GASOLINE FUEL

SYSTEM

MAZDA 2.0L AND 2.2L

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS

(H30FT, H35FT, H40FTS) [F001];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177]

PART NO. 1580509

900 SRM 1127

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Gasoline Fuel System

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

1

Abbreviations .....................................................................................................................................................

1

Engine Tune-up..................................................................................................................................................

1

Engine Tune-Up Preparation........................................................................................................................

1

Idle Speed Adjustment ..................................................................................................................................

1

Idle-Up Speed Check .....................................................................................................................................

1

Intake-Air System..............................................................................................................................................

3

Intake-Air System Manifold Vacuum Check................................................................................................

3

Throttle Body .................................................................................................................................................

4

Remove.......................................................................................................................................................

4

Install .........................................................................................................................................................

4

Electronic Governor.......................................................................................................................................

4

Remove.......................................................................................................................................................

4

Install .........................................................................................................................................................

4

Intake-Air Control (IAC) Valve .....................................................................................................................

4

Remove.......................................................................................................................................................

4

Install .........................................................................................................................................................

6

Intake Manifold .............................................................................................................................................

6

Remove.......................................................................................................................................................

6

Install .........................................................................................................................................................

6

Fuel System........................................................................................................................................................

7

Before Repair Procedure ...............................................................................................................................

7

Fuel Line Safety Procedure ......................................................................................................................

7

After Repair Procedure..................................................................................................................................

7

Fuel Hose, Install ......................................................................................................................................

7

Fuel Leakage Check ..................................................................................................................................

8

Fuel Line Pressure Check .............................................................................................................................

8

Fuel Injector...................................................................................................................................................

9

Remove.......................................................................................................................................................

9

Install .........................................................................................................................................................

9

Pressure Regulator ........................................................................................................................................

10

Remove.......................................................................................................................................................

10

Install .........................................................................................................................................................

11

Exhaust System .................................................................................................................................................

12

Exhaust System, Inspect...............................................................................................................................

12

Three-Way Catalytic (TWC) Converter ........................................................................................................

12

Remove and Install ...................................................................................................................................

12

Exhaust Manifold ..........................................................................................................................................

12

Remove.......................................................................................................................................................

12

Install .........................................................................................................................................................

12

Positive Crankcase Ventilation (PCV) Valve................................................................................................

14

Remove.......................................................................................................................................................

14

Inspect........................................................................................................................................................

14

Install .........................................................................................................................................................

14

Control System...................................................................................................................................................

14

Engine Control Unit (ECU)...........................................................................................................................

14

Remove.......................................................................................................................................................

14

Install .........................................................................................................................................................

16

Intake Air Temperature (IAT) Sensor ..........................................................................................................

17

Remove.......................................................................................................................................................

17

Install .........................................................................................................................................................

17

©2005 HYSTER COMPANY

i

Table of Contents

Gasoline Fuel System

TABLE OF CONTENTS (Continued)

Mass Air Flow (MAF) Sensor ........................................................................................................................

17

Remove.......................................................................................................................................................

17

Install .........................................................................................................................................................

17

Throttle Position (TP) Sensor .......................................................................................................................

18

TP Sensor, Adjust ......................................................................................................................................

18

Remove.......................................................................................................................................................

19

Install .........................................................................................................................................................

19

Engine Coolant Temperature (ECT) Sensor.................................................................................................

19

Remove.......................................................................................................................................................

19

Install .........................................................................................................................................................

20

Camshaft Position (CMP) Sensor .................................................................................................................

20

Voltage Check ............................................................................................................................................

20

Oxygen Sensor ...............................................................................................................................................

20

Remove.......................................................................................................................................................

20

Install .........................................................................................................................................................

20

Manifold Absolute Pressure (MAP)/Boost Sensor........................................................................................

21

Remove.......................................................................................................................................................

21

Install .........................................................................................................................................................

21

Technical Data....................................................................................................................................................

22

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177]

ii

900 SRM 1127

Engine Tune-up

General

This section has the repair procedures for the engine
control unit (ECU) controlling the idle, fuel, spark,

and timing for the Mazda 2.0L and 2.2L gasoline en-
gines.

Abbreviations

AAS - air adjusting screw.

CMP Sensor - camshaft position sensor.

ECT Sensor - engine coolant temperature sensor.

ECU - engine control unit.

GCU - governor control unit.

IAC Valve - idle air control valve.

IAT Sensor - intake air temperature sensor.

MAF Sensor - mass air flow sensor.

MAP Sensor - manifold absolute pressure sensor.

PCV Valve - positive crankcase ventilation valve.

TP Sensor - throttle position sensor.

TWC Converter - three-way catalytic converter.

Engine Tune-up

ENGINE TUNE-UP PREPARATION

1.

Warm up the engine to normal operating temper-
ature.

