1992 MAZDA PROTEGE air condition

7 Schedule (Cont’d)
rile
iii
48
30
-
R
I
R !rs
25
40
25
-
-i- , whichever comes first
OPERATION MAINTENANCE Number of m
INTERVALS Months
x 1,000 km
x 1,000 miles
ii
is
G
-
i-
-
-
I
5-
T
-
-
-
-
-
-
- ii
z
ro
-
I-
-
-
I
- 45
72
45
-
-i-
-
-
I
-
ry 15 month:
I I I
A
t
A
j
milt Service data and inspection points Page
l Capacity
MTX B6, BP SOHC:
2.68 liters (2.83 US qt, 2.36 Imp qt)
BP DOHC
3.35 liters (3.55 US qt, 2.96 Imp qt)
ATX: 6.3 liters (6.7 US qt, 5.5 Imp qt)
l Level and condition
- Jl-7
J2-7
- Transaxle oil
l Wear and damaae -i- -i- -i- -
Brake fluid, clutch fluid
Brake fluid*3 -
Q-3, 5
Q-6
N-27
P-28
P-29 I I
- I
1,oo
-i
-
-
-
-
-
-
- I
G
T
-
-
-
-
-
-
- I
15,(
I Tire inflation pressure and wear l Proper pressure-
-
l Level and condition
l Wheel cylinder operation and leakage l Lining for wear or damage l Lining thickness:
Minimum 1 .Omm (0.04 in)
l Drum inner diameter. 3s) or f
I I
I
:t r
- Rotate tires
Power steering fluid
Drum brake ? every
I I
Disc brake I I
Maximum 201mm (7.91 in)
l Caliper operation l Disd plate thickness:
Minimum Front.... 20mm (0.79 in)
Rear . . . . . 7.0mm (0.28 in)
l Pad thickness:
Minimum Front.... 2.0mm (0.08 in) P-20
P-25
P-l 8
P-25
N-27
N-8 Rear . . . . . 1 .Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozina
l Free play.... O--3OmmjO-1.18 in)
l Damage looseness and grease leakage
l Cracking and damage
l Insulator clearawp .-v
-
Steering operation and linkage
I
-i-
-I-
-i- Front suspension ball joint
Drive shaft dust boots
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor
Suspension components (front and rear)
All chassis and body nuts and bolts
All locks and hinaes
Washer fluid -
M-21
F-136
u-35
u-39
-
- IY efrigerant amount ann
*. I# mspec
Inspect operation annualry -
l Damaae
l Retighten all loose nuts and bolts
l Lubricate all locks and hinges
l Level
l ODeration - Function of all lights l !%t and damage -

F OUTLINE
COMPONENT DESCRIPTIONS
Component
Air cleaner
Airflow meter
Mr valve
Atmospheric pressure
Sensor
Catalytic converter Function Remark
Filters air entering throttle body
Detects amount of intake air; sends signal to intake air thermosensor and fuel pump
ECU switch included
Supplies bypass air into dynamic chamber
l Engine speed increased to shorten
when engine is cold warm-up period
l Thermowax type l Installed in dynamic chamber
Detects atmospheric pressure; sends signal Built in ECU
to ECU
Reduces HC, CO, and NOx by chemical Monolith type
reaction Charcoal canister
Stores fuel tank fumes while engine stopped Check valve
Controls pressure in fuel tank Two-way type Circuit opening relay
Voltage for fuel pump while engine running Clutch switch (MTX)
Detects clutch condition; sends signal to Switch OFF when clutch pedal released
ECU Diagnosis connector
Concentrated service connector 25pin (located near left suspension mount-
Concentrated terminals: ing block)
1. EGI self-diagnostic terminal
2. EC-AT self-diagnostic terminal
3. Test terminal
4. Fuel pump check terminal
5. Cooling fan check terminal
6. Engine rpm output terminal Dynamic chamber
Interconnects all cylinders Engine control unit (ECU) Detects the following:
1. A/C operation 1. A/C switch
2. Air/fuel ratio (Oxygen concentration) 2. Oxygen sensor
3. ATF thermosensor
4. Atmospheric pressure 4. Atmospheric pressure sensor
5. Braking signal 5. Stoplight switch (MTX)
6. Cranking signal 6. Ignition switch (START Position)
7. DRL (Daytime Running Light) operation 7. DRL relay (Canada)
8. E/L operation 8. Blower motor switch, cooling fan relay,
headlight switch, and rear window
defroster switch
9. Engine coolant temperature 9. Water thermosensor
10. Engine speed 10. Distributor (Ne-signal)
11. Ignition ON signal 11. Ignition switch
12. In-gear condition 12. Neutral and clutch switches (MTX)
13. Inhibitor switch (ATX) 13. N range, D range, S range, L range
switch
14. Intake air amount 14. Airflow meter
15. Intake air temperature 15. Intake air thermosensor
(In airflow meter)
16. No.1 piston TDC of compression
17. P/S operation
18. Shift solenoid (ATX)
19. Test signal (Ignition timing, idle speed,
Malfunction code No.)
