' ' (uh exeds Gurpnyou}) Sauk, “voneioyiod pu wapSu0. | ae (onB6ped % wojsow0D "sna 10)) ‘yan ‘eBewep qwped 305 e0ep ns Apo Yoedsut ‘uoqypuce Apo "50K suequioul‘Suauodiuoo [acon vommananor pun seamen sme TT fal fel fal fel fel bl] ‘po 8 9569 U0 PU BSR "90088001 Fe Senay orn eee core! \ 1 1 si00q snp yeUsENIG *Se0u8800) pe obourep ‘201 ‘eBeye0 9018.0) odes | | ' ' ' ‘sw weq uorsuedsns yuoL 1 1 1 1 1 1 Uorsuedsns Woy 9 BUUORS 8 1 4 1 Wo epesuen enue ' 1 1 1 1 1 1 1 9804 9 wieishs Buve6Is 19MOd Tepe eae Piny Buyaers s0mog 1 1 1 1 \ , 1 1 seyeaq ura 1 1 ' 1 1 1 ' 1 D s0ye19 9810 “sypero ‘sseugyBa se wouypeye sodosdus 20} | | 1 1 1 1 ‘59904 9 UN eyeIq JoMOg ‘aNyen xpauD puB SUORoeUUCD 'seUy| LINNEA 24D, (98)| (oe) [va] @2)| Ce] 9) oad] (rs) (@e)] (ev) Ged] (oe)| wed] GN] Cen] ) | Coun ooo x) paunbor wom oyoeds fosr|ost lori aet|ozs|ort[oor| os | 08 |az | 09 [os [ar [oe Jaz Jor | wn 0001 | ay, soueueuren s6{ [va] fez[ |oo[ |ev| [eel [ve] |e ‘suo (Ge1y seuios zoneKDium eoHts) why 20 syIUOU JO ZOqUINN) feAe}U] SOUBUONUTER GI-7SCHEDULED MAINTENANCE “aBeeo| WEIOBIIO! PUP SYPEID “OBEHED} TO “estou 104 oodouy pur ‘uone1edo sosseudueo 904, ' 1 1 1 vojeiedo sosse1dwog Tunoure WeIeBW—1 8D 1 1 i 1 qunowe wereBueu J3ddINDA 4D WALSAS HANOLLIGNOO HIV ‘ropes: Bupa) KoweBrewejeouTaToed eeu06 sasi0u fensnun 40 sees ‘syeanbs/so8neB pue s1o}aUs jo uoyiedononuco | | ' ' ' 1801 pou Suyoers/uonesedo yornienuoneiedo eyed OUD (6) (od a) ](o2)] | (| (| (rs) CenI| Ce) | Ge) (OE) we) [CW] ev)[ | CSenw oot ~) | apie oeensete 221 ost|ort|oe+|ozs lout oor) 08 | 8 oz | 09 [as lor [oc jaz [or | w>r0001% | gy goueuension {esl [val [zz| |oo| [a {sel [vz] [a suHON (Geay s0wi00 sonayo;yn (eo) un 40 euyuOU Jo sequunh) leAsew) eoUNLOIUIEN GI-8ENGINE (RF Turbo, RF Turbo (Hi-power)) CAMSHAFT, ROCKER ARM, ROCKER BRIDGE ...... ABBREVIATIONS. B21 VALVE OUTLINE «...eseeeseeeee B24 OUTLINE OF CONSTRUCTION | B2-1 | SERVICE STRUCTURAL VIEW ....... B2-2 ‘SPECIFICATIONS . -.B2-3 DRIVEBELT ... B2-17 ENGINE PERFORMANCE CURVE ....... B2- 3 RIVE BELT INSPECTION » B2-17 COMPARISON BETWEEN RF Turbo AND DRIVE BELT ADJUSTMENT + B2-17 CONVENTIONAL RF : 4 VALVE CLEARANCE... - B2-18 DIRECT INJECTION ENGINE MECHANISM . B2- 5 VALVE CLEARANCE INSPECTION ....... B2-18 PISTON, PISTON RING, PISTON PIN ...., B2- 5 VALVE CLEARANCE ADJUSTMENT ....., B2-18 CYLINDER HEAD 7 COMPRESSION INSPECTION + B2-20 ENGINE MECHANISM sess B2- 8 TIMING BELT ........ vee B2-21 CYLINDER HEAD, CYLINDER HEAD TIMING BELT GASKET . B2- 8 REMOVAL/INSTALLATION + B2-21 CYLINDER BL¢ B2- 8 CYLINDER HEAD GASKET . + B2-25 (CRANKSHAFT, MAIN seveeees B2o 9 CYLINDER HEAD GASKET DRIVE BELT ........00005 porno REPLACEMENT . + B2-25 CONNECTING ROD, CONNECTING ROD FRONT OIL SEAL - B2-30 BEARING . seve B11 FRONT OIL SEAL REPLACEMENT + B2-30 VALVE MECHANISM 52-12 REAR OILSEAL.. - B2-31 OUTLINE .. B2-12 REAR OIL SEAL REPLACEMENT .. - B2-31 STRUCTURAL VIEW . B2-12 ENGINE ........... severe B2-33 CAMSHAFT PULLEY ENGINE REMOVAL/NSTALLATION ....., B2-33 TIMING BELT AUTO TENSIONER ENGINE DISASSEMBLY/ASSEMBLY ..... 82-36 ABBREVIATIONS ‘ABDC _| After bottom dead center BTDC | Before top dead center Ac | Airconsitioner x Exhaust, ‘ATOC | After top dead center IN intake BBDC | Before bottom dead center PS Power steering OUTLINE OUTLINE OF CONSTRUCTION The following are the major differences between the previous 323 (BA) model and the RF Turbo engine. ‘¢ The following have been adopted to improve fuel economy, increase output, and reduce emissions: ‘© A system in which fuel Is injected directly to the center of each cylinder. # Addouble-vortex combustion chamber. * A double tangential port (intake port), '* The following have been adapted to reduce weight and size: © Suspending the oil pump. ‘¢ SOHC four vaives per cylinder and rocker arm design. ‘* Acdrive system powered by the rear gear of the camshaft is used in the P/S pump, and a drive system powered directly by the rear gear of the camshaft is used in the vacuum pump to eliminate the drive belt, reducing the friction loss and improving reliability. * To reduce vibration created by the rotation of the flywheel during idling, crankshaft support has been made more rigid by adopting a bearing beam in the No.4 and No.5 main beating cap sections. ‘© The durability of the timing belt is improved by adopting: ‘A timing belt auto tensioner to maintain the tension of the timing bet. ‘© A dynamic damper in the camshaft pulley to reduce the change in angular velocity and suppress excassive tension of the timing belt. B2-1OUTLINE STRUCTURAL VIEWOUTLINE ‘SPECIFICATIONS: Engine tem RF Turbo RF Turbo (ipower) | The Diesel, aye (yin arangemont and number inne, 4 cylinders Combustion chamber Direct injection Vaie sytem ‘HC, bet-rive, 16 valves [Displacement (ent (6°, cu in) 1998 {1996, 122} Bore x stroke (ram {in} 86.0 x 86.0 {3.39 x 3.39} Compression ratio 168 Compression pressure (kPa {kat/cm®, psi} [rpm)) 2893 {29.5, 419} [260] [Open BTDC | e ve sning [Giose ‘ABDC 20° ox Open ja0c “ Chose ‘TDC e N (mm Gr) 0.12—0.18 {0.005—0.007} ave dlearance | (0.152003 (0.006 0.001) Engine oi 0.82-0.36 0.013-0.014} es (rm Ged) {0.36 + 0.03 {0.014 +0.001}) ENGINE PERFORMANCE CURVE @ 0 m000-2000rom g ® 1 ' nwt rom sexwon0 rom ' 1 1 1 = Lo ee ee ee "3500000" 4500 "500" 20002500 "9000 "35004000" A500 @ (om @ tom 1 AF Turbo ‘Output RF Turbo (Hi-power) “Torque 3 Engine speed B2-3OUTLINE COMPARISON BETWEEN RF Turbo AND CONVENTIONAL RF Improvement | No. Hem RF Turbo Conventional RF improved combus- [1 | Combustion cham- | Mazda's original "double-vortex chamber es- | Swi combustion tion and fue! econ: bor tablish a balance between swirl and squish | chamber (Pre omy while it a'so generates @ powerful flow of air chamber type) throughout the entire combustion chamber to promote diffusion and atomization of injected fuel 2 | Portlayout “The direct injection of fuelinto the center of | Straight port the cylinder combined with the powerful swit! ‘and high volumetric effciency of a “double tangential port’ ensures a controlled, symmat- ‘ical flow of air-fuel mixture in the cyinder, while atthe same time reducing intake resis- tance. Reduction offric: | 3 | Vacuum pump Direct-drive was adapted for auxiliary system, | Belt drive system tion loss, reduced such as the vacuum pump and power steering | powered by rear ‘weight and com- ump, reducing mechanical resistance toa | end pulley of cam- pact size lower ievel than attainable in engines with belt | shaft drive system. 4 | Ollpump ‘Overall engine length was reduced by sus- ‘Crankshaft direct pending the oil pump inside the oll pan. drive system 5 | Valve mechanism | Use of an SOHC 4 valves and rocker arm de-_| SOHC 2 valves ‘sign made it possible to lower the cylinder and camshaft direct hhaad and the overall height ofthe engine. drive system B2-4DIRECT INJECTION ENGINE MECHANISM DIRECT INJECTION ENGINE MECHANISM PISTON, PISTON RING, PISTON PIN ‘* The pistons are made of aluminum alloy and the double-vortex combustion chamber is adopted. ‘¢ The piston body has a cooling channel. Oil jets squirt oil into this cooling channel. The oil absorbs heat from around the rings and reduces piston ring and cylinder wall wear. Steel struts are cast into the boss to curb thermal expansion, thus minimizing the change in piston clearance by temperature and optimizing offset volume. cr «The fitting of the piston, connecting rod, and piston pin is a fullfloating type. 1_| Cooling channel 7_[Tepring -] 2_| Engine oi _| Second ring _ 3 Oiljet ‘9 | Ring carrier 4_| Steel strut 10_| Oilring 5 __ Piston pin 11 | Section piston and piston ring 6 | Snap ring 12 | Double-vortex combustion chamberDIRECT INJECTION ENGINE MECHANISM Double-Vortex Combustion Chamber ‘¢ The double-vortex combustion chamber establishes a balance between swirl and squish while it also generates a powerful flow of air throughout the entire combustion chamber to promote atomization of the injected fuel ® @ 1] Compression starts Powerful flow before fuel injection 2 ‘Airis compressed Fue! is injected ‘© As the piston rises, powerful airflow is created in th and diffusion of the injected fuel, lowering emission ie combustion chamber. This airfiow hastens atomization 8. 1_| Piston Injection nozzie Cylinder head B2-6DIRECT INJECTION ENGINE MECHANISM CYUNDER HEAD Double Tangential Port «The entire port has been configured with bends to create sulficient switl even during low engine speeds. ‘Adopting four vaives increases the vaive opening area, improving charging efficiency. « Straightening the intake port reduces intake resistance, «Direct injection of fuel in the centre of the cylinder ensures uniform injection of fue! throughout the entire ‘combustion chamber, and mixing fuel with the swirl produced in the double tangential port ensures a symmetrical flow of the air-fuel mixture in the cylinder. ‘tem RF Turbo Conventional RF ; @ @ portiavout | & 7 D INTAKE PORT GROSS SECTION Injection nozzle installation part 1] Intake port 3 2_| Exhaust port B2-7ENGINE MECHANISM ENGINE MECHANISM CYLINDER HEAD, CYLINDER HEAD GASKET ‘¢ The cylinder head is made of aluminum alloy. ‘© The cylinder head gasket is made of four laminated layers of stainless steel. + [Cylinder head CYLINDER BLOCK ‘e The cast iron alloy cylinder block is linerless, and has a deep skirt design for higher rigidity. ‘© The cross-crilled, coolant passages are provided between the cylinder bores. AAA 1_| Cylinder block 2_| Gross drit hole B2-8CRANKSHAFT, MAIN BEARING ‘¢ The steel crankshaft has five journals and four balance weights. ‘* The main bearings are made of aluminum alloy. The main bearings are grooved to provide extra cil. joper and lower halves of the main bearings are identical. However, the upper and lower halves of the third bearing are wider than the rest. ENGINE MECHANISM «© Thrust bearings are fitted fore and aft of the No.3 journal bearings. # To reduce vibration created by the rotation of the flywheel during idiing, flywheel support has been made more ‘igid by adopting a bearing beam in the No.4 and No.5 main bearing cap sections. 1_| Upper thrust bearing 5 _| Main bearing cap 2 Oll pump drive gear 6 _| Lower thrust bearing | Upper main bearing 7_| Ollpassage 4 | Lower main bearing 8 _| Bearing beam B2-9ENGINE MECHANISM DRIVE BELT ‘* The drive belts are V-belts. JAG 1_| Granksha pulley “4_| Idler (without A/C compressor) 2_| Generator 5 V-belts two belts-driven) '3_| AIC compressor B2-10ENGINE MECHANISM CONNECTING ROD, CONNECTING ROD BEARING ** The connecting rods are made of carbon steel. ‘¢ The upper and lower connecting rod bearings are made of aluminum alloy. 7] Bush 3__| Lower connecting rod bearing 2 | Upper connecting rod bearing 4 | Connecting rod cap B2-11VALVE MECHANISM VALVE MECHANISM OUTLINE '* An SOHC system driving 16 valves-two intake and two exhaust valves per cylinder with a single camshaft through the rocker arm is used. STRUCTURAL VIEWVALVE MECHANISM CAMSHAFT PULLEY ‘To improve the durabiity ofthe timing belt, a dynamic damper in the camshaft pulley to reduce the change in angular velocity and excessive tension of the timing bet « Aservice hole is designed in the camshaft pulley. It is used to stop the camshaft pulley from turning during instal of the timing bet 1 Rubber 2 | Detent bolt service hole B2-13VALVE MECHANISM TIMING BELT AUTO TENSIONER 1_| When cold 5 _| Chamber B 2_| When hot 6 _| Rod and plunger 3_| Timing belt 7_| Ball 4 _| Tensioner pulle @_| Chamber A By adopting a hydraulic auto tensioner for the timing belt train, the timing belt tension is always automatically maintained at the optimum level and is therefore maintenance-free. When cold 4. Belt tension is low. 2. The tensioner moves upward. 8. The auto tensioner rod and plunger are extended. 4, The rod moves upward by the spring force and the ball falls downward simultaneously so as to open the passage in the rod and plunger. The oil flows into chamber A. When hot 1. Bett tension is high. 2. The tensioner moves downward, 3. The auto tensioner rod and plunger are depressed. 4. The increased pressure in chamber A pushes the ball upward to block the passage. Oil passes by the wall and flows upward. B2-14VALVE MECHANISM. CAMSHAFT, ROCKER ARM, ROCKER BRIDGE ® Six journals support the cast iron camshaft. The flange on the No.6 journal controls end play. «The intake and exhaust rocker bridges are the same. + The rocker bridge transmits the movement of the rocker arm simultaneously to two valves. + Because the distance from the rocker shaft to the valve differs on the intake side and the exhaust side, the rocker arm is configured independentty on the intake side/exhaust side. + Adrive belt is no longer used due to the adoption of a vacuum pump and P/S pump in the drive system powered by the rear gear of the camshaft, thereby making the engine smaller and improving reliability. + Due to the change from a valve mechanism to a rocker arm type, the valve clearance is now adjusted with a screw. (Refer to page B2-18) + Valve clearance is adjusted at sections A and B. a { 1 [ Camshaft 5_| Drive gear 2_| Rocker arm 6 | Lock bolt with groove for driving vacuum pump 3 | Rocker bridge 7_| Vacuum pump 4_| Cylinder head 8 PiSollpump B2-15VALVE MECHANISM VALVE ‘¢ The valves are made of heat-resistant steel * An equal pitch spring is used for the valve spring, © The vaive guides are made of sintered metal. * Part of the exhaust valve stem is narrow and itis used as a carbon cutter. As a result, the valve guide does not have a carbon cutter and IN and EX use the same valve guide. C= moqmoe', 1_| Valve keepers (“5 Vaive seat 2_| Upper valve spring seat 6 _| Valve guide 3 _| Valve spring 7_| valve: 4 | Lower valve spring seat 8 _| Exhaust valve B2-16DRIVE BELT DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Inspection 1. Inspect the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has been stopped. Apply maderate pressure 98 N {10 kgf, 22 Ibf} midway between the specified pulleys. GENERATOR (WITH A/G COMPRESSOR) MEASURING POINT GENERATOR PULLEY] CRANKSHAFT PULLEY ‘nic COMPRESSOR PULLEY MEASURING ONT a tumour Nc COMPRESSOR) feenenavon Puller wersunndron Deflection mm fn} Divebel [New tut |.) 80-35 16 caneator, * | (032-057) | (088-059) | (063) wine [57 esto | 19415 030-039) | (52055) (059 Grom 1 80-95 | i914 | 15 wow AC (032-037) (052055) (059 * Absit that hes been on a running engine for less than five minutes. 2. the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT, Orive Belt Tension Inspection 1. Belt tension can be checked in place of belt deflection. Inspect the drive belt tension when the engine is cold, or at least 30 minutes after the engine has been stopped. Using the SST, inspect the belt tension between any two pulleys. B2- ETT Tension Nit bf Drive belt | *New Uses] _Limet 3a0—490 | 260-204 Generator 226 (40-50, {26.5—30.0, aoe se—1i0) 59-66) | 2.51) rn ‘without AC {45—55, {26.5—20.0, 423, 50} 99121) 5966) * Abell that has been on a running engine for less, than five minutes. 2. Ifthe tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT) DRIVE BELT ADJUSTMENT Generator Drive Belt Caution ‘¢ The two belts that drive the generator and AIC compressor must always be changed together. Changing only one belt will cause belt slippage. 41. Loosen mounting nuts A and B. 2. Adjust the belt tension by adjusting bolt C. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten bolts A and B, Tightening torque ‘A: 19-25 N-m {1.92.6 kgt-m, 14—18 ftibf} B: 3861 N-m {3.86.3 kat'm, 28-98 fbf} GENERATOR PULLEY 4. Inspect the belt deflection. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 17VALVE CLEARANCE VALVE CLEARANCE VALVE CLEARANCE INSPECTION 1. Remove the cylinder head cover. 2. Turn the crankshaft and align the timing mark 80 that the piston of the No.1 of No.4 cylinder is at TDC of compression. 3, Measure the valve clearances A with the No.1 cylinder at TDC of compression, and those of B with the No.4 cylinder at TDC of compression. Valve clearance [Engine cold] IN: 0.12—0.18 mm {0.005—0.007 in} (0.15 +.0.03 mm {0.006 + 0.001 in}) EX:0.32—0.38 mm {0.013—0.014 in} (0.35 4.0.03 mm {0.014 0.001 in}) MEASURING POINT 4. Ifthe vaive clearance is not within the specification, adjust the vaive clearance. (Refer to VALVE CLEARANCE, VALVE CLEARANCE ADJUSTMENT) 5. Turn the crankshaft one full turn and measure the remaining vaive clearances. Adjust if necessary. 6. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.) VALVE CLEARANCE ADJUSTMENT 1. Remove the cylinder head cover. 2. Tum the crankshaft clockwise and set the No.1 cylinder to compression TOC. Caution ‘If the crankshatt is turned without removing the glow plug, compression pressure acts on the injection nozzle and the Injection nozzle to move. When 1on nozzle Is moved, carbon stuck to the nozzle washer installation surface of the cylinder head may affect the seal. To avold this, remove the glow plug to release ‘the compression pressure, Ifthe injection nozzle is moved, remove the carbon with & clean cloth and replace the washer. 3, Remove the glow plugs. (Refer to section F2, INTAKE-AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION) Caution ‘© When the injection nozzle ts moved, carbon stuck to the nozzle washer installation surface of the cylinder head may affect the seal. After removing the injection nozzle bracket, do not move the injection nozzle. If the injection no: moved, remove the carbon with a cl cloth and replace the washer. 4. Remove the injection nozzle bracket. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REMOVAL/INSTALLATION.) 5. Adjust the valve clearance A with the No.1 cylinder at TDC of compression, and those of B with the No.4 cylinder at TOC of compression. (1) Hold the rocker bridge using the SST (49 G012 006). (2) Loosen the locknut (4) using the SST (49 (G012 004), and then turn the adjusting screw (©) using the SST (49 GO12 005) until itis separated from the valve stem completely. Ee ‘ADJUSTING SCREW (c) LOckNUT (a) ROCKER BRIDGE B2-18VALVE CLEARANCE (8) Loosen the rocker arm locknut (b) using the ‘SST (49 GO12 004), and then turn the ‘adjusting screw (a) using the SST (49 Go12 (005) unt it is separated from the rocker bridge completely. 23.6012 004) () Insert a fecler gauge between the rocker arm and rocker bridge (e). Valve clearance [Engine cold] IN: 0.12—0.18 mm {0.005—0.007 in} {(0.150.03 mm {0.006 + 0.001 in}) EX:0.32—0.38 mm {0.013—0.014 in} (0.95 0.03 mm {0.014 + 0.001 in}) (©) Adjust the valve clearance by turning the agjuster (a) using the SST (49 GO12 005). Then temporarily tighten locknut (b) using the SST (49 GO12 004) (©) With the feeler gauge inserted between the rocker arm and rocker bridge, verify that the feeler gauge remains firmly in place even when the adjusting screw (c) is loosened. It the feeler gauge does not remain firmly in place, repeat procedures from Step 1 () Turn the adjusting screw (c) using the SST (49, 6012 005) until it reaches the valve stem and the feeler gauge fits more firmly. Then tighten the locknut (d) using the SST (43 G012 004) to specified torque. Tightening torque 16—20 Nem {1.62.1 kgf-m, 12—15 ftlbf} (@) Loosen the locknut (b) using the SST (49 G012 004) and readjust the valve clearance ). Valve clearance [Engine cold) IN: 0.12—0.18 mm {0.005—0.007 In} (0.15 £0.03 mm {0.006 0.001 in}) X:0.32—0.38 mm {0.013—0.014 in} (0.35 + 0.03 mm {0.014 3:0.001 In}) (9) Tighten the locknut (b) using the SST (49 012 004) to specified torque. Tightening torque 16—20 Nem {1.62.1 kgf'm, 12—15 ftlbf} (10) Verify the valve clearance at (e).. Valve clearance [Engine cold] ).12—0,18 mm {0.005—0.007 in} (0.15+0.03 mm {0.006 #-0.001 in}) .32—0.38 mm {0.013—0.014 in} (0.35 + 0.03 mm {0.014 0.001 in}) 6. Tum the crankshaft one full turn and adjust the remaining valve clearances. 7. Install the injection nozzle bracket. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REMOVAL/INSTALLATION.) 8, Install the fuel leak pipe. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REMOVALIINSTALLATION.) 9. Install the glow plug. (Refer to section F2, INTAKE-AIR SYSTEM, GLOW PLUG REMOVALINSTALLATION.) 10. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.) ex: B2-19COMPRESSION II INSPECTION COMPRESSION INSPECTION Warning ‘¢ When the engine and the oil are hot, they can badly burn. Turn off the engine and walt until they are cool. ‘Compression 7. Crank the engine and note the maximum gauge reading, 8, Inspect each cylinder as above. kPa tkotfom2, psi} (ron Engine ftom 1. Verify that the battery is fully charged. Recharge it RE Turbo, RF Turbo (Hi-power} if necessary. (Refer to section G, CHARGING. [Standard 2,896 (295, 419} [260] ‘SYSTEM, BATTERY INSPECTION, Battery.) Minimum 2,599 (26.5, 377} [260] 2, Warm up the engine to the normal operating temperature. 