2.

Turn off all electrical loads.

3.

Verify that the steering wheel is at straight
ahead position.

4.

Connect a tachometer.

IDLE SPEED ADJUSTMENT

1.

Perform Engine Tune-Up Preparation.

WARNING

Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or
death and damage. Always perform the follow-
ing procedure with the engine stopped.

CAUTION

Only use a jumper wire with a momentary
switch located within the wire to prevent arc-
ing.

2.

Install a jumper wire across the engine control
unit (ECU) test port connector terminals. See
Figure 1.

3.

Verify that the idle speed is within the specifica-
tion. If not as specified, adjust the idle speed by
turning the air adjustment screw (AAS) of throt-
tle body. See Figure 2.

Specification: 775 to 825 (800 ±25) rpm

4.

Remove the jumper wire from ECU test port con-
nector.

IDLE-UP SPEED CHECK

1.

Perform Engine Tune-Up Preparation.

2.

Verify that the idle speed is normal. See Idle
Speed Adjustment.

3.

Verify that the idle-up speed is within the specifi-
cation. Load the engine at tilt relief, hoist relief,
and steer relief while checking the engine speed
at each condition. If not as specified with all load
conditions, inspect the IAC valve. If not as spec-
ified with some load conditions, inspect the sen-
sors (MAP/Boost, TP sensor, CMP sensor), har-
nesses, and connectors.

Specification: 900 to 1100 (1000 ±100) rpm

1

Engine Tune-up

900 SRM 1127

1.

FUEL PUMP TEST CONNECTOR

2.

ECU TEST PORT

3.

10 AMP FUSE, FUEL PUMP

4.

FUEL PUMP RELAY

5.

GCU INTERFACE

6.

ALTERNATOR RELAY

Figure 1. Relays and Test Connectors

2

900 SRM 1127

Intake-Air System

1.

THROTTLE POSITION (TP) SENSOR

2.

THROTTLE BODY

3.

AIR ADJUSTING SCREW (AAS)

Figure 2. Throttle Body

Intake-Air System

NOTE: Always use new O-rings, seals, and gaskets
when servicing the fuel and exhaust systems.

INTAKE-AIR SYSTEM MANIFOLD VACUUM
CHECK

1.

Verify that the intake-air system related parts
and hoses are securely installed.

2.

Remove the intake manifold blind cap and install
the vacuum gauge. See Figure 3.

3.

Warm up the engine.

4.

Measure the intake manifold vacuum while
idling (no load) using the vacuum gauge. If not
within the specification, perform the following
inspection:

Specification: -60.0 kPa (-17.8 inHg) or more

a. Accelerator cable free play.

b. Compression pressure.

NOTE: If any vacuum leaks exist, the change in en-
gine speed can be made apparent by spraying the
penetrant lubricating spray on the applicable part.

c.

Vacuum leaks (installation areas of throttle
body, electronic governor, fuel injector, IAC
valve, PCV valve, intake manifold).

5.

After measuring the intake manifold vacuum, in-
stall the intake manifold blind cap.

1.

VACUUM GAUGE

Figure 3. Intake Manifold Vacuum Check

3

Intake-Air System

900 SRM 1127

THROTTLE BODY

For the following procedures, refer to Figure 4.

Remove

1.

Drain the coolant from the radiator.

2.

Disconnect the air-intake hose from the throttle
body.

3.

Disconnect the wiring harness connector from
the TP sensor connector.

4.

Tag and disconnect the coolant hoses from the
throttle body.

5.

Disconnect the throttle cable.

6.

Remove the two bolts from the bottom of the
throttle body.

7.

Remove the two nuts from the top of the throttle
body.

8.

Slide the throttle body from the threaded studs
and remove the throttle body.

9.

Remove the gasket and discard.

Install

1.

Verify that the mounting surface of the throttle
body and the electronic governor are clean and
free of debris.

2.

Install a new gasket.

3.

Slide the throttle body onto the threaded studs.

4.

Install the two nuts and two bolts and tighten.
Tighten the two nuts to 22 to 30 N•m (16 to
22 lbf ft). Tighten the two bolts to 19 to 25 N•m
(14 to 18 lbf ft).

5.

Connect the throttle cable.

6.

Connect the coolant hoses.

7.

Connect the wiring harness connector to the TP
sensor connector.

8.

Connect the air-intake hose.

9.

Fill the radiator with coolant.

ELECTRONIC GOVERNOR

Remove

For the following procedures, refer to Figure 4.

1.

Remove the throttle body. See Throttle Body, Re-
move.

2.

Disconnect the wiring harness connector from
the electronic governor sensor connector.

3.

Slide the electronic governor from the threaded
studs and remove the electronic governor.

4.

Remove the gasket and discard.

Install

For the following procedures, refer to Figure 4.

