1992 MAZDA PROTEGE coolant

ON-VEHICLE MAINTENANCE
DEFLECTION CHECKING POINT
05UOBX-03 3 10. Measure the timing belt deflection by applying moderate
pressure (98 N, 10 kg, 22 lb) midway between the two cam-
shaft pulleys.
If the deflection is not correct, repeat from Step 7 above.
Deflection:
9.0-11.5mm (0.35-0.45 in) at 98 N (10 kg, 22 lb)
Harness
1. Connect the harness connectors. (Refer to page 82-l 8.)
Hose
1. Connect the hoses. (Refer to page 82-17.)
03UOB2-035
Accelerator cable
1. Install the accelerator cable.
2. Check the accelerator cable deflection.
If the deflection is not correct, adjust by turning nut A.
Deflection: l-3mm (0.04-0.12 In)
Steps After Installation
1. Fill the radiator with the specified amount and type of engine coolant. (Refer to Section E.)
2. Connect the negative battery cable.
3. Start the engine and check as follows:
(1) Engine oil and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page B2-8.)
(3) Operation of emission control system.
4. Recheck the engine coolant levels.
2311082-022
B2-21

REMOVAL
REMOVAL
Warning
l Release the fuel pressure. (Refer to Section F.)
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil,.
3. Remove in the order shown in the figure, referring to
Removal Note.
Step
1
1. Undercover and side cover 12. Oil cooler hose (ATX)
2. Resonance chamber 13. Cooling fan connector
3. Air cleaner assembly 14. Radiator switch connector (ATX)
4. Battery bracket 15. Radiator bracket
5. Battery cover 16. Radiator and cooling fan assembly
6. Battery
17. P/S and/or A/C drive belt
7. Battery carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2- 6
8. Battery duct 18. P/S oil pump and bracket
9. Accelerator cable Removal Note . . . . . . . . . . . . . . . . . . . . + . . . . . . page 82-32
10. Radiator hose 19. A/C compressor (if equipped)
11. Coolant reservoir hose Removal Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page 82-32
B2-31

92 ENGINE STAND DISMOUNTING
03UOB2 122
-l!----- - 0311082-70
05UOEX-25
__._.__ -- _... -- _____II-___p--.-
051JOBX-25
82-92
Water Inlet Pipe
1. Remove all foreign material from the water inlet pipe mount-
ing surface.
2. Install a new gasket and the water inlet pipe. -
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Water Bypass Pipe
1. Apply a small amount of engine coolant to the new O-ring.
2. install the water bypass pipe.
A/C Compressor Bracket (If equipped)
1. Install the A/C compressor bracket.
Tightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Exhaust Manifold
1. Remove all foreign material from the exhaust manifold con-
tact surface.
2. Install a new gasket and the exhaust manifold.
Tightening torque:
38-46 N*m (3.9-4.7 m-kg, 28-34 ft-lb)
Exhaust Manifold insulator
1. Install the exhaust manifold insulator.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 69-95 in-lb)
v

INSTALLATION
03UOB2-141
/ 03UOB2-14!
1 03UOB2-150
03UOB2-151
8,’
1
a : :“.;,
.’
s,::, ; i .:.;...
..:.a.. :..,:.
. .
. .
” . : 0 ,.: ::
: .:.. ..,
., ‘:;
.<.,:.,);
‘zi :
I 0311082-152
A/C compressor (If equipped)
1. Install the A/C compressor.
Tightening torque:
24-35 N,m (2.4-3.6 m-kg, 17-26 ft-lb)
2. Tighten the A/C pipe bracket to the engine mount member.
Tightening torque:
6.4-9.3 N-m (65-95 cm-kg, 56-62 in-lb)
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page B2-6.)
Radiator and cooling fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 69-95 in-lb)
2. Connect the upper and lower radiator hoses.
Caution
l Position the hose clamp in the original location on
the hose, and squeeze the clamp lightly with large
pliers to ensure a good
fit.
3. Connect the coolant reservoir hose.
4. Connect the cooling fan connector.
5. Connect the oil cooler hose. (ATX)
B2-101

92 INSTALLATION
RESOiANCE CHAMBER
03UOBZ-154
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut A.
Deflection: 1-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 Nlm (80-l 10 cm-kg, 69-96 In-lb)
2. Install the battery carrier.
Tightening torque:
7.8-l 1 N*m (80-l 10 cm-kg, 69-96 in-lb)
3. Install the battery and the battery bracket.
Tightening torque:
2.9-5.9 N*m (30-60 cm-kg, 26-52 in-lb)
Air cleaner assembly
1. Install the air cleaner assembly.
Tightening torque
@: 19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N*m (80-l 10 cm-kg, 69-95 In-lb)
2. Connect the air flow sensor connector.
Resonance chamber
I, Install the resonance chamber.
Tightening torque:
7.8-l 1 N#m (80-l 10 cm-kg, 69-95 In-lb)
Under cover and side cover
1. Install the under cover and side cover.
Steps After Installation
1. If the engine oil was drained, fill with the specified amount and type of engine oil.
(Refer to Section D.)
2. Fill the radiator with the specified amount and type of engine coolant.
(Refer to Section E.)
3. If the transaxle oil was drained, fill with the specified amount and type of transaxle oil.
(Refer to Sections J2, K.)
4. Connect the negative battery cable.
5. Start the engine and check the following:
(1) Engine oil, transaxle oil, and engine coolant leakage.
(2) ignition timing, idle speed. (Refer to page 82-8.)
(3) Operation of emission control system.
6. Perform a road test.
7. Recheck the engine oil and engine coolant levels.
B2-102
2311082.047

