1992 MAZDA PROTEGE low oil pressure

U TROUBLESHOOTING GUIDE
Case 1: Insufficient refrigerant
Measured pressure
Low-pressure side: Less than 78.5 kPa (0.8 kg/cm2, 11.4 psi)
High-pressure side: 785-883 kPa (8-9 kg/cm2, 114-128 psi)
Condition
l Outlet air from vents not cold.
l Bubbles seen in sight glass.
Step 1
1. Check for oil stains on the pipes, hoses and other parts, (Refer to illustration below.)
2. If oil staining is found at the connection of pipes or hoses, replace the O-ring; then, evacuate, charge,
and test the system.
3. If oil staining is not found, go to Step 2.
05UOUX-02
Step 2
1. Check for leakage from the following connections with a gas leak tester.
l Inlet and outlet of condenser.
l Inlet and outlet of receiver/drier.
l Inlet and outlet of compressor.
l Sight glass.
l Inlet and outlet of cooling unit.
2. If leakage is evident, go to Step 3.
3. If leakage cannot be found, evacuate, charge, and test the system. (System OK, but refrigerant leaked
gradually over time.)
Step 3
1. Check tightening torque of the connection where leak was detected.
2. If the connection is loose, tighten the connection to the specified torque; then evacuate, charge, and test
the system. --
3. If the connection is properly tightened, replace the O-ring; then evacuate, charge, and test the system.
U-16

U
COOLING UNIT
Removal / Installation AIR CONDITIONER
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Remove the glove box, glove box cover, undercover, and instrument panel stay. (Refer to Section S.)
3. Remove the cooling unit as shown in the figure. -
Note
l Immediately plug all open fittings to keep moisture out of system.
4. Install the cooling unit in the reverse order of removal.
Note
l Position the cooling unit so that its connections match those of the heater unit and blower unit.
l Apply clean compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fitting nuts.
l When installing a new cooling unit, add compressor oil through the high-pressure pipe port
of the compressor.
Compressor oil: 50 cc (3.05 cu in)
Tightening torque
Outlet pipe: 20-29 N*m (2.0-3.0 m-kg, 14-22 ft-lb)
lnla+ nina. Q n,7n N.m (I -0-2.0 m&a. 7,7-IA ftJh IIllcvb yap”. “.” -1 . . . . . \..’ -_- __- ..~, JII .- .I .-,
23UOUX-0: -.,
1. Cooling unit
Disassembly / Assembly.. . . . . . . . . . . . page U-39
U-38

AIR CONDITIONER U
CONDENSER
Removal / Installation
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Remove the radiator grille. (Refer to Section S.)
3. Remove the receiver/drier. (Refer to page U-52.)
4. Remove the condenser as shown in the figure.
Note
l Insert a protector such as cardboard between the condenser and the radiator.
l Immediately plug the open fittings to keep moisture out of the system.
5. install the condenser in the reverse order of removal.
Note
l Apply clean compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fitting nuts.
l Remove the protector before installing the radiator brackets.
l When installing a new condenser, add compressor oil through the high-pressure pipe port
of the compressor.
Compressor oil: 30 cc (1.83 cu in)
Tightening torque
Condenser inlet: 15-25 N*rn (1.5-2.5 m-kg, 11-18 ft-lb)
Condenser outlet: 9.8-20 N#m (1 .O-2.0 m-kg, 7.2-14 ft-lb)
1. Radiator bracket
2. Radiator 3. Condenser
23UOUX-01
Inspection
Check for the following and repair or replace the condenser
as necessary.;
1. Cracks, damage, or refrigerant leakage.
2. Bent fins.
3. Distorted or damaged condenser inlet or outlet.
u-53

AIR CONDITIONER
REFRIGERANT LINES
On-vehicle Inspection
Check for leakage at connections. (Refer to page U-32.)
Repair or replace as necessary.
Replacement
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Replace the faulty pipe or hose.
Note
l Immediately plug the open fittings to keep moisture out of the system.
l Apply clean compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fitting nuts.
Tightening torque (fittings):
Location Tightening torque
0 9.8-20 N.m
(1.0-2.0 m-kg, 7.2-14 ft-lb)
0 15-25 N-m (1.5-2.5 m-kg, 11-18 ft-lb)
0 9.8-16 N.m (1.0-1.6 m-kg, 7.2-12 ft-lb)
fa 20-29 N.m
(2.0-3.0 m-ka 15-21 ft-lb)
3. Evacuate, charge, and test the refrigeration system.
1. High-pressure hose
2. Low-pressure hose
3. Cooler pipe No.1 4. Cooler pipe No.2 6. Cooler pipe No.4
5. Cooler
pipe No.3 7. Cooler pipe No.5
u-54