1.

Verify that the mounting surface of the electronic
governor and the intake manifold are clean and
free of debris.

2.

Install a new gasket.

3.

Slide the electronic governor onto the threaded
studs.

4.

Install the throttle body. See Throttle Body, In-
stall.

INTAKE-AIR CONTROL (IAC) VALVE

Remove

For the following procedures, refer to Figure 4.

1.

Drain the coolant from the radiator.

2.

Tag and disconnect the the coolant hoses.

3.

Disconnect the electrical connector from the IAC
valve connector.

4.

Remove the two nuts and capscrew securing the
IAC valve.

5.

Remove the IAC valve and gasket.

4

900 SRM 1127

Intake-Air System

1.

THROTTLE BODY

2.

GASKET

3.

ELECTRONIC GOVERNOR

4.

GASKET

5.

THROTTLE BRACKET

6.

CAPSCREW

7.

BRACKET

8.

CAPSCREWS

9.

MAP/BOOST SENSOR

10. NUT
11. FUEL PRESSURE REGULATOR
12. BRACKET
13. CAPSCREWS
14. CAPSCREW
15. WASHER
16. CAPSCREW
17. BRACKET
18. GASKET
19. COOLANT HOSE
20. CLAMP

21. CAPSCREW
22. COOLANT HOSE (TO ENGINE COOLANT HOSE

ON RIGHT SIDE OF CYLINDER BLOCK)

23. CLAMP
24. IDLE AIR CONTROL (IAC) VALVE
25. NUT
26. GASKET
27. FUEL INJECTOR AND FUEL RAIL ASSEMBLY
28. PCV HOSE
29. CLAMP
30. INTAKE MANIFOLD
31. THREADED STUD
32. COOLANT HOSE (TO THERMOSTAT OUTLET

HOUSING)

33. CLAMP
34. COOLANT HOSE (TO ENGINE COOLANT HOSE

ON RIGHT SIDE OF CLYINDER BLOCK)

35. THROTTLE POSITION (TP) SENSOR
36. BOLT
37. NUT

Figure 4. Intake-Air System

5

Intake-Air System

900 SRM 1127

Install

For the following procedures, refer to Figure 4.

1.

Verify that the mounting surfaces of the intake
manifold and the IAC valve are clean and free
from dirt or debris.

2.

Install a new gasket.

3.

Place the IAC valve in position and secure with
the two nuts and capscrew.

4.

Torque the two nuts to 8.9 to 12.7 N•m (79
to 112 lbf in).

Torque the capscrew to 7.9 to

10.7 N•m (69.5 to 95.4 lbf in).

5.

Connect the electrical connector to the IAC valve
connector.

6.

Connect the coolant hoses to the IAC valve.

7.

Fill the radiator with coolant.

INTAKE MANIFOLD

Remove

For the following procedures, refer to Figure 4.

1.

Drain the coolant from the radiator.

2.

Disconnect the fuel line from the fuel rail. See
Fuel System, Before Repair Procedure.

3.

Remove the throttle body. See Throttle Body, Re-
move.

4.

Remove the electronic governor. See Electronic
Governor, Remove.

5.

Remove the capscrews retaining the front
bracket (7) to the intake manifold and remove
the bracket.

6.

Remove the IAC valve. See Intake-Air Control
(IAC) Valve, Remove.

7.

Tag and disconnect the vacuum hoses on the in-
take manifold.

8.

Remove the ECT sensors. See Engine Coolant
Temperature (ECT) Sensor, Remove.

9.

Remove the MAP/boost sensor. See Manifold Ab-
solute Pressure (MAP)/Boost Sensor, Remove.

10. Remove the capscrews retaining the rear bracket

(12) to the intake manifold and the cylinder head.
Remove the bracket.

11. Remove the capscrews retaining the lower sup-

port bracket (17) to the intake manifold and re-
move the bracket.

12. Remove the nut and the capscrews retaining the

intake manifold to the cylinder head.

13. Remove the intake manifold and gasket.

14. Remove the capscrew retaining the throttle

bracket to the intake manifold and remove
bracket.

15. Remove the fuel pressure regulator. See Pres-

sure Regulator, Remove.

16. Remove the fuel injectors and the fuel rail. See

Fuel Injector, Remove.

Install

For the following procedures, refer to Figure 4.

1.

Verify that the mounting surfaces of the intake
manifold and the cylinder head are clean and free
from dirt or debris.

2.

Install the fuel injectors and the fuel rail. See
Fuel Injector, Install.

3.

Install the fuel pressure regulator. See Pressure
Regulator, Install.

4.

Place the throttle bracket in position and install
capscrews. Tighten capscrews to 7.9 to 10.7 N•m
(69.5 to 95.4 lbf in).

5.

Place a new gasket in position on the cylinder
head.