20. Throttle valve fully closed/fully open
condition 16. Distributor (G-signal) DOHC)
17. P/S pressure switch
18. 1-2, 2-3, 3-4, Lockup solenoid
19. Diagnosis connector
(TEN terminal)
20. Throttle sensor (MTX)
21. Throttle valve opening angle
22. Turbine sensor 21. Throttle sensor (ATX) .__r
F-10

OUTLINE
Component Function Remark
Engine control unit (ECU) Controls operation of the following:
(Cont’d)
1. A/C (Cut-off) 1. A/C relay
2. Fail-safe function 2. Self-Diagnosis Checker and MIL
3. Fuel injection system 3. Injector
4. idle speed control 4. Idle speed control (ISC) valve
5. Ignition timing control system 5. Igniter
6. Monitor function 6. Monitor lamp (Self-Diagnosis Checker)
7. Pressure regulator control system 7. Solenoid valve
(Pressure regulator control) (BP)
8. Purge control system 8. Purge control solenoid valve
9. VICS 9. Solenoid valve (WCS) (DOHC) Fuel filter
Filters particles from fuel Fuel pump
Provides fuel to injectors l Operates while engine running l Installed in fuel tank Igniter
Receives spark signal from ECU and gener-
ates high voltage in ignition coil Ignition switch
Engine cranking signal sent to ECU (START position)
Inhibitor switch (ATX)
Detects in-gear condition; sends signal to Switch ON in N or P range
ECU Injector
Intake air thermosensor
Idle speed control (ISC)
valve
Main relay
(FUEL INJ relay)
MIL (Malfunction
indicator lamp)
Neutral switch (MTX)
Oxygen sensor
PCV valve
P/S pressure switch
Pressure regulator
Resonance chamber
Resonance duct
Separator
Stoplight switch
Solenoid valve
(Purge control)
Shutter valve actuator
(DOHC)
Throttle body
Throttle sensor
Injects fuel into intake port l Controlled by signals from ECU
l High-ohmic injector
Detects intake air temperature; sends signal Installed on dynamic chamber
to ECU
Controls bypass air amount Controlled by duty signal from ECU
Supplies electric current to injectors, ECU,
etc.
Lamp flashes to indicate malfunction code
number of input and output devices
Detects in-gear condition; sends signal to
ECU
Detects oxygen concentration; sends signal
to ECU
Controls blowby gas introduced into engine
Detects P/S operation; sends signal to ECU
Adjusts fuel pressure supplied to injectors
Reduces intake air noise
Reduces intake air noise
Prevents fuel from flowing into charcoal
canister
Detects braking operation (deceleration),
sends signal to ECU
Controls evaporative fumes from canister to
intake manifold
Closes/opens shutter valve to improve
torque characteristics
Controls intake air quantity
l Detects throttle valve fully closed/fully
opened condition (MTX) TEN terminal grounded
Switch ON in neutral
Zirconia ceramic and platinum coating
P/S: ON when steering wheel turned right or
left
Controlled by duty signal from ECU
For Variable inertia charging system (VICS*)
Integrated throttle sensor, dashpot, and ISC
valve
l Detects throttle valve opening angle
(A-W
l Sends signals to ECU
F-l 7

F TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
ENGINE CONTROL OPERATION CHART
Note
Input Device and Engine Conditions
l The data in this chart is for reference only.
INPUT DEVICES APPROX,- SENSORS
MATE TIME G& THROTTLE SENSOR
(BASED ON TRIBUTOR
WATER INTAKE
10-16°C, (G. OXYGEN AIRFLOW AIR
VT
POW
.50-6OOF
SIGNAL)” ;;;;;f- SENSOR METER
AMBIENT) (Ne-SIGNAL) THERMO- TERMINAL TERMINAL yE\MINAL
CONDITIONS SENSOR (ATX)
WX)
A
c
CRANKING
-COLD ENGINE Signal has Signal has Signal has Signal has Slgnal has Slgnal has
l COLD AIR zero no affect no effect no effect no effect no effect
no effect
. COLD COOLANT on ECU on ECU on ECU on ECU on ECU
on ECU
Cool to A A
COLD START
warm: Low volume Closed Closed
Closed
-FAST IDLE
One
Medium airflow: throttle: throttle:
l COLD AIR
minute
voltage High volt-
Low volt- Low volt- throttle.
