1992 MAZDA PROTEGE ignition

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

TROUBLESHOOTING GUIDE G
3 Cranks slowly
STEP INSPECTION ACTION
1 Check if engine cranks normally with fully Yes Check charging system CT page G-7
charged battery
No Go to next step
2 Check starter cable connection for looseness Yes Repair or replace connection
and corrosion
OBUOGX-OC
I 1 4
.
Alternator warning lamp illuminates when engine running
STEP INSPECTION ACTION
1 Check for correct battery voltage at idle Yes Check wire harness between alternator L terminal and aI*
Specification: 14.1--14.7V ternator warning lamp
No Check charging system w page G-7
03UOGX-008
5 I Discharged battery I 1TEP INSPECTION
f Check charging system w page G-7 -
6
TEF
1
r
--
Yes
03UOGX-009
ACTION
Turn ignition switch ON and check dark current as shown
Dark current: Below 20mA
No Repair or replace parts as necessary 1
Misfire
INSPECTION
-
Disconnect high-tension lead from each spark
plug and check for strong blue spark while
cranking
, i
Yes
No T-
I
ACTION
- Check spark plug w page G-f8
~3 If OK, engine electrical system normal
~3 If not OK, clean or replace spark plug
Check ignition system ci’ page G-16
1 03UOGX-010
G-5

G CHARGING SYSTEM
03UOGX-011
CIRCUIT DIAGRAM
CHARGING SYSTEM
PREPARATION
SST
I I
49 9200 020
Tension gauge,
V-ribbed belt For
inspection of
drive belt tension
STATOR
1 DIODE TRIO
T l-f-l /
-I J
WARNING
t
I --.- I I I I 15A
e I
I I -L
-E-
I IC REGULATOR
0
-
BATTERY = IGNITION
SWITCH
03u0tix-012
The alternator has a self-diagnostic function to warn of the following
If a problem arises, the alternator warning lamp illuminates. problems in the charging system.
1. S terminal circtiit open
2. No voltage output
3. Field coil circuit open
4. B terminal circuit open
5. Voltage output too high
G-6

IGNITION SYSTEM G
IGNITION SYSTEM
PREPARATION
SST
49 NO18 001
Adapter Harness
CIRCUIT DIAGRAM
ECU
T
IGNITION SWITCH
,
I
DISTRIBUTOR
7
1 ZL BATTERY
IGNITER
03UOGX-03t
G-15

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 G
r
03UOGX-03
SOHC
LOCK BOLTS
DOHC
A LOCK BOLTS I 03UOGX-0’
03UOGX-C
IGNITION TIMING
Adjustment
1. Warm UD the enaine to normal operating temperature.
2. Turn all ‘electricarloads OFF.
3. Turn the A/C switch OFF.
4. Connect the
SST.
5. Set switch A on the System Selector to position
SWITCH to SELF-TEST. 1 and TEST
Note
l To create the test condition without using the Sys-
tem Selector, connect terminals TEN and GND of
the diagnosis connector with a jumper wlre.
6. Check the ignition timing.
Specification
Engine
Ignition timing
BTDC B6 SOHC BP SOHC
60-8O 4O-6O
BP DOHC
9°-110
7. If the ignition timing is not as specified, loosen the distribu-
tor lock bolts and turn the distributor to make the adjustment.
8. Tighten the distributor lock bolts to the specified torque.
Tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
HIGH-TENSION LEAD
Inspection
1. Measure resistance of the high-tension leads.
Specification: 16 kg per 1 m (3.26 ft)
G-l 7

G IGNITION SYSTEM
-.-.. .----___ 03UOGX-042
03UOGX-04
--.---- J
03UOGX-044
WEAR AND CARBON
/
c- -BURNT
PLUG GAP
L--
c
DAMAGE AND
,llllll....*llll,lllf DETERIORATIOF
; -,DAMAGE
03UOGX.04
G-18
SPARKPLUGS
Removal / Installation
1. Remove and install the high-tension leads carefully.
Caution
l When the spark plug lead is to be pulled off, be sure
to pull the boot itself, not the wire.
Y’
2. Remove and install the spark plug with a plug socket.
Caution
l Be sure the socket is fit squarely over the spark
plug.
3. Apply anti-seize compound or molybdenum-based lubricant
to the spark plug threads.
4. Tighten the spark plug to the specified torque.
Spark plug Tightening torque:
15-23 N.m (1 S-2.3 m-kg, 11-17 f&lb)
Inspection
1. Remove the spark plug.
2. Connect the spark plug to a high-tension lead.
3. Hold the spark plug with insulated pliers
5-10mm
(0.20-0.39 in) from a ground.
4. Crank the engine and verify that there is a strong blue spark.
4
Note
l If there Is no spark, replace the spark plug.
5. Check the following points. If a problem is found, replace
the spark plug.
l Damaged insulation.
l Worn electrodes.
l Carbon deposits.
If cleaning is necessary, use a plug cleaner or a wire
brush. Clean the upper insulator also.
l Damaged gasket.
l Burnt condition.
Plug gap: 1.0-l .l mm (0.039-0.043 in)