1992 MAZDA PROTEGE relay

U
HEATER AND
AIR CONDITIONER SYSTEMS
INDEX ...................................................... u- 2
HEATER ................................................
AIR CONDITIONER ................................. ;r ;
TROUBLESHOOTING GUIDE.. .................... U- 4
CIRCUIT DIAGRAM ................................. u- 4
ELECTRICAL TROUBLESHOOTING TOOLS. U- 5
HEATER ................................................... u-20
STRUCTURAL VIEW ................................ u-20
HEATER UNIT ........................................ u-21
BLOWER UNIT ....................................... U-23
HEATER CONTROL UNIT.. ....................... U-26
AIR CONDITIONER .................................... u-30
STRUCTURAL VIEW ................................ u-30
REFRIGERANT SYSTEM ........................... u-31
COOLING UNIT ...................................... U-38
COMPRESSOR ....................................... u-41
MAGNETIC CLUTCH ............................... u-51
RECEIVER/DRIER .................................... U-52
CONDENSER ......................................... u-53
REFRIGERANT LINES .............................. u-54
REFRIGERANT PRESSURE SWITCH No.1.. . U-55
REFRIGERANT PRESSURE SWITCH No.2.. . U-55
A/C RELAY ............................................ U-56
CONDENSER FAN RELAY.. ......................
CONDENSER FAN .................................. z-f;
-
A/C SWITCH .......................................... u-57
23UOUX-001

INDEX U
AIR CONDITIONER
-1 c.Juuux-002
1 . Compressor 6. Refrigerant pressure switch No.2
Removal / Installation.. ................ page U-41 Inspection..
................................. page U-55
Disassembly I Assembly .............
page U-43 7. Condenser fan
Adjustment ................................. page U-46 Removal / Installation
.................. page U-57
2. Magnetic clutch Inspection ...................................
page U-57
Disassembly I Assembly .............
page U-51 8. Cooling unit
Inspection.. .................................
page U-51 Removal I Installation ..................
page U-38
Adjustment .................................
page U-51 Disassembly / Assembly..
........... page U-39
3. Condenser Replacement .............................. page U-39
Removal I Installation.. ................
page U-53 On-vehicle inspection..
............... page U-40
Inspection ...................................
page U-53 Inspection..
................................. page U-40
4 . Receiver/Drier
9. A/C relay
Removal I Installation.. ................
page U-52 Inspection ................................... page U-56
5. Refrigerant pressure switch No. 1
10. Condenser fan relay
Inspection.. .................................
page U-55 Inspection ................................... page U-56
u-3

TROUBLESHOOTING GUIDE
Symptom: Condenser fan does not operate. (Magnetic clutch operates normally.)
03uoux-009
I 23UOlJX-007
WITH
MTX AND
fi==Tl (B/O)...BP ENGINE
-’ WITH ATX
Step 1 Check condenser fan operation
1. Disconnect the condenser fan connector.
2. Apply battery voltage to terminal a and ground terminal b
and verify that the condenser fan operates.
3. If the condenser fan does not operate, replace it.
4. If the condenser fan operates, go to Step 2.
Step 2 Measure voltage at condenser fan
1. Disconnect the condenser fan connector.
2. Run the engine at idle.
3. Turn the A/C and blower switches ON.
4. Measure the voltage at the following terminal wire of the con-
denser fan connector.
VB: Battery voltage
Wire
WV Voltage
VB
ov Action -
Replace condenser fan
Go to Step 2
Step 3 Measure voltage at condenser fan relay
Measure the voltage at the following terminal wires of the con-
denser fan relay connector.
(BP engine with ATX)
VB: Battery voltage
(BP engine with MTX and 66 engine)
Ve: Battery voltage
Wire Voltage Action
o-/W) VI3 Repair wire (L/W)
ov Next check wire (L/Y)
VY) VB Repair wire (L/Y)
ov Next check wire (B/L)
VW VB Repair wire (B/L)
ov Next check wire (B)
03 Va Repair wire (B)
ov Replace condenser fan relay ,
U-8