Low volt-
* COLD COOLANT
(3.5” and :zo:o, ,,Pbove 1’,“,“$; a(ogi-O,8”) ;149&“) we W)
dropping) to high
(68OF)]:
COLD DRIVEAWAY voltage A
Above
-PART THROTTLE Two (O-0.9”) 2.3”
l COLD AIR minutes
l COLD COOLANT
v v ,,
Warm: Medi- Sensor Moderate II
WARM DRIVEAWAY
volume air-
-PART THROTTLE Three N&IGNAL um voitage hot:
flow: Low
l WARM AIR minutes Sends all Vvwrox switching l WARM COOLANT cylinders 0.7V and
from high to medium
Part Part
TDC signal dropping) voltage voltage
throttle: throttle.
)
A (0.9V) (1 .o-3.5”)
to ECU
.“~ Medium Medium
HOT CRUISE
s voltage voltage
Open
l WARM AIR G-
SIGNAL”’ to low (0.8-3.0”) (4.5-5.5”) throttle:
l WARM COOLANT High
Sends No. voltage
1 cylinder (0.1”) voltage
1 (battery
TDC (com-
1 I voltage)
HOT ACCELERATION pression)
-60% THROTTLE signal to
Moderate
ECU
to strong
High Cool lo warm
voltage ;$,“,” Of j-20-4OT
f t
HOT ACCELERATION
More’ than Hot: Low (0.9”) Low (-4-‘04”F)l: W,ds open
voltage 1.5-4.3v
throttle: Wide open
-WIDE OPEN
four voltage
High volt- throttle
THROTTLE (0.5-1.5V)
minutes (Below High
0.5”) age (Above
voltage (OV)
t 1 3.OV)
I,
A 1. /I
DECELERATION
-CLOSED THROTTLE
HOT CURB IDLE
-EXTENDED
HOT ENGINE
SHUTDOWN Low
voltage
(0”) Low Closed Closed
Closed
volume throttle: throttle.
throttle.
of airflow:
~~~~!$$ (Above Low Low
Low
voltage voltage
voltage
to low 3.OV) (0.2-0.N) (4.5-5 5V) (OV)
voltage
(0.75%
t t 1 0.25”)
r v 1 I I
Sensor
hot: Low
OFF OFF voltage
-
(0.1”) until OFF OFF OFF OFF
OFF
sensw
COOIS
._-

F TROUBLESHOOTING GUIDE
Output Devices and Engine Conditions
Note
. The data in this chart is for reference only.
INJECTOR
CONDITIONS
CRANKING
-COLD ENGINE
l COLD AIR l COLD COOLANT
COLD START
-FAST IDLE
l COLD AIR l COLD COOLANT
COLD DRIVEAWAY
-PART THROTTLE
l COLD AIR l COLD COOLANT
WARM DRIVEAWAY
-PART THROTTLE
. WARM AIR
l WARM COOLANT
HOT CRUISE
l WARM AIR l WARM COOLANT Zero
One
mrnute
Two
minutes
Three
minutes
I AIR
INJECTION “AL”E
INJECTION TlMlNG
A
All A
cylinders
each
ignition
pulse
1
Rich Open:
coolant
tem-
perature:
Below
40%
(104OF)
,
I/
Rich and
2-group” 1’
lean l-group” /I
,
i
HOT ACCELERATION
-60% THROTTLE
-lOT ACCELERATION
-WIDE OPEN
THROTTLE
Closed ISC
VALVE
1, THREE-WAY
SOLENOID SOLENOID
VALVE VALVE
(PURGE
(PRESSURE
CONTROL) REGULATOR
CONTROL)‘3
c
OFF
(Purge
cut)
Large
1
, AK
RELAY
amount or
bypass air
OFF
(Vacuum
to
pressure
regulator)
After start-
rng: ON dur-
ing hot start
only (Vacu-
um cut)
OFF
l 2 SOHC, *’ BP
F-22

TROUBLESHOOTING GUIDE F
USING THIS SECTION
Introduction
Most of the fuel and emission control system is electrically controlled, often making it difficult to diagnose
problems in the system, especially intermittent problems, Before undertaking actual checks, take a few minutes
to talk with a customer who approaches with a drivability complaint. The customer is often a good source
of information on such problems, especially intermittent ones. Through talks with the customer, one can find
out what the symptoms are and under what conditions they occur.