8, Stop the engine and allow it to coo! off for about 40 minutes. Warning ¢ Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries skin and eyes. To prevent fuel from spurting out of the glow plug hole, do not ground the fuel shut off (FSO) solenoid terminal. 4, Disconnect the FSO solenoid connector. 9. Ifthe compression in one or more cylinders is tow, our a small amount of clean engine oil into the cylinder and reinspect the compression. (1) Ifthe compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. Hf the compression stays low, a valve may be stuck or improperly seated and overhaul is required. If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head maybe distortet and overhaul is required. 2) ® 10. Remove the SSTs. Warning ‘Ifthe glow plug harness connector is connected, the glow plug harness and engine component can come into contact and cause a short when the ignition Is on. Disconnect the glow plug harness connector before turning the ignition on ignition. 1 CONNECTOR ; areu 5, Remove the all glow plugs. (Refer to section F2, INTAKE-AIR SYSTEM, GLOW PLUG REMOVAL! INSTALLATION.) 6. install the SSTs into the glow plug hole, OW PLUG HARNESS: 1. Install the glow plug. (Refer to section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVALIINSTALLATION.) 12, Reconnect the FSO solenoid connector.TIMING BELT TIMING BELT TIMING BELT REMOVAL/INSTALLATION 4, Disconnect the negative battery cable. 2.Drain the engine coolant. (Refer to section E.) 3. Remove the cylinder head cover insulator. 4 Remove in the order shown in the figure. 5. Install n the reverse order of removal. 6. Adjust the drive belt deflection/tension. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 7-Fillthe radiator with the specified amount and type of engine coolant. (Refer to section E.) 8 Inspect the pulleys and the drive belt for runout and contact. 15-108 (7.5-107, 550-773) 15-107%m (eo—Nokgrem, 225_Ds.aimion) Ta-1a7Hem {20—TloKgtem, tos toed a 6 eee Neat 165 1 | Upper timing belt cover 3 Lower timing bet cover 2 | Drive bet s Removal Note 3. | No. engine mount 6 | Guide plate «= Removal Note 7__| Crankshaft position sensor Installation Note___ | a | Timing bert Timing belt auto tensioner | 4 7 Crankshaft pulley | == Removal Note = Removal Note = Installation Note instalation Note B2-21TIMING BELT No.3 Engine Mount Removal Note © Suspend the engine using the SST. Crankshatt Pulley Removal Note ‘* Tur the SST adjusting bolt and lower the engine to remove the crankshaft pulley. Xo Lower Timing Belt Cover Removal Note Caution timing belt cover could be damage ily. Hold the timing belt cover at the locations indicated in the figure and remove the crankshaft position sensor harness slowly. Timing Bett, Timing Belt Auto Tensioner Removal Note 1. Tur the crankshaft clockwise and align the timing marks as shown. TIMING MARK Caution ‘* The following will damage the belt and shorten its life: forcefully twisting it, turning It inside out, or allowing oll or grease on it. « After removing the timing belt, do not move the crankshaft and/or camshaft Pulley from this position because it can cause the valve and piston to contact. 2, Remove the timing belt auto tensioner. 3. Mark the timing belt rotation on the belt for proper reinstallation. Sp Se SB FAULTY FAULTY may oTaTION Nail ame PAUL asmm(.anun ‘Timing Belt, Timing Belt Auto Tensioner Installation Note 1, Measure the tensioner rod projection length. Replace the auto tensioner if necessary. 2, Inspect the auto tensioner for oll leakage. Replace the auto tensioner if necessary. Projection (Free length) 12,9—-14.6 mm {0.508—0.574 in} B2-22TIMING BELT Caution ‘Placing the auto tensioner horizontally can cause oll leakage and damage the auto tensioner. Place the auto t vertically when using a vise. 3. Verify the thrust of the auto tensioner rod in the folowing order: (1) Hthe tensioner rod is rigid when it is pushed with a load of approximately 235 N {24 kgf, 53 Ibf, push it down slowly and fix the pin in the hole. @ Ifthe tensioner rod is not resistant and moves slightly when itis pushed with a load of approximately 235 N {24 kat, 53 Ibf push t down sionty two or thee times to the bottom end of the rod. © when the rod protrudes approximately 8.1 mm {0.32 in}, verify that the rod is resistant When the rod is resistant, push it down slowly and fix the pin in the hole. ifthe rod does not become resistant, replace the auto tentioner. B2-23 Caution ‘* To prevent the bolts (M8 x 1.25) from damaging the fuel Injection pump and pulley, do not fully tighten the detent bolt. If It contacts the pulley surface, it will damage the pulley. 4, Very that all timing marks are correctly aligned. 5. Fix the camshaft pulley to the cylinder head using bolt MB x 1.25. 6. Fix the injection pump pulley to the bracket using two bolts MB x'1.25. a 1.25 BOLT ‘TIMING MARI 7. Hf not, align all timing marks according to the procedure below, Caution ‘¢ Turn the crankshaft in the direction which will prevent the TDC and BDC from being passed. Otherwise It can cause the valve and piston to contact. (1) Turn the crankshaft and set it an angle of 45° ‘or more away from the TDG and BDC. (2) Align the timing marks of the camshaft pulley. (8) Align the timing marks of the injection pump. pulley. (4) Turn the crankshaft and align the timing marks of the timing belt pulley. 8. Install the timing belt on the pulleys in the order described below. (1) Timing bett pulley @) Idler Q) Injection pump pulley (4) Camshaft pulley (6) Water pump pulley (6) Tensioner 9, Remove the injection pump pulley fixed bolts and camshaft pulley fixed bolt M8 x 1.25. 10. Hand tighten the auto tensioner bolts in the order Ato,TIMING BELT 11. Tighten the auto tensioner bolts in the order A to B. A mi 12, Remove the pin from the auto tensioner to apply tension to the bet. 19. Turn the crankshaft clockwise twice, and align the timing marks, 14. Verify that al timing marks are correctly aligned. if Not, repeat from Timing Belt, Timing Belt Auto Tensioner Removal Note. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt, Timing Belt Auto Tensioner Removal Note.) Crankshaft Pulley Installation Note ‘@ Tighten the bolts in the order shown. No.3 Engine Mount installation Note ‘¢ Tighten the bolts in the order shown. B2-24CYLINDER HEAD GASKET CYLINDER HEAD GASKET (CYLINDER HEAD GASKET REPLACEMENT Warning ‘Fuel vapor is hazardous. It can very easily ignite, causing ‘sparks and flames away from fuel. ‘spllis and leakage are dangerous. Fuel can ignite and cause serious injuries or death and skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” in section F2. (Refer to section F2, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) rious injury and damage. Always keep 1. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 2. Remove the vacuum pump, (Refer to section P, CONVENTIONAL BRAKE SYSTEM, VACUUM PUMP REMOVAL/INSTALLATION, ) 8. Remove the P/S oll pump with the oll hose stil connected. Position the P/S oil pump so that its out of the way. 4. Remove the turbocharger. (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove all the glow plugs. (Refer to section F2, INTAKE-AIR SYSTEM, GLOW PLUG REMOVAU/INSTALLATION.) 6. Remove in the order shown in the figure, 7 Install in the reverse order of removal 8 Inspect valve clearance. (Refer to VALVE CLEARANCE, VALVE CLEARANCE INSPECTION.) 8. Inspect the engine ol level. (Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.) 10. Inspect the compression. (Refer to COMPRESSION, COMPRESSION INSPECTION.) 11, Start the engine and. (1) Inspect the engine oil, engine cootant, and fuel leakage. (@) Inspect the idle speed. (Refer to F2, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT) 15-1070 {feo—noughen, Secsaaimiot Gatien a 79-107 ¥m {a0—10KgFom, eos—as4inioy 7a—107 Nm 0110 Kgtem, os Us 79-107 4m 0 oto Kgrem, 60-70, 4¢-80) Gos —e8A iro, tem atm, 0A) B2-25CYLINDER HEAD GASKET 1] injection pump pulley = Removal Note = Installation Note 2 | Gear cover = Installation Note 3 | Drivegear Removal Note Installation Note 4 | Gear case = Installation Note eae nema 3. Loosen the injection pump pulley lock nut. 4. Separate the Injection pump pulley from the = injection purnp shaft using the SST. MBx1.25 BOUT = Installation Note 7 | Water outiet ‘+ Installation Note @ | Ollccoler hase ‘9 Gylinder head cover _= Installation Note 10 | Fuel leak pipe = Installation Note Injection pipe Installation Note 5, Remove the injection pump pulley fixed bolts 12_| Nozzle seal MB x 1.25, 13__| injection nozzle brackat 1a weal ee Drive Goar Removal Note [Injection nozzle |. Hold the camshaft using the SST. 15 | Side wall 2. Remove the crive gear lock bot. = Installation Note 76 | Rooker arm and rocker arm shalt © Removal Note * Installation Note W7_| Rocker bidge 18 Camshat 19 Broathor pips 20) Oyiinder head ‘= Removal Note = Installation Note 21 _| Oylinder head gasket ‘Camshaft Pulley Removal Note Injection Pump pulley Removal Note 1. Hold the camshaft using the SST. 1. Verify that timing marks are correctly aligned. 2, Remove the camshaft pulley lock bolt. Caution ‘¢ To prevent the bolts (M8 x 1.25) from damaging the injection pump and pulley, do not fully tighten the detent bolt. If it contacts the pulley surface, it will damage the pulley. 2. Fix the injection pump pulley to the bracket using ‘two bolts MB 1.25. 3. Remove the camshatt pulley using the SST. B2-26CYLINDER HEAD GASKET ECE {9601 Plato Removal Note Remove the seal plate from the engine ‘component. However, the seal plate cannot be removed completely. Separate the seal plate from the engine component by removing the fiting bolts ‘0 that the cylinder head can be removed. Rocker Arm And Rocker Arm Shatt Removal Note + Loosen the bolts in two or three steps in the order shown, Cylinder Head Removal Note ‘Loosen the cylinder head bolts in two or three steps in the order shown, 2ylinder Head Installation Note 1. Before installation, measure the length of each bok. Replace any that exceed the maximum. length. Maximum length 116.8 mm {4.598 in} LENGTH 2. Tighten the bolts in two or three steps in the orde shown. Tightening torque 29 Nem {3.0 kgt-m, 22 fbf} ENGINE FRONT 3, Put a paint mark on each bolt head. 4. Using the marks as a reference, tighten the bolts by turning each 80°—105° in the sequence shown. 5, Further tighten each bolt by tuning another 90°—105°, ‘SECOND PAINT MARK. 90"—105,, FIRST ‘29 Nm 20-105" BoKgte, zane, Rocker Arm And Rocker Arm Shaft Installation Note 1. Apply sealant as shown in the figure. Thickness ‘02 mm {0.079 in} min. B2-27CYLINDER HEAD GASKET 2. Install the camsha't caps according to the cap number, 3. Install the rocker arm shaft plane side upward. horizontally while It is installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust recelving area of the cylinder head journal. To avoid this, the following procedure must be observed. 4. Tighten the bolts in two or three steps in the order shown. 5, Apply clean engine oil to the new oil seal. 6, Push the oil seal slighty in by hand. 7. Tap the oil seal into the cylinder head using the SST and a hammer. =| INDER | 02-1.5em (0.020.050 1) HEAD ~ HAMMER (IL SEAL Sido Wall Installation Note ‘© Apply silicone sealant as shown in the figure. ‘Thickness. ‘92 mm {0.079 In} min, Injection Pipe Installation Note + Install the injection pipe in the order shown, ENGINE Front e222 | Fuel Leak Pipe installation Note Caution ® Ifthe gasket is reused, fuel can leak in the cylinder head, contaminating the oll and causing conditions such as abnormal wear to the friction parts. When a gasket is removed, be sure to Install a new gasket. 4. Tighten the fuel leak pipe in the order shown. 2. Apply soapy water to each installation part of the ‘uel leak pipe. ‘3. After instaling the fuel leak pipe, apply air pressure of 98 kPa {1.0 kgtfcm?, 14 psi} from the location marked A, and verify that there is no air 'eakage trom each installation part. B2-28CYLINDER HEAD GASKET Seal Plate Installation Note 1. Install the seal plate and hand tighten the bolt ir the order A to B. 2. Tighten the bolts in the order shown. 4. Inspect the fuel leak pipe for air leakage. Cylinder Head Cover installation Note ‘1. Apply silicone sealant to the shaded areas. Camshaft Pulley Installation Note Thickness 1. Hold the camshaft using the SST. ‘92 mm {0.079 In} min. Gear Case installation Note 1. Apply silicone sealant as shown in the figure. ‘Thickness 91.5—2.5 mm {0.059—-0.098 In} Water Outlet installation Note ‘¢ Tighten the bolts in the order shown. 2, Tighten the bolts in clockwise order. B2-29CYLINDER HEAD GASKET, FRONT OIL SEAL Drive Gear Installation Note 1. Hold the camshaft using the SST. 2. Tighten the drive gear lock bolt. allation Note 1. Apply silicone sealant to the shaded areas shown in the figure. ‘Thickness 91.5—2.5 mm {0.059—0.098 in} 2, Tighten the bolts in clockwise order. Injection Pump Pulley Installation Note Caution ‘* To prevent the bolts (M8 x 1.25) from damaging the injection pump and pulley, do not fully tighten the detent bolt, If it contacts the pulley surface, It will dama: the pulley. ‘© Fix the injection pump pulley to the bracket using two bolts MB x 1.25. FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Remove the timing bet. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 2, Remove in the order shown in the figure. 3. Install in the reverse order of removal. AA7=I76 (17.0180, 125-130) em gat, 109 1 | Timing bet pulley iock Bott == Removal/netalltion Note 2 | Timing bot put = Removal Note 3 | Frontoil sea Removal Note = instalation Note ‘Timing Bolt Pulley Lock Bolt Removal/installation Note ‘Hold the timing belt pulley using the SST. fy 49 G011 105 B2-30FRONT OIL SEAL, REAR OIL SEAL ‘Timing Belt Pulley Removal Note REAR OIL SEAL ‘Remove the timing bot pulley using the SST. \ REAR OIL SEAL REPLACEMENT 1. Remove the flywheel. (Refer to section H.) 2. Remove in the order shown in the figure, 3. Install in the reverse order of removal. Front Oil Seal Removal Note 4. Cut the oil seal lip using a razor knife, 1 | Rear oll soal | = Removal Note Installation Note Rear Oil Seal Removal Note 4. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag. Front Oil Seal Installation Note 4. Apply clean engine oil to the oil seal lip, 2. Push the oil seal slightly in by hand, 3, Tap the oil seal in eveniy using the SST anda hammer. The oll seal must be tapped in until itis flush with the edge of the oil pump body. P waumen OIL PUMP BODY ola 0-05 mm {00.019 in} FRONT OIL SEAL B2-31REAR OIL SEAL Rear Oil Seal installation Note 1. Apply clean engine oilto the oil seal lip. 2. Push the cil seal slightly in by hand. 3: Tap the oil seal in evenly using the SST and a hammer, DTP HAMMER 0—0.5 mm {0-0.019 np Li r\ EAR OIL SEAL B2-32ENGINE IENGINE MINGINE REMOVAL/INSTALLATION Warning ‘ Fuel vapor Is hazardous. it can very easily ignite, causing serious injury and damage. Always keep ‘sparks and flames away from fuel. ‘¢ Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” In section F2. (Refer to section F2, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Remove the radiator. (Refer to section E,) 3. Remove the cylinder head cover insulator. 4: Remove the air cleaner and air hose. (Refer to section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5. Disconnect the fuel hose. (Refer to section F2, FUEL SYSTEM, BEFORE REPAIR PROCEDURE) (Refer to section F2, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 6. Remove the transverse member. (Refer to section R.) 7. Remove the front pipe. (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 8, Remove the battery and carrier. 9, Remove the vacuum hose and the heater hose. 10, Remove the P/S oil pump with the oil hose stil connected. Position the P/S oil pump so that itis out of the way. 11, Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that itis out of the way. 12. Remove the drive shatt. (Refer to section M, DRIVE SHAFT, DRIVE SHAFT REMOVAL/INSTALLATION.) 48, Remove in the order indicated in the table. 14 Install in the reverse order of removal. 15.Filthe radiator with the specified amount and type of engine coolant. (Refer to section E.) 16, Adjust the drive belt deflection/tension. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT), 417, Bleed the air from the fuel line. (Refer to section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 18 Stat the engine and (1) inspect the pulleys and the drive belt for runout and contact. @ inspect the engine oil, engine coolant transaxle oil, P/S fluid, and fuel for leakage. (2) inspect the idle speed and idle mixture. (Refer to section F2, ENGINE TUNE-UP) 18, Pertorm a road test. 20. Reinspect the engine oil, engine coolant, transaxle oi, and P/S fluid levels. B2-33ENGINE tos—147H {H0—I80Kgrem, 78 scimeeo {5°25 5000) J bret tro~t07, 55077 \. on eorezasy E10 3 SN ons 87-119, 05.0—26.0) ereetrrey TNT km {90120 igre, gos—toninion 4 N 400 es fee a,s040) o7—03 ae {7.6—-10.7, 85.0—77.3) eB, 50-69 em eat, 6 1] Bationy bracket 7] Nos Engine mount ribber 2_| Air cleaner stay Installation Note @ | No Engine mount rubber 3_[ Nos Eng i rubber 47 [Enane mein marr isan te 3 9 No.4 Engine mount bracket 5 _| No.2 engine mount _= Installation Note 6 No.1 Engine mount boltENGINE No.4 Engine Mount Bracket, No.3, No.4 Engine Mount Rubber Installation Note 4. Tighten the bolt in the order shown. 2, Hand tighten the No.3 and No.4 engine mount rubber bolts and nuts (A-K), No.4 ENGINE MOUNT RUBBER No.3 ENGINE MOUNT RUBBER. 3. Tighten the No.4 engine mount rubber bolts and nuts (A-E). 4, Tighten the No.3 engine mount rubber bolts and nuts (F-K).. 5, Measure the No.4 engine mount rubber clearance. Itnot within the specification, repeat from Step 1 Standard clearance 4.0—6.0 mm {0.16—0.23 in} B2-35ENGINE ENGINE DISASSEMBLY/ASSEMBLY 1, Disconnect the engine and transaxle. (Refer to section J, MANUAL TRANSAXLE, TRANSAXLE REMOVAL/INSTALLATION) Remove the exhaust system. (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) Remove the generator. . Remove the clutch. (Refer to section H.) . Remove the vacuum pump. (Refer to section P, CONVENTIONAL BRAKE SYSTEM, VACUUM PUMP REMOVAU/INSTALLATION,) Remove the oll cooler. (Refer to section D, OlL COOLER, OIL COOLER REMOVAL/INSTALLATION.) Disassemble in the order shown in the figure. 8, Assemble in the reverse order of disassembly. NO gae = 17 (12-1401) Nem (igh Mbt) 1] Dipstick 3 | Ollpressure switch 2 AC compressor bracket, idler section D. = Installation Note A/C Compressor Bracket, Idler Installation Note ‘ Tighten the A/C compressor bracket bolts in the order shown. B2-36LUBRICATION —— FEATURES OUTLINE «20... essen ‘OUTLINE OF CONSTRUCTION SPECIFICATIONS . LUBRICATION SYSTE! oH LUBRICATION SYSTEM STRU VIEW... LUBRICATION FLOW CHART .. LUBRICATION MECHANISM D-4 OIL PUMP. D4 OIL COOLER, D-5 OIL FILTER, Ds OWLJET 0-6 SERVICE ‘SUPPLEMENTAL SERVICE INFORMATION .. OIL FILTER .. OIL FILTER REPLACEM! OILCOOLER....... ‘OIL COOLER REMO' OIL PAN ..ssesscseseveseesee a ‘OIL PAN REMOVAL/INSTALLATION pepoo Soeoyn 3P OUTLINE OUTLINE OF CONSTRUCTION ‘The construction and operation of the RF engine lubrication system are basically the same as those of the previous Mazda 323 (BA) models. (Refer to Mazda 323 RF Workshop Manual Supplement 1588-10-97C.) However, the following changes have been made: As the overall length of the engine has been made shorter, a suspended type of oll pump has been adopted. ‘ The bypass fiter has been eliminated in the RF Turbo engine due to low carbon output compared with the previous RF engine. ‘© Cilis supplied to the vacuum pump from the rear of the camshaft because the vacuum pump has been changed to a drive system powered by the rear end of the camshaft. ‘SPECIFICATIONS tem LC Engine RF Turbo RF Turbo (Hi Lubrication system Force-Fed type epee Type Trochoid gear oma Relief pressure (kPa {kal/om?, psi) 510-608 {5.2-6.2, 74-86} aps Type Ful-fiow Bypass pressure (kPa {kato pel) 79117 (081.2, 12-17 Total (ary engine) —_(L {US at, imp ath) 5.4 (5.7, 48) Oil capaciy [Ol teplacement_—(L (US a, Imp a) 4516.8, 40) (it and ol iter replacement (L{US at imp ot) fea ena Engine oll ‘API service OD e Below 10 °0 (60 FY ‘SAE SW-30 ome ~15 °0 —40 °C (6 °F —104-F} SAE 10W-30) D-1LUBRICATION SYSTEM LUBRICATION SYSTEM LUBRICATION SYSTEM STRUCTURAL VIEW 7] Olen | Oi pressure sich 2 | Ol staner 7__| Turbocharger 3 [01 pump @ | Oyindor read [Ol oot 9 Vacuum pump 31 olierLUBRICATION SYSTEM LUBRICATION FLOW CHART 1_| Oipan 40 _| Piston 2 Oistrainer 11] Ollpressure switeh 3 | Olpump. 