1992 MAZDA PROTEGE technical data

TECHNICAL DATA
D. LUBRICATION SYSTEM
Item I I bhricatinn mothnd
Engine
B6 SOHC BP SOHC
Force-fed BP DOHC 1
Requlated pressure kPa (kg/Cm”, p
Inner rotor tooth tip to outer rotor Standard
I-‘---- -.----,
clearance mm (in) Maximum 0.20 (0.0078)
Outer rotor to body clearance mm (in) Standard 0.09-0.18 (0.0035-0.0071)
Maximum 0.22 (0.0087)
Side clearance mm (in) Standard 0.03-0.11 (O.pniq n nnn=’
Maximum n4rl ‘-
“” I r-“.““+..I,
I “. I ‘t (U.0055)
I
1
Oil filter
_ Type
Relief pressure differential
Engine oil
I
Capacity
liters (US qt, Imp qt)
Grade
I Viscosity Full-flow, paper element
kPa (kg/cm’, psi) 1 78-l 18 (0.8-I .2, 1 l-l 7) Tntal /An, nnr*inol 3.4 (3.6, 3.0) 1 4.0 (4.2, 3.5)
3.0 (3.2, 2.6) 1 3.6 (3.8, 3.2)
VII 111Lb1 0.17 (0.18, 0.15)
API Service SG Energy Conserving II (ECQ
1
SA!f InW-Xl 1~ Above -25% (-13OF _ .-.. --
I
I
number
1 Below O’C (32OF) SAE 5W-30
1
E. COOLING SYSTEM
Cooling method EnginelTransaxle
MTX ] ATX 1 MTXl
Water-cooled, forced circulation
J B6 SOHC BP SOHC BP DOHC
, ATX 1 MTX ) ATX
LThermostat
Type Opening temperature
Full-open temperature
Full-open lift
Radiator
_ Type
Cap valve opening pressure
Cooling circuit checking pressure Wax, two-stage
“C (OF) Sub: 83.5-86.5 (182--188), Main: 86.5-89.5 (188-193)
OC (OF) 100 (212)
mm (in) Sub: 1.5 (0.06) min., Main: 8.0 (0.31) min.
Corrugated fin
kPa (kg/cm2, psi) 74-103 (0.75-1.05, 11-15)
kPa (kg/cm’, psi) 103 (1.05, 15)
~..
Cooling fan
Type Electric .-
Number of blades 4
_.---- _I___-
Outer diameter mm (in) 320 (12.6)
--_ ~~-
Capacity w-v 80-12 - 160-12 80-l 2 160-12
6.6 Hi : 13.3
6.6 Hi : 13.3
Current A
Low : 8.8 Low : 8.8
_------ ._____
Water thermoswitch
“c (OF) 1
OFF-ON 97 (207)
I--.
Radiator thermoswitch
__-I____-
OFF+ON “C (OF) 1 1105 (221)( - (105 (221)
TD-8

TECHNICAL DATA TD
Item
Coolant Engine/Transaxle B6 SOHC BP SOHC BP DOHC
MTX 1 ATX 1 MTX 1 ATX 1 MTX 1 ATX
Capacity
liters tus qt, Imp qt) (5Z.4) (8.E.3) (5&4) (SE.3) (5.?i.4) (S.E.3)
Coolant protection Volume percentage %
Specific gravity at
Water Coolant 20% (68OF)
Antifreeze solution Above -16OC (3OF)
65 35 1.054
Above -26OC (-15OF) 55 45 1.066
I Above -4OOC (-40°F) 45 55
1.078
F. FUEL AND EMISSION CONTROL SYSTEMS Item
idle speed*‘**
Ignition timing** Fuel pump
Maximum output pressure Fuel filter Engine
B6 SOHC BP SOHC BP DOHC
vm 700-800
BTDC 6O--8O 4O---6O 90-l 10
kPa (kg/cm*, psi) 1 441-637 (4.5-6.5, 64-92) ‘Type
Low-pressure side Nylon element (in fuel pump)
High-pressure side Paper element Pressure regulator
Regulating pressure kPa (kg/cm*, psi) 1 265-314 (2.7-3.2, 38-46) Injector
Type
High-ohmic
Type of drive Electromechanical
Resistance n 12-16 Idle speed control (ISC) valve
Type
Rotary
Resistance n ] 11-13 Purge control solenoid valve
Resistance n 1 23-27 Water thermosensor
-20°C( -4OF) 14.6-17.8
Resistance k6 20°C( 68QF) 2.21-2.69
40% (104OF) 1.0-l .3
80°C(1760F) 0.29-0.35 Airflow meter
E2++Vs Fully closed 20-600 q D Fully open 20-l ,000
E~HVC 200-400
Resistance g Ez++THAA -2O%(-4OF) 13,600-18,400
(Intake air 20%( 68OF) 2,210-2,690
thermosensor)
60°C(1400F) 493-667
Eic*Fc Fully closed 00
Fully open 0 Fuel tank
Capacity liters (US gal, Imp gal) I
Hatchback 50 (13.2, 11.0) PROTEGE . . . . 55 (14.5, 12.1) Air cleaner
Element type Oil permeated Fuel
Specification Unleaded regular (RON 91 or higher)
*’ With parking brake applied (Canada)
*’ TEN terminal of diagnosis connector grounded
TD-9