Work flow
CHECK IN
LISTEN TO CUSTOMER COMPLAINTS
REFER TO TROUBLESHOOTING PAGE THAT - - - - - - - - - - - DIAGNOSTIC INDEX
CORRESPONDS TO ACTUAL SYMPTOM (Refer to page F-23)
CHECK FOR WHAT IS BAD IN SYSTEM - - - - - - - - - - - - - INSPECTION
1
CHECK FOR WHAT PART IS BAD - - - - - - -,- - - - - - - ACTION
i I
REPAIR/REPLACEMENT - - - - - - - - 1
I
DETERMINE IF TROUBLE HAS BEEN ELIMINATED
1 Yes
CHECK OUT
13lJOFX-008
Diagnostic index
No.:
Each troubleshooting item is
assigned a number.
TROUBLESHOOTING ITEM: There are 29 troubleshooting
items. Choose the item that
most closely
corresponds to
the actual symptom.
TROUBLESHOOTING GUIDE
‘ROUBLESHOOTINl3 ITEM
f H
DESCRIPTION
iE
7
-
DESCRIPTION:
Describes each troubleshooting
item.
/
PAGE:
Shows the reference page.
OWOFX-014
F-25

F TROUBLESHOOTING GUIDE
Troubleshooting chart
6 I
CRANKS NORMALLY BUT HARD TO START - WHEN ENGINE COLD
*Engine cranks at normal speed but requires excessive crankmg time before starting
IESCRIP-
l Batterv in normal condition
llON l Restans OK after warmup l Engine runs normally at idle [If Idle condrtron is not OK, refer to “Rough idle” (Nos. S-12)]
TROUBLESHOOTING HINTS]
B Air/Fuel mrxture too rrch @Air/Fuel mixture too lean
l Arrflow meter stickrng l Fuel iniectron control malfunction
l Aw cleaner element clogged
*Idle weed control malfunction (Correction for coolant temperature)
0 Poor atomizatron
- ~~ ~~ *Low RVP (summer) fuel is used rn cold weather >
f INSPECTION T Check If “00” is displayed on Self-Diagnosis
Checker wth Ignition switch ON -
Yes
No CT page F-73
SYSTEM SELECT: 1
“SELECT SW: A
Check if ECU terminal voltages are OK
(Especially 1C. 2D. and 2Q)
cc page F-144
Check If engine starts easily when throttle valve -
Yes
-
NO
-
Yes ACTION
Go to next step
Malfunctlon Code No. dlsplayed
Check for cause (Refer to specified
check sequence)
“58” flashes CT- page F-79
Check ECU terminal 1F voltage
Speciflcetlon: Battery voltage CT page F-144
(Ignition ewltch ON)
+ If OK, replace ECU CT page F-143
e If. not OK, check wrring between
ECU and Self-Diagnoos Checker
Go to next step
Check for cause CI page F-145
(-!hnrlr ,‘ ICP ..-I..- .^ nv
c+ page F-103
13UOFX-009
DESCRIPTION:
Further describes the symptom. Confirm that the chart addresses the actual symptom before beginning
troubleshooting.
TROUBLESHOOTING HINTS:
This describes the possible point of malfunction.
STEP:
This shows the order of troubleshooting. Proceed with troubleshooting as indicated.
INSPECTION:
This describes an inspection to quickly determine the malfunction of parts. If a detailed procedure is necessary
to perform the INSPECTION, refer to the page shown by the “~7” mark.
ACTION:
This recommends the appropriate action to take as a result (Yes/No) of the INSPECTION. How to perform
the action is described on the reference page shown by the “~7” mark.
OWOFX-016
F-26

F TROUBLESHOOTING GUIDE
3 CRANKS NORMALLY BUT WILL NOT START (PARTIAL COMBUSTION) - WHEN ENGINE COLD
DESCRIP- *Engine cranks at normal speed but shows only partial combustion and will not continue to run
TION
l Battery in normal condition
*Fuel in tank
[TROUBLESHOOTING HINTS]
0 Air/Fuel mixture too rich
*Air cleaner element clogged
l Airflow meter stuck @ Low engine compression
@ Air/Fuel mixture too lean
l Fuel injection control malfunction
(Correction for coolant temperature)
*Low fuel line pressure
*Air leakage of intake air system
Checker with ignition switch ON
CT page F-83
w page F-150
Specification: Battery voltage
(Ignition switch ON)
W: SELF TEST w page F-149
Fuel line pressure:
285-314 kPa (2.7-3.2 kg/cm’, 38-48 psi) If fuel line pressure quickly in-
creases, check pressure regulator CF- page F-129
d If fuel line pressure gradually in-
creases check for clogging be-
I pump and pressure
Check if fuel return hose is clogged or
F-32