12 | Orica 4 | Oiicooler 33] Camshaft 5 _| Oifiter Tia] Rocker arm shaft 6 _| Main bearing [45] Rocker arm, rocker bridge 7_| Crankshaft 16 | Vacuum pump _ ‘8 _| Connecting rod bearing 17_| Turbocharger Oijet D-3LUBRICATION MECHANISM LUBRICATION MECHANISM oll PUMP '¢ ‘The oll pump is trochoid type. * Crankshaft rotation is transmited to the ol pum criven gear trough the ol pump cive gear installed to the crankshat ‘The oll pressure relief valve is mounted in the oll pump cover. 1_] Oil pump driven gear 4 | Oilpump cover 2 | Oil pump body 5 | Oi pressure relief valve 3 Outer rotor D-4LUBRICATION MECHANISM OIL.COOLER ‘¢ The oil cooler is a water cooled, 5 layer type. * The oll cooler lowers the engine oil temperature to prevent engine oil premature deterioration. OIL FILTER '* The oll fiter is small-sized full low type with a paper element,LUBRICATION MECHANISM OWL JET ‘¢ The oil jets are employed. * The oll jets continuously spray oil to cool the pistons when the oil pressure is 188—196 kPa {1.4—2.0 kat/om?, 20—28 psi} or more. When the oil pressure is below the specified pressure, the oll jets stop spraying oil to. avoid the oll pressure drop, ® | vider block main gallery 1 [[o Tome: — 2 | Engine of 7) Chock ball 3 | Check valve 8 | Check bal sping a | Nozze | Ollhole to nozzle) 5] OF pressure 410_| Check vaveSUPPLEMENTAL SERVICE INFORMATION, OIL FILTER SUPPLEMENTAL SERVICE OIL FILTER INFORMATION OIL FILTER REPLACEMENT ‘¢ The following additions have been made since 1. Remove the ol ter using the fer wrench, publication of the Mazda 626 Workshop Manual (1577-10-970). Engine oll ‘Engine ol capacity specification has been added. {Rter to section TD) Oil pressure * Oil pressure specification has been added. (Reter to section TD.) oul tiner '* Replacement procedure has been added. Oi cooler ‘+ Removal / Installation procedure have been 2. Tighten the fter according to the installation added. direction on the side of it or packing box using the Olt pan filter wrench. ‘* Removal / Installation procedure have been 3. Start the engine and inspect for oll leakage. ‘added. 4, Inspect the oil level and add oil if necessary. (Rieter to section 0.)OIL COOLER OIL COOLER OIL COOLER REMOVALJINSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E) 3. Remove the oil fiter. (Refer to OIL FILTER, OIL FILTER REPLACEMENT) 4, Remove in the order shown in the figure. 5. Install in the reverse order of removal. 6. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E.) 7. Inspect the engine oil level. (Refer to section D.) 8. Start the engine and inspect for the engine cooiant leakage. ey = ros 95, 10-29 em (agtm, tor) 1 | Olrcooler = Installation Note Oil Cooler installation Note ‘ Install the oil cooler with the detent against the rib of the cylinder block. CYLINDER _, BLOCK DETENT ‘lL COOLER RIB D-8OIL PAN OIL PAN OIL PAN REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine oll. (Refer to section D.) 3. Remove in the order shown in the figure. 4. Install n the reverse order of removal. 5. Fill with the specified amount and type of engine oil. (Refer to section D.) 6. Start the engine and inspect for the engine oll leakage. 79-107 Nm {0—10 Hatem, 69.525. 79-10,7 Wa (60-110 kate, 605-064 Intbg Nem gt, eo T | Water pipe 3_| Clutch under cover = Removal Note 4] Olpan 2 | Gusset plate == Removal Note = Installation Note Water Pipe Removal Note 3. Screw an oil pan bolt into the weldnut to make a ‘* Remove the water pipe with the water hoses stil ‘small gap between the cylinder block and the oil ‘connected. pan. ll Pan Removal Note 1. Remove the oll pan mounting bolts. 2. Remove the sealant ftom the bolt threads, 4. Using a separator tool, separate the oil pan. D-9OIL PAN ‘SEPARATOR TOOL Oil Pan Installation Note Caution If the bolts are reused, remove the old sealant from the bolt threads, Tightening a bolt that has old sealant on can cause bolt hole RACKS (OL SEALANT 4. Apply silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends. Thickness. 62.5—3.5 mm {0.099—0.137 in } jand tighten the flangeless bolts, and tighten the janged bolts. D-10COOLING SYSTEM FEATURES OUTLINE . OUTLINE SPECIFICATIONS . COOLING SYSTEM oe COOLING SYSTEM STRUCTURAL VIEW .. COOLANT FLOW CHART .... : SERVICE SUPPLEMENTAL SERVICE INFORMATION THERMOSTAT . : THERMOSTAT REMOVAL / INSTALLATION . THERMOSTAT INSPECTION . WATER PUMP ......0..0-.. ao WATER PUMP REMOVAL | INSTALLATION . . COOLING FAN MOTOR . ‘COOLING FAN MOTOR REMOVAU/INSTALLATION COOLING FAN RELAY ... aoe ‘COOLING FAN RELAY INSPECTION baad mm mommmmm o OUTLINE OUTLINE OF CONSTRUCTION '* The construction and operation of the RF engine cooling system are basically the same as those of the previous Mazda 923 (BA) models. (Refer to Mazda 323 AF Workshop Manual Supplement 1588-10-97C). However, the coolant flow is different as the cylinder head has been modified. SPECIFICATIONS Nom Engine RF Turbo: RF Turbo (Hi-power) Coaing Sytem Water co0}d, force circulation Coolant capacty = TRS ain 80 (85,79) Water pump | Type Centrfoga. tring bot aren Type Wax, bottom bypass emoses — _eipening omparaixe Orr 8084 {176-189} [ Futkopen temperature Corry) 95 (209) Fulropen it (eam inp 85 (035) min T Type Corrugated fin Radiator ‘Cap valve opening pressure a 94122 0951.25, 195-17.) Type Bete Cooling fan Blade: Outer diameter {mm fin) 300 {11.6} Nurnbor 5 E-1COOLING SYSTEM COOLING SYSTEM COOLING SYSTEM STRUCTURAL VIEW © 1_| Radiator reservoir 4] Water pump 2_| Radiator 5 | Oitcooter '3_| Thermostat 6 | Heater unit E-2COOLING SYSTEM COOLANT FLOW CHART @ ® 1 _| Radiator reservoir | Oylinder block 2_| Radiator 6 _| Oylinder head 3_| Thermostat 7_| Oilcooler [Later pump | Heater unit E-3SUPPLEMENTAL SERVICE INFORMATION SUPPLEMENTAL SERVICE INFORMATION © The following additions have bean made since publication of the Mazda 626 Workshop Manual (1577-10-970). ‘Thermostat * Removal/installation procedure have been added. * Inspection procedure has been added. Water pump ‘* Removal/installation procedure have been added. Cooling fan motor ** Cooling fan motor specification has been added, (Refer to section TD.) ‘ Removal/installation procedure have been added. Cooling fan relay * Inspection has been added.THERMOSTAT THERMOSTAT ‘THERMOSTAT INSPECTION Inspect the thermostat for the following and replace it ‘THERMOSTAT REMOVAL/INSTALLATION necessary. 1. Disconnect the negative battery cable. ‘* Closed valve in room temperature 2. Drain the engine coolant. (Refer to section E.) ‘¢ Opening temperature and lift of the valve 3. Remove the transverse member. (Refer to section R. Tntia-opering 80-84 (176163) 4, Remove in the order shown in the figure. temperature _°C °F} 5, Install in the reverse order of removal. Fulhopen temperature 95 203} 6. Fill the radiator with the specified amount and type SCF) of engine coolant. (Refer to section E.) Ful-open itm {inp 85 (0.39) min \ Ae 79-10. (90-110, 605-05.4) Nom ogtem, into 1_] Radiator hose: 2 | Thermostat cover 3. | Thermostat = Installation Note ‘Thermostat Installation Note «Install the thermostat into the thermostat cover, aligning the projection on the gasket to the thermostat cover as shown. ‘THERMOSTAT COVER PROJECTION E-5WATER PUMP. WATER PUMP WATER PUMP REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant, (Refer to section E.) 3, Remove the timing belt, (Refer to section B2, TIMING BELT, TIMING BELT REMOVALIINSTALLATION.) 4. Remove in the order shown in the figure. 5. Install in the reverse order of removal. 6. Fill the radiator with the specified amount and type of engine coolant. (Refer to section .) 38-51 (38-53,20-35) tas tto26, a8) 7910.7 Non {80110 kgm, 68.5964 In) Nem (eat, fb 1_| Hose | Thermostat case 2 | Lower radiator hose = Instalation Note. 4 | Water pump = Instalation Note E-6WATER PUMP. Water Pump Installation Note © Install a new gasket with the sealing ring facing the water pump. ‘SEALING Ri > WATER PUMP SIDE Thermostat Case Installation Note ‘Install a new gasket with the sealing ring facing the thermostat case. SEALING, FIN > ‘THERMOSTAT CASE. SIDE E-7COOLING FAN MOTOR, COOLING FAN RELAY COOLING FAN MOTOR COOLING FAN RELAY COOLING FAN MOTOR REMOVAL/ INSTALLATION COOLING FAN RELAY INSPECTION 1. Remove the cooling fan component. (Refer to 1. Apply battery positive voltage and inspect for section .) Continuity between terminals of the cooling fan 2. Remove in the order indicated in the table. relay by using an ohmmeter. 3. Install in the reverse order of removal. O-0 : Continuity ‘Terminal Step a B c D 1 oj 2 8 | GND oo EE] | 0 3 O—® 2. If not as specified, replace the cooling fan relay. 20-3.9Nm (2040 kgtem, 27-34 ino 1_| Cooling fan blade 2 Cooling fan motor '3_| Radiator coming E-8FUEL AND EMISSION CONTROL SYSTEMS (RF TURBO) FEATURES OUTLINE .... F2- FEATURES. F2- SPECIFICATI F2- ‘SYSTEM DIAGRAM SYSTEM WIRING DIAGRAM INTAKE-AIR SYSTEM OUTLINE . 2 2 2 F2- 3 Fe- 4 Fo. 8 Fo- 8 8 AIR CHARGING SYSTEM F2- DOUBLE TANGENTIAL PORT F2- 9 GLOW SYSTEM . bee F2- 10 FUEL SYSTEM F2- 11 OUTLINE . Fon INJECTION PUMP « SPILL VAVLE .. TIMER CONTROL VALVE (TCV) - FUEL SHUT OFF (FSO) SOLENOID « FUELFILTER ..s.seseeseeveee INJECTION NOZZLE « EXHAUST SYSTEM .... F2- 21 OUTLINE . F2- 21 STRUCTURAL VEIW EMISSION SYSTEM . OUTLINE . BLOCK DIAGRAM . CONTROL SYSTEM DEVICE AND. ‘CONTROL RELATIONSHIP CHART . PUMP SPEED SENSOR .. FUEL TEMPERATURE SENSOR TDC SENSOR «0-02-1000 ACCELERATOR POSITION SENSOR . IDLE SWITCH ..... ENGINE COOLANT TEMPERATURE (ECT) SENSOR «0... F2- 31 INTAKE AIR TEMPERATURE (AT) SENSOR ...... BOOST SENSOR pene NEUTRAL/CLUTCH SWITCH PCM CONTROL RELAY SPILL VALVE RELAY . RELAY FUEL INJECTION AMOUNT CONTR FUEL INJECTION TIMING CONTROL . IDLE SPEED CONTROL, GLOW CONTROL . EGR CONTROL ... ELECTRICAL FAN CONTROL AIC CUT-OFF CONTROL IMMOBILIZER SYSTEM . ON-BOARD DIAGNOSTIC SYSTEM OUTLINE «....4 3 SSSSGRE2VRSS SRBRE SERVICE ENGINE TUNE-UP ENGINE TUNE-U IDLE SPEED INSPECTION .. IDLE-UP SPEED INSPECTION .... INJECTION TIMING INSPECTION INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION TURBOCHARGER INSPECTION . GLOW PLUG REMOVAL/INSTALLATION . F2- 60 GLOW PLUG INSPECTION «....+-+++++. F2- 60 GLOW PLUG RELAY REMOVAL/INSTALLATION - F2- 60 GLOW PLUG RELAY INSPECTION ...... F2- 61 GLOW PLUG LEAD INSPECTION :F2- 61 ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION ... - F2- 61 ACCELERATOR PEDAL DISASSEMBLY/ASSEMBLY .. ACCELERATOR POSITION SENSOR ADJUSTMENT ..s.ssseeeserseesseeees F2> IDLE SWITCH ADJUSTMENT. 2 F2- FULLY OPEN STOPPER ADJUSTMENT . F2- FUEL SYSTEM «2.0... .se0000 000 BEFORE REPAIR PROCEDURE AFTER REPAIR PROCEDURE - FUEL TANK REMOVAL/INSTALLAI FUEL TANK INSPECTION .... NONRETURN VALVE INSPECTION FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION ......2.0. FUEL FILTER REMOVAL/INSTALLATION . F2- FUEL WARMER INSPECTION F2- FUEL LINE AIR BLEEDING F2- ‘SEDIMENTOR WATER DRAINING - F2- 67 ‘SEDIMENTOR SWITCH INSPECTION ... F2- 67 INJECTION PUMP INSPECTION .. F2- 68 INJECTION NOZZLE REMOVAL/ INSTALLATION. . se F2- 68 LEAKAGE INSPECTION . F2- 69 INJECTION PUMP REMOVAL/INSTALLATION F2- 69 INJECITON NOZZLE INSPECTION. F2- 70 FUEL SHUT OFF (FSO) SOLENOID INSPECTION . SPILL VALVE INS! EXHAUST SYSTEM . EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL/INSTALLATION EMISSION SYSTEM .......... EGR SOLENOID VALVE (VACUUM) INSPECTION . Fe. 74 EGR SOLENOID VALVE (VENT) INSPECTION . - EVAPORATIVE CHAMBER INSPECTION . F2- 75 CONTROL SYSTEM . Fe PCM REMOVAL/INSTALLATION «-..... F2- 71 F2- 71 F2- F2-1OUTLINE PCM INSPECTION... on ON-BOARD DIAGNOSTIC SYSTEM ....... F2- 90 FUEL TEMPERATURE SENSOR) READ/CLEAR DIAGNOSTIC TEST INSPECTION . - F2- 80 RESULTS... " TIMER CONTROL VALVE (TCV) PARAMETER IDENTIFICATION ' INSPECTION . - F2- 80 (PID) ACCESS F2- 90 PUMP SPEED SENSOR INSPECTION ... F2- 81 SIMULATION TEST F2- 90 INJECTION PUMP EPROM INSPECTION’ F2- 82 DIAGNOSTIC SUPP( F2- 80 SPILL VALVE RELAY INSPECTION . cA ON-BOARD DIAGNOSTIC TEST F2- 90 FUEL SHUT OFF (FSO) SOLENOID’ DTC READING PROCEDURE . F2- 80 RELAY INSPECTION 1-0... 83 PID/DATA MONITOR AND RECO! ‘TDC SENSOR INSPECTION «. 83 PROCEDURE . 92 INTAKE AIR TEMPERATURE (AT) PLAYBACK OF S' SENSOR No.1, No.2 INSPECTION ..... F2- 84 PROCEDURE .. 92 ENGINE COOLANT TEMPERATURE (ECT) SIMULATION TEST PROCEDURE ....... F2- 93 ‘SENSOR INSPECTION . 85 AFTER REPAIR PROCEDURE .. 94 IDLE SWITCH INSPECTION * 868 ‘ON-BOARD DIAGNOSTIC TROUBLE PCM CONTROL RELAY INSPECTION ... F2- 86 CODE INSPECTION .. vesee F2> 95, ACCELERATOR POSITION SENSOR ‘TROUBLESHOOTING F2-119 INSPECTION ... seveeses F2= 87 FOREWORD .. F2-119 EGR VALVE POSITION SENSOR TROUBLESHOOTING ITEM TABLE F2-119 INSPECTION ... - F2- 87 QUICK DIAGNOSTIC CHART . F2-120 BOOST SENSOR INSPECTION 122.012.) F2- 88 ‘SYMPTOM TROUBLESHOOTING « F2-124 CLUTCH SWITCH INSPECTION "1.0.1.1 F2- 88. ENGINE SYSTEM INSPECTION ......... F2-152 NEUTRAL SWITCH INSPECTION 88 OUTLINE ‘© The fuel and emission control system has the following features compared to Mazda 323 (BA) RF engine model. FEATURES Improved power and drivabllity ‘* Due to the adoption of an electronic control type injection pump corresponding to the increased fuel injection pressure, a direct injection system can be adopted. ‘* Aturbocharger with a charge air cooler is adopted to realize high output and torque. ‘© The “double tangential port” has been adopted as the intake port ofthe cylinder head to improve intake efficiency and realize an ideal combustion state. Improved exhaust gas purification performance ‘A direct injection system is adopted to increase fuel injection pressure and realize clean exhaust. Due to the increase in fuel injection pressure, a two-stages type injaction nozzle is adopted. ‘© The air charging pressure of the turbocharger is increased to reduce black smoke gas under heavy load or, when accelerating Improved serviceability '* The on-board diagnostic system equivalent to the CIS vehicles is adopted to improve serviceability. ‘* The PCM has been modified to simplify the procedures of "ENGINE TUNE-UP” and "INJECTION TIMING ADJUSTMENT”. ‘* For cold areas, the fuel warmer fs adopted to prevent the light oll component from hardening to block the fuel filter when the outside air temperature is low. SPECIFICATIONS Tom RF-Turbo Air cleaner element type Wat type ‘Supercharger type Turbocharger Injection pump type Electric distribution Fueltank capacity (CUS eat Imp a) 64 (67.6, 56.3) ‘Glow plug type Metal EGR typo Duty contrat Catalyst type Oxidation catalyst Evaporative emission contol system 5 Positive crankcase ventilation (PCV) system Closed F2-2OUTLINE SYSTEM DIAGRAM 1_| Aircieaner 20_| Injection pump EPROM 2_[ TAT sensor No.1 21 _| Injection nozzle | IAT senor No2 22_| Engine coolant temperature sensor 4_| Turbocharger 23__| TOC sensor 3 | Boost sensor 26 | POM 6 _| Oxidation catalytic converter 25 _| POM control relay 7__| Accelerator postion sensor 26 | Engine switch | tale switch 27_| Neutalcutch switch 9 | EGR vane 28_[ NC switch 10_| EGR solenoid valve (vacuum) 29 | ouc 11_| EGR solenoid vavie (vert) '30__| Vehicle speed sensor 12_| EGR valve position sensor 3t_| Glow plug 13_| Vacuum pump 32_| Giow plug relay 14 | Spill vave 33_| Charge air cooler 15 | Spill valve relay ‘34 _[ Fuel shut off (FSO) solenoid 16 _| Injector diver module (OM) 35 | Fuel warmer 17_| Timer contol valve (TCV) 36_| Fuel shut off (FSO) solenoid relay 18_| Pump speed sensor ‘37 Fueltank 5 19 | Fuel temperature sensor 38_| Fuel iter F2-3OUTLINE SYSTEM WIRING DIAGRAM Immobilizer unit equipped F2-4OUTLINE 7 [oLc 26_| Condenser fan 2_| Immobilizer unit 27_| AC relay '3_| Neutral switen 28_| Magnetic clutch 4_| Clutch switch 29 | Refrigerant pressure switch | Injector driver module (IDM) 30_| AC pressure switch 6 | Spill vave 31_| ACampitier 7_| Fuel shut off (FSO) solenoid ‘32 _| Cooling fan relay [8 _| Fuel shut off (FSO) solenoid relay 33_| Cooling fan 9 | Spit vaive relay 34_| Vacuum switch 10_| Timer control valve (TCV) 35_| Fuel warmer 11_| Fuel temperature sensor 36_| Instrument cluster 12_| Pump speed sensor 37_| Grow indicator ight 13. Injection pump EPROM '38_| Vehicle speed sensor 14_| EGR solenoid valve (vacuum) '38_| Generator warning light 18_ | EGR solenoid valve (vent) 40_| Sedimmentor switch 16_| Glow plug relay 41_| Generator 17_| TOC sensor 42_| Starter 18 | Intake air temperature (IAT) sensor No.2 43_[ Engine switch 19 | Intake air temperature ((AT) sensor No.1 44_| Battery 20_| Engine coolant temperature (ECT) sensor 45_| Glow plug 21_| Accelerator position sensor 46 | POM, 722_| EGA position sensor 47_| With AIG 23 | Boost sensor 48_| Idee switch 24 | POM control relay 49_| With fuel warmer 25 _| Condenser fan relay '50_| to instrument cluster F2-5OUTLINE Immobilizer unit not equippedOUTLINE + [oe 26_] AG relay 2__| Neutral switch 27__| Magnetic cutch 3_| Clutch switch 28 _| Refrigerant pressure switch 4__| Injector driver module (]OM) 29 ACC pressure switch 5_| Spllvaive 30_| AC ampitior 6 _| Fuel shut off (FSO) solenoid 31_| Cooling fan relay 7_| Fuel shutoff (FSO) solenoid relay 32_| Cooling fan 8 _| Spi valve relay '33_| Vacuum switch | Timer contro valve (TOV) '34_[ Fuel warmer 10_| Fuel temperature sensor 35_| Instrument cluster 11_| Pump speed sensor 36_| Grow indicator ight 12 | injection pump EPROM 37_| Vehicle speed sensor 18 __ EGR solenoid valve (vacuurn) ["38__| Generator warning light 14_| EGR solenoid vaive (vent) 38 Sedimmentor switch 15 | Glow plug relay '40_| Generator 16 | TOC sensor ‘a1_| Starter 17_| Intake air temperature (AT) sensor No2 42_| Engine switch 48 | Intake air temperature (AT) sensor No.1 43_| Battory 19_| Engine coolant temperature (ECT) sensor 44_| Giow plug 20_| Accelerator position sensor 45_| POM 21_| EGR position sensor 46_| With AIG 22_| Boost sensor 47_| Ile switch 23, | POM control relay 48_| With fuel warmer ‘24 | Condenser fan relay 49__| To instrument cluster 25 | Condenser fan F2-7INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM OUTLINE '* The intake-air system consists of the parts shown in the figure below. ‘* Amixed flow turbocharger with charge air cooler is adopted to realize high output and torque in low and middle speed renge. ‘* The valve opening pressure of the wastegate valve of the turbocharger is set higher than that of the Mazda MPV WL Turbo engine model to reduce the emission of black smoke when load is heavy and/or accelerating. ‘* Due to the adoption of the “double tangential port, the powerful swirl is generated, reducing intake resistance and improving fuel economy. ‘Structural View {7 Frost ut fiegrted wih resonance charbo}] [5] Take mano Air cleaner 6 __ Double tangential port Turbosnarger 7 [ Combustion chambers 4 | Charge ar cooler F2-8INTAKE-AIR SYSTEM AIR CHARGING SYSTEM ‘A mixed flow turbocharger with charge air cooler is adopted as in the Mazda MPV WL Turbo engine model (Refer to Mazda MPV Training Manual 3294-10-96C.) «By increasing the force of the diaphragm spring in the wastegate actuator, the wastegate valve opening, pressure of the turbocharger has been increased approximately 15% compared to the Mazda MPV WL Turbo engine model. As a result, air charging pressure has been increased and intake air charging efficiency has been improved. In addition: = High output and torque has been realized. = Emission of black smoke, caused by incomplete combustion due to the increase in fuel injection amount under heavy load or when accelerating, has been greatly reduced. Mazda 626 Mazda MPV F-Turbo WL Turbo Wastogate valve | 24562575 | 213.4~-222.6 pee {2.505—2.625, | {2.176-2.269, eee 35.63-37.32} | 30.95—32.26) kPa fugllom?, pai DOUBLE TANGENTIAL PORT ‘© The direct injection of fue! into the center of the cylinder combined with the powerful swirl and high volumetric efficiency of the double tangential port ensures a controlled, syjmmetrical flow of the air-fuel mixture in the cylinder, while at the same time reducing intake resistance. The advantage of this system is high charging efficiency of air and fuel, and the realization of an ideal combustion state. 7_| Intake port (Double tangential por) 3] Piston 2 | Exhaust port F2-9INTAKE-AIR SYSTEM GLOW SYSTEM '¢ The glow system consists of the parts shown in the figure below. ‘* Due to the adoption of the direct injection system, the glow plug is installed shown in the figure below. 