1992 MAZDA PROTEGE clutch

TECHNICAL DATA TD
J2. MANUAL TRANSAXLE (G5M-R)
tern EnginelTransaxle BP DoHc
-__-
G BM-R
hansmission
shift lever position
First
Second
Third
;ear ratio
Fnt rrth Floor shift
3.307
1.833
1.310
1.030
3il Reverse
Viscosity
Capacity All-season
Above -18OC (OOF)
liters (US qt, imp qt) a. IOD
ATF Dexron@II, M2C33-F or SAE 75W-80
API service GL-4 SAE 8OW-90
3.35 (3.55, 2.96)
Clearance
Clearance of
idler gear
Clearance of
clutch sleeve
Clearance of lever and reverse Standard 0.1-0.32 (0.004-0.013)
mm (in) Wear limit 0.5 (0.020)
-
1 st-2nd 0.08-0.228 (0.003-0.009)
Standard 3rd-4th 0.1-0.5 (0.004-0.020)
shift fork and 5th~Rev. 0.15-0.458 (0.059-0.018)
mm (in)
1 st-2nd 0.728 (0.029)
Wear limit 3rd-4th 1.000 (0.039)
5th~Rev.
0.958 (0.03
synchronizer ring and gear Standard
mm (in) Wear limit I
First Standard
Limit
I I I 8) 1.5 (0.059)
0.8 (0.032)
0.05-0.28 (0.002’-0.011)
0.33 (0.013)
Gear thrust clearance
mm (in) Second
Third
Fourth
Fifth Standard
Limit
Standard
Limit
Standard
Limit
nr- --,_-..I
3tariuaru
Limit 0.175-0.455 (0.0069-0.0179)
0.505 (0.0199)
0.05-0.20 (0.002-0.008)
0.25 (0.010)
0.165-0.365 (0.0065-0.0144)
0.415 (0.0163)
al-O.22 (0.0039-0.0087)
0.27 (0.0106)
Bearing preload of primary shaf t gear
N.m (cm-kg, in-lb) 0.1-0.25 (1.0-2.5, 0.87-2.18)
Bearing preload of secondary shaft gear
N.m (cm-kg, in-lb)
Bearing preload adjust shim mm (in)
Drive and differential
Type
Final gear
Reduction ratio
Bearing preload N.m (cm-kg, in-lb)
Bearing
preload adjust
shim (in) mm
Backlash of side gear and pinion gear mm (in) 0.2-0.4 (2.0-4.0, 1.7-3.5)
0.20 (0.008) 0.30 (0.012) 0.40 (0.016) 0.50 (0.020)
0.25 (O.OlO), 0.35 (0.014) 0.45 (0.020) 0.55 (0.022)
0.60 (0.023) 0.65 (0.025) 0.70 (0.028)
Helical
4.105
1.4-2.0 (14-20, 12.2---17)
0.10 (0.004) 0.20 (0.008) 0.25 (0.010) 0.30 (0.012)
0.35 (0.014) 0.40 (0.016) 0.45 (0.018) 0.50 (0.020)
0.55
(0.022) 0.60
(0.024) 0.65 (0.026) 0.70 (0.028)
0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035)
0.95 (0.037) 1.00 (0.039), 1.05 (0.041) 1.10 (0.043)
1 ,15 (0.045) 1.20
(0.047)
o-o.1 (O-0.004)
TD-13