6.

Place the intake manifold in position on the cylin-
der head.

7.

Install the nut and capscrews to retain the intake
manifold to the cylinder head. Tighten the nut
to 22 to 30 N•m (16 to 22 lbf ft). Tighten the
capscrews to 19 to 25 N•m (14 to 18 lbf ft).

6

900 SRM 1127

Fuel System

8.

Place the lower support bracket (17) in position
and install the capscrews. Tighten the capscrew
to the intake manifold to 19 to 25 N•m (14 to
18 lbf ft). Tighten the remaining capscrew to 38
to 51 N•m (28 to 38 lbf ft).

9.

Place the rear bracket in position and install
the capscrews. Tighten the capscrews to 19 to
25 N•m (14 to 18 lbf ft).

10. Install the MAP/boost sensor. See Manifold Ab-

solute Pressure (MAP)/Boost Sensor, Install.

11. Install the ECT sensors.

See Engine Coolant

Temperature (ECT) Sensor, Install.

12. Connect the vacuum hoses to the intake mani-

fold.

13. Install the IAC valve. See Intake-Air Control

(IAC) Valve, Install.

14. Place the front bracket (7) in position and install

the capscrews. Tighten the capscrews to 19 to
25 N•m (14 to 18 lbf ft).

15. Install the electronic governor. See Electronic

Governor, Install.

16. Install the throttle body. See Throttle Body, In-

stall.

17. Connect the fuel line to the fuel rail. See Fuel

System, After Repair Procedure.

18. Fill the radiator with coolant.

Fuel System

NOTE: Always use new O-rings, seals, and gaskets
when servicing the fuel and exhaust systems.

BEFORE REPAIR PROCEDURE

Fuel Line Safety Procedure

WARNING

Fuel vapor is hazardous. It can 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
following procedure:

NOTE: Fuel in the fuel system is under high pressure
also when the engine is not running.

1.

Remove the fuel-filler cap and release the pres-
sure in the fuel tank.

2.

Disconnect the fuel pump relay. See Figure 1.

3.

Start the engine. After the engine stalls, crank
the engine several times.

4.

Turn OFF ignition.

5.

Connect the fuel pump relay.

AFTER REPAIR PROCEDURE

Fuel Hose, Install

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 the following procedure and the
Fuel Leakage Check procedure.

1.

Replace damaged or deformed fuel hoses, fuel
lines, and hose clamps.

2.

When installing the fuel hose on the fuel line,
fit the hose onto the line over 25 mm (0.98 in.).
When the line has a stopper, fit the hose until it
contacts the stopper. See Figure 5.

7

Fuel System

900 SRM 1127

1.

FUEL LINES

2.

STOPPER

3.

FUEL HOSE

Figure 5. Fuel Hose Installation

NOTE: Do not use a clamp larger than the recom-
mended size for the hose outside diameter.

3.

Install a hose clamp over the fuel hose within the
clamp installation range as shown, avoiding the
original clamp position. Tighten the clamp screw
to 2.45 to 2.77 N•m (22 to 25 lbf in). See Figure 6.

1.

AVOID ORIGINAL CLAMP POSITION

2.

CLAMP INSTALLATION RANGE

Figure 6. Clamp Installation

Fuel Leakage Check

WARNING

Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or
death and damage. Always perform the follow-
ing procedure with the engine stopped.

CAUTION

Only use a jumper wire with a momentary
switch located within the wire to prevent arc-
ing.

1.

Install a jumper wire across the fuel pump test
connector terminals. See Figure 1.

2.

Turn the ignition ON to operate the fuel pump.

3.

Pressurize the system this way for at least 5 min-
utes to be sure of no leakage. If there is fuel leak-
age, inspect the fuel hoses and fuel pipe sealing
surface for damage. Replace as needed.

4.

After repair, assemble the system and repeat
Step 1 through Step 3.

FUEL LINE PRESSURE CHECK

WARNING

Fuel line spills and leaks are dangerous. Fuel
can ignite and cause serious injuries or death.
Fuel can also irritate skin and eyes. Always
perform the following procedure with the en-
gine stopped.

1.

Complete the Before Repair Procedure.

2.

Disconnect the negative battery cable.

3.

Connect a fuel pressure gauge between the fuel
filter and the fuel rail. See Figure 7.

4.

Connect the negative battery cable.

5.

Install a jumper wire across the fuel pump test
connector terminals. See Figure 1.

8

900 SRM 1127

Fuel System

1.

FUEL PRESSURE GAUGE

Figure 7. Fuel Pressure Gauge

6.

Measure the fuel line pressure. If less than the
specification, inspect the fuel pump for fuel line
leakage. If it exceeds the specification, inspect
the pressure regulator and fuel line for clogging.

Specification: 260 to 310 kPa (38 to 45 psi)

7.