1_| Glow plug, 4 | Injection nozzle 2_| Glow plug lead 5_| Piston 3 | Glow piug relay 6 Cylinder head Glow Plug '® A solf-temperature control type has been adopted as in the Mazda 323 (BA) RF engine model. F2-10FUEL SYSTEM FUEL SYSTEM OUTLINE ‘© Due to the adoption of an electronic control type injection pump, the PCM adjusts to the optimal fuel injection amount and time according to the engine driving condition. * An electronic control type injection pump, which controls the fuel injection amount directly with the spill valve, is adopted. ‘© The fuel injection timing is controlled by the timer control valve(TCV), as well as Mazda 323 (BA) RF engine model. ‘* Due to the adoption of the direct injection system, a small, two-stages type nozzle, which suits the high-pressure injection" of injection nozzle intake port pressure, is adopted for the injection nozzle. ‘© For cold district, the fuel warmer is adopted. “|; Comparison Rem Now Mazda 626 RF Turbo engine model | __ Mazda 323 RF engine model Injection nozzle intake sure | Approx. 100 MPa rox. 30 MPa: , si Inject lo intako port pressure | (9 watom 14490 pa ‘Approx. 90 MPa {805 kgtiem?, 4337 psi} Structural View Flow Diagram 1 _] Fuel tank 4] Overfiow pipe 2_| Fuel iter | Injection nozzle 3_| injection pump F2-11FUEL SYSTEM INJECTION PUMP Outline ‘¢ The injection pump is equipped with a spill valve that directly controls the fuel injection amount. + The spill valve is installed in the passage connecting the pressure chamber and the pump chamber. When the PCM cuts off the electrical current in the spill valve, the passage between the pressure chamber and the pump chamber opens to reduce the fuel pressure, and the fuel injection is finished ‘+ The function and operation of the TCV are the same as those of the 323 (BA) RF engine model. Caution ‘® The injection pump cannot be disassembled, as woll as Mazda 323 (BA) RF model. Disassembling ‘the Injection pump can damage ts function. Do not disassembie the Injection pump. Structure 1_| Spillvaive T_| Overflow vaive 2__| Fuel temperature sensor 8 _| Roller ring 3 Injection pump EPROM 9 _| Pulser 4_| Timer control valve (TCV) 10 Cam plate ‘5 _[ Pump speed sensor 11_| Pinger 6 | Fuel shut off (FSO) solencid F2-12FUEL SYSTEM High Pressurization and Distribution of Fuel ‘© The plunger increases the fuel pressure and distributes it by repeating the following stages. 4. Intake ‘As the plunger lowers, the fuel flows into the pressure chamber. * Intake port ~ Open * Distribution slot ..2.00.2.2... Closed Spill valve .....2....2.24.2.. Open (Deenergized) 2. Injection The plunger rotates while it rises, and compresses and feeds the fuel. © Intake port ... -. Closed Distribution siot Open # Spill valve . Closed (Energized) 3. Injection end Power supply to the spl valve is stopped, and the valve opens. Pressurized fuel in the plunger Is forced back into the pump chamber. Pressure in the plunger lowers, and fuel injection is completed. © Intake port ...........5 Closed # Distrbution Slot 2222.12.22) Open © Spill valve .....0.0..0.012! Open (Deenergized) 1] Intake 8 _| Distribution siot 2_ | Injection ‘9 _| Pressure chamber '3_| Injection end 10_| Injection nozzle ‘4_| Pump chamber 11, Intake port 5_| Roller 12 | Spill valve (closed) 6 | Camplate 13 | Spill valve (open) 7_| Phunger F2-13FUEL SYSTEM SPILL VALVE Function © A direct acting, electromagnetic spill valve is adopted to obtain high withstanding pressure, quick response and a large spill amount. ‘+ The fuel injection amount control signal is sent from the PCM to the injector driver module (IDM), and the IDM ‘sends the signal to make the spill valve drive current fiow, driving the spill valve and opening/closing the fuel passage (return passage). Structure ‘¢ The spill valve is installed in the passage connecting the injection pump rotor chamber and pump chamber, and opensicioses the passage at fuel intake and injection end. 1_| Injection pump 5 _| Coll 2_| Spill valve 6 _| Spring (3 | Spill valve cross-sectional view 7__ Valve body 4 | Spool vaive F2-14FUEL SYSTEM Operation 1. The spill valve is opened/closed by the spill valve drive signal from the IDM. 2. The spl vaive is closed (the relief passage is closed) during the fuel force-feeding stage. 3. During the fuel injection end stage, the spill valve is open (the relief passage is open) 4. The pressure on the plunger changes according to the opening/closing of the relief passage. 1 | intake | Valve is open 2_| Force toed 9 | Valve is closed 3_ Spill 10_| Armature | cam itt 11_| Cot 5 _| Plunger pressure 12_| Core 6 _| Injector driver module (DM) current 13_| Spring 7_ Spill valve operation 14_| Valve bodyFUEL SYSTEM TIMER CONTROL VALVE (TCV) Outline ‘© The function and installation position of the TCV is the same as those of the Mazda 323 (BA) RF engine model. ‘© The sensor shape and the internal structure of the fuel line, etc. are different from those of the Mazda 323 (BA) RF engine model, ® Q ro o— - - . Cf LoL ® 6 7] From pun chamber 7 Need 2__| To low-pressure chamber 51 Spring 3 cor F2-16FUEL SYSTEM FUEL SHUT OFF (FSO) SOLENOID utline ‘© The structure and the operation of the FSO solenoid is the same as those of the Mazda 323 (BA) RF engine ‘model, but the installation position has been changed. “| Injection pump 2] Fuel shut off (FSO) solencic FUEL FILTER Outline '¢ The cartridge type fuel fier integrated with the sedimentor is adopted. ‘* When a certain volume of water is collected in the sedimentor, the sedimentor switch is turned on and the Sedimentor warning ight in the instrument cluster iluminates to not the user that more than the allowable volume of water is collected and the water should be drained. ‘© Apriming pump is equipped to drain the water easily from the sedimentor. Structure/operation ‘¢ Aneater, which dissolves the light ol (fuel) hardened when the engine is cold, and the vacuum switch for fuel pressure detection to operate the heater are integrated and installed in the fiter cap. 1_| Fuel filter body cross-sectional view @_| Priming pump 2_| Fiter (| Fuel warmer cross-sectional view 3_| Sedimentor 10_| Switch 4_| Float 11 _| Heater element | Sedimentor switch 12_| Filter outiet pressure 6 Drain 13 _| Diaphragm 7_| Fue! warmer 14 | Atmospheric pressure F2-17FUEL SYSTEM When driving while the engine is cold, the fuel component hardens to block the fuel fiter and the fuel negative pressure after passing the fier is increased. ‘+ When the negative pressure reaches -34.7 kPa {-260 mmHg, -10.2 inHg}, the vacuum switch for fuel pressure detection is turned on and the heater is energized. As a result, the heat is generated in the heater to dissolve the wax. When the wax is dissolved and the negative pressure drops below -22.0 kPa {-165 mmHg, 6.50 inHg}, the switch for fuel pressure detection is turned off, stopping the electrical current to the heater. 00 “es mt, £389 argh on © orF “Arie {260 mmHg, Soar 7 Foetiane 3 inecion pare Saaliaastwaal | Fe 3_| Engine switch 7_| Fuelfiter 4 [ jester nazz | Vac si operating prosureFUEL SYSTEM INJECTION NOZZLE Outline Caution Disassembling the injection nozzle can damage Its function. Do not disassemble the injection nozzle. ‘The injection nozzle is installed in the cylinder head (in the head cover), and the nozzle head is located directly in the combustion chamber. ‘¢ The two-stages type nozzle, which suits the high-pressure injection, is adopted for the injection nozzle. ‘© There are five jets on the injaction nozzle head, which is the conical suck type and the volume of the suction artis lessened to reduce HC. 1_| Oylinder head cover 6 _| Injection nozzle bracket 2_| Injection pipe 7_[ injection nozzie 3 | Nozzle seal 8 _| Cylinder head 4 _| Side wall @ | To injection pump 5_| Fuclieak pipe F2-19FUEL SYSTEM Operation '® ‘The two-stages type nozzle sets the injection-vaive opening pressure and the needle lift amount to two stages. First stage This generally happens when the engine is running at low speed under light load. The injector nozzle opens at a pressure of 17.1—18.1 MPa {175—185 kgticm?, 24892631 psi}. The needle lft is Lp (mm). ‘Second stage This generally happens when the engine is running at high speed under heavy load. The injector nozzle opens at a pressure of 27.9--28.9 MPa {285295 kgt/cm?, 4053—4195 psi). The nozzle lift is Hp (mm) bo Ho (Gem) (emmy 7_[ Spang Not 6_| Injection nozzle rass-sectonal view 2 | Jets (Five) 7 _| Injection nozzie 3_| Conical suck @_| Piston 4__| Pressure pin 9 Fuel 5 | Spring No.2 10_| Fuel ark (Five) Caution ‘¢ The two-stages type injection nozzle cannot be disassembled, and the valve opening pressure cannot be adjusted. F2-20EXHAUST SYSTEM EXHAUST SYSTEM OUTLINE ‘© The exhaust system consists of the parts shown in the figure below. ‘© Due to the adoption ofthe turbocharger, the following changes have been made compared to the Mazda 323 (BA) RF engine 4SD model. = The exhaust manifold has been modified to shorten the distance from the cylinder head to the turbocharger. Because of this, the exhaust resistance is reduced and the exhaust pressure is transmitted to the turbine wheel efficiently in a shorter time, improving the response of the turbocharger. ~ The front pipe has been eliminated and the joint pipe has been adopted. ‘* Due to the change in the body shape, the shape of each part has been changed. ‘STRUCTURAL VIEW New model with RF-Turbo 1 _| Exhaust manifold 4 | Oxidation catalytic converter “Joint pipe '5_| Main Silencer 3_| Flexible pipe Mazda 323 (BA) RF 4SD 1_| Exhaust manifoid 4] Oxidation catalytic converter 2_| Front pipe 5_| Main silencer 3 Fiexibie pipe F2-21EMISSION SYSTEM OUTLINE EMISSION SYSTEM ‘* The EGR control, which is controlled by two duty vaives, has been adopted. © The ventilation hose, which leads the blowby gas to the intake manifold. And the oxidation catalytic converter, are the same as those of the Mazda 323 (BA) RF engine model. Structural View EGR valve 4_| Blowby gas ventilation hose 2_| EGR solenoid valve (vacuum) 5_| Oxidation catalytic converter '3_|_ EGA solenoid vavie (vent) ‘System Diagram 1_| EGR valve 4 _| Blowby gas ventilation hose 2__| EGR solenoid valve (vacuum) 5 Oxidation catalytic convertor 3 _| EGR solenoid vavie (vent) F2-22CONTROL SYSTEM CONTROL SYSTEM OUTLINE ‘¢ The differences in the control system parts between the new model with RF-Turbo engine and 323 (BA) RF engine model are as follows. Input Parts x: Applied ~: Not applied New model with | 323 (BA) with ftom Signal Rene aneeesta a Comee engine Engine coolant temperature ECT) | Engine coolant (instalation . - sensor temperature postion is Inmobtzr nt Tnetilaa 9 EGR vaive poston sons EGR vaive poston x : : Corl steove (CS) sor Seow eston : x 5 “er positon sensor Tiner piston poston = x 5 "1; Immobilizer unit is equipped. Output Parts x: Applied ~:Not applied "T New model with (BA) with: cae dul Signal RF Turbo. RF engine coe cine Tier coral vahe TOW Tove e Scams) Powerit Fuel shut off (FSO) solenoid relay FSO solenoid drive x - ‘driving FSO sound Seite way TOM power x = rower toon Ijctor vr module (OM) spi vave ave : pene (aaa EGR coool valve (asa EGR vate ave x - T Opensicioses: Spe EGR solenoid vaive (vent) EGR valve drive x - sage which acts ' cnr vave dewey Glow neato Glow ndator ight low : - Glow pg relay Glow pg ve : : Conia coal Siove potion and adjusts : eink governor - 5 nto ing according the contol sal femecnt NE ray At coal 5 = Condenser fan lay Condenser ' Goong any Cooling an cara : : F2-24CONTROL SYSTEM F2-25CONTROL SYSTEM 1 _| Engine coolant temperature (ECT) sensor 16_| EGA solenoid vaive (Vent) 2__| Accelerator position sensor 17_| EGR solenoid vaive (Vacuum) 3_| Idle switch 18 | Spill valve relay 4 _| Intake air temperature (IAT) sensor No.1 19_| PCM control relay 5 _| Intake air temperature (IAT) sensor No.2 20_| Fuel shut off (FSO) solenoid relay 6 _| Pump speed sensor 21_| Glow plug relay 7_| 10¢ sensor 22_| ACrelay 8 _| Fuel temperature sensor 23 Condenser fan relay ‘9_| Boost sensor 24 | Cooling fan relay 40 | Clutch switen 25_| Injector driver module (IDM) 11_| EGR valve position sensor 26 | POM 12 | injection pump EPROM 27_| RHO. 13, Battery - 28 | LHD. 14 _| Data link connector (OLG) 29 | Clutch pedal 15 _| Timer control valve (TCV) '30_| Accelerator pedal F2-26CONTROL SYSTEM BLOCK DIAGRAM F2-27CONTROL SYSTEM 1 Fuel injection amount contro! 22 | Refrigerant pressure switch (A/C equipped) 2_| Fuel injection tiring control 23_| EGR valve postion sensor 3_| lle speed control 24 | Injection pump EPROM 4_| Glow contol 25. | Immobilizer unit 5_| EGR control {lmmabiizer system equipped) 6 _| Electrical fan control 26 | Battery 7_[ AIC cut-off control 27 | Buc | Immobilizer system (Immobilizer unt equipped) 26 | Starter (Starter signal) 8 | PCM 29_| Timer contro valve (TOV) [10_| Engine coolant temperature (ECT) sensor 30_| EGR solenoid valve (vacuum) 11_| Accelerator position sensor 31_| EGR solenoid vaive (vent) 12_| Idle switch 7 | 32_| Spill valve relay 13 __ Intake air temperature (IAT) sensor No.1 33_| Fuel shut off (FSO) solenoid relay [14 _| intake air temperature (IAT) sensor No.2 imal 34 Glow indicator light (Instrument cluster) 15 | Pump speed sensor 36_| Glow plug relay 16, TDC sensor 36 AC relay 17_| Fuel temperature sensor '37_| Cooling fan relay 1@_| Boost sensor '38_[ Condenser fan relay 19_| Neutral switch 29 Injector eriver mobule (TOM) 20 | Clutch switch 40_| Spill valve 21_| Vehicle speed sensor F2-28CONTROL SYSTEM CONTROL SYSTEM DEVICE AND CONTROL RELATIONSHIP CHART : Applied Control item Fuel injection amount contro! Fuel injection timing control {ale speed controt EGR contro! Glow control Electrical fan control AIC cutoft control Immobilizer system (immobilizer equipped) Engine coolant temperature (ECT) sensor ‘Accelerator position sensor Idle switch Intake-air temperature (IAT) sensor No.1 Intake-air temperature ((AT) sensor No.2 Pump speed sensor Fuel temperature sensor Injection pump EPROM xx |x] x TDC sensor Input Boost sensor NeutralClutch switch Vehicle speed sensor Refrigerant pressure switch (AIC equipped) EGA valve position sensor Immobilizer unit (immobilizer equipped) Battery Data link connector (DLC) (TEN terminal) ‘Starter signal “Timer control valve (TCV) EGR solenoid valve (vacuum, vent) ‘Spill valve relay Fue! shut off (FSO) solenoid relay {Glow ingicator light Glow plug relay AIG relay Cooling fan relay Condenser fan relay (A/C equipped) Injector driver module ((DM) F2-29CONTROL SYSTEM PUMP SPEED SENSOR Outline ‘* The pump speed sensor is installed on the roller ring in the injection pump. ‘The pump speed sensor is installed opposite to the teeth surfaces of the pulser that is pressed in the drive shaft in the injection pump. Function © The pump speed sensor detects the pulse (alternating voltage) generated by the pulser and outputs to the PCM as an engine speed signal, '* The detected engine speed is used to control the fuel injection amount and timing. Operation '® ‘The pump speed sensor has a magnet and a coil inside. When the pulsar rotates, the magnetic flux that passes the coll increases/decreases and the alternating voltage is generated. The PCM detects the engine ‘speed by counting the pulses. The pulser has 52 teeth, missing three teeth in four locations, and detects the pulser rotating angle per 11.25° CA. 8 T_| Pulser 6] Noteeth 2 Rollerring 7_| Outout vohage '3_| Magnet 8 | Output voltage characteristics 4 _| Pump speed sensor 9 | Time 5 Coll FUEL TEMPERATURE SENSOR, Outline '* The function and detection method of the fuel temperature sensor are the same as those of the Mazda 323, (BA) RF engine model, but the installation position and the shape of the sensor are different. 1__| Fuel temperature sensor F2-30CONTROL SYSTEM ‘TDC SENSOR Outline ‘¢ The TDC sensor is installed near the crankshaft pulley in the timing belt cover. Funetion ‘ The TDG sensor detects the pulse (alternating voltage) generated by the projection on the pulser in the back of the crankshaft pulley and outputs to the PCM as a crank angle standard position signal. @ The detected crank angle standard position is used for the injection timing control (calculation of the actual injection timing), Operation ‘© The TOC sensor has a magnet and a coil inside. When the pulser rotates, the magnetic flux that passes the coil increases/decreases and the alternating voltage is generated. The TDC sensor outputs a pulse to the PCM every engine rotation. ® @®o 1) Pulser 3] Output vottage (V) 2_| TDC sensor 4 | Output voltage characteristics ACCELERATOR POSITION SENSOR Outline ‘© The structure and the function of the accelerator position sensor are the same as those of the 323 (BA) RF engine model. IDLE SWITCH Outline © The structure and the function of the idle switch is the same as this of the 323 (BA) RF engine model. ENGINE COOLANT TEMPERATURE (ECT) SENSOR Outline ‘¢ The structure and the function of the ECT sensor are the same as those of the 323 (BA) RF engine model, but the installation position is different. (in this model, the ECT sensor is installed in the middle of the injection pump side cylinder head.) INTAKE AIR TEMPERATURE (IAT) SENSOR Outline «The structure and the function of the IAT sensor are the same as those of the 323 (BA) RF engine model, but two IAT sensors are installed in this model to control the fuel injection timing and fuel injection amount accurately. IAT Sensor No.1 Function ‘¢ The intake air sensor No.1 is installed in the air cleaner case. By utlizing a thermistor of which resistance varies with temperature, the sensor detects temperature in the air cleaner case. ‘* The detected intake air temperature is used for correction of fuel injection timing control. IAT Sensor No.2 Function ‘The intake air sensor No.2 is installed in the air pipe between the charge ai cooler and the intake manifold. By utilizing a thermistor of which resistance varies with supercharged air temperature, the sensor detects temperature in the intake manifold ‘* The detected intake air temperature is used for correction of fuel injection amount control. F2-31CONTROL SYSTEM BOOST SENSOR Function ‘ The boost sensor detects the intake air pressure as an absolute pressure, and sends itto the PCM as an intake air pressure signal. ‘© The boost sensor is installed in the air pipe between the charge air cooler and the intake manifold. Operation ‘* The boost sensor is filled with crystal (silicon) and itis the semi-conductor pressure sensor which utilizes the characteristic of the electrical resistance that changes when the crystal is pressurized, “Absolute pressure Is the pressure when vacuum is set as 0 kPa {0 mmHg, 0 inHg). ® @® ‘ t w @® kPa fmt, ing) 4 ® 1_| Boost sensor 4_| Output voltage 2 | Vacuum chamber 5 Sensor output characteristic (integrated with a siicon chip) cal iemearel — '3 | Supercharged pressure NEUTRAL/CLUTCH SWITCH Outline ‘© The structure and the function of the neutral/clutch switch are the same as those of the 323 (BA) RF engine model, PCM CONTROL RELAY Outline '¢ The structure and the function of the PCM control relay are the same as those of the 23 (BA) RF engine model, ‘SPILL VALVE RELAY Function ‘ The spill valve relay supplies/stops the power to drive the injector driver module (IDM). The structure of the spill valve relay is the same as that of the PCM control relay. Operation ‘¢ The spill vaive relay is energized (ON) when the engine switch is tumed from off to on. * The power supply to he sil valve rely stops (OFF) three seconds ater turing the engine switch from onto of ‘© The power supply to the spill valve relay is stopped under any of the following conditions. (The PCM detects the following conditions.) 1. Spill valve control system is abnormal. 2. Pump speed sensor is malfunctioning, 3, FSO solenoid is malfunctioning, 4. IDM is malfunctioning, 5. Immobilizer control is operating. (During fuel injection inhibition) F2-32CONTROL SYSTEM FUEL SHUT OFF (FSO) SOLENOID RELAY Function # The FSO solenoid relay supplies/stops the power to drive the FSO solenoid. The structure of the FSO solenoid relay is the same as that of the PCM control relay. Operation '* The FSO solenoid relay is energized (ON) when the engine switch is tumed from off to on. ‘© The electrical current flow to the FSO solenoid relay stops (OFF) when the engine switch is turned from on to off INJECTOR DRIVER MODULE (IDM) Function ‘¢ The IDM is the unit which has the high voltage generating circuit for converting the battery positive voltage to a high vottage. ‘© The high voltage (approx. 150 V) output from the IDM is output to the spill valve as the driving signal, and controls the high speed driving of the spill valve and the high-accuracy injection amount. 110M 5_[ Spill valve (4) (Driving current) 2 | Spi valve relay (Battery positive voltage) 6 _| Spill valve (-) (Driving current) 3 _| PCM (injection signal) 7_| Spillvaive ‘4_| PCM (Injection confirmation signal) F2-33CONTROL SYSTEM Operation ‘¢ The battery positive voltage (approx. 