TD TECHNICAL DATA
I-
Item Enainc , 66 SOHC BP SOHC
Piston
, 1
-97 n-1 7-7 /t-r”
82.954-82.974
I -’
Piston diameter
Standard size I I I.Y34--1 l.YlG + I,-. nnnn
n r,Prx< > Measured at 90’ to pin (J.uoYY-mJoYo) (3.2659-3.2667)
bore axis and 165mm
I 78.211-78.217 83.211-83.217
(0.650 in) below oil ring 0.25 (0.010) oversize
(3.0792-3.0794) (3.2760-3.2763)
groove
0.50 (0.020) oversize 78.461-78.467 83.461-83.467
mm (in)
(3.0890-3.0892) (3.2859-3.2861)
Piston-to-cylinder clearance mm (in) Standard 0.039-0.052 (0.0015-0.0020)
Maximum 0.15 (0.006) Piston ring
Thickness
End gap
(Measured in cylinder) mm (in) Top
Second
Top
Second
mm (in) Oil (rail) I 1.47-l .49 (0.0579-0.05E
1.47-l .49 (0.0579-0.05E
0.15-0.30 (0.006-0.01~
0.15-0.30 (0.006-0.01; I Connectina rod and connectin
‘I ‘I 0.20-0.70 (0.008-0.028) 0.20-0.70 (0.008-0.028)
Maximum 1 .o (0.039) 1 .o (0.039)
Top 1,520-l ,535 (0.0598-0.0604) 1,520-l ,535 (0.0598-0.0604)
Ring groove width in piston
mm (in) Second 1.520-l ,535 (0.0598-0.0604) 1.520-l ,535 (0.0598-0.0604)
Oil
d d 117-4 04 (0 1583-O 1591) f ‘.02-3.04 (0.1189-0.1197) 117-4 04 ..“_ ..“. (0 1583-O 1591) f 1.02-3.04 (0.1189-0.1197)
\-“--- -’ - I
Piston ring-to-ring groove clearance Top 0.030-0.065 (O.O( 312-0.0026)
mm (in) Second 0.030-0.065 (O.O( 312-0.0026)
I
( Maximum
0 15 [email protected]) Piston pin
Diameter u,a, I KaEil mm (in) 1 111111 ,888, 19.974-19.980 (0.7864-0.7866) .“.“. _.__ J (0.7864-0.7866)
Interference in connecting rod ‘(0.0005-0.0015)
mm (In) 1 0.013-0.037 (0.0005-0.0015)
lnstallina pressure
N (kg, lb) 1 4,90614,715 (500-l ,500, 1 ,l oo-3,300) 4,90614,715 (500-l ,500, 1 ,l oo-3,300)
Length (Ceiter to center) Length (Ceiter to center) lg rod bearing lg rod bearing
mm (in) 1 mm (in) 1 132.85-132.95 (5.2303-5.2342) 132.85-132.95 (5.2303-5.2342)
Bending Bending mm (in) 1 mm (in) 1 0.075 (0.0030) max./50 (1.97) 0.075 (0.0030) max./50 (1.97)
Small end bore mm (in) 19.943-19.961 (0.; ‘852-0.7859) ‘852-0.7859)
Big end bore
mm (in) 48.000-48.016 (1 .f 3898-l .8904) 3898-l .8904)
Big end width mm (in) 21.838-21.890 f0.f 3598-0.8618)
I Connecting rod side clearance mm (in) Standard
! 0.11 O-O.262 (0.0043-0.0103)
Maximum 0.30 (0.012) Crankshaft
Crankshaft runout
mm (in) 0.04 (0.0016) max.
Standard Standard 49.938-49.956 (1.9661-I .9668)
size
Minimum 49.904 (1.9647)
0.25 (0.010) Standard 49.704-49.708 (1.9568-l .9570)
Main journal diameter undersize
Minimum 49.652 (1.9548)
mm (in)
0.50 (0.020) Standard 49.454-49.458 (1.9470-l .9472)
undersize
Minimum 49.402 (1.9450)
0.75 (0.030) Standard 49.204-49.208 (1.9372-I .9373) 1 -
undersize
Minimum 49.152 (1.9351) -
~.. Crankshaft
3598-0.8618j 1
I 0.11 O-O.262 (0.0043-0.0103)
0.30 (0.012)
1 Main iournal taoer and out-of-round
mm (in) I 0.05 (0.020) max.
Standard Standard 44.940-44.956 (i.7693-1.7699)
size
Minimum 44.908 (1.7680)
0.25 (0.010) Standard 44.690-44.706 (1.7594-l .7601)
undersize
Crankpin diameter mm (in) Minimum 44.658 (1.7582)
0.50 (0.020) Standard 44.440-44.456 (1.7496-I .7502)
undersize
Minimum 44.408 (1.7483)
0.75 (0.030) Standard 44.190-44.206 (1.7398-l .7404)
undersize
Minimum 44.158 (1.7385)
0.05 (0.020) max.
b
I I , I - \“‘---I 0.05 (0.020) max.
b
I I Crankuin taper and out-of-round
mm (In) I Main bearing
I
Main journal bearing oil clearance Standard
I 0.018-0.036 (0.0
mn-, ,i” .A- :-- -
c-l*,- ‘^’
Available undersized bearing
TD-4
007-0.0014)
I& II I I \” ‘,
, I”ld*llT,UIr1
I “. I J (U.004)
mm (in) 0.25 (O.OlO), 0.50 (0.020) 0.75 (0.030) . . . 86 Otily

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
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