Mazda MPV 1989, B 1989, RX-7 User Manual

RX-7

CONTENTS

•

TITLE

ENGINE LUBLICATION COOLING SYSTEM FUEL AND EMISSION

CONTROL

-----

---

FUEL AND EMISSION

CONTROL ENGINE ELECTRICAL SYSTEM MANUAL AUTOMATIC TRANSMISSION

(ELECTRONICALLY -CONTROLLED) FRONT AND REAR AXLES STEERING SYSTEM BRAKING SYSTEM SUSPENSION BODY 14 BODY ELECTRICAL SYSTEM 15

-

--

---

--

-

SYSTEM

-

SYSTEMS

--- ---

SYSTEMS (TURBO)

--

TRANSMISSION

--

----

(NON-

----

-

--

-

-----

TURBO)

---

--

SECTION

1 2 3

4

5

7

9

10

11

13

•

-

c

ENGINE

e

OUTLINE

OUTLINE OF CONSTRUCTION STRUCTURAL VIEW SPECIFICATIONS INTERCHANGEABILITY

TENSION BOLT FRONT COVER ROTOR

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

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

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

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

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

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

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

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

C-

CC-

C-

CC-

97UOCX

2

2 2

4

5

6

7 8

501

e

OUTLINE

OUTLINE OF CONSTRUCTION

The 13B improved engine performance.

Major changes

1.

Rotor : Lighter, rotor recess shape change to increase compression ratio

2.

Tension bolt : Strengthening ribs added

3.

Front cover : Shape changed for new metering

4.

Side housings : Inlet port erea enlarged

STRUCTURAL VIEW

HOUSING-RELATED PARTS

in

the 1989

RX-7

is

basically the same as

FRONT HOUSING

in

the previous model but with some modli

oil

pump

FRONT ROTOR HOUSING

c:=:-

_

FRONT OIL SEAL

._)

REAR HOUSING

REAR ROTOR HOUSING

INTERMEDIATE HOUSING

C-2

·-

97UOCX·502

;:;'"'TA

~

TING-RELATED

PARTS

BALANCE WEIGHT

ECCENTRIC PULLEY

REAR ROTOR

' •

FRONT ROTOR

DRIVE PLATE

COUNTER WEIGHT

FLYWHEEL

-.

C-3

SPECIFICATIONS

cc

Model

(cu

1n)

Item

Eng1ne type Rotary eng1ne

Displacement

Number

Combustion

Compression

A1r

Port

of cyl1nders and

chamber

Induction

t1m1ng

rat10

Intake

Exhaust

arrangement

type

Open

Close

Open

Close

Pnmary 4S0 ATOC

Secondary Auxiliary Pnmary

Secondary

Auxil1ary

Turbo Non-Turbo

6S4 X 2 (40.0 X

2 rotors. longitudinal

Bathtub

9.0 1

4 port

1nduct1on

32°

ATOC

S0°

ABOC

soo

ABOC

0

7S

BBDC

48°

ATOC

2)

6 port

32°

4S

40°

30°

80"

9.7 1

1nduct1on

ATOC

0

ATOC

ABOC

~~

\

Fuel

supply

lgn1t1on (Green

Idle grounded)

t1ming

1-p1n)

speed

system EGI

(w1th

grounded)

(w1th

test

connector

(Green

Tra1l1ng

Lead1ng

1-pln)

rpm

± 2 ' ATOC (REO)

20°

so

±

1 o ATOC (YELLOW)

750 ± 25

l,~

97UOCX 504

C-4

INTERCHANGEABILITY

:::

,.,,ng

chart shows interchangeability of major components of the previous model and the 1989 mode'

X Not interchangeable

...

ousmg-

·~

ated

;:.a

r1S

;;

:~at1ng-

-~

a~ed

=~~s

Part

Front rotor hous1ng Rear rotor hous1ng

Front

hous1ng

i ntermed1ate housing

Rear housing

seal1ng

nner

Outer sealing rubber Front cover Orl

pan Tens1on ::ccentnc shaft

Rotor

~~pex

S de

seal

:::orner

3a',ance weight I

J I pump dnve sprocket

: :centr1c

'C

=centnc shaft bypass valve - -

~

. ·ey lock bolt

~

.

:.

heel

• · beanng .1ter

rubber

bolt

seal

shaft pulley t

(MIT)

we1ght

(A/T)

-1

. -

i

---1

I

+

J

-~·

.

l

I,

Interchangeability

X

0

X

0

X

0

X

0 0

0

X

0

X 0 0

X

0

X

Remark

• Knock sensor boss added

• Inlet port area enlarged

• Shape changed to Incorporate new

tng

Oil

pump

• Ribs added

•

We1ght

•

Combustion chamber shape changed

• Shape changed

•

We1ght

•

Shape changed

•

We1ght

'

to

center of shank

reduct1on

metw

•

C-5

TENSION BOLT

...

OTHERS

No.18 BOLT

(}1

T

STRENGTHNING RIBS

128 ± 2mm

HEAT-SHRINK PROTECTOR

lllllllllllllllllllllllllllllll

(5.04 ± 0.08 in)

NOTE No.1? SOL OTHERS. THERE IS AN IDENTIFICATION

The strength of the tension bolts The tension transmiss1on of eng1ne noise. To reduce this noise. the heat-shrik protector through the intermediate housing boss. The No. 18

protector). shrunk

bolt installed into the No. 18 hole differs from others

If

the bolt

w1th

a l1ghter or match.

T IS LONGER THAN

MARK.

1s

increased by addit1on of strengthening ribs

is

reused and the protector

No.18 BOLT

bolt

is

damaged, replace the protector. The protector

C-6

in

that

is

supplied as an assembly (bolt

in

the middle of the shank.

it

is

not fully enclosed. lead1ng to

is

used on the bolt where

w1th

washer and

97UOCI 506

1t

goes

1s

easily

,

.•

FRONT COVER

FRONT COVER GASKET

FRONT COVER

~.

~BACKUP

0-RING

RING

•

~

· 989

:::::ded

RX-7

front cover

between the front cover and front housing for improved sealing.

is

changed to incorporate a new metering

C-7

oil

97UOCX 507

pump.

ROTOR

TURBO

RIBS

NON-TURBO

RIBS

~

\

A

/J

I

c--~~

v

A A

~

A~

1 0.9mm (0.43 in)

,_

4

8.8mm (0.35 in)

r---/1

~-

The rotor

9.7 : These improvements The rotor ribs are redesigned for increased strength. The combustion chamber rotor recess

The rotor for turbo and non-turbo engines are distinguished by the rotor recess shape.

in

the 1989

1 for non-turbo model) than the previous engine.

RX-7 results

is

lighter and provides a higher compression ratio (9.0 : 1 for turbo model and

in

a engine with more power and torque.

1s

made more uniform by utilizing a mechanical cutting process.

97UOCX 508

C-8

...

D

LUBRICATION SYSTEM

OUTLINE

OUTLINE OF CONSTRUCTION STRUCTURAL VIEW SPECIFICATIONS INTERCHANGEABILITY

METERING OIL PUMP

OUTLINE OPERATION FAIL-SAFE FUNCTION

SERVICE POINT

OIL FILTER

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

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

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

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

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

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

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

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

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

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

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

D-

DDD-

D-

97UODX 501

2

3

4

4 5 5

6

-

OUTUNE

OUTLINE OF CONSTRUCTION

-~e

lubncation system of the 1989

"lents have been made

1 A new electronically controlled metering

oil

pump for reduced

2 A smal!-size

oil

filter

as

described below.

oil

consumption and improved reliability.

is

used and

STRUCTURAL VIEW

RX-7

its

installation procedure

is

basically the same

oil

pump

is

adopted instead

as

the previous model. but some improve-

of

the previous mechanical metering

is

different.

MANIFOLD OIL NOZZLE

TURBOCHARGER

HOUSING

0-2

SPECIFICATIONS

Items

Lubncat1on system

Type

011

pump

Control valve relief pressure

Oil cooler

Regulator valve

Oil filter

Eccentnc shaft bypass valve

Oil

capaCity

Eng1ne

oil

(API

Number

1

1 D1ameter x

Type

Rel1ef

Type

Rel1ef

Total (dry

011

Oil cooler

011

serv1ce)

of rotors

w1dth

temperature pressure dlfferent1al kPa

rel1ef

pressure kPa

pressure

eng1ne)

pan

filter , actory-1nstalled l1ters

(US qt Imp qt) i Serv1ce parts

of rotor

d1fferent1al

rel1ef

temperature

Engine model

kPa (kg/cm

(kg/em'.

kPa

(kg/em'.

l1ters

(US qt. Imp qt)

liters

(US qt. Imp qt)

l1ters

(US

\ F

I

qt

_____

mm

2

oc

Imp

.

ps1)

(°F)

ps1)

(°F)

(1n)

ps1)

qt)

_[_________

50 X 17.5

Turbo

(1

97 X

A1r

349

Fuel

Force-fed

Trocho1d

069)

1.079 (11.0.

cooled.

60-65

(140-149)

(3

56. 50) 490 (5.0. 71)

Full flow.

98

60 (140) or below

5.8 (6 1 5.1)

4.4 (4.7. 3

0.85 (0.90. 0

0.19 (0.20 0 17)

0.17 (0.18. 0 15)

eff1c1enr·

2

50 X 12.5 (1.97 X 0.49)

156)

w1th

bypass valve

or below

at

60°C

paper

element

(1.0. 14)

9)

75)

SF

(M1neral oil only)

Non-Turbo

(140"F)

----

___

97UODX

_j

507

INTERCHANGEABILITY

The following chart shows interchangeability of major components of the previous model and the 1989 model.

Interchangeable X Not Interchangeable

Interchangeability

X

______________________________

Remark

Oil

pump

unchanged

Baffle plate for turbo model Shape

changed Small-s1ze filter used

Shape

changed

el1m1nated

97UODX

j

503

011

pump

rl1eterlllg 0 I

f1lter

--1ous1ng

J

_c_o_o_le_r

Part

oil

pump

oil

nozzle Shape cr1anged

______________

~

0-3

METERING OIL PUMP

OUTLINE

An electronically controlled metering oil

pump The ECU bases It

then sends a pulse signal to control the

for reduced

it

calculation of engine

oil

consumption. This new metering

temperature and intake air amount (load condition). The same metering

TURBO

oil

pump

is

used for turbo and non-turbo engines, but the

HOUSING OIL NOZZLE

oil

pump

is

used instead of the previously used mechan1cal metering

oil

needs on the input from various sensors.

oil

discharge amount according to engine speed,

oil

pump

is

controlled by the

oil

nozzle plumbing

eng1ne

control unit.

coolant

1s

different

...

~

MANIFOLD OIL NOZZLE

NON-TURBO

~

I

NON-TURBO

0-4

97UODX·504

OPERATION

The

oil

discharge mechanism

the previous mechanical metering

is

ing worm, which

The

oil

discharge amount

The plunger rides against the taper

changes to Stepping motor operation

the optimum

control the

oil

driven by the eccentric shaft.

oil

discharge for

in

the new electronically controlled metering oil pump

oil

is

controlled by movement

discharge amount.

is

monitored by the

all

driving conditions.

is

the same

pump. The plunger and differential plunger are driven through the driv-

of

the control pin.

pos1t1on

the control

As

the

sensor, which results

p1n.

p1n

moves up or down, the plunger stroke

in

the engine control unit setting

STEPPING MOTOR

as

that

/

in

CONTROL PIN

f

OIL

DRIVING WORM

DIFFERENTIAL PLUNGER

FAIL-SAFE FUNCTION

If

the engine control unit senses a malfunction of the stepping motor or

place.

takes

The engine control unit fixes the control pin to tion to engine speed The

vehicle can be driven normally

step range.