TD TECHNICAL DATA
K. AUTOMATIC TRANSAXLE
TransaxlelEngine F4A-EL
Item
66 SOHC
I BP SOHC
I BP DOHC Torque converter stall torque ratio
2.2 : 1
2.1 : 1
I 1st
2.800
Gear ratio .-.
2nd
1.540
3rd 1 .ooo
nn /“a..
n 7nn
I f-8 ^. .^ _^^ I
3 ,a?? I
Engine stall speed rpm D, S, L and A
Time lag -iOf I 7 Ann-3 7nn
I 7 7.513-7 550 I ran+ L,7”” +,I “V , -,--- . . ..--- , ,,200-2,500
0.5-0.6
, .
I 0.6-0.7
( D, S and L ranges
~-t- -r” I
&L :-I,- “7” \T.” V.“, “i)---,a,
nr IUlt:
I k :^^ -I ^^^.._^ Llllt: p,txis”ra R range 736---c-- . 983 17.5-9.0, 107-l 28)
I l/PI Ilsnlrm2 nci 1\1 u \‘.y,Y”’ , y-8, I n c lrw-4 I *n”nPc Y, ” UI I” L I UI ‘yvu I I FWA-1 no1 ma- ---
At stall ,_ - \-._ -10.2, 125-145)
R range I,41 3-1,638 (14.4-l 6.7, 205-237)
At idle 60-129 (0.61-1.31, 9-19)
At stall D range
I All.3 E?, ,A E,
Outer and inner rotor Standard “.“_ “... \-.-... - -v.vvru,
clearance
mm (in) Maximum
I n n!i (I7 nn7rv
.,.-- - . _ - - -,
Outer rotor clearance Standard n no-n 1.5 m mid- n n=m Y,YY “. * - \~ .--- -v.v.Jil I)
mm (in) Maximum 0.170 (0.0067)
Inner rotor inner Standard 0.04-0.115 (0.0078-0.0453)
diameter
mm (in) Maximum 0.125 (0.0049)
Number of drive/driven plates 414 I
Lt-+c---,,c) , \-t.d , -5.41, 64-77)
n n7-n n4 fn nn78- n finTQ
I I
T I Throttle pressure
kPa (kg/cm2, psi)
Oil pump
3-4 clutch
I Drive plate thickness 1.6 (0.063)
. ..I.. \‘..I , ,“,III,IIIUI,I
3-4 clutch clearance mm (in) 1.4 (0.055)
1.3-l .6 (0.051-0.063)
’ A ‘Ant==’ ’ C ‘“.063), 1.8 (0.071).
I Snan rim-7 ciza
mm fin I I.-t \“.“Qd,, I.” \”
^ ^ ,^ ^_... ,. ,. I,. “1 ,-I-’ I II ,y VI+...
.““’ \‘..I z.u (UUIY), z.z (U.O87j, 2.4 (0.095j.
1 Number of drive/driven plates
I 313
1.6 (0.063)
Drive plate thickness 1 Standard
mm (in) Minimum
Forward clutch clearance mm (in) ,
1.0-I .2 (0.039-n ’ 1.4 io.05si
I
“.347)
(0.071) 1.95 (0.07;), 2.1 (0.083) 2.25 (0.089)
I--’ ^^_ ,^ .,^
Snap ring size mm (in) 1.8 I
2.4
(u.uY~), L.CCJ (u. IUU), L.I
Number of drive/driven plates 2/z
Drive plate thickness Standard 1.6 (0.063)
mm (in) Minimum 1.4 (0.055)
Coasting clutch clearance mm (in) 1.0-l .2 (0.039-0.047)
4 c In Yj3), 1.75 (0.069), 1.9 (0.075) 2.05 (0.081)
.
L.C (u.u87), 2.35 (0.093) 2.5 (0.098), 2.65 (0.104)
1 Number of drive/driven plates I
2/z
1.6 (0.063) Forward clutch
Coasting clutch
IS nao rina size
Drive plate thickness Standard
I
mm (in) Minimu
Reverse clutch clearance mm (in) 1.0-l .3 (0.031
Snap ring size mm (in) 2.0 (0.079), 2.
2.6 (0.102) 2.” ,v., ,v,, J.V \v. g
Number of drive/driven elates 414
m- I i .4 io.055j
3-0.051)
2 (0.087) 2.4 (0.095),
cth3i1n Qn~n*~o
-=----I
Reverse clutch t
1 Drive plate thickness 1 Standard 1 1.6 (0.063)
mm (in) 1 Minimum 1.4 (0.055)
Low and reverse brake clearance mm (in) 2.1-2.4 (0.08: 3-0.094)
I
2.0
(0.079), 2.2 (0.087) 2.4 (0.095)
I I 2.6 (0.102), 2.8 (0.110)
3.0 (0.118) Snap ring size mm (in) 1 Low and
reverse brake
TO-I 4