12V) from the spill valve relay is amplified and converted to a high voltage (approx. 150V), and output as an injection signal. ‘¢ When the injection signal is output to the spill valve, the injection confirmation signal is sent to the PCM from the IDM. ‘© The signals from each terminal of the IDM are as shown below. Holding current control value: Approx. 2.00 Spill valve driving current Fail signal (High side) Fall signal (Low side) POM (Injection confirmation signal) PCM (Injection signal) ‘Spill valve (+) (Driving current) Holding current switching time: Approx. 1.0 ms > | co] no] = F2-34CONTROL SYSTEM FUEL INJECTION AMOUNT CONTROL, Outline ‘© The fuel injection amount is controlled by opening the spill valve according to the signal from the PCM through the injector driver module (IDM) reducing the fuel pressure in the fuel force feed line, and finishing the fuel injection. Block Diagram ® o@ © & — = ECT sensor 8 | vss ? 2 | Accelerator position sensor 9 | Starter | Fosloperare er Lom | Pump pend sone = [rom +l Besomeoe F2-35CONTROL SYSTEM Operation '® The fue! injection start timing is determined by the cam plate position as conventional. 1 _] Pump chamber 3_| Camplate 2_| cama ‘4 | Spill vaive (open) 3_| Cam plate © To increase/reduce the injection amount is to contral the injection end timing; the injection Is finished when the spill valve opens and the high-pressure fuel is spilled into the pump room. ‘¢ The spill valve opening timing is controlled by the pump speed sensor, which detects the cam angle corresponding to the cam lift amount. The figure below shows the relations between the cam lift amount, spill valve opening timing, and the injection. amount. z | ® i al 1 | ove oe ee @ ; EL ® gL ® jor ® on [err ow 4 E ® |® 1] Cam iit 3_| End ofinjecion 2_| Spl vave 6 | Camancle 3_| Acylinder 7_[ Injection 4_| Start of injection @ | increased injection amouni F2-36CONTROL SYSTEM Spill vaive opening timing The spill valve opening timing is determined by the pump speed sensor signal. ‘The pump speed sensor detects the cam angle which corresponds to the cam lift amount. 1. The cam lit amount is determined by the rotating angle of the cam plate, which rotates together with the pulser opposite to the pump speed sensor. 2. The rotating angle of the cam plate is detected by the ro! output (per 11.25° CA), 3, The pump speed sensor detects the timing and number of pulser teeth beginning with a gap (no teeth) in the pulser. The PCM determines the spill valve opening timing (injection end) according to the detected pump speed sensor signal 19 angle of the pulser, .., the pump speed sensor Co a — ® ® 1 [Pulser 10] Startof injection 2_| Drive shaft 11_| End of injection 3_| Pump speed sensor 12 | Noteeth 4_| Camplate 13 | Open 5 Driving of cam plate 14 | Close 6 | Camiit 15 | Injection 7_| Pump speed sensor signal 16 | Camangie 8 _| Spill vaive 17 | Injection end control 9 [Acyiinder Injection amount calculation ‘The PCM calculates the optimal injection amount according to the engine driving condition; the following two items. 1. Basic injection amount The theoretical necessary injection amount is calculated based on the accelerator opening angle and the engine speed. 2. Maximum injection amount The maximum injection amount while engine is rotating is calculated by adding the corrections of intake ait pressure, intake air temperature, and fuel temperature, to the injection amount which is determined according to the engine speed ‘The values of items 1. and 2. above are compared, and the lesser amount is selacted as the final injection amount. F2-37CONTROL SYSTEM FUEL INJECTION TIMING CONTROL Outline ‘¢ The PCM detects the engine condition according to each sensor signal and calculates the optimum injection. timing to control the injection timing by duty controlling the timer control valve (TCV). ‘* The actual injection timing was detected by the timer position sensor to control the fuel timing system in Mazda 323 (BA) RF engine models. In this new 626 RF-Turbo engine model, the timer position sensor has been eliminated, and the actual injection timing is calculated from the difference between the crank angle standard position signal and the pump speed signal. Block Diagram ® 1_|EGT sensor 6 _| Boost sensor 2_| TAT sensor Not 7_| Starter 3-_| Pump speed sensor 8 Tov 4_| Injection pump EPROM o [Pow 5 _| TOC sensor F2-38CONTROL SYSTEM Operation The function ofthe TCV fs the same as that ofthe Mazda 829 (BA) RF engine model, but the contol method is different. ‘¢ The TCV in the new model with RF—Turbo engine change the fuel pressure (hydraulic pressure) in the low-pressure chamber of the TCV and controls the timer piston positon. © When the TCV is open, the fuel pressure (hydraulic pressure) in the low-pressure and high-pressure chambers in the TCV are the same. The low-pressure chamber has a timer spring, which moves the timer piston to the high-pressure chamber side with the spring force when the fuel pressure (hydraulic pressure) in the low-pressure and high-pressure chambers are the same. This is called fuel injection retard direction. The {uel injection advance direction is the condition when the TCV is closed. 1_[ Roter ring 3] Neods 2_| low-pressure chamber 7_| Col 3_| High-pressure chamber 8! Spring 4_[-Timer piston @ | ToPow Valve body F2-39CONTROL SYSTEM Injection timing calculation Based on the basic target injection timing and according to the signals from each sensor, the PCM calculates the ‘optimal injection timing to the driving condition. Then, the PCM calculates the actual injection timing using the crank angle standard position signal (TDC signal) from the TDC sensor for feedback operation to the target injection timing, 1. Target injection timing ‘The target injection timing is calculated based on the fuel injection amount and the engine speed. 2. Injection timing correction ‘The injection timing is corrected with the intake air pressure, and the engine coolant temperature, and the atmospheric pressure. 3. Injection timing at start When starting, the target injection timing is corrected with, engine coolant temperature and the engine speed. Feedback contro! ‘¢ The feedback control corrects the TCV duty ratio so that the actual injection timing correspond to the target injection timing, ‘¢ The feedback contol is to control the crank angle @ between actual TDC and injection start as shown in the figure, However, the actual TDC and the injection wave-form are not detected as signals. The actual injection timing is calculated as follows. } r_}e @ LL ® UL, © ® 7 [Ravart06 = Eno ice 2 T06 sal 6 | incon puro aie 3 NE pulse 7 [injection sian [nection waverorn (1) The actual TDC position and the signal of the TDC sensor are correlated. (2) The injection timing and the NE pulse of the pump speed sensor are correlater @) The actual injection timing can be obtained by calculating the phase difference @1 between the TDC signal and the NE pulse. 7] Rover ing 7 Noteath 2 _| Drive shaft 5 _| Pulsar (52 teeth) 3] Timer piston 6 | Purp speed soneo? ~| F2-40CONTROL SYSTEM IDLE SPEED CONTROL Outline ‘* The PCM calculates the target speed according to the engine driving condition, and determines the injection amount to control the idle speed. Block Diagram i o Vo ® @— ® &—_- 7 [EO sensor 7] Vehicle speed sensor 2__| Accelerator position sensor 8 | Refrigerant pressure switch (A/C equipped) 3_[ late swten [1M ‘| Pump speed sensor 10_| POM 5_| Neutral switch 11 Spi vale 6 | Guten switch edback contro! © The PCM compares the target idle speed with the actual idle speed (pump speed sensor) signal), When any difference is found, the PCM sends the signal to the spill valve to control the injection amount and adjusts to the target idle speed. Idle, LOADED: 750—800 (775.25) rpm UNLOADED: 750—800 (775 3:25) rpm Idle speed control when warming up ‘¢ The idle speed is controlled to be the optimal fast idle speed at warm-up by the engine coolant temperature. One-shot contro! '* After switching the A/C, a set injection amount is changed to prevent the idle speed from fluctuating with the engine load changes. Rotation fluctuation prevention control for each cylinder «The fluctuation of the engine rotation when iding 's detected and the ijection amount fs corrected for each cylinder. jecause of this, the injection amount differences between each cylinder owing to the uneven pumps (in each cylinder) and the injection nozzles are reduced, as well as the engine rotation fluctuation during ide and in low-speed, light load range. Note ¢ This control is also used for the Mazda 323 (BA) RF engine moeds F2-41CONTROL SYSTEM GLOW CONTROL Outline '* To obtain the optimal startabilty according to the vehicle conditions, the PCM controls the operating time of the glow plug through glow plug through relay which raises the temperature in the combustion chamber (hot spot), ‘* When before starting the engine, the glow indicator light control is operated and shows the driver when the engine can be started by turning the glow indicator light on/off. ‘¢ The hold temperature control and the atter-glow control are also operated to Improve the vehicle condition ‘when before starting the engine and stability after the engine is started. Block Diagram D Ri, we @ eB oG- Qe o@ — (3 © ToT sor 3 Gotha wey | Boost sneer | iow nda 3 Baty 7 aM 4 [vehi speeder F2-42CONTROL SYSTEM Glow indicator light control ‘¢ When the engine switch is tured on, the PCM controls the illuminating time of the glow indicator light in the instrument cluster. ‘© The fluminating times of the glow indicator light are preset in the PCM as the engine coolant temperature and the atmospheric pressure. ‘© When a matfunction occurs in the inputvoutput pars, etc., the glow indicator light flashes to notify the user that there is a matfunction. Quick glow control ‘¢ Even when the engine switch is left at ON position after the glow indicator light goes off, power is supplied to the glow plug relay to hold the temperature in the combustion chamber and obtain startability when starting the engine. ‘* The power is supplied to the glow plug relay for 15 seconds at maximum when the engine coolant temperature is below 25 °C {77 After-glow control ‘© To obtain etticient and stable combustion in the combustion chamber while engine is cold just after the engine started, the power is supplied to the glow plug relay for four minutes just after the engine is started. + The afterglow contls inhibited under any ofthe following conltons to ensure the engine condition and frivability. ( indicates the related inputloutput device. ~ Engine coolant temperature is above 10°C {50 °F}. (Engine coolant temperature sensor) F2-43CONTROL SYSTEM EGR CONTROL Outline ‘¢ The PCM recirculates the exhaust gas, which is controlled to be optimal according to the engine condition, to the combustion chamber to slow the combustion and lower the combustion temperature, reducing the amount of NOx in exhaust gas. Block Diagram ® ey, @ 1_| ECT sensor '5_| EGA solenoid valve (vacuum) 2_| Pump speed sensor 6 __ EGR solenoid valve (vent) 3__| Boost sensor 7 [Pow ‘4 EGR valve position sensor ‘Target EGR valve position ‘¢ The basic EGR vaive position is determined in the PCM according to the engine speed and the fuel injection ‘amount injected to each cylinder. The target EGR valve position is determined by adding corrections such as engine coolant temperature, atmospheric pressure, intake air temperature and accelerator opening angle to the basic EGR valve position. ‘* After the target EGR position is determined, the actual EGR position is detected by the EGR position sensor, and compared with the target EGR position. Then the PCM outputs the electrical current (duty signal) to the EGA solenoid valves (vent, vacuum) and changes the EGR position to reduce the deviation. ‘* The EGR control is inhibited under any of the following conditions to ensure drivabilty and low-level emission. = Engine speed is below 500 rpm. - Engine coolant temperature is below 60 °C {140 °F. F2-44CONTROL SYSTEM ELECTRICAL FAN CONTROL Outline ** By operating the cooling fan and condenser fan according to the condition of the vehicle, the electrical fan ‘cools the engine and the condenser and thereby improves engine reliability and idling stabil. Block Diagram he. @ |—-Q ® a |_-@ ® 1] EoT sensor 6 [DLC (TEN terminal) 2 | Accelerator postion sensor 7_| AC relay 3 _| tate switch | Cooling fan relay 4__| Pump speed sensor 9 | Condenser fan relay 5 | Refrigerant pressure switch (A/C equipped) 10 | Pow Operating condition '® The operations of the cooling fan and the condenser fan are as follows. Relay Operation Condition * Engine coolant temperature is above 100°C. oN ‘* Engine coolant temperature sensor is malfunctioning. Cooling fan relay ‘© TEN terminalis shorted and accelerator pedal is depressed, OFF Except above ingine coolant temperature is above 105°C. oy AIC switch is on Condenser fan relay ‘* Engine coolant temperature sensor is malfunctioning. ___|_¢ TEN terminal is shorted and accelerator pedal is depressed Except above, F245CONTROL SYSTEM AIG CUT-OFF CONTROL uti '* A/C is tured off under any of the following conditions to improve acceleration performance. Block Diagram ® Oe. @ Q — be 08 ome 08 ree aaa + eae oi oe Rea an an AC Hee Tee + orp per ana HS ae Operating Condition Engine condition Condition "AIG cut time (second) Vehicle isin gear and accelerator opening Under heavy load ange babes TO, 5 seconds Engine coolant temperature is high. Repeats ON/OFF until engine coolant Engine coclant temperature is above 110°C. | ierhearsure crops below {05% F2-46CONTROL SYSTEM IMMOBILIZER SYSTEM {if Equipped) © When the immobilizer system is actuated, the following controls will also be carried out. (Refer to Section 7). ~ Spill valve relay: OFF = Fuel shut off (FSO) solenoid relay: OFF © 1_| Immobilizer urit '3_| FSO solenoid relay 2 | Spill vaive relay 4 | PCM F2-47ON-BOARD DIAGNOSTIC SYSTEM ON-BOARD DIAGNOSTIC SYSTEM OUTLINE '* The on-board diagnostic system has the following functions: ~ Failure detection function: Detects input/output signal malfunctions ~ PID/DATA MONITOR AND RECORD function: Reads specified inouvoutput signals, — SIMULATION function: Drives output system parts '* The on-board diagnostic system can be used by connecting the NGS tester to the DLC. Block diagram TEN ® aN Fail-safe function 1_| Failure diagnosis function 9] input parts 2_| Memory function 10_| Normal control range 2_| Failure indication function 11_| Output parts 4_| Serial communication function 12 | Duc. 5 _| Fallure detection function 13_| Glow indicator light 6 _| PID/DATA monitor and record function 14_| NGS tester 7_| Simulation function 15_[ POM 3ON-BOARD DIAGNOSTIC SYSTEM Failure detection function © The failure detection function detects malfunctions in the i while driving) ‘¢ When a failure is detected, the DTCs shown in the table below (Diagnostic Trouble Code (DTC) Table) are output through the failure indication function and the serial communication function to FEN and KLN terminals inthe DLC. At the same time, the detection results are also sent to the fail-safe function and the memory function. ut/output system (when the engine switch is on or Foll-safe function ‘The fail-safe function ensures the minimum vehicle driveability by switching the signal judged as a failure in the failure detection function to the preset value and limiting the PCM control. Memory function ‘¢ The memory function memorizes the signal systems judged to be abnormal in the failure detection function, The memory cannot be erased even if the engine switch is tumed of (LOCK positon) or after recovering from the failure, ‘+ To erase the failure information, disconnect the negative battery cable or use the NGS tester. Diagnostic Trouble Code (OTC) Table ‘© The differences in the DTC compared to the Mazda 323 (BA) RF engine model (referred as 323 (BA) hereatter) are as follows: 1. The DTC numbers have been changed to four digits. 2. Though the diagnosed circuits ofthis model are the same as those of the 923 (BA), the DTC numbers are different from those of the 323 (BA), due to the adoption of fourdigit DTCs. Note © The DTC numbers with “x” in the DTC table below differ in the DTC numbers compared to the 323 (BA), though each diagnosed circuit is the sam ‘The DTC numbers without “>” are adopted for the new model with RF-Turbo engine. x: Applied : ~ Not applied BTC | utput pattern | GMOS T Detection conlion Fall-eate Memory * Input voltage from boost sen- | setae 2s Vor above 4 Vvhon neuen uments Ieee voros soos sina | «Seagernoe mun anvie | *fmetiaaes | oreat Irutearonbocsereort> | Boss Extn ange speed tbove 2400 pv an slr topring ang ran Be Taio ar —] + put voage For TNT | , rove | FIM torpeence | “somorstioworazver | *FoaeIATatamc |, Sgratorat | tome 4318 Engine | a couant | Mpatvotags om EST seo |S rggecrateorc | ferment | 2b ra) Sigua apt woinge Fo aor poten soa polw03¥ cower | report? wren contd ote poston | fw odosec, + Foes tsttjeton |, iret” | « Gupuvotage tom acct” sou ort tr poston seme above 1.6 V for 0.3 sec. continuously vin Kove stu on F2-49ON-BOARD DIAGNOSTIC SYSTEM Toei names ® © Dre Diagnosed Memory BET Supurpanem | PABST | Snecton conan none @ | Fuel erases porsoe temoaanne |" Sresorserspooworay | *FogseTatsoe | L ‘signal or above 4.915 V. (1.91). “Teaaneaninns . renee aes vone wiesen | See _ . ee syst warm-up of while driving manera a Te a rn ee voais Sewage ectines as ereceonaen fee | Sop el Ee ceca ne eel tar Sea testcase | onecener aa ener caiane | + Cone manage]. esse cor Garmmnonerimn | *mastovencs | 1M @ signal the engine speed Is above at 2%. ‘a oes : tare gor a Ta the current voltage signal of eer osama ed eorne | rcnascerccreape P0380, relay signal 1.0 sec. eee plug x J creutt ‘© When the glow plug relay is off, ul irate goepareays "e eto useester Sasiten oaney Iamabar ated es Saeco eeeiercroust | « re Gn soe vos con | Sitecencemincat| + Tamaecr aoe | | | ER, | BSR amee | *roitave er ecttiaes | umvetet see a re? ones than Ok {Omph) for more |, sets vehicle speed rence eme eam | + Saavenesp pom | ca ede Tokewioret | J L < Engrs Spoor 200 * Pera a Aenea Sree ean nt |g sacontanaians rostot asl vances aca . : Lie abe | aca tcsn se canoe Scion a > pet eon peed = fn : : iors Soa emee iniako ar | Mut volage rom IAT No? | weueaate | srmuraco |, pinto [| fanporaire | above 4918 Vwhon continued |" (.48V) re ue “e F2-50ON-BOARD DIAGNOSTIC SYSTEM >: Applied : - Not applied oe Tiagroned cacon ae erry BT Outputpaterm | Paghon Detection coton Fai-aate [Moms T Fuel shut off |» POM 2D terminal volage Neieo* (50) "| “Sayeuncoropesetvotage | « Tunsspitvave | | Scone | frmorotnanosee ater” |" rouyef C ‘signal circuit turning engine switch off. eae TNE signal] + PCM cannot datoct NE signal - lx Creat” _| * hot eraele oun | Engine © [9b signal rom starter to PeMccrnuetormreinan | «Ture stare sna | ewe Ill Sn g| (Oancanteengne speed | oh ever 00 t Command signals oubu Td from PCM to IDM, but con- pune som n rae ira Tune savers | x ioral | (Smtonsgnais atau | * TUNE from IDM to PCM. y Of T T ~ Input voltage from EGR valve 1 EGR vane «Ture EGR wow P1402 position fpcexion senieon i nelow 0:25 Vj noid valve (vacuum x Posting Seaport 73 onen nada conned 0b L Pree Immaiter | + Oonmandtarsnision fem en wnepew" | ” polteimmeor wnt : - inno |_| commineat| reas tint Ne eoponee system) ‘online from immobilizer unit. P1603" mt DDnunboris| wo outers | «cos mot ngs . . ore J UWL Grmeoscoy POM |system) Preos* om | demos «ayo runt ae at . . bilizer J (immobilizer) registered in PCM. ‘system) Pret Cio wars, ‘ [|_| donot © Code word stored in PCM and . . oe L | mater immobilizer unt do nat mat fs ci system) Seen = =D daedin Pre 5 tora unt ard PCM co ‘ numbers do | not match. (This OTC is . . inne tarmac’ | fected ocr maiz a | Gmreize| tnt repced on eva reprogramming system.) Cale presse wor (wath IT] number |» PCM intemal EEPROM re Wig ang_| * POM : - Sie J L Teane site om (immobilizer) Pei dove reoue ratreave win tater” | « POM dtedsimobiza Soe Sgraton |" getemmatuncton mor ther - : vice iol: | Srowtines tor w(t is okay.) F2-51ON-BOARD DIAGNOSTIC SYSTEM BTS 7 Oumput pattem | SPER T Detection conan weno Foi] + POM aledto comranicaia co FIST, | * Wanineston pone Een. : x circuit (User warning light flashes.) Diagnostic trouble code and user's warning dlspay (glow Indietor ight) table x: Applied : - Not applied f T User's warning display? pre Related part Malfunction confirmation condition (Glow indicate light) Fash Mio