Turn the ignition OFF to stop the fuel pump.

8.

Measure the fuel hold pressure after 5 minutes.
If not within the specification, inspect the fuel
line for clogging or leakage.

Specification: More than 140 kPa (20 psi)

9.

Disconnect the jumper wire.

10. Disconnect the fuel pressure gauge.

11. Complete the After Repair Procedure.

FUEL INJECTOR

Remove

1.

Complete the Before Repair Procedure.

2.

Disconnect the negative battery cable.

3.

Disconnect the vacuum hose from the pressure
regulator. See Figure 8.

4.

Disconnect the wiring harness from each fuel in-
jector.

5.

Disconnect the fuel lines from the fuel rail.

6.

Remove the two capscrews retaining the fuel rail
to the intake manifold.

7.

Remove the fuel rail and fuel injectors.

8.

Remove the fuel rail insulator.

9.

Remove the fuel injector insulator.

10. Remove the fuel injectors.

11. Remove and discard O-rings.

Install

1.

Apply a small amount of engine oil to the new
O-rings and install them into the fuel rail.

2.

Verify that the O-rings and the fuel injector seal-
ing surfaces are free of foreign material.

3.

Install the fuel injectors in the fuel rail with light
twisting motion so that the O-rings will not be
folded.

4.

Install the fuel injector insulator.

5.

Install the fuel rail insulator.

6.

Install the fuel rail and fuel injectors onto the
intake manifold. Install the two capscrews and
tighten to 19 to 25 N•m (14 to 18 lbf ft).

7.

Connect the wiring harness for each fuel injector.

8.

Connect the vacuum hose to the pressure regula-
tor.

9.

Connect the fuel lines to the fuel rail.

10. Connect the negative battery cable.

11. Complete the After Repair Procedure.

9

Fuel System

900 SRM 1127

1.

INTAKE MANIFOLD

2.

CAPSCREW

3.

PRESSURE REGULATOR

4.

VACUUM HOSE

5.

FUEL RAIL INSULATOR

6.

FUEL INJECTOR INSULATOR

7.

FUEL INJECTOR

8.

O-RING

9.

FUEL RAIL

Figure 8. Fuel Injector Assembly

PRESSURE REGULATOR

Remove

1.

Complete the Before Repair Procedure.

2.

Disconnect the negative battery cable.

3.

Disconnect the vacuum hose from the pressure
regulator. See Figure 9.

4.

Disconnect the fuel return line from the pressure
regulator.

5.

Remove the two capscrews retaining the pres-
sure regulator.

6.

Remove the pressure regulator.

7.

Remove and discard the O-ring.

10

900 SRM 1127

Fuel System

Install

1.

Apply a light coat of engine oil to the new O-ring
and install the O-ring.

2.

Place the pressure regulator in position and in-
stall the two capscrews. Tighten the capscrews
to 7.9 to 10.7 N•m (70 to 95 lbf in).

3.

Connect the fuel return line to the pressure reg-
ulator.

4.

Connect the vacuum hose to the pressure regula-
tor.

5.

Connect the negative battery cable.

6.

Complete the After Repair Procedure.

1.

INTAKE MANIFOLD

2.

O-RING

3.

PRESSURE REGULATOR

4.

CAPSCREW

5.

VACUUM HOSE

Figure 9. Pressure Regulator Removal/Installation

11

Exhaust System

900 SRM 1127

Exhaust System

NOTE: Always use new O-rings, seals, and gaskets
when servicing the fuel and exhaust systems.

EXHAUST SYSTEM, INSPECT

Start the engine and inspect the exhaust system com-
ponent for exhaust gas leakage. If leakage is found,
repair or replace components as necessary.

THREE-WAY CATALYTIC (TWC)
CONVERTER

Remove and Install

WARNING

When the engine and exhaust system are hot,
they can cause severe burns. Turn off the en-
gine and wait until they are cool before remov-
ing the exhaust system.

1.

Refer to the section Frame 100 SRM 1120 for the
removal and installation of the TWC.

EXHAUST MANIFOLD

Remove

WARNING

When the engine and exhaust system are hot,
they can cause severe burns. Turn OFF the en-
gine and wait until cool before removing the
exhaust system.

1.

Disconnect the negative battery cable.

2.

Remove the three capscrews retaining the ex-
haust manifold insulator and remove the insu-
lator. See Figure 10.

3.

Remove the four nuts and washers retaining the
exhaust pipe to the exhaust manifold.

4.

Remove the six nuts and washers retaining the
exhaust manifold to the cylinder head.

5.

Remove the exhaust manifold and gaskets.

6.

Discard all of the old gaskets.

Install

1.

Place the new gaskets in position on the cylinder
head and the exhaust manifold.

2.