' the

oil

injection needs exceed the lowest compensation step range. fuel injection

~1gine

speed and resultant oil injection requirements.

only without any load compensation.

as

long

its

lowest compensation step, and

as

the

oil

injection needs are within the lowest compensation

D-5

posit1on

SUB-PLUNGER

97UODX 505

sensor. fail-safe function

oil

is

discharged

is

restricted to limit the

in

propor-

SERVICE POINT

OIL FILTER

The 1989 The service oil filter

RX-7

has a small-size

is

oil

filter. The factory-installed oil filter differs from the service parts oil filter.

the same as that used for the Mazda 323 B-series engine. '

.....

Oil filter capacity

ctory 1nstalled

rvice part

-

--·-----·-----

019

0.17

(0.20, 0.17) (0

18.

0.15)

liters (US qt,

_,]

Imp

qt)

97UODX 508

Replacement

1.

Remove the oil filter with a suitable wrench.

2.

Use a clean rag to wipe clean the mounting surface on the engine.

3.

Apply a small amount of clean engine oil to the rubber seal of the new filter.

4.

Hand tighten the oil filter until the rubber seal contacts the base, and then tighten the filter an additional 1-1/6 turn with a wrench.

5.

Start the engtne and inspect for leaks around the filter seal. ·

6.

Check the oil level and

add

oil as necessary.

.J

0-6

COOLING SYSTEM

E

OUTLINE

OUTLINE OF CONSTRUCTION STRUCTURAL VIEW SPECIFICATIONS INTERCHANGEABILITY

COOLING FAN WATER PUMP THERMOSTAT

RADIATOR

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

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

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

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

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

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

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

E-

EEE-

E-

EEEE-

97UOEX 501

2

2 2 3

3

4 5 6 7

-

OUTLINE

The cooling system of the 1989 have been

1.

The number of cooling fan blades

2.

In

3.

A new radiator with a filler

4.

In

STRUCTURAL VIEW

OF

CONSTRUCTION

RX-7

is

basically the same as the previous model but certain improvements

made conJunction with the cooling conjunction with the radiator modification, the thermostat cover and thermostat gasket shapes are changed.

as described below.

fan

modification, the shape of the water pump

cap

body

is

increased from 8 to 1 0 for improved cooling performance.

is

changed for improved rigidity.

is adopted for improved serviceability.

THERMOSTAT

~

WATER PUMP

RESERVOIR

FROM HEATER

(/

fj

ELECTRIC

COOLING

FAN

FAN RELAY

RADIATOR CAP

FILLER CAP BODY

DRAIN PLUG

E-2

97UOEX-502

SPECIFICATIONS

nts

Item

Cool1ng

Coolant capac1ty

/Vater

Tl1ermostat

Rad1ator

'ller

Cool1ng fan

method

pump

cap

W1th

heater

Type

Pulley

rat1o

Type

Open1ng

Full

[

Type

Relief pressure

Type

Number

Outer

Type

temperature

ope'l

open

of blades

d1ameter

liters (US qt.

(speed)

temperature

l1ft

Engine

kPa

mode~

Imp

°C

oc

mm

2

(kg/cm

•

mm

qt)

(°F) i

(oF) i

(1n)

ps1)

(1n)

Turbo

Water-cooled,

8.7 (9.2 7.7)

forced

Ce'ltnfugal

Non-Turbo

c1rculat:o'l

7.3

(7

7 c

~

1 1.22

Wax. bottom

I

80.5-83.5

95

I

8-10

Corrugated

74-103

(0.75-1.05.

Thermo-modulated

bypass

(177

-182)

(203)

(0.31-0.39)

f1n

11-15)

10

390

(15 35)

Electncal

-

mm

w

(1n)

255

90

5

(10.04)

:

(;CtriC

COOling

i Capac1ty

Number

Outer d1ameter

of blades

INTERCHANGEABILITY

~.

;co

following chart shows the major components interchangeability between the previous model

· ?39 model.

· ·_?•changeable

· ":Jstat

:

c::or

:

:::Jr

cap

'lQ fan

Parts

X

Not

Interchangeable

Interchangeability

X

c

X

Shape

Rubber

Shape

Blade

changed

gasket used

changed

number

Increased

Remark

c:·

)02

··::

::ooling fan

0

E-3

COOLING FAN

FAN DRIVE

The thermomodulate cooling fan used

in

the 1989 RX-7 has 10 blades and a blades and double bearing of the previous model, which result ing fan drive characteristics cause the water

pump

is

the same as the previous model but the fan-dr1ve

shaft bearing mounting diameter

is

larger.

E-4

s1ngle

in

improved cooling performance. The cool-

bear1ng 1nstead of 8

1s

not Interchangeable be-

•_/

WATER PUMP

SHAFT BEARING

PULLEY BOSS

\

BEARING HOUSING

@~

EXTRA RIBS

I

WATER

WATER PUMP BODY

PUMP GASKET

"'

\ -

-

97UOEX

:.

:=::er

pump shape

•.

·-g

housing : Extra ribs are used for improved rigidity.

·-.·

:Jump gasket : The shape

...

:::earing and pulley boss : The shaft bearing shaft outer diameter and pulley boss inner diameter are

·.

· :Jump body : The body shape

·-=-·~al

parts are interchangeable with the previous

is

changed to incorporate the new cooling fan and thermostat.

is

changed because of the bearing housing change .

increased to incorporate the new

is

changed to incorporate the new thermostat and cover. The water thermoswitch for automatic transmission and Turbo is

in

the

pump

body.

RX-7.

cooling fan.

models

E-5

505

THERMOSTAT

RUBBER GASKET

JIGGLE

A new thermostat with a rubber gasket same

as

the prev1ous model. The outer diameter

use

w1th

the rubber gasket.

Assemble the rubber gasket with the notch positioned around the Jiggle valve

is

used for improved serviceability. The open1ng temperature

VALVE

is

decreased from 54mm (2.13

1n)

to 52mm (2.05

is

in)

the

for

E-6

'

RADIATOR

..

RADIATOR CAP

FILLER CAP BODY

RADIATOR

-

.:::::of

the radiator core

J 98

in))

because of the cooling fan improvements. The radiator has a filler cap body for improved

· :::J

l1ty.

By moving the radiator cap from the middle of the radiator to the filler

, - bleeder plug and the filler cap at the thermostat cover

':'j

is

decreased (width

561

.Smm (22.12

E-7

in)

x height 415mm (16.34

is

eliminated. Coolant replacement

in)

cap

body, the need

97UOEX-507

x thickness

is

done

F1

•

FUEL

AND

EMISSION

CONTROL SYSTEMS

{NON-

OUTLINE

OUTLINE OF CONSTRUCTION EMISSION CONTROL SCHEMATIC

DIAGRAM

SYSTEM DIAGRAM

VACUUM WIRING DIAGRAM SPECIFICATIONS

VARIABLE DYNAMIC EFFECT INTAKE

(VDI) SYSTEM

FUEL SYSTEM

MIXING PLATE SERVICE POINT

CONTROL SYSTEM

AIRFLOW METER

THROTTLE-IDLE-POSITION AUTO-

ADJUSTING SYSTEM

LEAN BEST-IDLE CONTROL SYSTEM SPARK ADVANCE FEEDBACK SYSTEM SERVICE POINT

SELF-DIAGNOSIS FUNCTION

DESCRIPTION

MALFUNCTION

SWITCH MONITOR FUNCTION

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

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

HOSE ROUTING DIAGRAM

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

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

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

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

TURBO)

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

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

.......

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

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

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

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

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

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

.......

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

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

CODE

NUMBER

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

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

....

'J7UOII

F1F1-

F1F1F1F1-10 F1-11

F1-12 F1-13 F1-13

F1-14 F1-15 F1-15

F1-16

F1-17

F1-18 F1-19 F1-20

F1-20

F1-21

F1-25

c,[11

2 2

4 8

9

•

OUTLINE

OUTLINE OF CONSTRUCTION Development

The

development concepts for the new model are

1.

Increased horsepower

2.

Improved performance

3.

Improved fuel economy

4.

Improved serviceability

Concepts

as

follows

Areas of

Improved parts

Airflow

M1x1ng

Vanable

Throttle-1dle-pos1t1on auto-adJUSting system

Lean best (Vanable res1stor el1m1nated)

Spark '.

Related X

Improvement

Development concepts

meter

(L1near type)

plate

(Pnmary

dynam1c effect 1ntake (VOl) system

1dle

advance

fuel

1nJ8ct1on)

control system

feedback

Non

system

horsepower

X

Improved

performance

X

Improved

fuel

I

economy

X

X X

X

Improved

serviceability

X

97UOF1 502

System Construction

ENGINE CONTROL UNIT

I

THROTTLE-IDLE-POSITION

AUTO-ADJUSTING SYSTEM

IMPROVED SERVICEABILITY

[AIRFLOW

IMPROVED PERFORMANCE

METER]

SPARK ADVANCE

FEEDBACK SYSTEM

IMPROVED PERFORMANCE

LEAN BEST-IDLE CONTROL SYSTEM

MPROVED MPROVED SERVICEABILITY

FUEL ECONOMY

--MIXING '.CREASED HORSEPOWER '.'PROVED PERFORMANCE '.'PROVED

PLATE~~--,

FUEL ECONOMY

'

L____

97UOF1 503

F1-3

EMISSION CONTROL SCHEMA TIC DIAGRAM Input

Devices

OXYGEN SENSOR

ENGINE

CONTROL UNIT

(INCLUDES

ATMOSPHERIC PRESSURE SENSOR) i '

WATER

THERMOSENSOR /

PRESSURE SENSOR

/'J

,../'

/

r,/'•'

THROTTLE SENSOR

(FULL RANGE)

THROTTLE SENSOR (NARROW

~'

l·

.•

··y"'l

,

(o

;:((/

1

J

..

t',l

-\~v

'\\,

<~))

~

,-,

/'

).\

.-

/,

;J

. I

I

<""'

.,)

RANGE)

HEAT HAZARD SENSOR

INHIBITOR SWITCH

(A/T)

IGNITION SWITCH

NEUTRAL SWITCH (M/T)

,,~L--,--------BACK-U

LIGHT

(MIT)

5TH

P

AND

SWITCH

AIRFLOW METER

(INCLUDES INTAKE

AIR

THERMOSENSOR) /

CRANK ANGLE SENSOR

F1-4

MILEAGE SENSOR

CIRCUIT OPENING

OIL PRESSURE SWITCH

MAIN RELAY

RELAY

(A/T)

97UOF1-504

Output Devices

SOLENOID VALVE

(BYPASS AIR CONTROL)

FUEL PUMP RESISTOR

RELAY

INJECTOR

(SECONDARY)

/

DOUBLE THROTTLE DIAPHRAGM

DASH POT

.

~~

CHECK CONNECTOR

(GREEN: 3-PIN)

'.