Poros [Waker pressure soot | Engin aod or gio nah om 3 : orig | make a temperature Engin is started or engine switch on : E POT rae conor | ETRE Sate ore ven x : oTa0 Accelerator potion sensor Eng is saried or erga swith on. z : aie | Fl onperare sensor | Eng stared or eniesvch on r = P0216 injecon ting system | Engine dad x : Po2i9 | Spill valve Engine is started. — x _ = | u325 | TOC sensor Enge aed x = 0880 | Glow pg relay Engel aed fee Eh o. x wenn P0408. EGR system Eng is tod x : so | Venice speed sensor | Eng sre x = os | Ide wih Engine sae or ogie vith o, r E oso | POH Engie fied or engine evlch on x = rio | hile a mpeare engine or ng schon P : pre | Fuslentof FSO) | engines stated or engine schon. ; : 70 | Pum speed sossr Engine wae x : ree | Engin ewich Engine ised : : 288 | 1 Ege sre x 402 | EGR valve postion senso | Engine i started orange Svc o x E |P1602"' | immobilizer Engine is started or engine switch on. - - P1603" | Immobilizer Engine is started or engine switch on. S 5 P1604] immobilizer Engine is started or engine switch on. S 5 P1621"! Immobilizer Engine is started or engine switch on. = = P6227] Immobilizer Engine is started or engine switch on. = = P1623"1| Immobilizer Engine is started or engine switch on. = = P1624" | Immobilizer Engine is started or engine switch on. - - 1629 njcton uno EPAOM | Engin is stared or engine ewich on x 7 = [rou Engine tart or engine eh on = x “1; With immobilizer system: *2: User's waming will be indicated as shown, when DLC TEN terminal is OFF. @ ON OFF [ i Glow indicator ightON-BOARD DIAGNOSTIC SYSTEM PID/DATA MONITOR AND RECORD function © The Mazda 323 (BA) RF engine model does not have PID/DATA MONITOR items, but the following PID/DATA. MONITOR items have been incorporated in the new model with RF-Turbo engine. PID/DATA MONITOR Table Se Monitoring tem Conditionunit | PCM terminat {___ACRLY ‘AG relay ON/OFF 10 ACSW AG switch ONOFF s Be Batery postive wotage v e BARO Barometric pressure kPa Hg = oP sw ie seh ONOFF 7 er Engine coolant emperaure | 26 ECTV Engine coolant temperature signal voltage v 2G EGAPV EGR valve postion signal votage v 2 EGRVAC EGR solenoid valve (vaguum) % 7K EGRVENT GR solenoid valve (vet % 10, FANE Condenser fan cone ONOFF 1N FANG Cooling fan contre ONOFF 30, Fur Fuel temperature sensor < zi ATV Fuel temperature signal volage v zi Ta irtake air temperature (AT) sensor Not oF 2 waTV Intake air temperature (IAT) No.1 signal voltage Vv ‘2E wATOC Intake air tem»perature (IAT) sensor No.2 ad 2K iaTOCV intake air tempereture (AT) No. signal vohage v 2K Tesw Engine switch ONOFF 1F MAP Boost sensor wa_| Fa 20 WAPV Boost signal votage v 20 NLSW | Loadinoload condition signal =~S=S*~*é<“‘*C*SN Cd Ww APM Engine speed pm 36,34 TEN TEN termina (a DLO) ONOFF 3 TeV Accelerator postion signal vokage v oF - vs Vehicle speed ‘KMH KPH su F2-53SIMULATION function ON-BOARD DIAGNOSTIC SYSTEM ‘* The Mazda 323 (BA) RF engine model does not have SIMULATION items, but the following SIMULATION items have been incorporated in the new model with RF-Turbo engine. ‘Simulation Test Table x: Applied :~ Not applied ‘Simulation tem Test condition puree Full name Operation TT PCM terminal ‘AIC RLY ‘AC relay ‘ON or OFF x x a EGR solenoid vave | Actuates by any duty y y oman (vacuum) value (0-100%) 1« EGR solenoid valve] Actuates by any duty y x poe (vent) value (0-100%) 70 FANS Cooling fan relay ON or OFF x x 30 Fuel shut of (FSO) FSOVALY pease OFF x : 20,9x GLP Glow indicatorlignt | ON iM GLWRLY Glow plug relay ON ow SPV RLY Spl valve relay OFF 1D Data link connector (DLC) Funetion # The DLC is the concentrated connector for sending/receiving the aforementioned functions to each tester. ‘Terminal description ‘© The DLC consists of a 17-pin connector in which +B, and GND terminals are located. Tax] fray a] T feed l | | 7 ic-[end | | { Terminal Funetion Remark i z * Outputs diagnostic trouble codes related to PCM « PID/DATA MONITOR AND RECORD NGS communication line ma function sheet Connected to SST «SIMULATION function TEN POM test “Terminal grounded=Test modo +B Battery postive voltage for SST _ = ic For engine speed measurement ‘Connected to tachometer GND___| Ground = F2-54ENGINE TUNE-UP ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION 1. Warm up the engine to normal operating temperature. 2, Shift the transmission into neutral 3. Tum off all electrical loads. ‘¢ Headlight switch Fan switch © Rear window defroster switch '* AC switch 4. Verify that the battery is fully charged. (Refer to section G, CHARGING SYSTEM, BATTERY INSPECTION). 5. Tum the engine switch on and let the engine idle, 6. Verify that no DTC is displayed. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, DTC READING PROCEDURE.) Using the SST (NGS tester) 1. Connect the SST (NGS tester) to the data link connector (DLC) and select “PID/DATA MONITOR AND RECORD’. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TEST, New Generation Star (NGS) Tester Hook-up Procedure.) ETE 2. Access RPM PID. Press the trigger key to enter this selection. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.) 3, Wait unt the electrical fan stops. Not Using the SST 1. Connect a dwell tachometer to the DLC terminal IG. auc = =a] I WELL Cs TACHOMETER ie 2. Wait until the electrical fan stops. IDLE SPEED INSPECTION 1. Perform “ENGINE TUNE-UP PREPARATION’. (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verity that the value of the RPM PID or dwell tachometer is with in the specification, Specification "750—800 (778 + 25) rpm 8. Ifnot as specified, inspect the following ‘Accelerator position sensor ‘© Engine coolant temperature (ECT) sensor Vehicle speed sensor * Engine switch Neutral switch ‘© Clutch switch * Starter 4, Ifthe devices are normal, replace the PCM. IDLE-UP SPEED INSPECTION 1. Perform the "ENGINE TUNE-UP PREPARATION" and “IDLE SPEED INSPECTION’. (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION, IDLE SPEED INSPECTION.) 2. Tur the A/C switch or fan switch on. 3. Verify that the idle speed is within the specification. Specification 780—800 (775 +25) rpm 4. If does not idle up, inspect output voltage of the ‘ANC switch and fan switch. 5. Verify that it runs at the idle speed when the A/C. ‘switch or the blower switch is turned to off 6. Hf not within the specification, perform the "IDLE ‘SPEED INSPECTION’. F2-55ENGINE TUNE-UP INJECTION TIMING INSPECTION Note ‘The injection timing adjustment of this engine is maintenance-tree. ‘¢ The injection timing is adjusted by the PCM when the injection pump Is installed according to the following procedure. 1. Loosen two injection pump mounting nuts and a bolt. 2. Install the injection pump so that the worked part of the injection pump bracket is fitted within the ‘two marks on the injection pump flange. (Refer to FUEL SYSTEM, INJECTION PUMP REMOVAU/INSTALLATION.) 8. Tighten injection pump mounting nuts and bott. Tighten torque 19-25 N-m{1.9—2.6 kgf-m, 1418 ft:lbf} 4. Ifthe injection timing cannot be adjusted or is. abnormal, the DTCs are indicated by the blinking Of the indicator light. If the glow indicator light blinks, repair according to the "Diagnostic Trouble Code Troubleshooting,” (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION, Diagnostic Trouble Code Troubleshooting.) F2-56EGR SOLENOID ‘VALVE (VACUUM) ‘VACUUM PUMP EGA SOLENOID VALVE (VENT) VENTILATION HOSE, INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM F2-57INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION ingine and intake-air system are hot, they can badly burn. Turn off the engine and walt until they are cool before removing or installing the intake-air system. ‘* Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep ‘sparks and flames away from fuel. Fuel line spilis and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel Line Safety Procedure 1. Disconnect the negative battery cable. 2, Remove in the order indicated in the table. 3 Install in the reverse order of removal TO ENGINE HEAD COVER AB) -esi-2nsein 20-298m {20-90 kgfem, 18-26 no Leeks Qe 7 - a Zz oe ZR oasskghem, T8107 Nem AS ino” {80-110 Karem, so arin (Not foes, oe hd 335 ee i a D Est Bae Ren rapenene aa Ears lias fore so arr aloes Hl goss) 2 [ake ope a \< Aiteee altace al hia senes ele a = [ape ars a sz res ica een eS a [aaa ore oe F2-58INTAKE-AIR SYSTEM Fresh-air Duct Removal Note ‘¢ Remove the front bumper before removing the fresh-air duct. (Refer to section S.) Air Pipe Removal Note ‘* Remove the battely and the battery tray before temoving the air pipe. (Refer to section G, CHARGING SYSTEM, BATTELY REMOVALJINSTALLATION.) EGR Pipe Removal Note ‘© Put the hamess bracket aside to prevent it from getting in the way during removal. STEERING OL PUMP HARNESS BRACKET Intake Manifold Removal Note ‘* Remove the injection pump before removing the intake manifold. (Refer to FUEL SYSTEM, INJECTION PUMP REMOVAL/INSTALLATION.) ‘* Drain the engine coolant from the radiator before removing the intake manifold. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT) TURBOCHARGER INSPECTON Wastegate Actuator Inspection Caution ‘* Compressed air used In the workshop Is highly pressurized and can damage the actuator. Adjust the air pressure with a transformer, and inspect the actual Pressure using an air gun before actual use. Stop blowing alr if the rod moves. 1. Disconnect the air hose of the wastegate actuator ‘on the compressor housing side. 2, Connect an air gun to the wastegate actuator. 3. Apply the compressed air gradually and verify that the compressed air is within the specication ‘when the rod of the wastegate actuator starts to move. Note ‘The following pressure indicates absolute pressure. Specification '245.6—257.5 kPa {2.505—2.625 kgt/cm?, 35.63—37.32 psi} WASTEGATE ACTUATOR 4, Ifnot as specified, replace the turbocharger. (Refer to EXHAUST SYSTEM, EXHAUST ‘SYSTEM REMOVALJINSTALLATION.) Compressor Wheels Inspection ‘.. Remove the air pipe between the air cleaner and the turbocharger. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVALIINSTALLATION.) 2. Visually inspect the compressor wheel from view ‘Aand verify that all fins are free from damage, cracks or bends. Note ‘¢ To make the inspection easier, set a small mirror as shown in the figure and use a penlight. «Ifthe compressor whee! is interfering with the compressor housing, itis likely that the fin edges are cracked, damaged, or bent. MIRROR F2-59INTAKE-AIR SYSTEM 8. If there are damaged fins, cracks or bends, replace the turbocharger. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION,) Turbine Whesls Inspection 1. Remove the joint pipe. (Refer to EXHAUST ‘SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 2, Visually inspect the turbine wheel from view B and verify that al fins are free from damage, cracks or bends. Note ‘¢ To make the inspection easier, set a small mirror as shown in the figure and use @ penlight. « Ifthe turbine wheel is interfering with the turbine housing, itis likely that the fin edges are cracked, damaged, or bent. GRINDING MARK 3, If there are damaged fins, cracks or bends, replace the turbocharger. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) GLOW PLUG REMOVAL/INSTALLATION Caution ‘* Do not damage the heated section of the glow plug. Do not reuse a glow plug that has been dropped from a height of 10 cm {0.4 in} or more. ‘* When removing the glow plug, first loosen itat least one pitch using a tool, then loosen by hand. 1. Disconnect the negative battery cable. 2. Remove in tho order indicated in the table. 3. Install in the reverse order of removal. 09-15Nm eoiskgtem, aainon 1s-20 e209, so Nom eat, 109, 1_| Glow plug te 2 | Glow plug GLOW PLUG INSPECTION Resistance Inspection Note ‘© Perform the following test only when directed, 1. Carty out the “Glow System Inspection”. (Refer to ‘TROUBLESHOOTING, SYSTEM INSPECTION, Giow System Inspection.) 2. Hf not as specified, do as follows. 3, Remove the glow plug lead from the glow plug. 4. Inspect the resistance between the glow plug terminal and the cylinder head. Specification Glow plug resistance ‘Approx. 0.60 [20°C {68 °F}] Glow pus LEAD) 5. Ifnot as specified, replace the glow plug. (Refer to INTAKE-AIR SYSTEM, GLOW PLUG. REMOVALIINSTALLATION.) 6. Install the glow plug lead to the glow plug, GLOW PLUG RELAY REMOVAL/INSTALLATION 1, Disconnect the negative battery cable, 2, Remove the glow plug relay. 3. Install the glow plug relay.INTAKE-AIR SYSTEM as-127Nm {80—130 gfe, 78112 nog Low PLUS RADIATOR, Cd 4, Connect the negative battery cable. GLOW PLUG RELAY INSPECTION Continuity Inspection Note ‘ Perform the following test only when directed. 1. Carry out the "Glow System inspection”. (Refer to ‘TROUBLESHOOTING, SYSTEM INSPECTION, Glow System Inspection.) 2, Remove the glow plug relay. 3, Inspect for continuity between terminals C and D of the glow plug relay under the following ‘conditions. e o OO : Continuity ‘Step A 8 c D 1 2 | 8+ | Ground | OO 4. If there is no continuity, replace the glow plug relay. if as specified but the System Inspection is failed, inspect the following: Open circuit ‘* Power circuit (Glow plug relay connector terminal F (1-pin: L) and battery through common connector) ‘© Power circuit (Glow plug relay connector terminal A (2-pin) and PCM connector terminal 3W through common connector) © Ground circuit (Glow plug relay connector terminal F (1-pin: LW) and glow plug lead through common connector) ‘© Ground circuit (Glow plug relay connector terminal B (2-pin) and engine ground through common connector) © Glow voltage circuit (Glow plug relay connector terminal F (1-pin: LW) and PCM connector terminal 2M through common. connector) GLOW PLUG RELAY ro yd (WIRE COLOR) (WIRE COLOR: LW) HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circuit ‘© Glow plug relay connector terminal F (1-pin: L) and battery through common connector to ground ‘* Gow plug relay connector terminal A (2-pin) ‘and PCM connector terminal 3W through ‘common connector to ground * Glow plug relay connector terminal F (1-pin: UW) and PCM connector terminal 2M througn common connector to ground 5, Repair or replace faulty areas. 6. Install the glow plug relay. GLOW PLUG LEAD INSPECTION 4. Remove the glow plug lead from the glow plug (Refer to INTAKE-AIR SYSTEM, GLOW PLUG REMOVALIINSTALLATION,) 2. Verify that the glow plug lead is not broken or bent. 3. Verify there is continuity at both ends of the glow plug lead, Note ‘* When inspecting for continuity in the glow plug lead, do not let the uncovered parts (A) come into contact with other parts and be shorted. 4. If there is no continuity, replace the glow plug lead. ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. . Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4, Perform "IDLE SPEED INSPECTION’ (Refer to ENGINE TUNE-UP, IDLE SPEED INSPECTION.) F2-61INTAKE-AIR SYSTEM 7o-108Km {80—110 gem, 7006 nt) 1_| Accelerator position sensor connector 2 Accelerator pedal component ACCELERATOR PEDAL DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assembla in the reverse order of disassembly. 3. Perform “IDLE SPEED INSPECTION" (Refer to ENGINE TUNE-UP, IDLE SPEED INSPECTION.) {100—1d0Kgtem, Nem oat, 89 1] Accelerator pedal ‘= INTAKE-AIR SYSTEM, FULLY OPEN STOPPER ADJUSTMENT 2 | idle switch |x INTAKE-AIR SYSTEM, IDLE SWITCH ‘3 | Accelerator position sensor = INTAKE-AIR SYSTEM, ACCELERATOR, POSITION SENSOR ADJUSTMENT ACCELERATOR POSITION SENSOR ADJUSTMENT ‘After assembling the accelerator position sensor and connecting the accelerator position sensor connector, perform the following. 1. Confirm that the accelerator pedal is not depressed, 2. Confirm that the voltage of the PCM 2F terminal (accelerator position sensor) is within specification: ‘Specification 0.75—0.95 V 3. If as specified, perform “IDLE SWITCH ADJUSTMENT”. If not as specified, adjust the installation position by moving the accelerator position sensor so that the voltage is within ‘specification. Note ‘¢ Make sure there is no space between the arm and roller. ACCELERATOR, POSITION SENSOR, 4. If as specified, perform “IDLE SWITCH ADJUSTMENT". If not as specified, perform “ACCELERATOR POSITION SENSOR INSPECTION". (Refer to CONTROL SYSTEM, ACCELERATOR POSITION SENSOR INSPECTION.) IDLE SWITCH ADJUSTMENT After assembling the idle switch and connecting the ile switch connector, perform the following. 1. Perform steps in “ACCELERATOR POSITION SENSOR ADJUSTMENT”, 2. Press the accelerator pedal by hand until the ‘output voltage of the PCM 2F terminal (accelerator position sensor) is 1.21.4 V. ‘ACCELERATOR PEDAL F2-62INTAKE-AIR SYSTEM 3, Move the idle switch with the accelerator pedal as described in Step 2, and install a locknut where there is continuity in the idle switch. Tightening torque FULLY OPEN 1516 Nem (1.5—1.7 kgtm, 1112 fbf} STOPPER aS - ® = 2. Confirm that the voltage of the PCM 2F terminal {accelerator position sensor) is within fr. IDLE SWITCH specification. LocknuT ‘Specification '3.60—3.88 V 4, Press the accelerator pedal gradually by hand and verify that the output voltage of the PCM 2F terminal (accelerator position sensor) is within the specification when the output voltage of the PCM 3. If not as specified, tighten the fully open stopper ‘and adjust the position ofthe fully open stopper, 0 that the voltage of the PCM 2F terminal is 1T terminal (idle switch) changes to B+ from within specification under the condition of Step 1 below 1.0 V. Tightening torque Specification 421—6.17 Nm 12—1.4V {43.0—62.9 kgf-om, 37.4—54.5 In-bf} 5. If not as specified, loosen the locknut, adjust the position of the idle switch, and verify again by following the procedure in Step 4. 6. Ifthe output voltage of the PCM 2F terminal (accelerator position sensor) is stil out of specification, perform the “IDLE SWITCH INSPECTION”. (Refer to CONTROL SYSTEM, IDLE SWITCH INSPECTION.) 7. Release the accelerator pedal gradually and verify that the output voltage of the PCM 2F terminal (accelerator position sensor) is within the specification when the output voltage of the PCM 1T terminal (idle switch) changes to below 1.0 V from Br. Specification 12—-1.4V 8. If not as specified, loosen the locknut, adjust the position of the idle switch, and verify again by following the procedure in Step 7. 9. Ifthe output voltage of the PCM 2F terminal {accelerator position sensor) is stil out of specifocation, perform the “IDLE SWITCH INSPECTION”. (Refer to CONTROL SYSTEM, IDLE SWITCH INSPECTION.) FULLY OPEN STOPPER ADJUSTMENT ‘After assembling the accelerator pedal, perform the following. 1. Press the accelerator pedal by hand unti the fully ‘open stopper comes in contact with A shawn in the figure. F2-63FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning ‘© Fuel vapor is hazardous. It can very easily ignite, causing serious Injury and damage Always keep sparks and flames away from fuel. ‘* Fuel in the fuel system is under high pressure when the engine is not running. Warning * Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious Injuries ‘or death and damage. Fuel can aiso irritate ‘skin and eyes, To prevent this, always complete the following “Fuel Line Safety Procedures”. Fuel Line Satety Procedures ‘Avoid fuel line spills and leakage by completing the following procedures. 1. Remove the fuel filer cap and release the pressure in the fuel tank. 2, When disconnecting a fuel hose, wrap a rag around it to protect against fuel leakage. 3. Plug the fuel hose after removal. AFTER REPAIR PROCEDURE Warning © Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe “Fuel Hose installation” described below. Fuel Hose Installation ‘Verify that there is no damage or deform on the fue! hose and fuel pipe wien installing. F2-64FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION fire may cause death or serious injuries. Always properly steam clean a fuel tank before repairing it, 1. Complete the "BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE) 2. Disconnect the negative battery cable. 3. Remove the rear seat cushion 4. Lovel the vehicle. 5. Remove the service hole cover and disconnect the connector. 6 Disconnect the fuel hose from the fuel pump and remove the fuel pump. 7. Siphon the fuel from the service hole using a fuel drawing pump. 8, Remove the presilencer. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 9. Remove in the order indicated in the table, 10. Install in the reverse order of removal 11: Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 2s-asiem 1am Beaton {11-22 kgtom, 10-19 treibty een eee oO ao-127Km {80—190 Kgtom, 79-112 nth) Neat 109 7] Breatherhose 5 _| Fuettank 2 | soint hose 6 _| Fuetfiler pipe = Installation Note 7_[ Nonretum valve Evaporative hose | Evaporative chamber Check vaive (TWO-WAY) 9 _| Fuel gauge sender unit, F2-65FUEL SYSTEM Joint Hose Installation Note Install clamps as shown, o-12mm 032047 np 457 ‘812mm viewa view g 1232-047 int FUEL TANK INSPECTION 1, Remove the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Attach an air hose to the SST. ‘8. Plug the main and return fuel pipe on the fuel pump 4. Set the SST to port A and plug port B as shown in the figure. Pua AIR HOSE 5. Verify that there is airflow trom port C when pressure of +0.98 kPa {+7.4 mmHg, +0.29 inHg} is applied to port A. 6. If there is no airflow, replace the fuel tank. 7. Turn the fuel tank upside-down with port B plugged as shown in the figure. EOE 8. Verify that there is no airflow from port C when pressure of +0.98 kPa {+7.4 mmbg, +0.29 inHg} is applied to por A. 9. If there is airflow, replace the fuel tank. NONRETURN VALVE INSPECTION 1. Remove the fue/-filer pipe. (Refer to FUEL SYSTEM, FUEL TANK REMOVALIINSTALLATION.) 2. Verify that the projection on the nonretum vaive is aligned with the notch on the fuel-filler pipe. PROJECTION : 3, if not, remove the nonretum valve and align the projection with the notch, then reinstall. 4. Verify that the nonretur vaive is closed when the {uel-fler pipe end is held up vertically 5. Ifit opens, replace the nonretumn valve. 6. Verify that the nonreturn valve opens under its own weight when the fuelfiller pipe end is held ‘down vertically. 7. fit does not open, replace the nonreturn valve. FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION,) FUEL FILTER REMOVAL/INSTALLATION 4. Disconnect the negative battery cable. 2. Complete the "BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE) 3, Remove in the order indicated in the table. 4, Install in the reverse order of removal. 5. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE) 6. Bleed air from the fuel fiter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING) 7. Start the engine and verity that fuel does not leak from the fuel system. 8. If fue! leaks, reassemble the fuel fer F2-66FUEL SYSTEM Connector Fuel hose Priming pump Fuel fiter = Installation Note. 5] Sedimentor switch ‘= Installation Note 6_| Drain plug 7_| Fuel warmer Sedimentor Switch installation Note © Apply a small amount of fuel to a new O-ring. Tighten the sedimentor switch enough to the fuel filter by hand. Fuel Filter Installation Note * Apply a small amount of fuel to the fuel filter (O-ring. Tighten the fuel fiter approx. 3/4 by hand atter the O-ring contacts the priming pump. FUEL WARMER INSPECTION 1, Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 8, Remove the fuel warmer. (Refer to FUEL SYSTEM, FUEL FILTER REMOVAL/INSTALLATION) 4. Verity that the resistance between terminal A and the fuel warmer body is within the specification when vacuum of -26.6-—40.0 kPa {-200—300 mmHg, -7.9—-11.8 inHg} is applied to port A of the fuel warmer. Water temperature “C (FD 20 (68) 5. Ifnot as specified, replace the fuel warmer. FUEL LINE AIR BLEEDING Caution ‘* Continuously cranking the engine for over 30 seconds can damage the battery and the starter ‘¢ Repeat cranking the engine for 30 seconds and stop for 5—10 seconds until the engine starts. ‘SEDIMENTOR WATER DRAINING 1. Disconnect the negative battery cable. 2, Complete the "BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSETM, BEFORE REPAIR PROCEDURE.) 3, Loosen the drain plug located at the bottom of the fuel fier. 4. Pump the priming pump and drain the water. 5. After all the water has been drained, tighten the drain plug. 6. Complete the “AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 7. Reconnect the negative battery cable. ‘SEDIMENTOR SWITCH INSPECTION Continuity Inspection Note Perform the following test only when directed. 1, Disconnect the negative battery cable. 2. Drain fuel from the fuel fier. (Refer to FUEL SYSTEM, SEDIMENTOR WATER DRAINING.) 8. Remove the sedimentor switch. 4. Inspect continuity of the sedimentor switch using an ohmmeter. F2-67FUEL SYSTEM Specification Float Continuity Up Yes Down No 5, Ifnot as specified, replace the sedimentor switch. tas specified, inspect the following: Open circuit ‘* Ground circuit (Sedimentor switch connector terminal B and body ground) ‘* Power circuit (Sedimentor switch connector terminal A and instrument cluster connector terminal 3N) SEDIMENTOR SWITCH HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circult ‘© Power circuit (Sedimentor switch connector terminal A and instrument cluster connector terminal 3N to ground) 6. Repair or replace faulty areas. 7. Install the sedimentor switch. 8, Reconnect the negative battery cable. 8. Bleed air from the fuel fter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) INJECTION PUMP INSPECTION Injection Pump Auxillary Parts Inspection (Refer to CONTROL SYSTEM, FUEL TEMPERATURE SENSOR, TIMER CONTROL VALVE (TCV), PUMP SPEED SENSOR, INJECTION PUMP EPROM) Injection Pump Inner Parts Inspection Caution ‘* Injection pump is sealed to maintain proper function. Special tools and testers are required when disassembling the Injection pump. Disassembling the injection pump without special tools and testers will cause ‘a malfunction. ‘© Consult your distributor for disassembly if any injection pump internal parts are possibly ‘malfunctioning. INJECTION NOZZLE REMOVAL/INSTALLATION Caution ‘® Fuel line splils and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the parts. To prevent this, always cover the mouths of the removed parts In the fuel system with rags to soak Up the fuel. 1, Disconnect the negative battery cable. 2. Complete the "BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR, PROCEDURE.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE”, (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE) Note ‘© When the leak pipe is removed, be sure to install a new gasket and perform the “LEAKAGE INSPECTION To107Km {00—10 ghem, joasintey oo-tteNm {100-120 kgtem, 67104 In 19-107"m Sscazinon em gem, 09, F2-68FUEL SYSTEM 1 _| Injection pipe = Installation Note Cylinder head cover Nozzle seal ‘Side wall Fuel leak pipe = Installation Note Injection nozzle bracket 7_| injection nozzle Fuel leak Pipe Installation Note Caution ‘¢ If the gasket Is roused, fuel can leak in the cylinder head, contaminating the olf and causing conditions such as abnormal we to the friction parts. When removed, be sure to install a new gasket. ‘* Perform the leak pipe fuel “LEAKAGE INSPECTION’ Injection Pipe Installation Note + Install the injection pipe in the order shown, INJECTION PIPE ENGINE = ® FRONT D/\®@ \@ @ LEAKAGE INSPECTION 1. Apply pressure of 98 kPa {1.0 kgt/om?, 14.22 psi} from the location marked A. CYLINDER HEAD — LEAK PIPE ENGINE FRONT A 2. Apply soapy water to the joint area of the leak pipe and the injection nozzle, and verify that there is no leakage. Specification No pressure failure or leakage for 10 sec. 3, If not as specified, replace replace the washer, etc, and reassemble. F2-69 INJECTION PUMP REMOVAL/INSTALLATION. Caution ‘¢ Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the parts. To prevent this, always cover the mouths of the removed arts In the fuel system with rags to soak up the fuel. 1. Disconnect the negative battery cable. 2, Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE) 3, Remove the cylinder head cover. 4, Remove in the order indicated in the table, 5. Install in the reverse order of removal. 6. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE) \e Ae 1 ih or 2940.0, 22) ®| me © (s-28, sss, wate) 28-38) tem gt, 1] Injection pipe ‘= Installation Note Nozzle seal 3 | Stay ‘Installation Note 4 | Injection pump © Section 82, CYLINDER HEAD GASKET REPLACEMENT, Injection Pump Pulley Removal NoteFUEL SYSTEM Injection Pipe Installation Note ‘© Install the injection pipe in the order shown. INJECTION PIPE. ENGINE = FRONT Stay Installation Note 1. Align the marks ofthe injection pump and fue! injection pump bracket. , =r PUM) INJECTION NOZZLE INSPECTION Caution ‘¢ Fuel and fuel tank used for the nozzle tester must be kept clean. Otherwise, foreign material may stick between the nozzle and the nozzle tester, causing damagi * Injection nozzle is sealed to maintain its function, and specical tools are required for overhaul . Do not overhaul the injection nozzle by yoursely when a malfunction Is observed, as the injection nozzle will not function normally. maintenance-free. Starting Pressure inspection Warning ‘¢ The fuel vapor from the injection nozzle ‘may penetrate deeply into the fingers and hands and damage tissue. Fuel vapor entering the blood may also cause blood polsoning. Do not touch the fuel vapor ‘when using the nozzle tester. 1. Connect the injection nozzle to nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Slowly lower the nozzle tester handle and note the pressure when injection starts. Injection starting pressure 17.1—18.2 MPa {175—185 kgtiem?, 2489-2630 psi} 4. Ifthe injection starting pressure is not within the specification, replace the injection nozzle. ‘Atomization Condition inspection 1. Connect the injection nozzle to the nozzle tester. 2, Bleed the air by pumping the nozzle tester handle several times, 3, Lower the handle several times as quickly as possible so that a pulsating whistling sound is heard, and note the atomization pattem. (1) Uniform, proper atomization (2) Incorrect injection angle and direction Note ‘© The injection nozzle has five injection holes. FUEL INJECTION ‘VIEW FROM PISTON SIDE, Specification 0 @ | | ill FAULTY FAULTY NORMAL sary FAULTY a, 4. If the atomization condition is not within the specification, replace the injection nozzle. F2-70FUEL SYSTEM FUEL SHUT OFF (FSO) SOLENOID INSPECTION On-Vehicle Inspection Note ‘© Perform the following test only when directed. ‘© Power supply circuit (FSO solenoid connector terminal B and PCM connector terminal 2D through common connector) '* Ground circuit (FSO solenoid body and ground). FSO SOLENOID 1. With the engine idling, disconnect the FSO Rear solenoid connector and verify that the engine jane stops ale 2. ifthe engine does not stop, carry out the following inspection. af ol HARNESS SIDE HARNESS SIDE corey Inspection ‘CONNECTOR CONNECTOR isconnect the negative battery cable, (view FROM (view From 2 Dsconres! the FSO solenols {TERMINAL SIDE) ‘TERMINAL SiD=) 3. Inspect for continuity between the terminals under the following condition, ee eee Short circuit FSO SOLENOID ‘COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) ‘* Power supply circutt (FSO solenoid connector terminal A and FSO solenoid relay connector terminal D through common connector to ground) ‘* Power supply circuit (FSO solenoid connector terminal B and PCM connector terminal 2D through common connector to ground) 3. Repair or replace faulty areas. 4, Reconnect the FSO solenoid connector. SPILL VALVE INSPECTION Resistance Inspection 4, When no continuity is detected, perform resistance inspection. Resistance Inspection 1. Measure the resistance of the FSO solenoid using an ohmmeter. Note ‘¢ Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the spill valve. 3. Inspect the resistance between the terminals under the following condition. FS0 SOLENOID SPILL VALVE COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) ui ‘COMPONENT SIDE CONNECTOR Specification (VIEW FROM TERMINAL SIDE) FCV temperature °C {°F} Resistance () specification 2068) 8513 ee) ‘Terminal | Atmospheric tom- | Resistance 2. If not as specified, replace the FSO solenoid Berature °C °F} (2) When the reading is out of specification, send AB 20 (68) 1014 FSO solenoid to a distributor to repair. f the FSO A-Spil = “Above 10M solenoid is okay, but PCM terminal voltage is out valve body of specification, inspect as follows and repairor replace as necessary, Open circuit '* Power supply circuit (FSO solenoid connector terminal A and FSO solenoid relay connector terminal D through common connector) F2-71 4. If not as specified, replace the spill valve. When the reading is out of specification, send spill valve toa distributor to repair. If the spill valve is okay, but PCM terminal voltage Is out of specification, inspect as follows and repair or replace as, necessary.FUEL SYSTEM Open circult '* Power supply circuit (Spill valve connector terminal A and Injector Driver Module (IDM) Connector terminal D trough common connector) ‘© Ground circuit (Spill valve connector terminal B ‘and Injector Driver Module (IDM) connector terminal E through common connector) SPILL VALVE, OM HARNESS SIDE CONNECTOR HARNESS SIDE ea (VIEW FROM TERMINAL SIDE) (VIEW FROM ‘TERMINAL SIDE) Short circult ‘* Power supply circuit (Spill valve connector terminal A and Injector Driver Module (IDM) connector terminal D through common connector to ground) ‘© Ground circuit (Spil valve connector terminal B and Injector Driver Module (IDM) connector terminal E through common connector to ground) F2-72EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect each exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning ‘© When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing or installing the exhaust system. Caution ‘¢ The turbocharger will not function normally if the rod of the wastegate actuator Is bent. Do not hit the wastegate actuator or hold the rod and the actuator hose when carrying the turbocharger. © Contamination at the inlets/outlets of air, exhaust gas, and oll will cause a turbocharger malfunction. Cover the inlets/outlets with adhesive tape to keep foreign materlals out. ‘* Use only the specified type of studs. Studs of unspecified material will extend under high heat and cause insufficient tightening. ‘© Turbocharger runs at high speed and high h pipe can cause turbocharger malfunction. 3t. Foreign material in the oll line and deformed oll 1, Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 79-107" {20110 gem, 7025 nb) as-27 Wm {S0—1aoughem, Feo1al ino a aa secures ae a Bate FETT fen retest! | gh Betton Basen re-s070= Sign, i res foosemoy Hott Beha aon fa weet {3.0-6.3, —@ Nem fkotm, fb TT Mah sloncor © [vortpine 2 | Onidaion cataye convener 7 [Ole pipe 3 Flexble pipe © | Tubooharger 4 | Exhaust manifold insulator == Removal Note ©] Exhaust manta 3 | doit pipe insuator Joint pipe insulator = Ret Note. F2-73EXHAUST SYSTEM, EMISSION SYSTEM ‘Turbocharger Removal Note ‘* Remove the air pipe and alr hose before removing the turbocharger. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVALINSTALLATION.) Exhaust Manifold Removal Note ‘* Remove the EGR pipe before removing the exhaust manifold. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAUINSTALLATION.) EMISSION SYSTEM EGR SOLENOID VALVE (VACUUM) INSPECTION Airflow Inspection Note ‘* Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the EGR solenoid valve (vacuum). \. EGR SOLENOID VALVE yacuunn Z 0 Cc 3. Inspect for airflow between each port under the following condition. Specification =O : Continuity O=O : Airflow PS Terminal Port a 8 a B 1 o—f-o 2 B+ | Ground | _O—- =O 4. Itnot as specified, replace the EGR solenoid valve (vacuum). Ifthe EGR solenoid valve (vacuum) is ‘okay, but PID value or PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary. ‘© Vacuum hose improper routing, kinks or leakage. Open circuit ‘¢ Power supply circult (EGR solenoid vaive (vacuum) connector terminal A and PCM control relay connector terminal D through common connector) ‘* Ground cirouit (EGR solenoid valve (vacuum) ‘connector terminal B and PCM connector terminal 1K through common connector) F2-74EMISSION SYSTEM EGR SOLENOID VALVE (VACUUM) HARNESS SIDE CONNECTOR: (VIEW FROM TERMINAL SIDE} Short circuit ‘¢ Power supply circuit (EGR solenoid valve (vacuum) connector terminal A and PCM control relay connector terminal D through common ‘connector to ground) 5. Repair or replace faulty areas. 6. Install the EGR solenoid valve (vacuum) connector. EGR SOLENOID VALVE (VENT) INSPECTION Airflow Inspection Note ‘* Perform the following test only when directed. 4. Disconnect the negative battery cable. 2, Remove the EGR solenoid valve (vent). “\ EGR SOLENOID VALVE (en ble oY, A) & 3. Inspect for airfiow between each port under the following condition, (eta) GND. Specification OO : Continuity O=O : Airflow ‘Terminal Port Ke A 8 A B c 1 2 4. Ifnot as specified, replace the EGR solenoid valve (vent) 5. Ifthe EGR solenoid valve (vent) is okay, but PID value of PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary. ‘© Vacuum hose improper routing, kinks or leakage. Open circult ‘© Power supply circuit (EGR solenoid valve (vent) connector terminal A and PCM control relay connector terminal D through common connector) © Ground circuit (EGR solenoid valve (vent) connector terminal B and PCM connector terminal 10 through common connector) EGR SOLENOID VALVE (VENT) TaD HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circult ‘* Power supply circuit (EGR solenoid valve (Vent) connector terminal A and PCM control relay connector terminal D through common connector to ground) 6. Repair or replace faulty areas. 7. Install the EGR solenoid valve (vent) connector. EVAPORATIVE CHAMBER INSPECTION 1, Remove the evaporative chamber, 2. Blow air into port A and verity that air lows out from the holes B on the evaporative chamber. ft 8. Visually inspect that there is no damage nor crack on the evaporative chamber. 4. If not as specified, replace the evaporative chamber. F2-75CONTROL SYSTEM CONTROL SYSTEM PCM REMOVAL/INSTALLATION Note '* The PCM equipped on a vehicle with immobilizer system operates normally only when the corract ID number and code word are inputted it. (Refer to section T, IMMOBILIZER SYSTEM, KEY NUMBER INPUT PROCEDURE.) ‘* The PCM with the ID number and code word stored is only applicable to the vehicle that the PCM has originally been equipped. 4, Disconnect the negative battery cable. 2. Lift up the floor mat in front of the passenger's seat. 3, Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Input the ID number and code word. (Refer to section T, IMMOBILIZER SYSTEM, KEY NUMBER INPUT PROCEDURE.) LHD. RHO. 79-107 {00—110 kgm, 68.596.) rte eens Sse, eo "2. Without immobilizer system em (kgm, fib e Team 7 [oor ecane nes + eet cammaae Ecemmennas 4 {rou Tes Set Nut Removal Note Set Nut instalation Note 1, Using a chisel and a hammer, cut a groove on the © Install a new set nut and tighten it until the neck of nou ot ese nat 20 to france can be tenuis eu inserted. 2. Loose the set nut using an impact screwdriver or ‘SET NUT. a i et , eed er [7 CHISEL CHISEL, F2-76CONTROL SYSTEM PCM INSPECTION Using SST (NGS tester) Note ** PIDs for the following parts are not available on this model. Go to the appropriate part inspection page. 1. Water temperature sender unit (integrated with engine coolant temperature (ECT) sensor) (Refer to CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) INSPECTION.) 2. PCM control relay (Refer to CONTROL SYSTEM, PCM CONTROL RELAY INSPECTION.) 3. FSO solenoid (Refer to CONTROL, ‘SYSTEM, FUEL SHUT OFF (FSO) SOLENOID INSPECTION.) 4, Spill valve (Refer to CONTROL SYSTEM, SPILL VALVE INSPECTION.) 5. Spill valve relay (Refer to CONTROL, SYSTEM, SPILL VALVE RELAY INSPECTION.) 1. Connect the NGS tester to the DLC. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TEST, New Generation Star (NGS) Tester Hook-up Procedure.) 2. Tum the engine switch on. 3. Select the "PID/DATA MONITOR AND RECORD" function on the NGS tester display and press TRIGGER. (Refer to ON-BOARD DIAGNOSTIC ‘SYSTEM PID/DATA Monitor and Record Procedure.) 4. Select the appropriate PID on the NGS tester display and press START. 5. Measure the PID value. Note ‘¢ When measuring the following PID value, inspect the following: * TPVPID (Refer to CONTROL SYSTEM, PID/DATA MONITOR INSPECTION, Not Using SST (NGS tester) at Constant Voltage Terminal inspection.) (Refer to CONTROL ‘SYSTEM, PID/DATA MONITOR INSPECTION, Not Using SST (NGS tester) at Ground Terminal Inspection.) 