1992 MAZDA PROTEGE no spark

B2 ON-VEHICLE MAINTENANCE
HLA
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. install in the reverse order of removal, referring to Installation Note --- ----- -__ __-- ,‘.
11.3-14.2 N.m
(1.15-1.45 m-\g, 100-126 in-lb)
49-61
(5.0~6.2,-36-45)
4.9-6.6 N.m
(50-90 cm-kg, 43-76 in-lb)
7.6All N-m
(80-110 cm-kg, 69-95 in-lb) 1 Q’-25
(1.9-2.6, 14-19)
N.m (m-kg, ft-lb)
0311082-03
1. High-tension lead
10. Cylinder head cover
2. Distributor
Installation Note..
....................
Installation Note.. ......................
page 62-25
11. Camshaft pulley
3. P/S and/or A/C drive belt
Removal note ..........................
Removal / Installation..
.............. page E32-
6
Installation Note .......................
4. Alternator drive belt
12. Seal plate
Removal / Installation
......... . ...... page B2- 6
13. Camshaft
5. Water pump pulley
Removal Note.. ........................
6. Timing belt cover, upper
Installation Note.. .....................
7. Timing belt cover, middle
14. HLA
8. Spark plug
Removal note ..........................
9. Timing belt
Installation
Note.. .....................
Removal Note.. .........................
page B2-18 Inspection
................................
Installation Note.. ......................
page B2-20
7
page 62-19
page 82-23
page 82-24
page B2-23
page 62-23
page B2-23
page B2-23 ‘--’
page 82-60
82-22

REMOVAL
Step 3
1. Disconnect the hoses shown in the figure.
J”“DC-” I I
1. Fuel hose
3. Brake vacuum hose
Removal
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
below
4. Vacuum hose (Purge control)
2. Heater hose
Removal Note . . . . . . . . . . . . . , . . . . . . . . . . . .
05UOBX-078
0311082-052
. . . . .
below 5. Vacuum hose (Cruise control)
Removal note
Fuel hose
Warning
l Keep sparks and open flame away from the fuel
area.
Caution
l Cover the hose with a rag because fuel will spray
out when disconnecting.
l Plug the disconnected hoses to avoid fuel leakage.
1. Disconnect the fuel hoses.
Heater hose
Caution
l Heater hose joint has O-rings and spacer.
l Do not lose them when removing.
1. Push the heater hose retainer and remove the heater hose.
82-33

B2 DISASSEMBLY
AUXILIARY PARTS
1, Drain the engine oil.
2. Disassemble in the order shown in the figure
GASKET, REPLACE ..______-.
-___ -
03UOB2-064
1. Distributor and high-tension lead 7. Oil cooler
2. Intake manifold assembly 8. Oil pressure switch
3. Injector and distribution pipe assembly 9. Spark plug
4. Alternator and drive belt 10. Oil level gauge
5. No.3 engine mount bracket 11. Oil level gauge pipe stay
6. Oil filter 12. Engine hanger
82-42

82 ASSEMBLY
Oil Level Gauge Pipe Stay
1. Install the oil level gauge pipe stay.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 89-95 in-lb)
Oil Level Gauge
1. Install the level gauge.
Spark Plug
1, Install the spark plugs.
Tightening torque:
15-23 N*m (1.5-2.3 m-kg, 11-17 ft-lb)
Oil Pressure Switch
1. Install the oil pressure switch.
Tightening torque:
12-18 N-m (120-180 cm-kg, 104-156 in-lb)
Oil Cooler
1. Remove all foreign material from the oil cooler mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil cooler.
3. Install the oil cooler with paint mark (white) facing up.
4. Tighten the oil cooler lock nut.
Tightening torque:
29-39 N.m (3.0-4.0 m-kg, 22-29 ft-lb)
5. Connect the harness to oil pressure switch.
Oil Filter
1. Remove all foreign material from the oil filter mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil filter.
3. Install the oil filter and tighten it by hand until the rubber
seal contacts the base.
4. Tighten the filter 1 and 116 turns with a filter wrench. --_