Place the exhaust manifold in position on the
cylinder head and secure with the six nuts and
washers.

3.

Tighten the six nuts evenly to 19 to 25 N•m (14
to 18 lbf ft).

4.

Verify the position of the new exhaust manifold
gasket to exhaust pipe is correct.

5.

Connect the exhaust pipe to the exhaust mani-
fold and secure with the four nuts and tighten
evenly.

6.

Place the exhaust manifold insulator in position
and secure with the three capscrews. Tighten the
capscrews to 19 to 25 N•m (14 to 18 lbf ft).

7.

Connect the negative battery cable.

Legend for Figure 10

1.

VALVE COVER

2.

CYLINDER HEAD

3.

CAPSCREWS

4.

EXHAUST MANIFOLD INSULATOR

5.

NUT

6.

WASHER

7.

GASKET

8.

EXHAUST MANIFOLD

9.

GASKET

10. GASKET
11. GROMMET
12. POSITIVE CRANKCASE VENTILATION (PCV)

VALVE

13. CLAMP
14. VACUUM HOSE
15. NUT
16. LOCKWASHER
17. EXHAUST PIPE
18. GASKET
19. THREE-WAY CATALYTIC (TWC) CONVERTER
20. NUT
21. PLUG
22. OXYGEN SENSOR
23. HEAT SHIELD
24. EXHAUST PIPE

12

900 SRM 1127

Exhaust System

Figure 10. Exhaust System

13

Control System

900 SRM 1127

POSITIVE CRANKCASE VENTILATION
(PCV) VALVE

Remove

1.

Slide the clamp back on the vacuum hose con-
nected to the PCV valve. See Figure 10.

2.

Disconnect the vacuum hose.

3.

Remove the PCV valve.

Inspect

1.

Blow air through the PCV valve and verify that
air flows as specified. See Table 1 and Figure 11.

Table 1. PCV Valve Specifications

Condition

Airflow

Air applied from port A

Yes

Air applied from port B

No

2.

If not as specified, replace the PCV valve.

Install

1.

Install the PCV valve into the grommet in the
valve cover.

2.

Connect the vacuum hose.

3.

Slide the clamp into position.

Figure 11. PCV Valve

Control System

NOTE: Always use new O-rings, seals, and gaskets
when servicing the fuel and exhaust systems.

ENGINE CONTROL UNIT (ECU)

Remove

1.

Disconnect the negative battery cable.

2.

Remove the capscrews retaining the drip shield
to the ECU assembly mounting bracket and re-
move drip shield. See Figure 12.

3.

Disconnect the wire harness connector from the
ECU assembly.

4.

Loosen the socket head shoulder bolt retaining
the ECU assembly to the mounting bracket.

5.

Slide the ECU assembly up in the bracket until
the socket head shoulder bolts are aligned with

the large portion of the mounting holes in the
mounting bracket and pull the ECU assembly
away from the mounting bracket.

6.

Remove the socket head shoulder bolts.

7.

Remove the capscrews retaining the ECU cover
to the ECU box. See Figure 13.

8.

Remove the ECU cover.

9.

Remove the capscrews retaining the ECU to the
ECU box.

10. Disconnect the ECU connectors from the ECU.

11. Remove the ECU.

12. Remove all old sealant from the ECU cover and

ECU box mating surfaces.

14

900 SRM 1127

Control System

1.

DRIP SHIELD

2.

CAPSCREWS

3.

GCU

4.

MOUNTING BRACKET

5.

SOCKET HEAD SHOULDER BOLT

6.

ECU ASSEMBLY

7.

FRAME

8.

WIRE HARNESS CONNECTOR

Figure 12. ECU Assembly Mounting

15

Control System

900 SRM 1127

1.

CAPSCREWS

2.

ECU COVER

3.

SILICONE BEAD

4.

ECU CONNECTORS

5.

ECU BOX

6.

ECU

Figure 13. ECU Assembly

Install

1.

Place the ECU in position in the ECU box. See
Figure 13.

2.

Connect the ECU connectors to the ECU.

3.

Install the capscrews to secure the ECU to
the ECU box. Tighten the capscrews to 7.9 to
10.7 N•m (69.5 to 95.4 lbf in).

4.

Apply solventless RTV silicone sealant, Hyster
Part No. 1584621 or equivalent [thickness: 1 to
2 mm (0.040 to 0.078 in.)], to the ECU cover along
the inside of the bolt holes, and overlap the ends.

5.

Place the ECU cover in position on the ECU
box. Install the capscrews and tighten to 7.9 to
10.7 N•m (70 to 95 lbf in).

6.

Install the socket head shoulder bolts, but do not
tighten.

7.

Align the ECU assembly and socket head shoul-
der bolts with the large openings of the mounting
holes of the mounting bracket. Slide the ECU
assembly down until the socket head shoulder
bolts seat at the bottom of the mounting holes.
Tighten the socket head shoulder bolts to 20 N•m
(15 lbf ft).

