1992 MAZDA PROTEGE Workshop Manual

HEATER U
4. Verify that the mode lever is in the defrost position.
5. Set the mode wire to clip A as shown, Keep natural tension
of the mode wire. (It is all right if the mode wire is slightly
pulled to the direction a) Push areas b and c simultaneous-
ly when setting the wire to the clip.
Note
l Do not push the inner wire of the mode wire when
setting, if pushed, it may result in deformation of
the wire and prevent the corret setting.
6. Check the function of the mode lever. If the result is not
good, pull the mode wire 2mm (0.08 in) in direction a.
7. Confirm the function of the mode lever.
8. Remove the set pin.
u-29

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 U
REFRIGERANT SYSTEM
Safety Precaution
1. R-12 liquid refrigerant is highly volatile. A drop of it on the
skin could result in localized frostbite. When handling the
refrigerant, be sure to wear gloves.
2. If the refrigerant splashes into the eyes, wash them with clean
water immediately. Always wear goggles or glasses to pro-
tect the eyes.
9MUOUX-125 3. The R-12 container is a highly pressurized vessel.
Never subject it to high heat, and be sure that the temper-
ature where it is stored is below 52OC
(125.6OF).
4. A halide leak detector is often used to check the system
for refrigerant leakage. R-l 2, upon coming into contact with
the flame, produces phosgene, a toxic gas. Always provide
adequate ventilation.
o3uoux-11 4
9MUOUX-12
Refrigerant System Service Basics
Refrigerant container service valve
1. Turn the handle fully counterclockwise before connecting
the valve to the refrigerant container.
2. Turn the outlet valve counterclockwise until it reaches its
highest position.
3. Turn the outlet valve fully clockwise by hand. Connect the
center hose to the valve fitting.
4. Turn the handle clockwise to puncture the sealed can.
5. Turn the handle fully counterclockwise to fill the center hose.
Do not open the high- or low-pressure manual valves.
6. Loosen the hose nut connected to the center fitting of the
manifold gauge. Allow air to escape. Then retighten the nut.
13uoux-012
u-31

CHARGING HOSE
CLOSED
CLOSED
23UOUX-061
CHARGING HOSE
CHARGING VALVE CLOSED 0
23UOUX.061
3. Connect high-and low-pressure side charging hoses and
stop valves to the refrigerant system service valves.
23UOUX-062
FREON (REFRIGERANT RECOVERY
ND RECYCLING
CONTAINER
VALVE
Manifold gauge set/Stop valve installation
Caution
l Connect all charging hoses via stop valves to avoid
venting the refrigerant remaining in the hoses into
the atomosphere. _A
l Do not disconnect the stop valve from the charg-
ing hose when there is refrigerant remaining in the
hose.
1. Turn the knob counterclockwise to close the stop valve.
2. Install the stop valve to the end of the charging hose of the
manifold gauge set.
Caution
l Verify that high-and low-pressure side valves of the
manifold gauge set are fully closed before connect-
ing the charging hose and stop valve to the refriger-
ant system service valve.
23UOUX-063 Evacuation/Airtiahtness test
1. Connect the manifold gauge set and stop valves to the
refrigerant system service valves.
2. Connect the center hose of the manifold gauge set to the
vacuum pump inlet.
3. Prepare as follows according to the charging method.
Charging from service container.
Connect the charging hose and service container valve to the
manifold gauge set air purge valve.
I
23UOUX-06
U-32
4
Refrigerant recovery operation.
Remove the refrigerant from the refrigerant system by using
a freon (refrigerant) recovery and recycling system.
Caution
. Never vent the refrigerant into the atomosphere.
l When using a freon recovery and recycling system,
follow the operation instructions provided by the
equipment manufacturer.
_-,

U
r
I
23UOUX-061
23UOUX-067
23UOUX-061 3
Caution
l Connect the charging hose to the air purge valve
via its tap pin side.
l Do not disconnect the charging hose or the serv-
ice container valve until the charging operation is
completed.
l Do not open the service container valve when not
used.
Charging from freon recovery and recycling system.
Connect the charging hose and stop valve to the manifold
gauge set air purge valve.
23UOUX-065
Caution
l Connect the charging hose to the air purge valve
via its tap pin side.
l Do not disconnect the charging hose or stop valve
until the charging operation is completed.
l Do not open the stop valve when not used.
4. Start the vacuum pump and open the high-and low-pressure
side valves of the manifold gauge set.
5. Start the pump and let it operate for 15 minutes.
6. Check high- and low-pressure side gauge readings. When
both of them are at 750 mmHg or more, close the manifold
gauge set valves.
7. Stop the vacuum pump and wait for about 5 minutes.
8. Verity that the low-pressure side gauge reading does not
change.
9. If the reading changes, retighten the piping connections and
repeat the evacuation operation.
10. If not changed, check for leaks (see below) and charge the
system.
u-33