TROUBLESHOOTING GUIDE
Symptom: Condenser fan and magnetic clutch do not operate.
03uoux-023
r
3EAR WIPER 10A OA
L
03uoux-02.
I
1 Step 1 Check fuses
1. Check the following fuses.
Fuse Amperage Location
AD FAN 20A In main fuse box
REAR WIPER 10A In fuse box
2. If the fuse is burned, check for a short-circuit in the wiring
harness before replacing it.
3. If the fuses are OK, go to Step 2.
I
23uoux-011
Step 2 Measure voltage at A/C relay connector
1. Run the engine at idle.
2. Turn the A/C and blower switches ON.
3. Measure the voltage at the following terminal wires of the
A/C relay connector. VEX Battery voltage
,
Wire
0-Q
W) Voltage Action
VB Next check wire (L/Y)
ov Repair wire (L/G)
V0 Next check wire (B/L)
ov
VB
ov
VB
ov Repair wire (L/Y)
Repair wire (B/L)
Next check wire (LIB)
Go to Step 3
Replace A/C relay
Step 3 Measure voltage at A/C switch
Measure the voltage at the following terminal wires of the A/C
switch connectors.
VB: Battery voltage
Step 4 Measure voltage at thermoswitch
Measure the voltage at the terminal wires of the thermoswitch
connector.
VB: Battery voltage
Wire
(G/R)
WB)
Voltage
VB
ov
VB
OV
Action
Repair wire (G/R)
Next check wire (G/B)
Go to Step 5
Check ECU ooeration
1 -. [ Refer to Secti6n F
u-12

U AIR CONDITIONER
AIR CONDITIONER
STRUCTURAL VIEW
/
23UOUX-02
6. Refrigerant pressure switch No.2
Inspection.. ................................. page U-55
7. Condenser fan
Removal / Installation.. ................ page U-57
Inspection.. ................................. page U-57
8. Cooling unit
Removal / Installation .................. page U-38
Disassembly / Assembly.. ........... page U-39
Replacement.. ............................ page U-39
On-vehicle inspection ................. page U-40
Inspection ................................... page U-40
9. A/C relay
Inspection ................................... page U-56 --’
10. Condenser fan relay
Inspection ................................... page U-56 1. Compressor
Removal / Installation . . . . . . . . . . . . . . . . . . page U-41
Disassembly / Assembly... . . . . . . . . . . page U-43
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-50
2. Magnetic clutch
Disassembly / Assembly . . . . . . . . . . . . . page U-51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-51
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-51
3. Condenser
Removal / Installation . . . . . . . . . . . . . . . . . . page U-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-53
4. Receiver/Drier
Removal / installation . . . . . . . . . . . . . . . . . . page U-52
5. Refrigerant pressure switch No.1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-55
u-30

AIR CONDITIONER
23UOUX-051
23UOUX-05
23UOUX-05
U-56
Caution
l While testing refrigerant pressure switch No.2, care-
fully note the high-pressure side refrigerant pres-
sure. If the pressure increases above 1,766 kPa (18
kg/cm2, 256 psi), stop the testing. _,
7. Disconnect the condenser fan connector.
8. Run the engine at 2,000 rpm, and operate the air condi-
tioner at maximum cooling position.
9. Check that the refrigerant pressure switch turns on when
the high-pressure side refrigerant pressure increases above
1,570 f 98 kPa (16 f 1 kg/cm2, 228 f 14 psi).
IO. If not as specified, replace the switch together with cooler
pipe No.2. (Refer to page U-54.)
A/C RELAY
Inspection
1. Disconnect the A/C relay connector.
2. Check continuity between terminals of the switch.
Terminals
Tester probe: + 1 Tester probe: -
a b Continuity
Yes
3. If not as specified, replace the relay.
4. If correct, go to the next step.
5. Apply battery voltage to terminal d and ground terminal a.
6. Check for continuity between terminals a and d.
Terminals
a-d Continuity
Yes
7. If not as specified, replace the relay.
CONDENSER FAN RELAY
Inspection
1. Disconnect the condenser fan relay connector.
2. Check continuity between terminals of the relay.
Terminals Continuity
I a-b Yes I
2
I c-d I No I
A 3. If not as specified, replace the relay.
4. If correct, go to the next step.
5. Apply battery voltage to terminal a and ground terminal b.
6. Check for continuity between terminals c and d.
Terminals Continuity
c-d Yes
7. If not as specified, replace the relay.