8.

Connect the wire harness connector to the ECU
assembly.

9.

Place the drip shield in position and install cap-
screws. Tighten capscrews to 10 N•m (89 lbf in).

10. Connect the negative battery cable.

16

900 SRM 1127

Control System

INTAKE AIR TEMPERATURE (IAT)
SENSOR

Remove

1.

Disconnect the wiring harness connector from
the sensor connector.

2.

Remove the IAT sensor and aluminum seal
washer from the air intake manifold. See Fig-
ure 14.

Install

1.

Install the IAT sensor and new aluminum seal
washer. Tighten sensor to 8 to 12 N•m (71 to
106 lbf in).

2.

Connect the wiring harness connector to the sen-
sor connector.

1.

AIR INTAKE MANIFOLD

2.

ALUMINUM SEAL WASHER

3.

IAT SENSOR

Figure 14. Intake Air Temperature (IAT) Sensor

MASS AIR FLOW (MAF) SENSOR

Remove

1.

Disconnect the wiring harness connector from
the sensor connector.

2.

Loosen the hose clamps on both sides of the sen-
sor. See Figure 15.

3.

Disconnect the intake-air hose from both sides of
the sensor.

4.

Remove the nuts retaining the sensor to the
mounting bracket and remove sensor.

5.

Remove isolators and spacers from sensor hous-
ing.

Install

1.

Install isolators and spacers.

2.

Place the sensor in position on the mounting
bracket and install retaining nuts.

3.

Connect the intake-air hose on both sides of the
sensor.

4.

Tighten the hose clamps on both sides of the sen-
sor.

5.

Connect the wiring harness connector to the sen-
sor connector.

17

Control System

900 SRM 1127

1.

AIR FILTER ASSEMBLY

2.

CLAMP

3.

AIR HOSE

4.

NUT

5.

MAF SENSOR

6.

AIR HOSE

7.

SPACER

8.

ISOLATOR

Figure 15. Mass Air Flow (MAF) Sensor

THROTTLE POSITION (TP) SENSOR

TP Sensor, Adjust

CAUTION

Since the TP sensor is adjusted by the manufac-
turer, adjusting the TP sensor excessively can
adversely affect the engine. Do not adjust the
TP sensor excessively.

1.

Verify that the throttle valve is at closed throttle
position.

2.

Disconnect the TP sensor connector.

3.

Turn the ignition ON.

4.

Measure and record the voltage of the discon-
nected harness side connector between terminals
C (reference voltage) and terminal A (ground) us-
ing a voltmeter. See Figure 16.

Specification: 4.5 to 5.5 V (Closed Throttle)

Figure 16. TP Sensor Harness Connector (on

TPS)

5.

Reconnect the TP sensor connector.

6.

Loosen the TP sensor screws. See Figure 17.

7.

Use the voltmeter to adjust the TP sensor so the
voltage of terminal B (signal) is within the spec-
ification below when the throttle valve is at the
closed throttle position. See Table 2.

18

900 SRM 1127

Control System

1.

SCREWS

2.

TP SENSOR

Figure 17. TP Sensor

Table 2. Closed Throttle Position Specifications

TP Sensor Voltage (V)

Between Terminal C

and Terminal A

TP Sensor Voltage (V)

Between Terminal B

and Terminal A

4.5 to 4.9

0.4 to 0.5

4.9 to 5.1

0.4 to 0.6

5.1 to 5.5

0.5 to 0.6

8.

Tighten the TP sensor screws to 1.6 to 2.3 N•m
(14 to 20 lbf in).

9.

Use the voltmeter to adjust the TP sensor so the
voltage of terminal B is within the specification
below when the throttle valve is at the wide open
throttle position. If not as specified, replace the
TP sensor.

Specification: 3.7 to 4.9 (Wide Open Throttle)

Remove

1.

Disconnect the TP sensor connector.

2.

Remove the TP sensor screws. See Figure 17.

3.

Remove the TP sensor from the throttle body.

Install

1.

Verify that the throttle valve is fully closed.

2.

Install the TP sensor to the throttle body.

3.

Tighten the TP sensor screws to 1.6 to 2.3 N•m
(14 to 20 lbf in).

4.

Verify that the throttle valve moves smoothly.

5.

Connect the TP sensor connector.

6.

Adjust the TP sensor. See TP Sensor, Adjust.

ENGINE COOLANT TEMPERATURE (ECT)
SENSOR

There are two ECT sensors located on the bottom of
the intake manifold. See Figure 18. The inboard
ECT sensor, closest to cylinder head, provides the in-
put to the engine control unit (ECU). The outboard
ECT sensor provides input to the governor control
unit (GCU). The removal and installation procedures
are the same.