6. If PID value is not within the specification, follow the instruction in ACTION column, Note # Perform the SIMULATION TEST for the output device (A/C RLY, FAN2, FAN3, EGR PV, GLW RLY, GLW LP) after PID/DATA measurement |s completed PID MONITOR Table oritor ten | — Ua = (Definition) | Condition (Conation Specification coun terminal omy Engine sich on OFF igen long PDS RPM. TPV AS, | owore | Aemnichenartenemtnson | EET ACS, 10 econ "A ich ad Tan chon at ACSW owyoge engine switch on: ON Inspect retigerant pressure switch fe (AIC switch) ACC switch is off at engine switch on: = section U or BE T inspect main relay. (eater postive v-_—_| Engine eich on: Bs w= FOM contd RELAY NISPECTON | 4p vetage) seston T DTC P0105 is indicated. ano Folew OTe rowbhoatng ceacretc | jog g | RAAB EAS mi aooween | CER Eoano oASNOSTIC : fees SYSTEM, ONBOARD In PCM) ee eee nel DIAGNOSTIC TROUBLE CODE INSPECTION GTPSW | Nog | Accelerator pedal is depressed: OFF | Inspect ide switch. = {ide switch) Accelerator pedal is released: ON er (OLE SWITCH INSPECTION = Ergo coolant tomperae 20° | rept ECT sore vp | comps wrExone cooLaNt (Eraneconlart °C | “F | Engine coolant temperature 860°C |” TEMPERATURE (ECT) SENSOR | 76 se {140 °F: 60 °C {140 °F} INSPECTION ecrv | vewan-o | Mapecl ECT sensor CEncngcoolant |_| Eeipecouttemperaueis20°C. | TENGE COOLANT 1 temperature sig- ‘After warm up: Below 1.0 V TEMPERATURE (ECT) SENSOR nal voltage) al “ INSPECTION F2-77CONTROL SYSTEM Monitoritem | __Unity PCM foacaenytll eco Condition/Specitication ‘Action pa EGRPV | ] Inspect EGR valve postion sensor. KER vate post y_/ Engine awichison:04—-O6V | SEGA VALVE POSITION SENSOR 21 pany INSPECTION. EGAVAC . inspect EGR solenoid valve (vacuum). (EGR solenoid x Fngino etch ison: On == EGR SOLENOID VALVE 1k valve (vacuum) af — (VACUUM) INSPECTION. EGRVENT | inspect EGR solenoid valve (vent). | {EGR solenoid %* laren one = EGR SOLENOID VALVE (VENT) 10 valve (vert) " _ INSPECTION. Engine coolant temperature is above 4108 °C (226 °F }: ON FAN2 Terminal TEN (O16) is shortedto | ene uoweg FIRS: RPM. TP V. (Condenserfan | ON/OFF | ground and accelerator pedal is naan eosene erie 1N control) depressed: ON oer ‘NIG is operating: ON thors: OFF Engine coolant temperature is above 400 °C {212 °F}: ON FANS Terminal TEN (OLC) is shortedto |, ramet ong FINS: RPM. TP V. (Cooing tan | ON/OFF | ground and accelerator pedalis de- | FOTN AC SW TEN 3a conta) preseec: ON inspect coin fan rely. ‘NIC Is operating: ON Othore: OFF 7 Fur ays * Pusi COMPONENT SIDE CONNECTOR (view From ‘TERMINAL SIDE) Specification +O : Continuity Condition ce) a 8 Push the rod o— + —9 Except above 5. If not as specified, replace the clutch switch. If clutch switch is okay, but PID value is out of specification, inspect as follows: ‘Open circuit ‘© Power circuit (Clutch switch connector terminal A and PCM connector terminal 1V through common connector) ‘* Ground circuit (Clutch switch connector terminal B and ground) Short circuit ‘© Power circuit (Clutch switch connector terminal A and PCM connector terminal 1V through common connector to ground) 6. Repair or replace fauity areas. 7. Reconnect the clutch switch connector. NEUTRAL SWITCH INSPECTION Continuity Inspection Note ‘¢ Perform the following test only when detected. 1. Disconnect the negative battery cable. 2. Remove the neutral switch. 8. Inspect for continuity betwaen the neutral switch terminals using an chmmeter.CONTROL SYSTEM RK pus ‘COMPONENT JF sive CONNECTOR (VIEW FROM ‘TERMINAL SIDE) Specification (O-O : Continuity Measuring Condition cel nN 8 Push the rod O——O Except above 4. I not as specified, replace the neutral switch. f neutral switch is okay but PID value is out of specification, inspect as follows: Open circuit ‘* Power circuit (Neutral switch connector terminal A and PCM connector terminal 1V through common connector) ‘* Ground circuit (Neutral switch connector terminal B and ground through common connector) Short circuit '* Power circuit (Neutral switch connector terminal A and PCM connector terminal 1V through common Connector to ground) 5, Repair or replace faulty areas. 6. Reconnect the neutral switch connector. F2-89ON-BOARD DIAGNOSTIC SYSTEM ON-BOARD DIAGNOSTIC SYSTEM READ/CLEAR DIAGNOSTIC TEST RESULTS © This retrieves all stored DTCs in the PCM and clears the DTC, PARAMETER IDENTIFICATION (PID) ACCESS ‘* The PID mode allows access to certain data values, analog and digital inputs and outputs, caloulated values and system status information Since PID values for output devices are PCM internal data values, perform the Simulation Test 10 identify which output devices are malfunctioning. SIMULATION TEST ‘® Output devices can be turned on and off by sending simulation command signals from the NGS tester to the Powertrain Control Module. The “Idling Test” and “Ignition ON Test” are available in this test. These tests will verify the PCM status, output devices, and related circuit wiring harnesses. ON-BOARD DIAGNOSTIC TEST New Generation Star (NGS) Tester Hook-up Procedure Note ‘© Make sure the engine switch is at LOCK postion. 1. Insert the vehicle interface module and latest program card into the hand-held NGS control unit. ‘TRIGGER KEYS SS venous wrenrace 7* MODULE (Vig) 2, Plug the adapter hamess connector into the Vehicle interface module and the data link connector (DLC) located at the engine compartment. 8. Plug the NGS tester power connector into the cigarette lighter. Alternatively, enable to use a battery hook-up adapter. Ee ERE EC 4. Listen to the double beep. The NGS tester is now initialized. Begin the powertrain control system functional test. DTC READING PROCEDURE Using the SSTs (NGS Tester) Note Start engine and keep it running, If engine won't start, turn the engine switch on during the procedure. 1. Perform the necessary vehicle preparation and ‘visual inspection. Hook the NGS tester up to the vehicle. 77008 0900 CoO F2-90ON-BOARD DIAGNOSTIC SYSTEM 2, Move the cursor to VEHICLE & ENGINE SELECTION. Press the TRIGGER key to onter this function: DIAGNOSTIC DATA LINK ‘VIEW RECORDER AREAS DIGITAL MEASUREMENT SYSTEM NEW GENERATION STAR SETUP. 3. Move the cursor to SELECT NEW VEHICLE YEAR & MODEL. Press the TRIGGER key to enter this selection. rm Sep Romania 4, Move the cursor to 626 (GF) or 626 WAGON (GW). Press the TRIGGER key to enter this selection. Note ‘¢ Make sure the selected vehicle is correct. 5. Avehicle selection screen showing the selected vehicle will be displayed. Move the cursor to the vehicle selected. Press the TRIGGER key. 6. Move the cursor to DIAGNOSTIC DATA LINK on. the main menu screen, Press the TRIGGER key to enter into menu system diagnostics. 'VIEW RECORDER AREAS DIGITAL MEASUREMENT SYSTEM NEW GENERATION STAR SETUP___ 7. Move the cursor to PCM-POWERTRAIN CONTROL MODULE. Press the TRIGGER key to center this selection. ‘AIC~ AIR CONDITIONER MODULE ‘ABS-ANTI LOCK BRAKE SYSTEM }. Move the cursor DIAGNOSTIC TEST MODES. Press the TRIGGER key to enter this selection. PST PIDIDATA MONITOR AND RECORD ‘SIMULATION TEST DIAGNOSTIC TROUBLE CODE LIBRARY 1 9. Move the cursor to READ/CLEAR DIAGNOSTIC. ‘TEST RESULTS. Press the TRIGGER key to ‘enter this selection. OST TEST RESULTS F2-91ON-BOARD DIAGNOSTIC SYSTEM PLAYBACK OF STORED PIDS PROCEDURE 10. Press START. 11, Retrieve DTCs. PID/DATA MONITOR AND RECORD PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 8 from the DTC READING PROCEDURE. 3. Tum the engine switch on or run the engine. 4. Move the cursor to PID/DATA MONITOR AND RECORD. Press the TRIGGER key to enter this. selection. SIMULATION TEST DIAGNOSTIC TROUBLE CODE LIBRARY 5. Move the cursor to PID values to view. Press the TRIGGER key. A star symbol will appear next to the item when it is selected. Note ‘¢ Press the TRIGGER key once again to deselect a PID. ‘© Press the CLEAR to deselect all PIDs. Press START to begin. ‘When ready to capture and store the selected PIDs, press the TRIGGER key. Press the TRIGGER key again when ready to ‘save information. ). Move the cursor to STORE RECORDING IN AREA 1. Press the TRIGGER Key. © 2 xe ISTORE RECORDING AREA 2 STORE RECORDING AREA 3 10. Follow the instructions displayed on the NGS. tester to save the recording data. F2-92 Note ‘¢ Look for abnormal behavior or values that are Glearly incorrect. Inspect the signals for abrupt or unexpected changes. + Look for agreement in related signals. ‘* Make sure signals act in proper Sequence. 1. Select VIEW RECORDER AREAS. VEFICLE S ENGINE SELECTION DIAGNOSTIC DATA LINK ‘DIGITAL MEASUREMENT SYSTEM [NEW GENERATION STAR SETUP 2. Select a view areas. 3. Select up to the four PIDs to review in the table format or two PIDs to review in the graph mode. (1) Table format: Scroll through the PID data while analyzing the information. Look for sudden drops or spikes in the values. SUDDEN SPIKE POSSIBLE FAULT (2) Graph format: Scroll through the PID data while analyzing the information, Look for sudden drops or spikes in the linear lines showing the transformation of values to the line graph NON LINEAR-POSSIBLE FAULT IN SENSORICIRCUITON-BOARD DIAGNOSTIC SYSTEM SIMULATION TEST PROCEDURE Idling Test 1, Perform tte NGS Tester Hook-up Procedure, 2. Perform the Steps 1 through 8 from the DTC READING PROCEDURE. 4, Start the engine and run it at idle. 4, Move the cursor to SIMULATION TEST. Press the ‘TRIGGER key to enter this selection. DIAGNOSTIC TEST MODES PIDIDATA MONITOR AND RECORD DIAGNOSTIC TROUBLE CODE LIBRARY ‘5. Move the cursor to IDLING TEST. Press the TRIGGER key to enter this selection. 8. Pross the TRIGGER key. ‘GURRENT DATA, or SIMULATION DATA OFF =—— 9. The simulation is performed for 3 seconds, and a “SIMULATION ACTIVATED PLEASE WAIT” message is displayed during those 3 seconds. “CURRENT DATA SIMULATION DATA 6. The screen will display a list of simulation item, Select the appropriate simulation tem for testing, then pass the TRIGGER key. Note ‘© Only one simulation iter can be selected at a time. Jacauyciwor EGRVAc GLWRLY EGR VENT SPVRLY 7. Press START. Note ® If the screen displays “TEST CONDITION NOT CORRECT”, inspect the following signal conditions and determine whether or not they ‘© RPM: above 775 10. To perform the simulation again, press the TRIGGER key. To exit the idling test, press the CANCEL key. Ignition ON Test 1. Perform Steps { through 8 from the DTCs READING PROCEDURE. 2. Tum the engine switch on. Move the cursor to ‘SIMULATION TEST. Press the TRIGGER key to enter this selection. DIAGNOSTIC TEST NODES PID/DATA MONITOR AND RECORD. ‘DIAGNOSTIC TROUBLE CODE LIBRARY 3, Move the cursor to IGNITION ON TEST. Press the TRIGGER key to enter this selection. F2-93ON-BOARD DIAGNOSTIC SYSTEM AFTER REPAIR PROCEDURE Using the SSTs (NGS Tester) 1. After repairs have been made, perform the DTCs READING PROCEDURE. 2, Press CLEAR. 3. Press the TRIGGER key. 4, Press the CANCEL key. 5. Ensure that the customer's concem has been resolved Not Using the SSTs (NGS Tester) 1. After repairs, disconnect the negative battery fon it ble for at least 20 seconds, and depress the 4. The screen will display a list of simulation item. ae Select the appropriate simulation item for testing, SE eee eeeeiee ened en ceeeee cena 2. Warm up the engine to normal operating temperature. Note aa ‘If the engine will not start, keep the starter EGRvac SLwALY ‘operated for 5-6 seconds. EGR VENT SPVALY FAN Fzovnty 8, Perform the "DTC READING PROCEDURE” again. 4, Vay that the DTC isnot detected. a 5. Press START. 6 Press the TRIGGER key. CURRENT DATA tz ‘SIMULATION DATA ON. 7. The simulation is performed for 3 seconds, and a “SIMULATION ACTIVATED PLEASE WAIT” message is displayed during those 3 seconds. ‘CURRENT DATA FE ‘SIMULATION DATA (o) SSS eeeeeeeereeeecrereeneenee 8. To perform the simulation again, press the TRIGGER key. To exit the ignition on test, press the CANCEL key, — —-._-F2-94ON-BOARD DIAGNOSTIC SYSTEM. ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION Diagnostic Trouble Code Table BTC No. | Indetor Paton Dialay one NE Conaion potas MAPIP-CIRCUTT MALFUNCTION | Boos senor mancton Potro IATGIRCUT MALFUNCTION | AT sensor Not metuncton pots ECT-OIRCUT MALFUNCTION | ECT sensormauncton Povo | TP-CIRCUT MALFUNCTION Aselerator postion sonsor oreo | FLT SENSORIA-CIRCUT | et tgnperatue senor maluncton poste | INI TIMING CTAL-CIRGUT | ineton yng esa matuncton pocte ENGINE OVERSPEED Splvahe system atnton ess l CRANKSHAFT FOS, | roc saneormafunton ose I Low vast Clow pu rly matin poca | EGR-IRCUT MALFUNCTION | EGR sysem mafinton 0800 | VEHICLE SPEED | vec speed sonar matuncton sto I Ghose THROTTLE FOS | gg evich mation oboe POU-PROCESSOR FAULT | PM matincion PIN10 IATS(D/C)-OPEN OR SHORT IAT sensor No.2 malfunction iia L SOLENOIDAALFUNCTION _ FSO stleno matvncton P1189 PUMP SPEED SIGNAL-FAULT Pump speed sensor malfunction rise STASWOPENOR SHORT | Engine sich matuncion prose 1oM FAURE 1OM matncton race | EGRS-OPENOR SHORT | EGR ave poston sneer moa TMMOBILZER UNT-PCM COMM | blz an POM L ERROR comraniston oor P1603 ID NUMBER-UNREGISTERED 'D number is unregistered. {(mmobizer) F2-95ON-BOARD DIAGNOSTIC SYSTEM —— a Fae aE ns ameaaaal vem (TIMI, (cove mono innecsreneo | Sree ] Code words do not match. eee JIM coveworosco norway | Seer waa emcee cose nna vanes ane | aparece = aoa cotnenacenl | eensecicarsered aera snarky reonon rN evo TMOTUNIIIIL, | SEES son | wens rou manON-BOARD DIAGNOSTIC SYSTEM DTC Troubleshooting DTC P0105 | BOOST SENSOR MALFUNCTION « Input voltage from boost sensor is above 4.90 V when engine switch is tured on. ‘* Voltage more than 1.95 V is inputted from boost sensor to PCM when engine speed is above 2400 ‘pm and accelerator opening angle is more than 52%. ‘Boost sensor malfunction POSSIBLE —_¢ Open or short cccult in wiring from PCM terminal 2C to boost sensor terminal 8 DETECTION CONDITION CAUSE © Open or short circuit in wiing from PCM terminal 2A to boost sensor terminal C + Open crcuitn wing from PEM terminal 28 to boost sensor trminal A STEP INSPECTION ‘ACTION 1 | Does Boost sensor connector or POM 'Yes_| Repair or replace connector, then go t sop 7 Connector have poor connection? ND|ICGo renter 2 | Implement PIDIDATA MONITOR AND Yes | Goto Stop 6. RECORD (MAP V) of DIAGNOSTIC DATA LINK using NGS. Is the voltage as No Gotonex step. specited? 3 _] Disconnect boost sensor connector Yes | Gore next sep, Tum engine switch on. Is there 5V at No. | Inspect for open or short circuit in wiring harness, (POM ‘connector terminal C’ terminal 2A-boost sensor terminal C) 4 _| Is there continuity between connector Yes | Go to next step. terminal A and PCM terminal 28? No_| Repair or replace wiring harness, then go to Step 7. % | Is boost sensor okay? Yes | Go tonext step * CONTROL SYSTEM, BOOST SENSOR INSPECTION No. | Raplace boost sensor, then go to Step 7 @ | Crear agnostic trouble code rom memory. | Yes | Goto Step 1 {s same code No. Present after performing [Ne | Intrmitent poor connection In hamess or connector. ‘After Repair Procedure” Repair connector andor harmess, then goto next step 7 Clear diagnostic trouble code from memory. | Yes | Go to applicable DTC inspection. Is there any diagnostic trouble code present aiter pedorming "ARer Repair Proceaure"” | NO_| Troubleshooting completed. Pom 00ST SENSOR j2d2a, = be HARNESS SIDE 16 PIN'CONNECTOR HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE) (WiEW FROM TERMINAL SIDE) F2-97ON-BOARD DIAGNOSTIC SYSTEM DTC P0110 _| INTAKE AIR TEMPERATURE (IAT) SENSOR No.1 DETECTION | input voliage from IAT No.1 sensor is below 0.142 V or above 4.915 V. GONoTiON TT ear naan ossiaus |S Gpenor sor crak wing fm AT sino (tr eae) toil Ato POM tinal 2 + Shen or shart retin wing or sone fa clare tial fo PEM emia 26 sree INSPECTION ACTION 1 Does A ssa connec or POM Yes | Repaarropac omnecor, hen got ap comodo nave por comestan? a Bera ‘2 | Implement PID/DATA MONITOR AND Yes Go to Step 6. AECOND (AT) of AGNOSTIC DATA LINK using NGS. Is the voltage as No Goto next step. soostoa? 3 Biaconec I sere connect Yes | Govan wn: TJ ‘Tum engine gwitch on. Is there SV at No | Inspect for open or short circuit in wiring harness. (PCM connactar tarminal A? terminal 2E-IAT sensor terminal A) 7 [tether coniny baron canneaar | Yo | Go ext sp serminal B and PCM terminal 257 No _| Repair or replace wiring hamess, then go to Step 7. 5 Is IAT sensor (air cleaner) okay? Yes | Gotonext step. * CONTROL SYSTEM, NTAKE AR SePERATURE SENSOR Ta Popa enor ane, tan GoW ST. INSPECTION. \ z “ ° 3] Gear saqnoste rosie ade For many | ex [ Govo Sept. 1s same code No. Present after performing No | Intermittent poor connection in hamess or connector, “After Repair Procedure"? Repair connector and/or hamess, then go to next step. 7 | Gir dagncsie wade oie ram amor | Ys [ Goo appleaie OT heparin. |s there any diagnostic troubie code present ater peorming “After Repair Procedure"? NO_ Troubleshooting completed poal IAT SENSOR No.1 E | HARNESS SIDE 16 PIN CONNECTOR HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE) (VIEW FROM TERMINAL SIDE) F2-98ON-BOARD DIAGNOSTIC SYSTEM DTC PO115 | ENGINE COOLANT TEMPERATURE (ECT) SENSOR DETECTION |” input voltage from ECT sensor is below 0.142 V or above 4.915 V. CONDITION © EGT section matfunction POSSIBLE | > Spon ar ano cutin wing tom ECT sense tein! Ato POM tribal 28 ‘© Open or short cicuitn wiring from ECT sensor terminal to PGM terminal 26 STEP INSPECTION ACTION 1 | Does EGT sensor or POM connector have | Yes | Repair or replace connector then goto step 7 Poor connection? No_| Goto next step. 2 implement PID/DATA MONITOR AND Yes | Goto Step 5. RECORD (ECT V) of DIAGNOSTIC DATA LINK using NGS. Is the votlage as No | Goto nent step. specified? 3 | Disconnect ECT sensor connector. Yes_| Goto next step. ‘Turn engine switch to on. Is there SV at No | Inspect for open or short circuit in wiring harness. (PCM _| Sanmector termined 6 terminal 2G-ECT sensor terminal B) 4 Is there continuity between connector Yes Go tonoxt stop. terminal A and PCM terminal 287 No_| Repair or replace wiring hamess, then go to Step 7. 3] ISEOT sensor onay? Yes | Goto next step. == CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE SENSOR No Replace ET sensor, then go to Step 7 INSPECTION © | Clear diagnostic trouble code trom memory. | Yes | Goto Step 1. |s same code No. Present tte performing [No | Intermitent poor connection n harness or connector "Aft Repair Procedure"? Repair connector and/or harness, then goto next step. 7 | Clear diagnestc trouble code from memory. | Yes | Goto applicable DTC inspection Is there any diagnostic trouble code present Shor poverng Ata: Repair Proceaure’? | NO_| Troubleshooting complete. ET SENSOR Fea ca ale Bal E a HARNESS SIDE 16 PIN CONNECTOR HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDS) (EW FROM TERNAL SIDE) F2-99ON-BOARD DIAGNOSTIC SYSTEM DTC P0120 | ACCELERATOR POSITION SENSOR “Input voltage from accelerator position sensor Is below 0.3 V or above 4.7 V when continued for 0.06 DETECTION S00. CONDITION» input voltage from accelerator position sensor is above 1.6 V when engine switch turned on for 0.3, sec. '* Accelerator position sensor malfunction '* Open circuit in wiring from throtle position sensor terminal E to PCM terminal 28 POSSIBLE | © Open or short circuit in wiring from throttle position sensor terminal C to PCM terminal 2A CAUSE ‘© Open or short circuit in wiring from throttle position sensor terminal D to PCM terminal 2F « Idle switch malfunction «Accelerator position sensor or idle switch misadjustment STEP INSPECTION ‘ACTION 1 | Does throttie position sensor connector or | Yes | Repair or replace connector, then go to Step 9. PCM connector have poor connection? No | Goto next step. 2 _| Implement PID/DATA MONITOR AND Yes | Go to nent step, RECORD (TP V) of DIAGNOSTIC DATA LINK using NGS. Is the voltage as No_| Goto Step 4 specified? 3 | Verify that the accelerator pedal and idle Yes | Goto Step7. switch are property installed, s@ INTAKE-AIR SYSTEM, ACCELERATOR [No | Goto Step. PEDAL DISASSEMBLY/ASSEMBLY “| Disconnect accelerator position sensor Yes | Goto next ste connector. Turn engine switch on. 1s there S |" No | inspect for open or short circuit in wiring harness. (PCM V at connector terminal C? terminal 2A-acceleratot postion sensor terminal C) 3 _| Is there continuity between connector Yes | Goto next step. terminal D and PCM terminal 2F? No_| Repair or replace wiring hamess, then go to Step 8. @ | |S there continuity between connector ‘Yes _ Replace thratle position sensor, then go to Step 8 terminal E and PCM terminel 287 'No_| Repair or replace wiring hares, then go to Step 9. 7 | Isidlo switch okay? Yes | Goto next step. "CONTROL SYSTEM, DLESWITON 7a ca ae anh Hongo ap Clear diagnostic rouble code trom memory. | Yes | Goto Stop 1 's same code No. present after performing "No | Intermittent poor connection in hamess or connector. “Attar Repair Procedure"? Repair connector andlor harness, then go to next step. ‘9 | Clear diagnostic trouble code trom memory. | Yes | Go to applicable DTC inspection. Is there any diagnostic trouble code present after performing “After Repair Procedure”? No_ | Troubleshooting completed. [ACCELERATOR POSITION SENSOR Pom TT ete

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