ENGINE sro~i32 U
Leak test
1. Carry out the system evacuation and airtightness test as
described above.
2. Prepare as follows according to charging method.
Charging from service container.
Connect the refrigerant service container to the service con-
tainer valve (which is connected to the manifold gauge set air
purge valve) and open the service container.
Charging from freon recovery and recycling system.
Connect the charging valve of the system to the stop valve
(which is connected to the manifold gauge air purge valve).
23UOUX-06
23UOUX-070
I 23UOUX-072
I
80 x 0
23UOUX-07
u-34
3
3. Open the high-pressure side valve of the manifold gauge
set. Charge the system until the low-pressuer side gauge
indicates 98.1 kPa. (1 kg/cm*, 14.22 psi).
4. Close the high pressure side valve.
5. Check for leaks at the system piping joints by using a gas
leak tester.
6. If leaks are found, check the O-rings and tightening torques
at the joints. Replace or retighten as necessary.
7. If no leaks are found, fully charge the system.
Caution
l Carry out the leak test in an well-ventilated but still
air area because it is affected by moving air.
23UOUX-071
Initial charging from service container
1. Carry out the system evacuation, airtightness test, and leak
test.
2. Open the high-pressure side valve of the manifold gauge
set and charge the system as specified.
Charging amount: Approx. 400 g (14.12 oz)
3. Close the high pressure side valve.
4. Start the engine and actuate the A/C compressor.
Caution
l Do not turn the service container upside down while
charging when the engine is running.
l Do not open the high-pressure side valve while the
engine is running.
5. Open the low-pressure side valve of the manifold gauge set
and charge the system to specification.
Specified total refrigerant amount: 800 g (28.24 oz) -.

U
L
ENGINE STARTED
*-ENGINE STARTED
23UOUX.071
6. Close the low-pressure side valve.
7. Stop the engine.
8. Close the stop valves and the service container valve.
Caution
l Do not disconnect the stop valves or the service
container valve from the charging hoses when there
is refrigerant remaining in the hoses.
Refilling
Caution
l Do not overcharge the system.
l Note the sight glass during refilling the refrigerant.
Stop charging when no bubbles are observed in the
glass.
(Refer to page U-40).
l Care must be taken when the ambient temperature
is low. The bubbles may not be present even if the
refrigerant amount is insufficient.
1. Connect the manifold gauge set to the refrigerant system
charging valve.
(Refer to page U-32).
2. Start the engine.
3. Open the low-pressure side valve of the manifold gauge set
and charge the system as necessary.
4. Note the sight glass, and when no bubbles can be seen,
close the low-pressure side valve.
5. Stop the engine.
6. Close the stop valve and service container valve. Discon-
nect the stop valves quickly.
u-35

U AIR CONDITIONER
DRY AND WET THERMOMETER
13uoux-014
Performance test
After finishing repairs, conduct a performance test of the air
conditioning system as follows.
1. Connect the manifold gauge set. (Refer to page U-32.)
2. Start the engine and keep the engine speed at
1,500 rpm.
3. Operate the air conditioner at maximum cooling.
4. Open all windows and doors.
5. Place a dry-bulb thermometer in the center ventilator outlet.
6. Place a dry and wet thermometer close to the blower inlet.
7. Wait until the air conditioner outlet temperature stabilizes.
Stabilized condition
Blower inlet temperature: 25-35*C (77-95*F)
High-pressure side:
1,177-1,619 kPa (12.0-16.6 kg/cm’, 171-235 psi)
Note
l If the high-pressure side becomes too high, pour
cool water on the condenser. If It is too low, cover
the front of the condenser.
8. After the air conditioner stabilizes, read the dry and wet ther-
mometer at the air inlet.
9. Calculate the relative humidity from the chart below by com-
paring the wet- and dry-bulb readings.
05uoux-051
‘C ‘F
26
24
22
20
18
16
14
12
10
U
--k----
RELATIVE HUMIDITY ‘%’
I 96U16X.103
IO. Read the dry thermometer at the air outlet, and calculate
the difference between the inlet dry-bulb and outlet dry-bulb
temperatures.
11. Verify that the intersection of the relative humidity and tem-
perature difference is in the shaded zone.
U-36