I-::

VALVE

AIR CONTROL

INJECTOR (PRIMARY)

SOLENOID

(ACCELERATED

WARM-UP SYSTEM)

PURGE CONTROL

VALVE

··~

/?

(\.

::;c-lEF

c _ENCER

::::

· =

:::n

AIR

CHAMBER

A/C

:..BLE

DYNAMIC EFFECT INTAKE

INDUCTION

RELAY

AIR PUMP

(PRESSURE REGULATOR

SOLENOID

CONTROL)

'A

VALVE

IGNITION COIL WITH IGNITER

(LEADING)

TEST CONNECTOR

(GREEN 1-PIN)

'~~~IGNITION

COIL

L I WITH IGNITER

SOLENOID

(RELIEF)

SOLENOID

(SWITCH)

CHECK CONNECTOR

(SELF-DIAGNOSIS

CHECKER, GREEN: 6-PIN)

VALVE

(TRAILING)

F1-5

Fuel Devices

TO FUEL FIL TEA FROM PRESSURE REGULATOR TO CHARCOAL CANISTER

-

------

FUEL TANK

CHARCOAL----I-CANISTER

CHECK CONNECTOR

(FUEL PUMP,

YELLOW: 2-PIN) ',...

PULSATION DAMPER

(WITH DELIVERY PIPE)

FUEL

PUMP~

RESISTOR

RELAY .

~

...

~-

nc-n

•

:-------'-·

-

Q(_

PRESSURE

(WITH DELIVERY PIPE)

"---

REGULATOR

INJECTORS

~

~~F-f-1'"-------1

G

F1-6

'.I

97UOF' 506

Exhaust Devices

SPLIT

AIR

MAIN CONVERTER

FRONT CONVERTER

PIPE

INSULATOR COVERS

97UOF1 507

F1-7

CJ)

-<

CJ)

-i

m

3:

c

)> G)

::D

I

II

)>

3:

CJ)

T1

II

I

AIRFLOW METER

(INCLUDE INTAKE

THERMOSENSORI

AIR

.

i

if

~==~

~¢-'--~>..I/

PURGE CONTROL VALVE

INTAKE AIR

THERMOSENSOR

I I

I~

I

!

SOLENiiD (PRESSURE REGULATOR

I

~C~ON~T~R~O~L~)

