1992 MAZDA PROTEGE engine oil

FUEL SYSTEM I-
9MUOF2-17
INJEC
GRO
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OSUOFX-17
T MANIFOLD DELIVERY’ PIPE
MUOFX-17
Installation
Install in the reverse order of removal, referring to Installa-
tion Note.
Tightening torque:
Delivery pipe
19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Installation note
1. Use new injector O-rings.
2. Apply a small amount of clean engine oil to the O-rings be-
fore installing.
3. Install new injector insulators.
4. Install the injectors.
F-l 33

G
ENGINE ELECTRICAL SYSTEM
INDEX ......................................................
OUTLINE ..................................................
SPECIFICATIONS .................................... G- 3
TROUBLESHOOTING
GUIDE.. .................... G-
4
DIAGNOSTIC INDEX ................................
SYMPTOM TROUBLESHOOTING..
............. :- t
-
CHARGING SYSTEM ................................. G- 6
PREPARATION .......................................
CIRCUIT DIAGRAM ................................. :I ;
TROUBLESHOOTING .............................. G- 7
BATTERY ............................................... G- 6
ALTERNATOR ........................................ G-10
DRIVE BELT ........................................... G-14
IGNITION SYSTEM .................................... G-15
PREPARATION ....................................... G-15
CIRCUIT DIAGRAM ................................. G-15
TROUBLESHOOTING .............................. G-16
IGNITION TIMING ................................... G-17
HIGH-TENSION LEAD .............................. G-17
SPARK PLUGS ....................................... G-16
IGNITION COIL ....................................... G-19
DISTRIBUTOR ........................................ G-20
IGNITER ................................................ G-23
STARTING SYSTEM .................................. G-24
PREPARATION ....................................... G-24
CIRCUIT DIAGRAM ................................. G-24
STARTER ...............................................
G-25
STARTER INTERLOCK SWITCH (MTX)
........ G-31
03UOGX-001

OUTLINE G
OUTLINE
SPECIFICATIONS
Item EnginelTransaxle
‘-2, B6 SOHC BP SOHC BP DOHC
MTX 1 ATX MTX ( ATX
Voltage v 1 12
I
3attery
Dark current*’ Type and capacity
(20-hour rate)
mA 55D23L (60AH) 55D23L (60AH)
Max. 20.0
L\lternator
Starter
Type AC
output V-A 12-65
Regulator type Transistorized (built-in IC regulator)
Regulated voltage V 14.1-14.7
Brush length Standard 21.5 (0.846)
mm (in) Minimum 8.0 (0.315)
Drive belt deflection
New
98 N (10 kg, 22 lb)
mm (in) Used 8-Q (0.31-0.35)
Q-10 (0.35-0.39)
Type
I Direct Direct
I Coaxial
Direct Coaxial
reduction reduction I
output V-kW 12-0.95 12-0.95 12-1.4
12-0.95 12-1.4
Brush length Standard 17 (0.67) 17 (0.67) 17.5 (0.69) 17 (0.67)
17.5 (0.69)
mm (in) Minimum 11.5 (0.453) 11.5 (0.453) 10.0 (0.39) 11.5 (0.453) 10.0 (0.39)
Distributor
Ignition timing BTDC
(TEN terminal of diagnosis connector grounded) Electronic spark advance (photo diode)
6O--8O 4O-6O Q”-1 1 o
Ignition coil
Spark plug Resistance
(at 20% [68OF]) Primary
coil winding 0.81-O.QQg
Secondary
coil winding IO-16 kg
BKR5E-11 BKR5Ell BKR5Ell
NGK
BKR6E-11 BKRGEl 1 BKRGEli
BKR7Ell
Type NIPPON-
DENSON Kl GPR-Ul l
K20PRU 11 KIGPR-Ull
K20PR-Ul l KIGPR-Ull
K20PRUll
K22PR-Ul l
I Plua aao mm (in) I 1.0-l .l (0.039-0.043)
Firing order
’ Dark current is the constant flow of current while the ignition switch is OFF.
(i.e. engine control unit, audio, etc.) l-3-4-2
23lJOGX-00
G-3

TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
DIAGNOSTIC INDEX
No. Troubleshooting items
Page
1
Will not crank-starter motor does not operate G-4
2
Will not crank-starter motor spins G-4
3
Cranks slowly G-5 4
Alternator warning lamp illuminates when engine running
G-5
5 Discharged battery G-5
6
Misfire
G-5
03UOGX-004
SYMPTOM TROUBLESHOOTING -
1
iTEl
1
2
3 Will not crank-Starter motor does not operate
INSPECTION
T
Check if engine cranks with fully charged battery
Check if battery voltage is applied at B terminal
TERMINAL
battery voltaae is aoolied at S terminal
when clutch pedal depressed (MTX) and ignition
switch in START position
S TERMINAL
Yes
No
Yes ACTION Check charging system CT- page G-7
Go to next step
Go to next step
No Check wire harness
Yes
l Check magnetic switch l Check field coil l Check armature
No
l Check starter interlock switch (MTX) ccp: page G-31 l Check inhibitor switch (ATX) c=p Section K l Check ignition switch CI Section T l Check wire harness
1 L-T page G-28
CT- page G-29
CT- page G-29
23UOGX.001
03UOGX-006
G-4