TD TECHNICAL DATA
Spring name
2-3 accumulator
small spring Outer diameter Free length Wire diameter
mm (in) mm (in) No. of coil
mm (in) BP DOHC 11.6 (0.457)
59.7 (2.350)
16.9 1.8 (0.071)
56 SOHC
BP SOHC 10.0 (0.394) 71.8
(2.827) 24.2 1.4 (0.055)
2-3 accumulator BP DOHC 15.0
(0.591) 71.8 (2.827) 9.8
1.2 (0.047)
large spring B6 SOHC
BP SOHC 15.0 (0.591)
71.8 (2.827)
15.8 2.0 (0.079)
l-2 accumulator small spring
11.2 (0.441)
84.7 (3.335)
25.5 1.5 (0.059)
BP DOHC
- - -
-
l-2 accumulator
Accumulator large spring B6 SOHC
BP SOHC 16.0 (0.630)
84.7 (3.335) 19.5
1.9 (0.075)
B6 SOHC 10.8 (0.425) 101.2 (3.984)
28.2
1.2 (0.047)
N-D Accumulator
small spring BP SOHC
BP DOHC
10.8 (0.425) 101.2 (3.984)
28.2
1.2 (0.047)
B6 SOHC
15.0 (0.591) 94.2 (3.709)
16.5
1.6 (0.063)
N-D Accumulator
large spring BP SOHC
BP DOHC 15.0 (0.591) 94.2
(3.709) 16.5
1.6 (0.063)
N-R Accumulator small spring
9.8 (0.386)
93.2 (3.669) 31.5
1.3 (0.051)
N-R Accumulator large spring
14.0 (0.551) 106.5 (4.193)
23.0 1.7 (0.067)
3-4 clutch
Return spring
74.4 (2.929)
40.5 (1.594) 1 .o
5.0 (0.197)
Coasting clutch
Return spring
7.3 (0.287) 20.45 (0.805)
10.0 1 .o (0.039)
Low and reverse
brake Return
spring 5.55 (0.219)
14.3 (0.563)
12.0 0.75 (0.030)
Servo
Return spring
27.7 (1.091) 43.25 (1.703)
4.5
3.2 (0.126)
Vehicle Speed at Shift point Table -
lode
- -
angc
-
D Throttle condition
(Throttle sensor
voltage)
Fully opened
(4.0 volt)
Half throttle
(1.6-2.2 volt)
/ &%L) j 3 1 850-2,500 2,100-2,650 2,300-3,000 74-100 (46-62) 91-116 (56-72) 93-120 (58-74
Lock-up
[1,850-2,20011,950-2.550(2,300-2,700/74-88 (46--55)185-110 (53-68)(93-108 (58-67)1
Kir.kdnwn OD -+ DI
1,05U
%lly opened
i4.0 volt)
Half throttle
s2 -+ s3 5,000-5,45c
s3 -+ s2 2,900
S2 -+ ST 2,300-2,6OC
SI * 52
2.500-3.35C
(1.6-2.2 volt)
s2 -+ s3 v, v...
Fully opened Ll + L2 5,150-5,75(
w-dt I7w-ln
nlf throttle 6-7 7 vnltl I Ll + L2 (2.500-3.350(2,850-3,8OOj3.300-4.300125-34 (16-21$1-41 (19-25)j33-43 (20-27)1
TD-16