VALVE 1

~~~~~---_j

1

FUEL PUMP

RESISTOR RELAY

EC AT CONTROL p

UNIT

<D

---J

Ell

§ REAR DEFROSTER SWITCH

01

SWITCHES HEADLIGHT SWITCH SWITCH IAiTI

FOG LIGHT SWITCH '¥""

~~-------------B-L_o_w_E_R--SW--IT_c_H

l

_____________________

INHIBITOR •

Q}(

'V I IV

,(\

M_A_,I_N~~C-~0_-N~V-~E--R~T-E-R-----------------------------------------------------------------F~U~E~l~~F~IL~T~E~R----------------------------__j

FRONT CONVERTER .

I CHECK VALVE TANK

I(\

- - -l==r-FUEL PUMP

OXYGEN

SENSOR

-~~~--.

'\I

¥-'

FUEL

l

;-=fT!-;?

r =

CHECK-AND-CUT VALVE

,...

VACUUM HOSE ROUTING DIAGRAM

PRESSURE REGULATOR

---------,

ACTUATOR (VOl)

(

INTAKE

---"'RESSURE REGULATOR CONTROL

MAN IF OLD--tt--11--+--4+--+-

• ARIABLE JYNAMIC

;:>QAT

"

EFFECT INTAKE

INDUCTION

\

~

SOLENOID VALVE (VDI: WHITE)

SOLENOID VALVE

ORANGE)

(PAC:

SOLENOID

I (RELIEF BLUE)

SOLENOID VALVE (SWITCH GRAY)

VALVE

FUEL FILTER

-

--;:

BODY (A/T)

F1-9

97UOF 1

007

1N

PST

1(]

Q_T

VALV[

INJECTOR

(FRONT

PRII•t4.RYl

~

INJECTOR (FRONT

SECONOAIIYl

0

!Gl

-El

INJECT()!;>

II?EAII Pllltr.IAIIYJ

I

E

A 6

IYI

Q£0<:

(YELLOW:

iNJECTOR

I

REAR

SECONOMlYJ

CCHECT~

2--PINl

.

~

AIR

TI-EFMJ-

SENSrn

Lfi

~

Tf£Ml-

SENSOO

J]

POSITION

""'

SENS<f>

E}J

SENSOR

AIRFLOW

I£TER

c=-

~t---{a]~

~(GY)

SD....e«liD "'ALliE

(SWITOil

~-Ill

SCLENOIO

VALVE

fF£LIEF)

H(G)

~"'

CCHECTOO

GHEEN J P1N1

'-----f-++~---1SQEjjjl_NOIO

'-----+++~-liiil

~(0)

18YPA.SS AIH

POflT

AIR

SCLENOIO

16-PORT

SOlEI'<liO

•PRESSURE

VALVE

CON'HOL

'"'

SOLENOID

68

VALVE

INDUCTION

VALVE

REGULATOH

I

CONTROL!

sa...EN'liO

VALVE

I

>-I-

I

FUEL

PL'o!P

liES I STOll

RELAY

161

jh~

FAN

SWITO+

0 0

:~~:

:~~

:§§:

,,_,_,

•...:...:,

~

~-~

~

(R'

EC-A.T

TH~BmE

SENSOR

1NARROW

1-1ANGE•

~~J

TI-A:ITill

~~ANGE

~------+-~ra~~~

'------------jc---4JE

(ACCELERATED

~~w

SOLENJID

(VAAIABL.E

f--CF=

f--Dn

B

STEP

1MfTEHtNG

EFFECT

;--\

MOTORS

VALVE

DYNAMIC

INTAKE)

OIL

WARM-UP

PUMP

1MOP

SYSlEMt

1

m~--------------------------------------------------------------------------------------------------------------------------------------------------------------~

~

(J

•

SPECIFICATIONS

Item

Idle speed (Test connector (green

A1r

cleaner Element type

Type

Throttle body

Dash pot Fuel

tank

Fuel

f1lter

Pressure regulator

Fuel

pump

11ector

Secondary) "leal

\,ja1n

(Pnmary and

hazard sensor

silencer

;;n1t1on

t1m1ng

(Test connector (green 1-pln) grounded)

J stnbut1on

advance

Spark

: e up system

= . :lass

a1r

control system

· afterburn valve Operat1on

Throat d1ameter i Pnmary mm

Water thermovalve

Adjustment speed rpm Capacity

Low pressure High pressure _ Type Regulated pressure Type Outlet pressure kPa (kg/cm Dr1ve InJeCtion Operation temperature Capac1ty cc (cu

Type Type A/C "D"

range

Model

1-p1n)

grounded) rpm

Secondary Operat1on temp.

l1ters

(US gal. Imp gal)

kPa (kg/cm

volume cc (cu ln)/15 sec. i

t1me

mm

oc

2

oc

(In)

(1n)

(oF)

,

ps1)

,

ps1)

(°F) i

in)

rpm rpm

sec.

138

EGI

750 ± 25 (for AlT

Long

Honzontal - draft

45 (1.772)

(1

45

M/T.

67-77

A/T

60-70

Nylon

235-275

441-588

MIT 10.300 (628.3) x

Lead1ng Tra1l1ng

(153-171)

(140-158)

2,700-3.100 70 (18.5, 15.4) 6 (164 and 45 mesh)

F1lter D1aphragm

(2.4-2.8,

Impeller

(4.5-6

Voltage dnve

111-118

105-115

20° ± 2°

Eng1ne Eng1ne

MIT. 875 A/T 800

750

(at warm

L1near

MIT

AlT. 0

engine

..

N Range)

l1fe

wet

(2

slaj:l~---

772) X 2

paper

34.1-39

(1ntank)

0,

64.0-85

(6.8-7.2)

(221-239)

2,

A/T

5°

± 1 o ATDC

control control

1.60-2.20

un1t un1t

eng1ne)

soleno1d

52-0.92

3 barrel)

or more

8)

3)

12.000 (732) x 2

ATDC

97UOF1 511

F1-11

VARIABLE DYNAMIC EFFECT INTAKE (VOl) SYSTEM

~.-

s systern cors.sts of the VOl valve, solenoid valve, and actuator. The

.

~

::::

Ooerat

-OeENGINE

~=EED

on

of

th1s

system

OPEN V %

~

,

·.

is

as shown below.

~

0

HIGH ENGINE SPEED J

(VDI VALVE: OPEN CONDITION)

VOl

valve

is

built into the exten mani-

VDI VALVE

= INTAKE AIR

·~

PRESSURE WAVE

•

co...,

I

..

.....

• • • PRESSURE WAVE

ABOVE

5,200

::

:.·,.;

ANGLE SENSOR

:

-::~;Jine

:

·-::::s~re

~~-::speed,

.

::: . ::

·· . :: :·-::

,·

;:::s

operation, when intake air flows to a port closed by the rotor a pressure wave

wave then goes toward the open intake port, compressing the intake air along the way.

the VOl valve

. e opens and the pressure wave quickly pressurizes the intake air through the shortened path.

'::xced

c-essunzation

1nto

remaining

VDI VALVE OPENING AREA

LARGE

rpm

_______

INTAKE AIR

AMOUNT

is

closed, causing the pressure wave path to be long. At high engine speed,

the combustion chamber

is

induced at the time of the opening of the intake port, when the high-pressure

in

the working chamber generates strong pressure waves that rush into the intake

at

all

engine speeds.

(m1/h)

SMALL~--------~------~

0

ENGINE SPEED

JI

5,200 8,000

(rpm)

97UOF1

is

created.

509

At

F1-12

FUEL SYSTEM

MIXING PLATE

INJECTOR

SECONDARY

INJECTOR

AIR SOCKET

BLEED

AIR

BLEED

SOCKET

· 19 plate

·

:J.ke

air port.

97UOF2-508

is

installed at the tip of primary Injector to direct the primary fuel inJection fuel directly into

F1-13

SERVICE POINT

PULSATION

®----INSULATOR

NEW 0-RING

~======s~~----AIR

INTERMEDIATE HOUSING

'---"

~MIXING

BLEED SOCKET

PLATE

~·

MIXING PLATE

The pr1mary inJector

1 Install the parts

2 Use a new 3

A1

gn 1re 1abs

in

Insulator and 0-rings.

of

NOTCH

is

installed noting the following:

the order shown

the mixing plate with the notches

in

the figure.

F1-14

TAB

in

the intermediate housing.

'UDF2 509

~··

CONTROL SYSTEM

AIRFLOW METER

SLIDING CORE

INTAKE

THERMOSENSOR

AIR

~

CONNECTOR

I

AIR BYPASS

PASSAGE

INTAKE AIR THERMOSENSOR

t

AIRFLOW METER

t

~-.

-~

eter

-

:

Jn.

97UOF2-513

is

changed from a vane type to a linear type. The sliding core moves parallel to the airflow

there

is

little air damping and low air resistance

as

a result of the streamlined shape.

F1-15

THROTTLE-IDLE-POSITION AUTO-ADJUSTING SYSTEM

· · · SENSOR OPEN

~·

NARROW

FULL

RANGE

NARROW

FULL RANGE

RANGE

SENSOR CLOSED

(0%)

150/o

SENSOR OPEN (100%)

I

: APPROX.

I

SENSOR CLOSED

AUTO-ADJUSTING

___..~

300/o

SENSOR CLOSED

SENSOR OPEN

AREA

SENSOR OPEN (100%)

50/o

.:.

··e:.ly

developed

-· ~ system automatically

.:. · =:

e

tre

narrow range throttle sensor

:

=:::on

·

.:: S-::

~:::erat1on

c.·

,

auto-adJUSting system, the eng1ne control unit will compensate for actual output values of

···

e output

respectively for fail-safe operation

:;;

~e

:::

25° o respect1vely for fall-safe operation.

is

for the full range sensor

control

throttle-idle-position auto-adjusting system

less than

un1t

15%

compensates

I~

:

THROTTLE AUTO-ADJUSTING AREA

IDLE

POSITION

compensates

or

more

within the range from

250/o

~'

for certain variations

is

set to

output

than

25%

at idle, the engine control

is

the same. The sensor

is

in

a signal of

is

set to reg1ster a

5%-25%.

850/o

I

FULL

THROTTLE

97UOF2 514

incorporated

the output signal of the throttle sensors .

20%

w1thin

of full-open. With the throttle idle-

the engine control unit.

15%-25%.

un1t

If

over or

fixes the value

15°/o

s1gnal

under

the s1gnal1s fixed at

at

1dle,

15%

and the

and

5%

\.!.

F1-16

LEAN BEST-IDLE CONTROL SYSTEM

WATER THERMO

INHIBITOR

SWITCH

(A/T )

SENSOR

EC-AT

CONTROL UNIT

~

rL

NEUTRAL SWITCH (M/T

CLUTCH

PiS PRESSURE SWITC

:::EAR DEFROSTER SWITCH

SWITCH (M/T

A/C SWITCH

BLOWER SWITCH

HEADLIGHT SWITCH

FOG LIGHT SWITCH

(ONLY

CANADA

)

H

)

I

~

---c:

=

~~LE

SENSOR (NARROW

RANGE)

ENGINE CONTROL UNIT

DETECTION OF ENGINE

WARM CONDITION

DETECTION OF ENGINE

NO-LOAD CONDITION

(ONLY FOG LIGHT SWITCH:

DETECTION OF

ENGINE LOAD CONDITION)

--

DETECTION OF ENGINE

IDLE CONDITION

t

~

DETERMINA-

TION

LEAN BEST-

~

f-

IDLE

CONDITION

OF

I

FUEL INJEC-

TOR

BATTER

y

re

--o ••

• ANGLE SENSOR (NE

. _

-::j

fuel consumption and reduced exhaust emissions

·.V1th

this system, the engine control unit sets fuel injection

- .

:;1ng

lean misfire and rough idle.

SIGNAL)

DETERMINATION OF LEAN

BEST-IDLE AMOUNT

at

idle, the lean best-idle control system

F1-17

K

97UOF2-515

at

idle to the leanest amount possible

is

SPARK ADVANCE FEEDBACK SYSTEM (ENGINE AT IDLE)

SPARK

ADVANCE

FEEDBACK

AMOUNT

DETECTION OF

ENGINE IDLE

THROTTLE SENSOR

(NARROW RANGE)

CONDITION

1

I

-50-------------~------~----

oo

- - - - - - - - -,..---'--'

I

1

I

CRANK SENSOR (NE SIGNAL)

ANGLE

DETERMINATION

OF

ADVANCE

SPARK

FEEDBACK

AMOUNT

I

IGNITION COIL

'

RS

rpm

DECREASED

TS: RS:

TS

TARGET ENGINE SPEED

REAL ENGINE SPEED

RS

INCREASED

rpm

To

prevent rough idle caused by incorrect idle speeds, the spark advance feedback system controls the spark advance. The engine tion

timmg to

obta1n

the preprogrammed target speed

control unit judges the engine speed (real speed:

(TS).

RS)

and then adjusts the igni-

F1-18

LJ7UOF2

516

SERVICE POINT

THROTTLE SENSOR ADJUSTMENT

IDLE MIXTURE ADJUSTMENT

/

.....

__________________________

::::' adJUStment: Not usually necessary unless throttle sensor unit

auto-adjusting system automatically compensates.

~

JJustment

Not

necessary because of lean best-idle control system. (Varrable

eliminated.)

F1-19

is

replaced.

_

Th

rottle-rdle-pos ~ :::

res

~-

~

=-

SELF-DIAGNOSIS FUNCTION

DESCRIPTION

When troubles are suspected

Failures of individual input and output devices are indicated and retrieved from the control unit as malfunc-

tion

code

numbers.

Note The control unit constantly checks for malfunction of the input devices. tion of output devices only during a 3-second period after the ignition switch has been turned

ON

while the test connector

in

the

ma1n

is

1nput

devices or output devices, check for the cause with the SST.

grounded.

It checks for malfunc-

IGNITION COIL

WITH

IGNITER---

(TRAILING SIDE)

~JE~~~~::LEJ~~-~

CRANK ANGLE '

SENSOR (G-SIGNAL)

~

_

---.

---,

FAIL-SAFE FUNCTION

_L

WATER

THERMOSENSOR

AIRFLOW~

METER

INTAKEAIR

THERMOSENSOR (AFM)

INTAKE AIR THERMOSENSOR / (ENGINE)

~~

~

\)

~

--

/

DETECTION

OF

MALFUNCTION

WARNING

FUNCTION

&

MALFUNCTION CODE

FUNCTION

-

-=-

~

Wu~~~~:GE;-1

~

THROTTLE~

SENSOR Q

(NARROW-RANGE) .

PRESSURE--SENSOR

OXYGEN

METERING PUMP POSITION c o

SENSOR o

SENSOR-\

OIL--~~1._

-~---·-

-

·-

1

- o

.__/

-~

-----'

ATMOSPHERIC

PRESSURE SENSOR

TEST CONNECTOR (GREEN: 1-PIN)

F1-20

97UOF2-024

MALFUNCTION CODE NUMBER SST

Jg H018

3elf-Dragnosis

Checker

9A1

SHF

UIAGIIlSrS

97UOF1-512

CHfClER

Inspection Procedure

1.

Warm

stop

2.

Connect the SST to the check connector (Green: 6-pin) and

the negative battery Set the select switch to position

3.

Connect a jumper 1-pin)

up

the

engine

it.

and a body

to normal

operating

terminal.

A.

wire between the test

ground.

temperature

connector

(Green:

and

,..

• • I

I~

:: :

J.AGNOSIS

~-,

11\T/"

• G

·1cr1:o:

G/

1_1.11_1!

0

~-,'-[-\-'---\-'-

SElF

--~

DIAGNOSIS

~

CHECKER

MALFUNCTION

V CODE NUMBER

::111-:1/

--

CHECKER

97UOF1

514

510

4.

Turn the ignition switch ON.

5.

Check

sounds

6.

If

7.

If

than 20 sec., control unit And voltage. Replace

88 88

that

88

flashes on the digital display

and

the buzzer

for 3 sec. after turning the ignition switch ON.

does

flashes

check

not flash,

and

check

(1

F)

the

check

the buzzer

the

check

sounds

continuously for

for a short circuit between the

terminal and

engine

the

check

control unit

engine

control unit

connector (Green: 6-pin).

(3X)

connector

and (3Z) terminal

if

necessary

perform Step 4 again.

8.

Check

9.

Start the

for any malfunction

engine

and

check

code

numbers.

for further malfunction

numbers.

10.

If

a malfunction

cause of the

code

problem.

number

is

indicated,

check

Note Cancel the malfunction code numbers by performing the after-repair procedure

following repairs.

F1-21

wiring.

more

engine

and

code

for the

Principle of code cycle

Malfunction codes are determined

1.

Malfunction code cycle break

The time between malfunction

as

below by use of the MIL and Self-Diagnosis Checker

code

cycles

is

4.0 sec. (the time the MIL and checker buzzer are off).

97UOF1-515

1 CYCLE

ON

OFF

MALFUNCTION CODE

CYCLE

4.0 SEC.

2. Second digit of malfunction code (ones position)

The digit are on

in

the ones position of the malfunction code represents the number of times the MIL and buzzer

0.4 sec. during one cycle.

4

0.4

~---~

MALFUNCTION

CYCLE BREAK

4.0 SEC.

1 CYCLE CODE

ON

JU\fl"

OFF

-1--!-

0.4

SEC. SEC.

BREAK

ffilll

-----

9MUOF 1

543

CODE No.: 03

89lll!4X

565

3. First digit of malfunction code (tens position)

The digit are on 1

The MIL and buzzer are off for 1.6 sec. between the long and short pulses.

in

the tens position of the malfunction code represents the number of times the MIL and buzzer

.2

sec. during one cycle.

1 CYCLE

;-----~----.,

FIRST DIGIT SECOND

1.6 4.0 SEC.

SEC.

MALFUNCTION

CODE

CYCLE BREAK

DIGIT

F1--22

CODE

No.

89U04X

22

566

Code number

Caution a)

If there

is

more than one failure present, the lowest number malfunction code

first, the subsequent malfunction codes appear

b)

After repairing ble,

at least 5 seconds to erase the malfunction code memory.

In

put devices

all

failures, turn the ignition switch OFF, disconnect the negative battery ca-

in

order.

is

displayed

Code

No.

l'

:2

devices

Input

lgn1110n with

(Trail1ng Crank angle sensor Broken

(Ne

coil

1gn1ter

s1de)

s1gnal)

Malfunction plug. broken ClfCUit

c1rcuit

Malfunction

of spark

w1re.

short

Fail-safe function

T

rail1ng-s1de

pulse cut

Fuel

InJeCtion

1 lion cut

1gn1t1on

and

1gn1-

Output signal pattern

(Self-Diagnosis Checker or MIL)

Jl

I

angle sensor Broken

Crank (G

s1gnal)

ClfCUit

short Fuel InJection and

w1re.

t1on

cut

1gn1

I

Bas1c

A1rflow

meter (AFM) Broken

Water thermosensor

a1r

Intake

'll

t

thermosensor (AFM)

;ntake

a1r

sensor

Throttle 1Full

Pressure sensor Broken

:

·1take

:Yessure)

-'ltmosphenc pres-

~u

Built

J x ygen sensor

:-

eedback system

-

· •ottle sensor .arrow range)

'.'eter1ng

· -s,t,on sensor

·

.'

.c:enng

'.'8P)

·.·-:c-:er '.':JP)

thermo- Broken

(Eng1ne)

sensor

range)

man1fold

re

sensor

(A

ECU)

oil

TP)

pump

1n

:1g

ClfCUII

Broken ClfCUI!

Broken ClfCUit

ClfCUit

Broken ClfCUit

ClfCUII

Malfunct1on1ng ECU

Oxygen below 0 55V system

operat1on

Oxygen ma1ns 0 SSV system

operat1on

Broken circuit

Broken CirCUit

Malfunct1onmg tors.

broken

or

malfunct10n1ng

Malfunct

on1ng

broken

111re.

1

t:on.ng

ECU.

short

w1re.

short

w1re.

short

w1re.

short

w1re.

sensor

output

rema1ns

80

sec

aher

beg1n1ng

sensor

output

· 0

sec

after

begm1ng

short Throttle valve open1ng

w1re.

short

w1re.

MOP.

steo

w1re.

short

ECU

MOP.

step

srort c rcu

t.

rralfunc-

alter1ator

or

' 1

FiB

re

FIB

mo

c1rcu1t

,"lotors battery

fuel InJection amount and t1m1ng

Coolant temp. input

f1xed

Intake f1xed

Intake

f1xed

Throttle valve open1ng angle input signal at

20%

Intake 1nput mmHg (29.9 inHg)

Atmospheric pressure 1nput 760

mmHg

Feedback system canceled (For EGI)

angle at

full open

MOP

f1xed Bas1c and

1Qn1t1on

MOP Bas1c and

1Qn1t1on

Basic fuel amount and ignit1on t1m1ng

F1-23

f1xed

at

80°C

a1r

temp.

at

20°C

a1r

temp.

at

20°C

open

man1fold

s1gnal

1nput

smallest

fuel

1nJect1on

f1xed

smallest

fuel

1nj8ct1on

InJeCtion

fixed

1gn1!10n

(176°F)

(68°F)

pressure

f1xed

(29.9

s1gnal

t1m1ng

tmng

1nput

at

amount

f1xed

amoun:

f1xed

760

at

1nHg)

f1xed

open

..

llll

n

fU

Jll

J1l

run

JUI

rull

JUII[

i

m

Jrull

ImJII

97UOFI-516

Output devices

Code

No.

25

! Soleno1d valve (Pressure regulator control (PRC))

I

26

Step motor (Metenng oil pump)

1

I I

I

f Split air solenoid valve

30

I

31

Soleno1d valve

j Soleno1d valve

32

Output devices

(Rel1et)

(Sw1tch)

I

Port

a1r

33

34

Soleno1d valve

soleno1d valve

(Bypass

a1r

control)

I

-

~---

1

Soleno1d valve

38

40

Soleno1d valve (6-port

41

Soleno1d valve (Vanable dynam1c ettect 1ntake (VOl))

51

I Fuel

pump

71

Injector

73

InJector (Rear secondary)

(Accelerated warm-up system (AWS))

1nduct1on)

res1stor

(Front secondary)

relay

97UOF1

'-I

517

F1-24

SWITCH MONITOR FUNCTION

Preparation

SST

i 49 H018

•

Self-D1agnos1s

· Checker

Individual switches can be monitored by the SST.

19.

9A1

Note The test connector must

NEUTRAL SWITCH CLUTCH SWITCH

BACK-UP LIGHT 5TH SWITCH (M/T)

HEADLIGHT

BLOWER REAR DEFROSTER

SWITCH

FOG LIGHT INHIBITOR SWITCH

SWITCH---------+---------'

(IF EQUIPPED)

r-.

~

,-,~~-:J

I I I I

1

S!

t:

~IAGJlO~IS