G IGNITION SYSTEM
TROUBLESHOOTING
iTEP
INSPECTION
ACTION
1
Check if MIL illuminates when engine is running Yes Check for malfunction code number
and perform troubleshooting (TEN ter-
minal grounded) c7 Section F
No Go to next step
2 Drsconnect high-tension lead from distributor and
Yes
check for strong blue spark while cranking en-
l Check distributor cap and rotor v page G-22
gine * Check high-tension lead
KP page G-19 c7 page G-17
+ Ignition system normal
No
Go to next step
3 Check if resistance of ignition coil is OK
Yes
Go to next step ~7
page G-19
Specification (at 20°C [66”9):
Primary coil winding: 0.81-0.99Q No
Replace ignition coil
Secondary coil winding: IO-16 kQ
-i
Check if resistance of high-tension leads is OK Yes Go to next step
D= page G-17
Specification: 16 kQ per 1 m (3.28 ft)
No Replace high-tension lead
5 Check if igniter is OK
m- page G-23 Yes
Replace ECU
No
Replace igniter
03UOGX-03
G-16

IGNITION SYSTEM . . . ._,
03UOGX-04
Lszl /
P
0 V
- 23UOGX-OC
03UOGX-048
03UOGX-04
03UOGX-0%
IGNITION COIL
Inspection
Spark test
1. Disconnect the high-tension lead from the distributor.
2. Hold it with insulated pliers 5-l
Omm (0.20-0.39 in) from
a ground.
3. Crank the engine and verify that a strong blue spark is
visible.
4. If there is no spark, disconnect the connector from the igni-
tion coil and check for voltage at the positive (+) terminal
of the connector with the ignition switch in the ON position.
Specification: Battery voltage
5. If there is no voltage, check the main fuse, ignition switch,
and wire harness.
Primary coil winding
1. Use an ohmmeter and measure resistance of the primary
coil winding. If not within specification, replace the coil.
Prlmary coil resistance: 0.81-0.99112 (at 2O*C [88*F])
Secondary coil winding
1. Use an ohmmeter and measure resistance of the secon-
dary coil winding. If not within specification replace the coil.
Secondary coil resistance: lo-18 kQ (at 20°C [68*F])
Insulation of case
1. Use a 500V megger tester to measure the insulation resis-
tance between each terminal and the case.
Speclficatlon: 10 MS1 min.
G-19

OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
-
-
Item
Clutch control Engine/Transaxle B6 SOHC BP SOHC BP DOHC
F!Wl-R GBM-R Hvdraulic
Clutch cover
Clutch disc Type
Set load Diaphragm spring
N
(kg, lb) 1 3,630 (370, 814) 1 3,826 (390, 858) 1 3,846 (392, 862)
30 17.48)
200 (7.87) 215 (8.46) Outer diameter mm (in)
Inner diameter mm (in)
Pressure plate
side mm (in)
Thickness
Flywheel side
mm lit-d
1! , I
130 (5.12) ’ ’
150 i5.91 j
3.5 (0.138) 3.8 (0.150)
3.5 (0.138)
Type Suspended
Clutch pedal
Master cylinder
Release cylinder
Clutch fluid Pedal ratio 6.55
Full stroke mm (in) 135 (5.32)
Height (With carpet)
mm (in) 196-204 (7.72-8.03)
Inner diameter mm (in) 15.87 (0.625)
Inner diameter
mm (in) 19.05 (0.750)
SAE J1703 or FMVSS116 DOT-3
23UOHX-003
TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page
Slipping
Clutch disc facing worn excessively Replace H-15, 17
Clutch disc facing surface hardened or oil on surface Repair or replace H-15
Pressure plate damaged Repair or replace H-15
Diaphragm spring damaged or weakened Replace H-15
Insufficient clutch pedal play Adjust H- 5
Clutch pedal sticking Repair or replace H- 6
Flywheel damaged Repair or replace H-15, 17 Faulty disen-
Excessive runout or damaged clutch disc Replace H-15, 17 gagement Clutch disc splines rusted or worn Remove rust or replace H-15
Oil on facing Repair or replace H-15
Diaphragm spring weakened Replace H-15
Excessive clutch pedal play Adjust H- 5
Insufficient clutch fluid
Add fluid H- 3
Leakage of clutch fluid Locate and repair or -
replace Clutch vibrates
Oil on facing Repair or replace H-15 when accelerating Torsion rubbers weakened Replace H-15
Clutch disc facing hardened or damaged Repair or replace H-15
Clutch disc facing rivets loose Replace H-15
Pressure plate damaged or excessive runout Replace H-15
Flywheel surface hardened or damaged Repair or replace H-15
Loose or worn engine mount Tighten or replace - Clutch pedal
Pedal shaft not properly lubricated Lubricate or replace H- 6 sticking
Abnormal noise
Clutch release bearing damaged Replace H-15, 17
Poor lubrication of release bearing sleeve Lubricate or replace H-15
Torsion rubbers weakened Replace H-15
Excessive crankshaft end play Repair Refer to Section E
Pilot bearing worn or damaged Replace H-15, 18
Worn pivot points of release fork Repair or replace H-15
^^. .^. I~, ^r
H-3

OUTLINE Jl
OUTLINE
SPECIFICATIONS
c EnginelTransaxle
B6 SOHC BP SOHC
Item FSM-R
I
Transaxle control
I Floor shift
Synchromesh system Forward: Synchromesh
Reverse: Selective sliding
1 1st
I 3.416
2nd 1.842
I
Gear ratio
4th
Final aear ratio 5th
Reverse I
0.918
0.731
3.214
4.105 3.619
Grade
I API service GL-4
Oil Viscosity
I SAE 75W-90
Capacity liters (US qt, Imp qt) 2.68 (2.83, 2.36)
13UOJl-00
Jl-3