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
SYMPTOM TROUBLESHOOTING
2 CRANKS NORMALLY BUT WILL NOT START (NO COMBUSTION)
l Engine cranks at normal speed but shows no sign of “firing”
DESCRIP-
*Battery in normal condition
TION
*Throttle valve not held fully open while cranking (Dechoke system not operate)
*Fuel in tank [TROUBLESHOOTING HINTS]
Because of no combustion, possibly no fuel is injected to engine or no ignition at all cylinders
:I) No spark
@I Low fuel line pressure
l Ignition control malfunction
@ Low engine compression l Ignition system component malfunction
3 No fuel injection
l Fuel pump inoperative l Injectors inoperative
TEP INSPECTION
ACTION
1 Check if strong blue spark is visible at discon-
Yes Go to Step 3
netted high-tension lead
No Go to Step 2
2 Check if “00” is displayed on Self-Diagnosis
Yes Check ignition system (Refer to
Checker with ignition switch ON
Troubleshooting “Misfire”) w page G-5
w page F-82
No Service Code No. displayed
Check for cause (Refer to specified
check sequence) w page F-83
“88” flashes
Check ECU terminal 1F voltage w page F-150
Specification: Battery voltage
(Ignition switch ON)
W: SELF TEST e If OK, replace ECU w page F-149 c3 If not OK, check wiring between
SELECT SW: A ECU and Self-Diagnosis Checker
3 Connect diagnosis connector terminals F/P and
Yes Check if engine starts in this condition
GND with jumper wire and check for fuel pump
operating sound with ignition switch ON c3 If starts, check circuit opening relay c7 page F-129
w page F-125
c3 If does not start, go to Step 5
DIAGNOSIS C
Go to next step ._-,
._. ,
F-30

TROUBLESHOOTING GUIDE
TEP INSPECTION ACTION
4 Check if ECU terminal voltages are OK Yes Go to next step
MTX...Especially IC, 20 and 2Q
ATX... Especially lC, 2E and 3D v page F-150
No Check for cause ~3‘ page F-151
5
Check for air leakage of intake air system com- Yes Repair or replace
ponents
No Go to next step
6 Check if engine starts when water thermosensor Yes Check water thermosensor c7 page F-158 is disconnected
Check for correct engine compression 82-10 ’ No
Check engine condition CIP page Bl-10
Engine compression: 82-10
l BP SOHC l Worn piston, piston rings or cylinder 834 kPa (8.5 kg/cm*, 121 psi)300 rpm
wall
l BP DOHC l Defective cylinder head gasket 883 kPa (9.0 kg/cm*, 128 psi)-300 rpm l Distorted cylinder head
l B8 l Improper valve seating 932 kPa (9.5 kg/cm*, 135 psi)300 rpm *Valve sticking in guide
9 Check if spark plugs are OK Yes Go to next step CT- page G-18
1.0-l .l mm
(0.039-0.043 in) DAMAGE AND
DETERIORATION No Clean, or replace c7 page G-18
10 Try known good ECU and check if condition
improves CT- page F-149
23UOFX-01 I
F-33

F TROUBLESHOOTING GUIDE
5
CRANKS NORMALLY BUT HARD TO START - ALWAYS
DESCRIP- l Engine cranks at normal speed but requires excessive cranking time before starting
TION l Battery in normal condition
*Engine runs normally at idle [If idle condition not OK, refer to “Rough idle” (Nos. 8-12)J [TROUBLESHOOTING HINTS]
@ Air/Fuel mixture too lean
@ Air/Fuel mixture too rich l Fuel injection control malfunction
(Correction for coolant temperature) *Air cleaner element clogged
l Airflow meter stuck
*Low fuel line pressure
l Air leakage @ Poor ignition spark
;TEP INSPECTION ACTION
1
Check if “00” is displayed on Self-Diagnosis Yes Go to next step
Checker with ignition switch ON W page F-82 No
Service Code No. displayed
Check for cause (Refer to specified SYSTEM SELECT: 1 check sequence) w page F-83
“88” flashes
Check ECU terminal 1F voltage w page F-150
Specification: Battery voltage
(Ignitlon switch ON)
* If OK, replace ECU w page F-149
W: SELF TEST c3 If not OK, check wiring between
ECU and Self-Diagnosis Checker
2 Check for correct intake manifold vacuum at idle
Yes Go to next step
VsCUUm: More than 450 mmHg (17.7 inHg) No Check for air leakage of intake air sys-
tem components
3 Check if air cleaner element is clean
Yes Go to next step w page F-79
No
Replace air cleaner element
4 Check if engine starts easily when throttle valve Yes Check throttle valve for carbon deposit
quarter open and then go to Step 6 Fuel line pressure:
265-314 kPa (2.7-3.2 kg/cm*, 38-46 psi)
(Vacuum hose to pressure regulator dis-
pressure while pinching
c3 If fuel line pressure quickly in-
creases, check pressure regulator w page F-129
c3 If fuel line pressure gradually in-
creases, check for clogging be-
tween fuel pump and pressure
If not clogged, check fuel pump
maximum pressure W- page F-126
F-36