~~~E~K!R

97UOF2 064

BATTERY

(M/T)-------1------------,

(M/T)--------+--------,

AND--------~------~~~~

SWITCH-----------11----------'

________

SWITCH--------:::::;~~=====~----t--.....,.

(A/T)'----------1

be

grounded and the ignition switch

ENGINE CONTROL UNIT

-+------~

ON

(engine stopped).

~~CTOR

IQIIUII:ftll

:1

517

97UOF2066

,..

Inspection Procedure

1.

Warm up the engine to normal operating temperature:::· stop

it.

2.

Connect the SST the negative battery terminal.

3.

Connect a jumper wire between the test connector (G';:c- 1-pin) and a ground.

4.

Turn the 1gnition switch ON, then check that the me· lamp illuminates cording to the function table.

Caution a)

When any one of the switches are activated, the monitor

b)

Do

lamp will be on.

not start the engine.

(GREEN: 1-PIN)

to

the check connector (Green:

when each switch

is

made to funct,c·-

6-pir'

::·

97UOF1 519

F1-25

Function Table

Switch

Neutral sw1tch (MIT)

Back-up light 5th

SWitch

Clutch

lnh1b1tor

Headl1ght

Blower sw1tch

and

(MIT)

switch (MIT)

sw1tch (A/T)

sw1tch

Self-Diagnosis Checker (Monitor lamp)

Lamp-ON Lamp-OFF

Sh1ft

1.2.3or4

Sh1ft 5th

1

Pedal

Except range

Sw1tch

Sw1tch (At OK)

gear

any

transmiSSIOn to

transmiSSIOn

depressed

N and P

ON

fan

speed

Neutral

Pedal released

N

Sw1tch

and

pos1t1on

P range

OFF

Possible cause

(When incorrect)

• Neutral sw1tch malfunction

•

Open

wcu1t

between neutral

ECU

1R

term1nal. neutral

ground

•

Back-up Open

• 5th sw1tch and

• Clutch sw1tch malfunction

•

Open ECU ground.

1 •

lnh1b1tor

! • EC-AT control

Open

• and

Headlight

• Open

•

ECU tery

•

Blower Heater relay malfunction

• Heater control

• Open

• and

l1ght

and

5th sw1tch malfunction

circuit between

and

ECU 1 T term1nal.

ground

c1rcu1t

between clutch sw1tch

10

term1nal. clutch sw1tch

clutch switch

switch malfunct1on

ur11t

malfunct1on

C1rcu1t

between EC-A T control

ECU.

sw1tch malfunction

c1rcu1t

betweer1 headl1ght

3L

terminal, headl1ght sw1tch

l1ne

sw1tch malfunct1on

un1t

malfunction

c1rcu1t

ECU

between heater control

30

term1nal

sw1tch

Back-up

and

ACC

sw1tch

and

l1ght

overdnve

and

circuit

sw1tch

and

un1t

and

un1t

and

bat

Rear defroster sw1tch

Fog

l1ght

sw1tch

(If equ1pped)

Sw1tch

1

Sw1tch (Only light)

ON

equip

fog

i Sw1tch OFF

Sw1tch

OFF

• Rear

i •

1

• Fog

•

defroster

Open

c1rcu1t

and

ECU 3P term1nal. rear defroster sw1tch

and

ground

l1ght

sw1tch malfunction

Open

c1rcuit between fog

ECU 1 S term1nal. fog

battery

sw1tch

malfunction

between rear defroster sw1tch

l1ght

switch

and

l1ght

switch

and

97U0r

I 5?0

F1-26

FUEL AND EMISSION

CONTROL SYSTEMS

(TURBO)

F2

20

OUTLINE

OUTLINE OF CONSTRUCTION EMISSION

DIAGRAM SYSTEM DIAGRAM VACUUM WIRING DIAGRAM SPECIFICATIONS

FUEL SYSTEM

MIXING PLATE SERVICE POINT

TURBOCHARGER CONTROL SYSTEM

SYSTEM CONSTRUCTION COMPLETELY-IN

TWIN SCROLL TURBO TURBO

SYSTEM

CONTROL SYSTEM

AIRFLOW METER THROTTLE-IDLE-POSITION AUTO-

ADJUSTING SYSTEM LEAN BEST-IDLE SPARK SERVICE POINT

SELF-DIAGNOSIS FUNCTION

DESCRIPTION MALFUNCTION SWITCH MONITOR FUNCTION

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

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

CONTROL

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

HOSE ROUTING DIAGRAM

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

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

BOOST PRESSURE

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

ADVANCE

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

SCHEMATIC

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

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

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

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

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

DEPENDENT

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

CONTROL

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

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

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

CONTROL

FEEDBACK

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

CODE

SYSTEM

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

NUMBER

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

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

.......

....

F2F2-

F2F2F2F2-10 F2-11 F2-12 F2-12 F2-13 F2-14 F2-14

F2-15 F2-16

F2-17 F2-17

F2-18 F2-19 F2-20 F2-21 F2-22 F2-22 F2-23 F2-27

97UOF 2 501

2 2

4

8

9

,.

OUTLINE

OUTLINE Development

OF

CONSTRUCTION

Concepts

The development concepts for the new model are

1.

Increased horsepower

2.

Improved performance

3.

Improved fuel economy

4.

Improved serviceability

Areas of Improvement

Improved parts

Airflow meter (L1near type)

M1x1ng

plate (Pnmary fuel InjeCtion)

Completely-independent

Duty solenoid valve (Turbo boost pressure control system)

Throttle-idle-position auto-adjuSting system

Lean best-Idle control system (Vanable resistor elim1nated)

Development concepts

twin scroll turbo

Increased

horsepower

as

X

0

()

C)

X

follows:

Improved

.

performance

I

'-

0

X

Improved

fuel

economy serviceability

X

('

J X

X X

X

.~\

,j

Improved

X

C)

0

Spark

U•

advance

X Non-related

system

X

0

X X

97UOF2 502

~·

F2-2

System construction

LEAN BEST-IDLE CONTROL SYSTEM

IMPROVED

IMPROVED SERVICEABILITY

FUEL ECONOMY

THROTTLE-IDLE-POSITIO;J AUTO-ADJUSTING SYSTEM IMPROVED SERVICEABILITY

--SPARK FEEDBACK

IMPROVED PERFORMANCE

ADVANCE

SYSTEM

DUTY SOLENOID VALVE

.-----MIXING

INCREASED HORSEPOWER IMPROVED PERFORMANCE IMPROVED

PLATE---

FUEL ECONOMY

~.

F2-3

[COMPLETELY-INDEPENDENT TWIN SCROLL TURBO

INCREASED HORSEPOWER

97UOF2 503

J

EMISSION CONTROL SCHEMATIC DIAGRAM Input

Devices

INTAKE AIR

THERMOSENSOR

(ENGINE)

NEUTRAL SWITCH

IGNITION SWITCH

ENGINE CONTROL UNIT

(INCLUDES

ATMOSPHERIC PRESSURE

SENSOR) •

~

~-

PRESSURE / SENSOR

AIRFLOW METER

(INCLUDES INTAKE

AIR THERMOSENSOR)

~\")

"··!

,VATER

THERMOSENSOR

~

·5-Jt.

'

. " ·

..

:~

··-~c-~.

•

' '

:1•

\ ..

1

CRANK ANGLE

·'

~·

·'(<)

KNOCK

~

SENSOR

CLUTCH

SWITCH

11.!

''

• P/S PRESSURE SWITCH

/

II''/

iff,~~

i'l/~

I,

-J

:I

BATTERY

SENSOR

TEST CONNECTOR (GREEN

MILEAGE SENSOR

(No.1 AND No.2)

1-PIN)

F2-4

97UOF2 504

Output Devices

INTERCOOLER

,.

- = CONTROL VALVE

INJECTOR

SOLENOID

(AIR SUPPLY VALVE

DASH

DOUBLE DIAPHRAGM

PURGE CONTROL

~CHECK

(GREEN: 3-PIN)

~~

VALVE

POT

THROr

~

CONNECTC=

VAL.

_o:

0:

'504

~.