TD TECHNICAL DATA
G. ENGINE ELECTRICAL SYSTEM
3attery Dark
current*’
Alternator 86 SOHC BP SOHC
I BP DOHC
MTX 1 ATX 1 MTX 1 ATX
Voltage V 12
Type and capacity (20-hour rate) 55D23L (60AH) 1 55D23L (60AH)
mA Max. 20.0
Type A.C
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 8-Q (0.31-0.35)
;riL’F,i Used Q-10 (0.35-0.39)
Coaxial
Type Direct Direct Coaxial
reduction Direct
reductior
Starter output V-kW 12-0.85 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 Electronic spark advance (photo diode)
Ignition timing BTDC
(TEN terminal of diagnosis connector grounded) 6O-8O 4O-6O 9”-11 O
Ignition coil Resistance Primary coil winding 0.81 -O.QQg
(at 20% [68OF]) Secondary coil winding lo-16 kg
SK&E-1 1 BKR5E-11
NGK
BKRGE-11 BKRGE-11
BKR7E-11
Spark plug Type
NIPPONDENSO KlGPR-Ull
K20PRUll KlGPR-Ull
K20PRUll
K22PRUll *:
. Plug gap
Firing order mm (in) 1.0-l .l (0.039-0.043)
l-3-4-2
---
’ Dark current is the constant flow of current while the ignition switch IS UFF.
(i.e engine control unit, audio, etc.) ..-
._*
T&l 0

TECHNICAL DATA
H. CLUTCH
1 Full stroke Englne/lransaxle
86 SOW
I BP SOHC
I BP DOW
Item 1 05M-R FSM-R
Clutch control Hydraulic Clutch pedal
Type
Suspended
Pedal ratio 6.55
mm (in) I 135 (5.3 2)
Height (With carpet) mm (in) 1 1E t6-204 (7.72-8.03)
Free olav
L .-- 7 --a mm (in) I
t I , 5.0-l 3.0 (0.197-0.512)
Distance to carpet when clutch fully
disengaged mm (in) Minimum 41.0 (1.61) Flywheel
Runout limit mm (in) I 0.2 (0.008) Clutch disc
, Type
Single dry plate
Runout limit mm (in) 1 LO.027)
Wear limit mm (in) I 0.3 1 (0.012) from rivet head
Outer diameter mm (in)
1s , I )O (7.48) 200 (7.87)
I 215 (8.46)
Inner diameter mm (in) 130 (5 150 (5.91)
-.
Facing thcknes! 3 mm (in) Flywheel side [O. 138)
Pressure elate side 3.5 10.1:
, 38) 3.8 (0.150)
1 3.8 (0.150) Clutch cover
Type
Diaphragm spring
Set load N (kg, lb) [ 3,630 (370, 814) 1 3,826 (390, 858) 1 3,846 (392. 862)
TD-11

TD TECHNICAL DATA
Jl l MANUAL TRANSAXLE (FSM-R)
BB SOHC
l- BP SOHC I
F %M.R
I
1
Floor shift Item
Transmission Shift lever oosition Engine/lransaxle
First
Second
-I?-:-.4
I 0.918
I
n ‘31
I Gear ratio lllll”
Fourth
Fifth
Reverse
Grade
Oil Viscosity
Capacity liters (US qt, Imp qt) Clearance
Clearance of lever and reverse Standard
idler gear
mm (in) Wear limit
1 st-2nd
Standard 3rd-4th
Clearance of shift fork and Sth-Rev.
clutch sleeve mm (in)
1 st-2nd
Wear limit 3rd-4th
I 5th~Rev. j
Clearance of synchronizer ring and gear Standard ) mm (in)
Wear limit 3.416
1.842
1.290
ce GL-4
SW-90
I
V.I.
3.214
API servil
SAE 7t
2.68 (2.83, 2.36)
0.1 O-O.32 (0.004-o.
0.37 (0.015)
0.1 O-O.36 (0.004-o.
0.20-0.50 (0.008-O.
0.40-0.75 (0.016-O.
0.86 (0.034)
1 .oo (0.039)
i 3c /n n/la
I .L” \“.“T”,
1.12-l .88 (0,044-O.
0.8 (0.032)
0.05-0.28 (0.002-0.011)
0.33 (0.013)
0.18-0.51 (0.007-0.020)
0.56 (0.022)
0.06-0.21 (0.002-0.008)
0.26 (0.010)
0.21-0.61 (0.008-0.024)
0.66 (0.026)
0.06-0.26 (0.0024-0.0102)
0.31 (0.0122)
(0.008), 0.3 (0.012), 0.4 (0.016) Fifth Standard
Limit
0.1 (0.004) 0.2
Rnnrinn nrdnari adjust Primary shaft
0.5 (0.020) 0.6
I shim mm (in)
Secondary shaft 0.15 (0.006) 0.20 (0.008) 0.25 (0.
~-~?r;liln I Final gear
Bearing preload
I Bearing preload adjust shim
[Backlash of side gear and pinion gear
I
I
030)
,074)
I
First Standard
Limit
Second Standard
Limit
Gear thrust clearance
mm (in) Third Standard
Limit
Fourth Standard
Limit
(0.024j
OlO), 0.30 (0.012)
I
I V.“” \“‘V I .,, “.~lV \Y... VW,? “I ,-
\... 018j, 0.50 (0.020)
Helical
4.105 : 1
I 3.619 : 1
N,m (cm-kg, in-lb) 0.03-0.74 (0.3-7.6, 0.3-6.6)
n qn
mm (in)
“.L” ,“.“U mnr78), 0.25 (o.oio), 0.30 (0.012) 0.35
(0.014)
0.40 (0.01 6) 0.45 (0.018),
0.50 (0.020) 0.55 (0.022)
-~ -1
mm (in) j o-o.1 (O-0.004 --
--’
TD-12