PARTS INDEX
‘I
A
ACCELERATOR CABLE ............................. F-l 14
ACCELERATOR PEDAL ............................. F-l 14
AIR CONDITIONER ...................................... u-30
A/C RELAY.. ........................................... U-56
A/C SWITCH ...........................................
U-57
COMPRESSOR.. ..................................... U-41
CONDENSER.. ....................................... U-53
CONDENSER FAN ................................. u-57
CONDENSER FAN RELAY .................... U-56
COOLING UNIT ..................................... U-38
MAGNETIC CLUTCH ............................. u-51
RECEIVER/DRIER .................................. U-52
REFRIGERANT PRESSURE SWITCH.. .. U-55
AIR FLOW METER ..................................... F-l 68
AIR VALVE.. ................................................ F-l 16
ALTERNATOR .............................................. G-10
ANTENNA FEEDER
AUDIO
....... .......................................................................................... T-i;
AUTOMATIC TRANSAXLE ............................. K-l
2-4 BRAKE BAND ................................ K-l 97
3-4 CLUTCH.. ....................................... K-l 87
ACCUMULATORS ................................ K-l 67
ATF ....................................................... K-135
ATF THERMOSENSOR ........................ K-142
BEARING COVER ASSEMBLY ............ K-208
CLUTCH ASSEMBLY ........................... K-l 72
CONTROL VALVE BODY.. .....
K-21 0,224,234
DIFFERENTIAL ..................................... K-236
DRIVE PLATE.. ..................................... K-267
EC-AT CONTROL UNIT ....................... K-144
HOLD SWITCH ..................................... K-140
HYDRAULIC CIRCUIT .......................... K-278
IDLER GEAR ........................................ K-203
INHIBITOR SWITCH ............................. K-l 41
LOW AND REVERSE BRAKE .............. K-192
MAIN CONTROL VALVE BODY .......... K-220
OIL COOLER.. ...................................... K-265
OIL PUMP ............................................
K-169
OIL SEAL ..............................................
K-209
ONE-WAY CLUTCH 2
CARRIER HUB ASSEMBLY ............... K-185
OUTPUT GEAR .................................... K-206
P RANGE SWITCH.. ............................. K-271
PREMAIN CONTROL VALVE BODY .a. K-218
PULSE GENERATOR ........................... K-142
SELECTOR LEVER ............................... K-272
SHIFT MECHANISM ............................. K-269
SHIFT-LOCK ACTUATOR
..................... K-271
SMALL SUN GEAR AND
ONE-WAY CLUTCH 1 ........................ K-l 82
SOLENOID VALVE.. ............................. K-l 43
SPEEDSENSOR .................................. K-l 43
THROTTLE CABLE .............................. K-l 37
TORQlJE CONVERTER.. ...................... K-l 66
TRANSAXLE UNIT. ......... K-149,153,246,261 UPPER CONTROL VALVE BODY.. ..... K-215
BACK-UP LIGHT SWITCH..
..........................
BATTERY T;4;
- .......................................................
BLOWER UNIT ............................................
U-23
BRAKE FLUID.. .............................................. P-8
BRAKE MASTER CYLINDER. ...................... P-10
BRAKE PEDAL ...............................................
P-8
C
CALIPER .................................................. P-21,26
CARGO COMPARTMENT LAMP ................. T-54
CENTRAL PROCESSING UNIT..
.................. T-55
CHARCOAL CANISTER ............................. F-l 41
CHECK VALVE (TWO-WAY) .......................
CHECK-AND-CUT VALVE - .......................... ;-;b$
CIRCUIT OPENING RELAY.. ...................... F-129
CLUTCH COVER ......................................... H-l 7
CLUTCH DISC ............................................. H-l 7
CLUTCH FLUID ............................................. H-4
CLUTCH MASTER CYLINDER.. .................... H-7
CLUTCH PEDAL ............................................ H-5
CLUTCH RELEASE CYLINDER..
................. H-12
CLUTCH SWITCH (MTX) ............................ F-l 72
COMBINATION SWITCH .............................. T-23
COWL GRILLE ............................................. S-53
CRUISE CONTROL UNIT.. ...................... T-78,85
D
DASHBOARD ............................................... S-94
DASHPOT ................................................... F-l 42
DISTRIBUTOR .............................................. G-20
DOOR LOCK TIMER UNIT ........................... T-17
DOOR MIRROR ............................................ S-54
REMOTE CONTROL MIRROR ............... S-56
REMOTE CONTROL MIRROR SWITCH. S-55
DOOR SPEAKER .......................................... T-98
DRIVE SHAFT.. ....................................... M-l 7,21
DRL RELAY.. ................................................ T-18
DRL RESISTOR ............................................ T-46
DUAL PROPORTIONING VALVE..
............... P-l 6
DYNAMIC CHAMBER ................................ F-l 12
E
ELECTRIC COOLING FAN SYSTEM ........... E-13
ENGINE (B6 & BP SOHC) ........................... Bl-2
CAMSHAFT ..........................................
Bl-58
CAMSHAFT PULLEY ...........................
Bl-65
CONNECTING ROD ............................. 81-63
PI-I