':"SILENCER

AIR CHAMBER

AIR PUMP

/

IGNITION COIL WITH IGNITER (LEADING)

F2-5

DUTY SOLENOID VALVE

(TURBO BOOST

CONTROL)

"'SOLENOID

REGULATOR CONTROL)

SOLENOID

CHECK CONNECTOR

(SELF-DIAGNOSIS CHECKER,

VALVE

VALVE (SWITCH)

PRESS~=::

(PRESSU~O:

GREEN ~ -

Fuel Devices

•

PRESSURE REGULATOR

(WITH DELIVERY PIPE)

CHARCOAL CANISTER

F2-6

/

•

Exhaust Devices

MAIN SILENCER

:R

=>E)

1

(

SPLIT AIR PIPE

-~"BOCHARGER

MAIN CONVERTER

FRONT CONVERTER

INSULATOR COVERS

J6

l

F2

7

MILEAGE SENSOR (No 1

BACK-UP LIGHT

INTAKE AIR

-n

f'\)

I

(X)

PIS

HEAT

MOP

POSITION SENSOR

WATER

THROTTLE

PRESSURE

CRANK

CIRCUIT

REAR DEFROSTER SW

AND

PRESSUA~C

HAZARD

SENSOR

CLUTCH

NEUTRAL

FOG LIGHT SW

AND

5TH SWITCH

AIRFLOW

OXYGEN

SENSSR

THERMOSENS

SENS8R SENS

THERMOSENS8R

KNOCK

SENS

ANGLE SENSOR

OPENING

HEADLIGHT SW.

BLOWER CANADA

STAR~TER

D

No

~~

SW

METER

RELAY

SW

SW.

SiGNAL

0

~

2)

SW

R R R

~

RELIEF SILENCER

ECU

SELF-DIAGNOSIS CHECKER

TEST CONNECTOR !GREEN

1-PIN)

~

(J)

-<

(J)

-i

m

s::

c

)>

C)

::::0

)>

s::

I

[I

(

FUEL

PUMP

-n

1'\.)

I

c.o

'

-

SULlNUID (ACCELELA TED WARM-UP SYSTEM)

VALVE:

L VALVE

FUEL TANK

<

)>

0

c c

s::

:I:

0

CJ)

m

JJ

0

c

-i

z

G')

c

)>

G')

:0

)>

s::

CHECK VALVE

(ONE-WAY)

L

FIL TEA (HIGH PRESSURE)

Q) SOLENOID VALVE

CD

§

@SOLENOID

-n

rv

@

:::;

3 SOLENOID VALVE

WAS ACTUATOR

(SWITCH)-GRAY

VALVE (PRESSURE REGULATOR

(RELIEF)-BLUE

TE

VALVE

CONTROL)-ORANGE

DUTY ENOID VALVE

(TURBO BOOST PRESSURE CONTROL)

'~~--------------------------------------------------------------------~

P/5

P~ESSUAE

~

ONLY

CANADA

NEUTRAL

SACK

UP

SWITCH

LIGHT

5TH

TEST CONNECTOR A ( HEUTIIAL ON)

(GREEN:

1-PIN)

SWITCH

AND

SW I TOt

PST

(l_T

~

1;3

~~

~ ~

~2

~

3

~

~a~~~~~

l*l*l:.l~li!il

u

8

[i]

~~u

3~33

~~~

~

~ ~

~~

1~1~1~1:;:1

~

0~~

·"·

~~~~~

~

~i~~

~l:;:lii!l\il«i

:E

:a

z

G)

c

)>

G)

:a

)>

s::

~

~~~~~~

H~H~~~~~~

j;:;j.iil:;;l~~~i!i~lii!~liiil;ll

~

>

.,

~

\

"Tl N

~

0

II

~

(N_y

CANADA

I

IGl

STARTER A 8 (Y)

AI...

TEJ=HAT(J:l

MALFUNCTION

INDICATOR

LANP

G3

~l

21

... , ·-

u

~

:t

~

~~

~ffi ~ ~

~~ ~~

~U)

::!'

[/)

·~

~

INJECTOR

(FRONT

SECONDARY)

Q£0<

(YELLOW;

I

NJECTOII

<REAR

SECONDARY)

CCN£CTOO

2-piNJ

i~

~h~

g~

~~

-:'

~

........

,...,..,

"""'

''I

!II

!I

~

FUEL

PLNP

RESISTOR

RELAY

(B)

h

FAN

SWITCH

~

c

0

~

N

6

0

~

INTAKE

AIR

T>£FM>-

SENSrn

WATER

~(L

II~-

c

"b:

A

...,

POSITION

flJ

AIRFLOW

I£TER

TI-AJTTLE

5ENSCf1

(N.lR"OW

RAta

I

~

THROTTLE

'3ENSOR

1F'JLL

RANGEl

(GY)

SOLENJIO

VALVE

(SWITCH)

SOLENJIO

VALVE

(FB.IEF)

'"'

PORT

AIR

SOLENOID

VALVE

t=u

DUTY

SOLEI'fJIO

VAL

BOOST

181

ID

PFESSIJE

VALVE

RfGULAT()f'l

VALVE

,AL\/f,

liE

I'Tl.RKl

i=::LJ(OI

SOLENOID

,PRESSURE

SOLENJ

,Aifl

')LIPPL•

~

:•H

"Fd-

--

STEP

MOTORS

!METERING

OIL

PU'v1P

r'IAOP))

CCNTROLJ

C()NTHCll

s•s

TE~1

OOL---------------------------------------------------------------------------------------------------------------------------------------------------------------~

(

~o..

~

SPECIFICATIONS

Item

Idle

speed

(Test connector (green

A1r

cleaner r Element

Throttle

Dash pot

Turbocharger

Waste gate Fuel tank

Fuel filter

Pressure regulator

f'uel

irld

--1eat \1a1n

'J S:Jark

-~

body

[ Lubncation

valve

f Capactty

pump

''Jector (Pnmary

Secondary)

hazard sensor silencer

Jn1t1on

t1m1ng

(Test

connector

stnbut1on Type

advance

-:

e

up

system A/C

·1t1-afterburn valve

·:ercooler

Model

1-p1n)

grounded)

type

Type Throat d1ameter Water

thermovalve Adjustment (Throttle sensor (narrow

range)

res1stance A·-r'El)) k\!

Type Boost pressure kPa (kg/cm

Type Type

Regulated pressure Type Output pressure kPa (kg/cm Dnve InJeCtion Operat1on temperature Capac1ty

Type

Operat1on Type

volume

(green 1

t1me

--

·-

Primary

Secondary Operation temp.

l1ters

(US gal, Imp gal)

1

Low

H1gh

kPa

cc

(cu ln)/15 sec

p1n)

grounded)

rpm

mm

(1n)

mm

(1n)

oc

(oF)

2

ps1)

,

pressure

(kg/cm2 ps1)

2

ps1)

,

oc

(°F)

cc

(cu

1n)

rpm

sec

138

Turbocharged engine

750 ± 25

l1fe

Long

Honzontal draft

45

55-65

Incorporated

235--275

490-637

1

(131-149)

Water cooled

57.0 (0.58, 8.25) Engine

70 (18

Nylon 6 (164 & 45 mesh)

F1lter

D1aphragm

(2.4--2.8,

Impeller (In-tank)

(5

Voltage dnve

133

-142

105-:15

12.000 (732) X 2

Leading 5u ± 1 o ATDC Tratl1ng

Eng1ne control Eng1ne control

1.60 A1r

~~~

wet

(2

stage-3 barrel)

(1

772)

(1

772) X 2

1.8-3.8

oil

w1th

turbocharger

5,

15.4)

paper

0-6.5,

(8.1-8.7)

(221

20" ± 2°

800

-2.20

cooled

or

34.

1-39.8)

71

1-924)

-239)

ATDC

un1t un1t

more

97UOF? 519

,..

F2-11

FUEL SYSTEM

MIXING PLATE

•

PRIMARY INJECTOR

A mixing plate

the intake air

PRIMARY INJECTOR

is

installed

port.

at

l b

J~

97UOF2 508

the tip of primary injector to direct the primary fuel inject1on fuel directly into

F2-12

\..··

SERVICE POINT

NEW

PULSATION DAMPER

0-RING

2

508

into

l-1-----AIR

~----------MIXING

INTERMEDIATE HOUSING

BLEED SOCKET

PLATE

MIXING PLATE

NOTCH

·

"lary

injector

·::

the parts

-'

"'

new insulator and 0-rings.

is

installed noting the following

in

the order shown

in

the figure.

:he tabs of the mixing plate with the notches

F2-13

TAB

in

the intermediate housing.

TURBOCHARGER CONTROL SYSTEM

SYSTEM CONSTRUCTION

INTERCOOLER

SOLENOID

DUTY

•

FRONT ROTOR

AIR CLEANER

TURBOCHARGER

EXHAUST MANIFOLD

(COMPLETELY-INDEPENDENT

TWIN SCROLL TURBO)

97UOF2-51

Two newly developed systems are employed to increase engine horsepower, a newly des1gned completely-

independent twin scroll turbo and a precise turbo boost pressure control system.

F2-14

0

COMPLETEL ¥-INDEPENDENT TWIN SCROLL TURBO

PREVIOUS OPEN-TYPE

SIDE HOUSING

ROTOR HOUSING

INTERMEDIATE

HOUSING

ROTOR HOUSING

SIDE HOUSING

COMPLETELY-INDEPENDENT TYPE

SIDE HOUSING

ROTOR HOUSING

INTERMEDIATE

TURBINE

WHEEL

PRESSURE

WAVE

:.

::ompletely-independent twin scroll turbo improves horsepower by utilizing more fully the inherent

··

:.aves created by the escaping exhaust gases.

· -otors

:

:.

as

it

is

directed straight toward the turb1ne wheel. The pressure waves are thus used rather

ed

to mix with the exhaust gases of the opposite rotor.

HOUSING

ROTOR HOUSING

SIDE HOUSING

97UOF2 5 · ·

It

does this by isolating the gas flow of the front

F2-15

TURBO BOOST PRESSURE CONTROL SYSTEM

This system controls the turbocharger maximum boost pressure by the duty signal from the engine control unit.

CRANK ANGLE S

(NE SIGNAL)

THROTTLE SENS (FULL RANGE)

PRESSURE SENS

ENSOR

OR

,-----------------------------l

ENGINE CONTROL UNIT

I I

I

I I

I I I I

I I

I

I I I

I

I I

L

______

ATMOSPHERIC PRESSURE SENSOR

r-

~

BASIC

OUTPUT

DUTY SIGNAL

TARGET

BOOST PRESSURE

REAL

BOOST

PRESSURE

DETERMINATION

u-~OUTPUT

L__

DUTY SIGNAL

FEEDBACK DUTY SIGNAL

u

_

_________

OF

__j

I

I I

I I I I

I

'

I

I I

I

I I I I

I

I I

BATTERY

DUTY SOLEN OlD VALVE

TURBO BOOST MAXIMUM PRESSURE GRAPH

·1

DUTY SIGNAL

ENGINE

CONTROL UNIT

AIR

CLEANER

BOOST! PRE-

SSURE

ENGINE SPEED

Operation

1.

The duty signal from engine control unit

is

varied from

5%

to

95%

based on information from the full range throttle sensor and the crank angle sensor (Ne signal). The output duty signal gine control unit by the

2 The duty signal 3

As

the duty increases, the duty solenoid valve opening increases, and the pressure

1s

bas1c

output duty signal, and feedback duty signal.

sent to the duty solenoid valve from the engine control unit.

ator decreases.

4 The wastegate valve then closes, and the turbo boost pressure increases.

The

eng1ne

The boost pressure

control

un1t

contains the data to set the turbo boost maximum pressure as shown

is

basically determined by the throttle opening angle and engme speed.