Remove

1.

Drain the engine coolant from the radiator before
removing the ECT sensor.

2.

Disconnect the ECT sensor connector.

3.

Remove the ECT sensor and packing from the
intake manifold. See Figure 18.

1.

INTAKE MANIFOLD

2.

COPPER WASHER

3.

ECT SENSOR (INBOARD)

4.

ECT SENSOR (OUTBOARD)

Figure 18. ECT Sensor Remove/Install

19

Control System

900 SRM 1127

Install

1.

Install the ECT sensor and the new packing.
Tighten the inboard ECT sensor to 24.5 to 29.4
N•m (18 to 22 lbf). Tighten the outboard ECT
sensor to 19 to 21 N•m (14 to 15.5 lbf).

2.

Connect the ECT sensor connector.

3.

Refill the radiator with engine coolant after in-
stalling the ECT sensor.

CAMSHAFT POSITION (CMP) SENSOR

Voltage Check

WARNING

Turning the ignition switch to the ON position
with the fuel injector connector still connected
will actuate the fuel injector. Disconnect the
fuel injector connector.

WARNING

Turning the ignition switch to the ON position
with the high-tension lead still connected will
generate sparks, which can cause electrical
shock. Disconnect the high-tension lead and
avoid it from grounding to the vehicle body.

1.

Verify that the ignition is OFF.

2.

Remove the distributor.

3.

Connect the distributor 4-pin connector.

4.

Disconnect the high-tension lead from the dis-
tributor side.

5.

Turn the ignition ON.

6.

Measure the voltage between terminal 3 (signal)
and terminal 1 (signal ground). See Figure 19.

7.

Rotate the distributor drive by hand and verify
the output signal. If not as specified, inspect the
related wiring harnesses for open or short. If
wiring harnesses are okay, replace the distribu-
tor.

Specification: 4 pulse (5.0 V)/rev.

OXYGEN SENSOR

Remove

1.

Disconnect the oxygen sensor electrical connec-
tor. See Figure 20.

2.

Remove oxygen sensor from the exhaust pipe.

Install

1.

Coat the oxygen sensor sparingly with an anti-
seize compound. Install the oxygen sensor and
tighten to 39 N•m (29 lbf ft).

2.

Connect the oxygen sensor electrical connector.

1.

DISTRIBUTOR

2.

DISTRIBUTOR (CMP SENSOR) CONNECTOR (ON DISTRIBUTOR)

Figure 19. Camshaft Position (CMP) Sensor Voltage Check

20

900 SRM 1127

Control System

1.

OXYGEN SENSOR

2.

ELECTRICAL CONNECTOR

3.

EXHAUST PIPE

Figure 20. Oxygen Sensor

MANIFOLD ABSOLUTE PRESSURE
(MAP)/BOOST SENSOR

Remove

1.

Disconnect the wiring harness connector from
the MAP/boost sensor connector.

2.

Disconnect the vacuum hose from the MAP/boost
sensor. See Figure 21.

3.

Remove the retaining screws from the MAP/boost
sensor and remove the MAP/boost sensor.

1.

RETAINING SCREWS

2.

MAP/BOOST SENSOR

3.

VACUUM HOSE

4.

INTAKE MANIFOLD

Figure 21. MAP/Boost Sensor

Install

1.

Place the MAP/boost sensor in position and in-
stall the retaining screws.

2.

Connect the vacuum hose to the MAP/boost sen-
sor.

3.

Connect the wiring harness connector to the
MAP/boost sensor connector.

21

Technical Data

900 SRM 1127

Technical Data

Table 3 shows the technical data specifications for
the Mazda 2.0L and 2.2L gasoline fuel systems.

Table 3. Gasoline Fuel Systems Technical Data

Engine

Item

2.0L

2.2L

Idle speed

775 to 825 (800 ±25) rpm

Idle-up speed*

GCU load ON

1000 ±100 rpm

Fuel line pressure

260 to 310 kPa (37 to 45 psi)

Fuel pressure

Fuel hold pressure

More than 140 kPa (20 psi)

Resistance ( 23 C (73 F))

14.2 to 14.8 Ohms

Fuel leakage

Less than 1 drop/2 minutes

Fuel injector

Injection volume

56 to 61 ml (1.9 to 2.0 oz)/15 seconds

(using a fuel injector tester).

Fuel line pressure (At vacuum ON)

200 to 240 kPa (29 to 35 psi)

Pressure regulator

Fuel line pressure (At vacuum
OFF)

260 to 310 kPa (37 to 45 psi)

*Excludes temporary idle speed drop just after the electrical or hydraulic loads are turned on.

22

TECHNICAL PUBLICATIONS

900 SRM 1127

5/05 (12/04) Printed in U.S.A.