E
COOLING SYSTEM
INDEX ...................................................... E- 2
OUTLINE .................................................. E- 4
SPECIFICATIONS .................................... E- 4
TROUBLESHOOTING GUIDE ...................... E- 4
ENGINE COOLANT .................................... E- 5
PREPARATION ....................................... E- 5
INSPECTION ..........................................
REPLACEMENT ...................................... :z ;
RADIATOR CAP ........................................
PREPARATION ....................................... ;I ;
INSPECTION .......................................... E- 7
RADIATOR ............................................... E- 8
REMOVAL / INSTALLATION ...................... E- 8
INSPECTION .......................................... E- 9
THERMOSTAT .......................................... E- 9
REMOVAL / INSTALLATION ...................... E- 9
INSPECTION .......................................... E- 9
WATER PUMP .......................................... E-l 1
REMOVAL / INSTALLATION ...................... E-l 1
ELECTRIC COOLING FAN SYSTEM ............ E-13
SYSTEM CIRCUIT .................................... E-l 3
SYSTEM INSPECTION .............................. E-14
FAN MOTOR ............................................. E-14
INSPECTION .......................................... E-l 4
REPLACEMENT ...................................... E-l 5
WATER THERMOSWITCH .......................... E-l 8
REMOVAL / INSTALLATION ...................... E-18
INSPECTION .......................................... E-l 8
RADIATOR THERMOSWITCH ..................... E-l 7
REMOVAL I INSTALLATION ...................... E-17
INSPECTION .......................................... E-l 7
FAN RELAY .............................................. E-l 8
REMOVAL I INSPECTION .......................... E-l 8
INSPECTION .......................................... E-l 8
23UOEX-001

INDEX
B6 SOHC AND BP SOHC
COOLANT RESERVOIR
@ ENGINE COOLANT
TOTAL CAPACITY
MTX: 5.0 liters (5.3 US qt, 4.4 Imp qt)
ATX: 6.0 liters (6.3 US qt, 5.3 Imp qt)
1. Engine coolant 6. Electric cooling fan system
23UOEX-00
inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E- 5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E-
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
page E- 2. Radiator cap
7
3. Radiator
Removal I Installation . . . . . . . ,.......... page E- 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E- 9
4. Thermostat
Removal / Installation . . . . . . . . . . . . . . . . . . page E- 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E- 9
5. Water pump
Removal / Installation ....t___.......... page E-i 1
System
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Water thermoswitch
Removal / Installation . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Radiator thermoswitch (BP ATX) System
Removal I Installation . . . . . . . . . . . . . . . . . inspection . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IO. Fan relay
7. Fan motor
Removal / Inspection . . . . . . . . . . . . . . . . . page E-13
page E-14
page E-14
page E-15
page E-16
page E-16
page E-17
page E-l 7
page E-18 ..--’
E-2

E
BP DOHC
-a TO HEATER
&$ No.1 RELAY
COOLANT ~~ESERVOI~~
@ ENGINE COOLANT
TOTAL CAPACITY
MTX: 5.0
liters (5.3 US qt, 4.4 Imp qt)
ATX: 6.0 liters (6.3 US qt, 5.3 Imp qt)
23UOEX-00
1. Engine coolant
6. Electric cooling fan system
Inspection ...................................
page E- 5 System circuit
.............................
page E-l 3
Replacement ...............................
page E-
6 System inspection
....................... page E-14
2. Radiator cap
7. Fan motor
Inspection ................................... page E- 7
Inspection ...................................
page E-14
3. Radiator
Replacement..
............................. page E-i 5
Removal / Installation..
................
page E-
8 8. Water thermoswitch
Inspection
.................. ................................... page E- 9 Removal / Installation
page E-16
4. Thermostat
Inspection ...................................
page E-l 6
Removal I Installation
.................. page E- 9 9. Radiator thermoswitch (ATX)
Inspection
.................. ...................................
page E- 9 Removal I Installation
page E-l 7
5. Water pump
Inspection
...................................
page E-l 7
Removal / Installation ..................
page E-i 1 10. Fan relay
Inspection ...................................
page E-l 8
E-3