SOLENOID

3

ACTUATOR

@)

WASTE GATE

VALVE

97UOF2 512

is

determine within the en-

a1r

actmg on the actu-

in

the graph.

F2-16

CONTROL SYSTEM

AIRFLOW METER

INTAKE

THERMOSENSOR

AIR

CONNECTOR

JR I

ATE

AIR

BYPASS

PASSAGE

INTAKE

THERMOSENSOR

AIR

~

lge

er-

ph

-

-=-:c?r

.. -there

1s

changed

from a

is little air

vane

damping

type

to a linear type. The sliding

and

low

air res1stance as a result of

F2-17

core

moves

the

parallel to the

streaml1ned

a,.

sr--::::.:c

_ -

CONTROL SYSTEM

AIRFLOW METER

CONNECTOR

INTAKE AIR

THERMOSENSOR

) 512

AIR BYPASS PASSAGE

INTAKE AIR THERMOSENSOR

~

AIRFLOW

~

POTENTIOMETER

METER

lge

en-

:tu-

ph.

· _

:.

=:es1gn.

meter

is

changed from a vane type to a

there

is

little air damping and low

l1near

type. The sliding core moves parallel

a1r

res1stance as a result of the streamlined

F2-17

to

the

sr

a,. ~ :.

:::~"'

THROTTLE-IDLE-POSITION AUTO-ADJUSTING SYSTEM

_1_ --

NARROW

RANGE

FULL RANGE

SENSOR CLOSED

NARROW

RANGE

FULL I

RANGEr-;---~

I

5%

,>------L.,--

SENSOR

(0%)

15125%

I....,._

..,...

%1

I

1

OPEN

20%

_____

_

15%

I

~'----~:

--~------------------------~~----~

:

I

25%

---

- - -

--

(100%)

--------AUTO-ADJUSTING

::,/APPROX.

--SENSOR

---SENSOR

'SENSOR

30%

OPEN

CLOSED

AREA

85%

/1

1

SENSOR OPEN

(100%)

:~

1

I

THROTTLE

IDLE POSITION

----...______AUTO-ADJUSTING

A newly developed throttle-idle-position auto-adjusting system This system

idle, the narrow range throttle sensor

At position auto adjusting system, the engine control unit If

the output

25%

respectively for fail-safe operation. Operation for the engine and

25%

automatically compensates for certain variations

is

set to output a signal of

will

is

less than

full range sensor

15%

or more than

25%

at

idle, the engine control unit fixes the value

is

the same. The sensor

control unit compensates within the range from

respectively for fail-safe operation.

compensate for actual output values

5%-25%.

F2-18

AREA

0

FULL THROTTLE

is

incorporated within the engine control unit.

in

the output signal

20%

is

set to register a

If

over or under the signal

of

full-open.

of

the throttle sensors.

W1th

the throttle idle

of

15%

signal at idle, and the

is

15%-25%.

at

15%

fixed at

CJ7UOF2514

and

5%

-EAN BEST-IDLE CONTROL SYSTEM

WATER THERM

OSENSOR

ENGINE CONTROL UNIT

OF

DETECTION

WARM CONDITION

ENGINE

~

'

NEUTRAL SWITC

CLUTCH SWITC

P/S PRESSURE SWITC

A/C SWITC

BLOWER SWITC

HEADLIGHT SWITC

:::::AR DEFROSTER SWITC

FOG

LIGHT SWITC

CANAD

(ONLY

~

THROTTLE

(N~

::RANK ANGLE SENS

SE

H H--

H H

H H H H

A)

NSOR GE)

~

OR

(NE

J

SIGNAL

DETECTION

ENGINE

NO-LOAD

CONDITION

FOG

(ONLY

DETECTION

CONDITION)

DETECTION ENGINE IDLE CONDITION

LIGHT SWITCH:

OF

ENGINE LOAD

OF

DETERMINATION

LEAN BEST-IDLE AMOUNT

OF

•

OF

DETERMINATION

LEAN BEST-

~

CONDITION

-

OF

IDLE

FUEL INJEC-

TOR

I

~

-

BATT

ER'

I

i

)

514

mit.

rs.

idle

)%.

3.nd the

5%

_

-=-~

fuel consumption and reduced exhaust emissions

::

'h

this system, the engine control unit sets fuel injection

-

.;J

lean misfire and rough idle.

F2-19

at

idle, the lean best-idle control s.

at

idle to the leanest amount

::::::··

::J:::::::

SPARK ADVANCE FEEDBACK SYSTEM (ENGINE AT IDLE)

SPARK ADVANCE

FEEDBACK

AMOUNT

THROTTLE SENSOR

(NARROW

RANGE)

DETECTION

OF

ENGINE IDLE

CONDITION

-5or----

oo

- - - - - - - -

______

I

I I

__._

_______

I I

-.--_...__-'

_

CRANK ANGLE

SENSOR (NE SIGNAL)

DETERMINATION

OF

ADVANCE

SPARK

FEEDBACK AMOUNT

I

IGNITION COIL

'

RS

rpm

DECREASED

TS:

TARGET ENGINE SPEED

REAL ENGINE SPEED

RS:

TS

RSrpm INCREASED

To

orevent rough idle caused by incorrect idle speeds, the spark advance feedback system controls the spark advance. The engine tlor

t~:<~

ng

to

obtain the preprogrammed target speed

control unit judges the engine speed (real speed:

(TS)

RS)

and then adjusts the igni-

F2-20

97UOF2516

SERVICE POINT

THROTTLE SENSOR ADJUSTMENT

)m

EASED

•

IDLE MIXTURE ADJUSTMENT

516

•

...

··

e sensor adjustment: Not usually necessary unless throttle sensor unit

auto-adjusting system automatically compensates.

· xture adjustment Not necessary because eliminated.)

of

F2-21

lean best-idle control system. (Vanable res::· • ·

is

replaced.

Throttle-idle-pas'~··

SELF-DIAGNOSIS FUNCTION

DESCRIPTION

Whefl troubles are suspected Fa1'1ures tion

of

1nd1V1dual

code

numbers.

Note The

control unit constantly checks for malfunction of the input devices. It checks for malfunction of output devices only during a 3-second period after the ignition switch has been turned ON

while the test connector

input and output devices are indicated and retneved from the control

in

the main input devices or output devices.

is

grounded.

check

for the cause with the SST

un1t

as malfunc-

IGNITION WITH IGNITER r

(TRAILING SIDE)

M~~~C:'EJ~-.

CRANK ANGLE SENSOR (G-SIGNAL)

KNOCK

COIL---~~---.'~'

SENSOR-0

\,,{J~

---,

'

----,

FAIL-SAFE FUNCTION

WATER----f7·~

THERMOSENSOR

AIRFLOW~

METER

INTAKEAIR

THERMOSENSOR (AFM)

INTAKE AIR THERMOSENSOR (ENGINE)

~;~

'0

~

--

7

DETECTION

OF

MALFUNCTION

WARNING

FUNCTION

&

MALFUNCTION CODE FUNCTION

_j_

-

-=-

~l~~~~:~;L

~

THROTTLE~-

(~~~~~~-RANGE)

PRESSURE--SENSOR

OXYGEN

METERING

PUMP POSITION

SENSOR

SENSOR-\

OIL--~

Q._"__

-~-

-~

-----'

ATMOSPHERIC

PRESSURE SENSOR

TEST CONNECTOR (GREEN: 1-PIN)