PARTS INDEX
I
CRANKSHAFT.. ....................................
I31 -64
CYLINDER BLOCK .............................. 61-60
CYLINDER HEAD..
............................... 81-54
CYLINDER HEAD GASKET .................
Bl-16
DRIVE BELT(S). ...................................... 81-5
FRONT OIL SEAL ................................ 81-23
HLA .............................................. Bl-7,20,60
OIL JET ................................................ 81-61
PISTON.. ...............................................
Bl-62
PISTON PIN..
........................................ 81-62
PISTON RING
....................................... 81-62
REAR
OIL SEAL..
................................. 81-25
TENSIONER, IDLER ............................. Bl-65
TENSIONER
SPRING ...........................
Bl-65
TIMING BELT ..................................
Bl-12,65
TIMING BELT PULLEY ........................
Bl-65
VALVE MECHANISM ........................... Bl-55
ENGINE
(BP DOHC) .................................... B2-2
CAMSHAFT ..........................................
82-58
CAMSHAFT PULLEY ...........................
B2-65
CONNECTING ROD..
........................... 82-63
CRANKSHAFT ......................................
B2-64
CYLINDER BLOCK ..............................
82-60
CYLINDER
HEAD.. ............................... B2-54
CYLINDER HEAD GASKET .................
82-16
DRIVE
BELTS.. .......................................
B2-5
FRONT
OIL SEAL ................................
82-26
H LA ..............................................
OIL JET .......................... B2-7iyL;;
......................
PISTON .................................................
B2-62
PISTON PIN ..........................................
82-62
PISTON RING..
..................................... 82-62
REAR OIL SEAL ................................... B2-28
TENSIONER, IDLER ............................. B2-65
TENSIONER SPRING ........................... B2-65
TIMING
BELT.. ................................
B2-12,65
TIMING BELT PULLEY ........................ 82-65
VALVE MECHANISM ........................... 82-55
ENGINE CONTROL UNIT (ECU) ............... F-149
ENGINE COOLANT
........................................ E-5
ENGINE OIL.. .................................................
D-7
ENGINE OIL FILTER.. .................................... D-8
’ EXHAUST SYSTEM. ...................................
F-136
EXTRACTOR CHAMBER .............................. S-53
F
FAN MOTOR (COOLING FAN). ................... E-14
FAN RELAY (COOLING FAN). ..................... E-18
FLASHER UNIT ............................................
T-17
FLOORMAT ..................................................
S-99
FLYWHEEL ..................................................
H-18
FRONT AXLE .................................................
M-4
FRONT BRAKE ............................................
P-l 8
FRONT BUMPER ......................................... S-39
FRONT DOOR ................................................
S-8
FRONT DOOR LOCK AND OPENER ..........
S-13
PI-2
FRONT FENDER PANEL ............................... S-7
FRONT LOWER ARM .................................. R-16
FRONT SHOCK ABSORBER AND SPRING R-11
FRONT SIDE WINDOW REGULATOR AND
GLASS ........................................................ S-10
FRONT STABILIZER..
................................... R-l 8
FRONT SUSPENSION .................................. R-l 0
FUEL FILLER LID AND OPENER..
.............. S-37
FUEL FILTER .............................................. F-l 24
FUEL GAUGE SENDER UNIT ..................... T-73
FUEL PUMP ............................................... F-125
FUEL TANK
................................................ F-123
FUSE AND JOINT BOX.. .............................. T-12
H
HEADLIGHT AND
FRONT COMBINATION LIGHT..
................ T-41
HEADLIGHT RELAY ..................................... T-l 8
HEADLINER ................................................. S-89
HEATER CONTROL UNIT.. ......................... U-26
HEATER UNIT
.............................................. U-21
HIGH-MOUNT STOPLIGHT
.......................... T-45
HIGH-TENSION LEAD ................................. G-l 7
HOOD ............................................................. S-5
HORN T-88
...........................................................
HORN RELAY
.......................................... T-18,88
.__. ’
I I
IGNITER .......................................................
G-23
IGNITION COIL.. .......................................... G-19
INJECTOR .................................................. F-l 31
INSTRUMENT CLUSTER
AND SPEEDOMETER CABLE
.................... T-69
INTAKE MANIFOLD ................................... F-113
INTERIOR LAMP ..................................... T-52,53
ISC VALVE.. ................................................ F-l 16
J
JOINT SHAFT (FRONT AXLE) .................... M-18
L
LATERAL LINK AND TRAILING LINK.. ....... R-26
LICENSE PLATE LIGHT.. ............................. T-47
i
M
I
---
MAIN RELAY (FUEL INJ. RELAY). ............ F-172
MANUAL STEERING ..................................... N-4
MANUAL TRANSAXLE (F5M-R). .................. Jl-2