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

TECHNICAL DATA TD
Item
Carrier hub
Sun gear drum
Small sun gear TransaxlelEngine
Clearance between pinion washer
and planet carrier mm (in) Maximum
Bushing inner diameter
mm (in) Maximum
Bushing inner diameter
mm (in) Maximum F4A-EL
B6 SOHC BP SOHC BP DOHC
0.2-0.7 (0.008-0.028)
30.425 (1.198)
21.021 (0.828)
Gear assembly
Total end play
End play adjust race
Idle gear bearing preload
Preload
adjust shims
Output gear bearing preload
Preload adjust shims
Differential
Bearing preload
Preload
adjust shims
Backlash of side gear and pinion mm (in)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
mm (in) Standard
Maximum 0.25-0.50 (0.010-0.020)
1.2 (0.047) 1.4 (0.055), 1.6 (0.063)
1.8 (0.071) 2.0 (0.079) 2.2 (0.087)
-
0.03-0.9 (0.3-9.0, 0.26-7.8)
3.80 (0.150) 3.85 (0.152) 3.90 (0.154) 3.95
(0.156)
4.00 (0.158) 4.05 (0.159) 4.10 (0.161) 4.15 (0.163)
4.20 (0.165) 4.25 (0.167) 4.30 (0.169) 4.35 (0.171)
4.40 (0.173), 4.45 (0.175) 4.50 (0.177) 4.55
(0.179)
4.60 (0.181) 4.65 (0.183) 4.70 (0.185) 4.75 (0.187)
0.03-0.9 (0.3-9.0, 0.26-7.8)
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 (0.032) 0.85
(0.034)
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) 1.25 (0.049)
1.30 (0.051), 1.35 (0.053) 1.40 (0.055) 1.45
(0.057)
2.9-3.9 (30-40, 26-35)
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 (0.032) 0.85 (0.034)
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). 1.25 (0.049)
1.30 (0.051) 1.35 (0.053) 1.40 (0.055), 1.45 (0.057)
0.025-0.1 (0.001-0.004)
0.5 (0.020)
Torque converter
Bushing inner diameter mm (in) Standard 1 53.030-53.075 (2.088-2.090)
Maximum 1 53.075 (2.090)
Spring Specification
Spring name Outer diameter Free length
No. of coil Wire diameter
mm (in) mm (in) mm (in)
Throttle modulator 8.1 I I--.._ ^^^1-^1 1 spring 1 (0.319)
1 43.4 (1.709) 1 10.5 1 0.8 (0.031)
1
” cJIJtz:I li”I IL, “I
valve body Throttle spring
Throttle assist spring 1 5.4 (0.213) 46.2 (1.819) 1 29.0
0.88 (0.035)
1 5.15 (0.203)
26.88 (1.058) 1 16.2 0.6 (0.024)
,
^ -- ,^ ^^^
Mnin contrnl I Low reducina sprina I 7.9 (0.311) .._... __.._. -
valve body
-. .- \“---I 29.98 (1.180) 10.0
0.8 (0.03lj
1 3-4
shift spring / 7.4 (0.291) I 36.6 (1.441)
12.0 0.8 (0.031)
B6 SOHC
23.0
Bypass spring BP
SOHC 4.9 (0.193) 27.6 (1.087) 0.55 (0.022)
Premain control BP
DOHC 4.9 (0.193) 30.5 (1.201) 23.0
0.55 (0.022)
valve body
2-3 shift spring 7.4 (0.291) 36.6 (1.441)
12.0 0.8 (0.031)
Converter relief spring
8.6 (0.339) 68.4 (2.693) 27.5
1.2 (0.057)
Lockup control spring
5.0 (0.197) 30.1 (1.185) 21.5 0.55 (0.022)
Control valve body Throttle relief spring
6.6 (0.260) 21.6 (0.850) 11.5
0.8 (0.031)
Oil
pump Spring
13.0 (0.512) 53.0 (2.087)
12.0 1.2 (0.047)
TD-15