F2-22

97UQF2 024

MALFUNCTION CODE NUMBER SST

49 H018

Self-D1agnos1s

Checker

9A1

• ..,

,-,

1-1

~----~-

~~~~.:~_

Sflf

OIAGJIOSIS

CHECKER

97UOF2 520

Inspection Procedure

1.

Warm up the engine to normal operating temperature and stop

it.

2.

Connect the SST the negative battery

the select switch to position

Set

3.

Connect a jumper wire between the test connector (Green:

to

the check connector (Green: 6-pin) and

terminal.

A.

1-pin) and a body ground

~\1\T/

•

"""11-11

O'd/

--/-H-'-1-'-

SElf

DIAGNOSIS

M()..,rTQR

LA

... P

0

49

HOle

!Mt

--

•G

1::111-:1/

•

ICil

SELF·DIAGNDSIS

MO~rTOft

LAMP

Q

000

0

I

•tlo4018MI

--.

-

1

1-1

-

-I

1_111_._,.11

CHECKER

SELECT

0

voo

[J'•

0

~.

flll&0f_O

..

v

--

CHHKER

SELECT SW

[g]:

lll.loO(

..

~

SW

J...,.

...

97UOF2 522

MALFUNCTION

CODE

NUMBER

97UOF2 518

4.

Turn the ignition switch ON.

5.

Check that sounds for

6.

If

88

7.

If

88

than control unit And check the engine voltage. Replace perform

8.

Check for any malfunction

9.

Start the engine and check for further malfunction

88

flashes on the digital display and the buzzer

3 sec. after turning the ignition switch ON.

does not flash, check the check connector wiring.

flashes and the buzzer sounds continuously for more

20 sec., check for a short circuit between the engine

(1

F)

terminal and check connector (Green: 6-pin).

control unit (3X) and (3Z) terminal

the engine control unit

if

necessary and

Step 4 again.

code

numbers.

10.

If

a malfunction

cause of the

code

problem .

number

is

indicated, check for the

Note Cancel the malfunction code numbers by performing the after-repair procedure

following repairs.

F2-23

code

Principle of code cycle

Malfunction codes are determined

1.

Malfunction code cycle break

as

below by use of the MIL and Self-Diagnosis Checker.

The time between malfunction code cycles

is

4.0 sec. (the time the MIL and checker buzzer are

97UOF2-523

off).

1 CYCLE

ON

OFF

MALFUNCTION CODE

CYCLE

4.0 SEC.

2. Second digit of malfunction code (ones position)

The digit are

in

the ones position

on

0.4 sec. during one cycle.

__llJl]

ON

OFF

of

the malfunction code represents the number

1 CYCLE CODE

-+---+-

_j____\_

0.4 0.4

SEC. SEC.

MALFUNCTION

CYClE

'-----------'

4.0 SEC.

BREAK

~~

'---------

9MUOF1 543

of

times the MIL and buzzer

CODE No.:

89U04X 565

03

3.

~\t'S.\

d\9.\\ ot

\"\\~

~\~'\\\\\"\\\<c'\<c\\'2>

are on 1.2 sec. during one

ma\tu.n~\\on

))\:J'2>\\\\:Jn

~od~

~~\'\%

d\

me

cycle.

~o%\\\on\

rnai'\unc1.\Dn

cooe represents \ne number

The MIL and buzzer are off tor 1.6 sec. between the long and short pulses.

1 CYCLE

f----.+

12

1.2 SEC. SEC. 1.6

1------l

FIRST DIGIT SECOND

.4

SEC.

MALFUNCTION

CODE

DIGIT

F2-24

o1

times tne

M\l

and buzzer

CODE No.:

22

89U04X-566

Code number

Caution a)

If there first, the subsequent malfunction codes appear

b)

After repairing all failures, turn the ignition switch OFF, disconnect the negative battery ca-

ble, and depress the brake pedal for at least 5 seconds

is

more than one failure present, the lowest number malfunction code

in

order.

to

erase the malfunction code memory.

is

Input devices

displayed

,..

\

I

Code 1

No.

01

02

03 Crank angle sensor Broken

05 Knock sensor Broken

08

09

10

13

'4

'']

Input

devices Malfunction

lgn1t1on w1th (Tra1l1ng

Crank angle sensor Broken (Ne

(G

A1rflow

Water thermosensor Broken

Intake

1

thermosensor (AFM)

coil Malfunct1on of spark plug. ,

1gn1ter

s1de)

s1gnal)

meter (AFM) Broken

a1r

:c'

thermo- Broken

·

'Cng1ne)

..

·c

._;:uli

SG\\SCl\

range) angle 1npu\

Pressure sensor

(Intake manifold

pressure)

Atmosphenc pres-

sure sensor (ATP)

(Built

1n

ECU) 760

Oxygen sensor

Feedback system

Throttle sensor (Narrow range)

oil

-

oil

pump

------

pump

Meter1ng pos1tlon sensor

Metering (MOP)

Metenng

(MOP)

broken

Broken

Bro\<..e11

Broken

Malfunct1on1ng ECU Atmosphenc pressure

Oxygen

below system

Oxygen

i

0.55V

operat1on

I

t

Broken

Malfunctioning tors or

-

--

---1-

I

Malfunct10n1ng broken

1

t1on1ng

w1re.

short

w1re.

short

w1re,

short

w1re.

short

w1re.

short

w1re.

short

w1re.

short

w1re.

short

\NI\e,

sllor\

w1re,

short

sensor

output

0

55V

80

sec.

operat1on

sensor

output

10

sec

after

beg1n1ng

w1re.

short

w1re.

short

w1re.

ECU

MOP.

w1re.

MOP.

short

alternator

broken

malfunct1on1ng

c1rcu1t

C1rcu1t

c1rcu1t

CI\C\.11\

C1rcu1t

rema1ns

after

beg1n1ng

rema1ns

F/8

system

C1rcu1t

step

short

C1rcu1t

ECU

step

motors

c1rcu't

malfunc-

or

battery

Fail-safe function

Trail1ng-s1de pulse cut

Fuel

inJeCtion

t1on

cut

Fuel

lnJ8Cllon

t1on

cut

lgn1t1on

Bas1c amount and ign1tlon t1ming

Coolant

1

f1xed

at

Intake f1xed

at

Intake f1xed

at

111\Cl\\\e

at

20%

Intake 1nput mmHg (29.9

1nput

Feedback system can

F/8

mo·

celed (For EGI)

Feedback system canceled (For

Throttle valve open1ng angle at full open

MOP Bas1c and

ign1t1on

MOP Bas1c and

1Qn1t1on

.

------

Bas1c amount and t1m1ng

1gn1t1on

and

t1m1ng

f1xed

fuel

1nj8ct1on

f1xed

temp.

1nput

80°C

(176°F)

a1r

temp '.nput

20°C

(68°F)

a1r

temp.

20°C

(68°F)

'Jai\Je

ope111119

s1gnal

open

man1told

s1gnal

f1xed

1nHg)

s1gnal

f1xed

mmHg

(29 9

EGI)

1nput

signal

f1xed

smallest

fuel

InjeCtion

tmng

f1xed

smallest

fuel

InjeCtion

tmng

-

fuel injeCtion

1Qn1t1on

f1xed

1gn1-

1nput

f1xed

pressure

at

760

at 1nHg)

f1xed

open amount f1xed

---

Output

'

(Self-Diagnosis Checker or MIL)

signal

pattern

Jl

I I

}~~L

I.

..

Jl

m

f\_~R

Ill

IUI

rJ~~l

JUII

Jlll[

Ilfl

---.

ITUI~~;~

nlln

J u u

~~c~---

~u~----

F2-25

Output devices

Code

No.

25

Soleno1d valve (Pressure regulator control (PRC))

26

Step motor (Metenng

30 Split

31

32 Solenoid valve (Switch)

33

34

a1r

soleno1d valve

Solenoid valve (Relief)

Port

a1r

solenoid valve

Solenoid valve (Bypass

Output devices

011

pump)

a1r

control)

Output

(Self-Diagnosis Checker or MIL)

signal pattern

----

---

Irul

Jru~~n~

m~

rm~L

Jrull

Jf{ll1

Jl'lfilll

-

38

Soleno1d valve (Accelerated warm-up system (AWS) and a1r

supply valve (ASV))

42

Duty soleno1d valve (Turbo boost pressure control)

51

71

73

pump

Fuel

1

Injector (Front secondary)

Injector (fiear secondary)

res1stor

relay

fffil~tiL

rrnwn~

runm

Jmrunlill

~mnlffil

97UOF2 525

F2-26

SWITCH MONITOR FUNCTION Preparation SST

149

H018

9A1

Self-D1agnos1s Checker

I

....

1-1

I

~~

-~~~-~..::::~_,

---

swnWiiCISIS

CHHIER

97UOF2 064

Individual switches can be monitored by the SST.

Note The test connector must

BATTERY

be

grounded and the ignition switch

ENGINE CONTROL UNIT

ON

(engine stopped).

NEUTRAL SWITCH BACK-UP LIGHT AND 5TH

CLUTCH SWITCH

HEADLIGHT SWITCH

BLOWER REAR DEFROSTER

FOG LIGHT SWITCH

(IF EQUIPPED)

KNOCK

SWITCH-------+--------'

SENSOR--------------~

-------t-----------,

-·------~---------r=~~~

-------+-----__j

SWITCH----+-------

------~;;;:::::=:=:=:=:=:::::::.4-----+---""'

SWITCH--+-------,

/~/;/

/

97UOF2 065

Inspection Procedure

1.

Warm up the engine to normal operating temperature and stop

it.

2.

Connect the SST the negative battery

to

the check connector (Green: 6-pin) and

term1nal.

97UOF2 066

3.

Connect a jumper wire between the test connector (Green:

1-pin) and a ground.

4.

Turn the ignition switch ON, then check that the monitor lamp illuminates when each cording to the function

table.

sw1tch

is

made to function ac-

Caution a)

When any one of the switches are activated, the monitor lamp will

b)

Do

not start the engine.

be

on.

F2-27

Function Table

Switch

Neutral

Back-up

sw1tch

l1ght

5th switch

Clutch

sw1tch

Headlight

Blower

sw1tch

Rear defroster

and

sw1tch

Self-Diagnosis Checker

Lamp-ON Lamp-OFF

Shift transmiSSIOn to

1,

2,

3 or 4

Sh1ft

transmiSSIOn

Neutral

5th gear

Pedal

depressed

Switch ON

Pedal released

Sw1tch

Sw1tch (At any fan speed OK)

Sw1tch

ON

Sw1tch OFF

(MEn~or

la_111p)

pos1t1on

OFF

Possible cause

(When incorrect)

i

Neutral

I •

Open

! •

ECU 1 R term1nal. neutral switch and ground

I • Back-up light

• Open circu1t between 5th switch and

• Clutch

•

Open ECU ground, clutch

• Headl1ght

•

Open ECU tery

• Blower

• Heater relay malfunct1on

•

Heater control

• Open and ECU

• Rear defroster

• Open ar1d and

sw1tch

malfunction

c1rcu1t

between neutral

and

ECU 1 T term1nal.

ground

sw1tch

c1rcu1t

10

malfunction

between clutch

terminal, clutch

sw1tch

c1rcu1t

between headl1ght

3L

term1nal. headl1ght

l1ne

sw1tch

malfunction

un1t

c1rcu1t

between heater control

30

terminal

sw1tch

c1rcu1t

between rear defroster

ECU 3P

termnal,

ground

5th

sw1tch

back-up

sw1tch

and ACC circu1t

malfunction

malfunct1on

malfunction

rear defroster

sw1tch

malfunct1on

l1ght

overdnve

sw1tch

and

sw1tch

and bat-

and

un1t

sw1tch

Fog

l1ght

(If equ1pped)

Knock

sensor

L

__

_

sw1tch

Sw1tch

ON (Only equ1p fog light)

While knock1ng Lamp

ON

0.5 sec

(IGN

sw1tch

ON.

engine

hanger

hammer)

---

-------------------'---------------:-:c--=---:-,-,J

h1t

w1th

Sw1tch

Others

OFF

• Fog

l1ght

! • Open

c1rcu1t

1S term1nal, fog

ECU battery

•

Knock

•

Open

C1rcu1t

ECU 2M terminal

sw1tch

malfunction

between fog light switch and

l1ght

sw1tch

sensor malfunction

between knock sensor

and

97UOF2

068

F2-28

ENGINE ELECTRICAL SYSTEM

G

OUTLINE

STRUCTURAL VIEW

SPECIFICATIONS

ALTERNATOR

CHARGING SYSTEM

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

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

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

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

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

G-2 G-2 G-4 G-5 G-5

97UOGX 501

L

OUTLINE

STRUCTURAL

NON TURBO

VIEW

ALTERNATOR

STARTER (FOR M/T)

CRANK ANGLE SENSOR

BATTERY\

IGNITION COIL

WITH IGNITER

(LEADING)

IGNITION

COIL WITH

IGNITER

(TRAILING)

SPARK

PLUGS

/

STARTER (FOR

A/T)

G-2

~·

97UOGX 502

TURBO

ALTERNATOR

HIGH TENSION LEADS

l

CRANK ANGLE SENSOR

IGNITION COIL

WITH IGNITER (LEADING)

STARTER

97UOGX 503

SPECIFICATIONS

Item

Voltage Battery

lgn1!1on system

Alternator

Starter

] Type and capaCity (20-hour rate)

1 (Maintenance free)

I

D1stnbu!lon Spark Spark advance

Spark plug

Output Regulated voltage

Brush length

Type Output

Output(No load)

Brush length

t1ming

(Test connector grounded)

Type Plug

[ Standard

I Wear

l

• Voltage

I Current

'

Speed Standard mm (in) Wear

gap

l1m1t

mm (in)

V-A

(1n)

mm mm

(1n)

KW

rpm

mm (in)

v

A

138

MiT

14.1

1.2

EGI

Lead1ng

ralimg

T

Trali1ng Leadmg ;

-14.7

Engine

i

A/T

12. Negative ground

55023L 65023L

20° ± 2°

(w1th

60

AH

55 AH (Coldproof area)

Control

5°

± 1 o ATDC

A TDC

Control

; NGK BUR9EO

NGK BUR7EO

14

12-80

temperature-grad1ent

16.5 (0.650)

8.0 (0.315)

Coaxial reduction

2.0 !

Max. 90

M1n.

17.5 (0.689) 10 0 (0.394)

-[-

13B_rurbo~~;-?~d

- -

Un1t

at

1dle

(AIT N range)

un1t

(0.056)

charactens!lcs)

1.2

11.0

3.000

Engir1e

97UOGX

003

G-4

ALTERNATOR

CHARGING SYSTEM

(003

l

I

DIODE TRIO

IGNITION SWITCH

~

>

j1c

___j_

BATTERY l

REGULA TOR

:-:::ect

and control the real battery voltage, the sensing for charg1ng rate

-

'lg

type insted of an

IC

regulator sensing type.

G-5

is

changed

to a battery

vo1·:::::;~

Mazda MPV 1989, B 1989, RX-7 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ENGINE

LUBRICATION SYSTEM

COOLING SYSTEM

ENGINE ELECTRICAL SYSTEM