TECHNICAL DATA TD
U. HEATER AND AIR CONDITIONER SYSTEMS
Item Specifications
Refrigerant amount
g (04
Refrigerant pressure kPa (kg/cm2, psi) 750-800 (26.5-28.2)
High: 1,177-1,619 (12.0-16.5, 171-235)
Low: 147-294 (1.5-3.0, 21-43)
Compressor
Magnetic clutch
Condenser fan
Recerver/Drier Capacity cc (cu in)
Compressor oil amount cc (cu in)
Electrical load w
Electrical load w
Capacity cc (cu in) 115 (7.0)
loo---120 (6.1-7.3)
31
77
330 (20.1)
STANDARD BOLT AND NUT TIGHTENING TORQUE
Diameter Pitch 4T 6T 8T
mm (in) mm (in) N-m m-kg ft-lb N.m m-kg ft-lb N.m m-kg ft-lb
6 (0.236) 1 (0.039) 4.2-6.2 0.43-0.63 3.1-4.6 6.9-9.8 0.7-1.0 5.0-7.2 7.8-11.8 0.8-1.2 5.8-8.8
8 (0.315) 1.25 (0.049) 9.8-14.7 1.0-1.5
7.2-10.8 16-23 1.6-2.3 12-17 18-26 1.8-2.7 13-20
10 (0.394) 1.25 (0.049) 20-28 2.0-2.9
14-21 31-46 3.2-4.7 23-34 36-54 3.7-5.5 27-40
12 (0.472) 1.5 (0.059) 34-50 3.5-5.1 25-37 55-80 5.6-8.2
41-59 63-93 6.4-9.5 46-69
14 (0,551) 1.5 (0.059)
- - - 75-103 7.7-10.5 56-76 102-137
lo-14 75-101
1 16 (0.630) 1 1.5 iO.059j 1 - 1 - - 116-157 12-16 85-116 156-211 16-22 115-156
1 18 ;0.709j Il.5 iO.O59 1 - 1 -
167
1 20 i0.787; Il.5 iO.059i 1 - 1 - 1 - 12:
31 _..
22 (0.866) 1 1.5 io.059j 1 - 1 - 1 - 1314-423 __ ._ ,--. -._,
1 I
24 (0.945) 1 1.5
(0.059) 1 -
- 1475-546 41-56 (298-4031536-7261 55-74 1396-536 -2251 17-23 123-166 221-299 23-31 163-221
-3141 24-32 171-231 308-417 31-43 227-307
37-43 331-312 417-564 43-58 307-416
TD-21

SPECIAL TOOLS
GENERAL INFORMATION ........................
ENGINE .................................................. i;-
- ‘3
CLUTCH AND MANUAL TRANSAXLE.. ...... ST- 4
AUTOMATIC TRANSAXLE.. ...................... ST- 5
FRONT AND REAR AXLES.. ..................... ST- 7
STEERING SYSTEM ................................ ST- 8
BRAKING SYSTEM .................................. ST- 9
FRONT AND REAR SUSPENSIONS.. ......... ST-10
HEATER AND AIR CONDITIONER
SYSTEMS ............................................. ST-l 0
CHECKER AND OTHER EQUIPMENT.. ....... ST-10
23USTX-001

ST SPECIAL TOOLS
ENGINE (CONT’D)
TOOL NUMBER
& DESCRIPTION PRIORITY
49 E301 144
Removing plate A ILLUSTRATION
CLUTCH AND MANUAL TRANSAXLE
TOOL NUMBER
8, DESCRIPTION
49 GO17 5AO
Support, engine
49 SE01 310A
Clutch disc
centering tool
49 1285 071
Puller, bearing
49 GO19 OAO
Hanger, transaxle
49 8017 001
Bolt set
(Except
BP DOHC)
49 GO30 370
Removing plate
ST-4
PRIORITY
A
A
A
A ILLUSTRATION
I
=-a==-=
TOOL NUMBER
81 DESCRIPTION PRIORITY ILLUSTRATION -
- -
TOOL NUMBER
!I DESCRIPTION PRIORITY ILLUSTRATION
19 0636 145
Uler, fan A
oulley boss
49 GO30 440
Holder, primary A
shaft (BP DOHC)
T
49 F401 440
Holder, primary
shaft (Except
BP DOHC) A
49 0187 520
Bearing puller,
rear axle shaft
(Except
BP DOHC) A
49 GO30 455
Holder,
differential
side gear A
49 0259 770B
Wrench, flare nut A

SPECIAL TOOLS ST
CLUTCH AND MANUAL TRANSAXLE (CONT’D)
49 GO30 380C
49 0839 425C
49 BOO1 795
49 GO17 1AO
49 FTOl 361
Remover, bearing
49 DO17 2A2A
Shim selector set
AUTOMATIC TRANSAXLE
TOOL NUMBER
& DESCRIPTION PRIORITY ILLUSTRATION
49 B019 007
Adapter, preload A TOOL NUMBER
& DESCRIPTION PRIORITY ILLUSTRATION
49 F401 3306
Installer set,
bearing A
49 GO30 338
Attachment E
(BP DOHC) A
49 8017 102 I I
Preload adapter A
(BP DOHC)
49 GO17 202
Preload adapter A
(BP DOHC)
49 8017 1AO
Remover set,
bearing (Except
BP DOHC)
49 FTOl 515A
Adapter, preload A
TOOL NUMBER
81 DESCRIPTION PRIORITY ILLUSTRATION
49 8092 365
Remover set,
bearing
ST-5

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