1992 MAZDA PROTEGE Workshop Manual

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

E OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
B6 SOHC
BP SOHC BP DOHC
MTX
1 ATX 1 MTX ATX 1 MTX
ATX
Cooling system
Water-cooled, forced circulation
Coolant capacity liters (US qt, Imp qt) 5.0 6.0
5.0
(5.3, 4.4) (6.3, 5.3)
(5.35.04.4) (6.zi.3) (5.3, 4.4) (6.::.3)
Water
pump
Thermostat
Radiator
Cooling fan
L Type
Water seal Centrifugal
Unified mechanical seal
Type Opening temperature
‘C (OF’) Wax, two-stage
Main: 86.5-89.5 (188-193)
Sub : 83.5-86.5 (182-188)
Full-open temperature
OC (OF)
Full-open lift mm (in)
Type
Cap valve opening
pressure 100 (212)
Main: 8.0 (0.31) min.
Sub : 1.5 (0.06) min.
Corrugated fin
74-103 (0.75-1.05, 11-15)
kPa (kg/cm2, psi)
Width
Core size Height
mm (in)
Depth
Fin pitch
mm (in) 647 (25.47)
390 (15.35)
16 (0.63) 1 25 (0.98) 1 16 (0.63) 1 25 (0.98) 1 16 (0.63) 1 25 (0.98)
1.3 (0.051)
Heat dissipation capacity
kcallh 1 38,800 [ 43,800 ( 38,800 1 43,800 1 38,800 1 43,800 1
Type
Transaxle Heat
oil cooler dissipation
capacity
kcallh
Tvoe
- Laminated - Laminated -
Laminated
1,700
I .I -?nn
- -
I,,“”
I
I - I 4 Ye,-. I,IVV 1
, a-
- Electric
Number of blades 4
Outer diameter mm (in)
320 (12.6)
Capacity w-v 80-12 1 160-12 ) 80-12 ) 160-12 1 80-12 1 160-12
1 Hi: 13.3+ 1 1 Hi: 13.3+ 1 1 Hi: 13.3+
Current
TROUBLESHOOTING GUIDE I I I I
Problem Possible Cause
Overheating
Coolant level insufficient
Coolant leakage
Radiator fins clogged
Radiator cap malfunction
Cooling fan malfunction
Thermostat malfunction
Water passage clogged
Water puma malfunction .- Remedy Page
Add
Repair
Clean
Replace
Replace
Replace
Clean
Reolace E- 6
E-9
E- 7
E-13
E- 9
E- 6
E-11
I Corrosion
1 Impurities in coolant 1 Replace
I E-6 I
03UOEX-005

ENGINE COOLANT E
ENGINE COOLANT
PREPARATION
SST
49 9200 145
For 49 9200 146
For
inspection of inspection of
cooling system Adapter A cooling system
pressure (Part of pressure
49 9200 145)
05UOEX-00
INSPECTION
Warning
l Never remove the radiator cap while the engine is
hot.
l Wrap a thick cloth around the cap when removing it.
l When removing the radiator cap, loosen it slowly
to the first stop until the pressure in the radiator is
released, and then remove it.
03UOEX~006
Coolant Level (Engine cold)
1. Verify that the coolant level is near the radiator filler neck.
2. Remove the coolant level gauge and check the coolant level.
Coolant Quality
1. Verify that there is no buildup of rust or scale around the
radiator cap or radiator filler neck.
2. Verify that coolant is free of oil. Replace the coolant if
necessary.
Coolant Leakage
1. Connect a radiator tester (commercially available) and the
SST to the radiator filler neck.
2. Apply
103 kPa (1.05 kg/cm2, 15 psi) pressure to the
system.
3. Verify that the pressure is held.
If not, check for coolant leakage.
E-5

E ENGINE COOLANT
SPECIFIC
GRAVITY COOLANT PROTECTION
l.OOd ’ ’ I I I I I
0, I I
-10 0 i 10 20 30 40 50 60
70 60 90
(14) (32) (50) (66) (66)(104)(122)(140)(158~176)(194)
COOLANT TEMPERATURE OC (OF)
Coolant Protection
Caution
l Do not use alcohol- or methanol-based coolant.
l Use only soft (demineralized) water in the coolant
mixture.
1. Measure the coolant temperature and specific gravity with
a thermometer and a hydrometer.
2. Determine the coolant protection by referring to the graph
shown.
If the coolant protection is not proper, add water or coolant.
Antifreeze solution mixture percentage
~1
05UOEX-010
REPLACEMENT
Warning
l Never open the radiator cap while the engine is hot.
l Wrap a thick cloth around the cap when loosening.
. Use caution when draining hot coolant.
Caution ..-
l Do not use alcohol- or methanol-based coolant.
l Use only soft (demineralized) water in the coolant
mixture.
1. Remove the radiator cap and loosen the drain plug.
2. Drain the coolant into a suitable container.
3. Flush the cooling system with water until all traces of color
are gone; then let the system drain completely.
4. Install the drain plug.
5. Fill with the proper amount and mixture of ethylene glycol
based coolant by referring to the table above.
Coolant 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)
6. Run the engine with the radiator cap removed until the up-
per radiator hose is hot.
7. With the engine idling, add coolant to the radiator until it
reaches the bottom of the filler neck.
8. Install the radiator cap.
03UOEX-010 -
E-6

RADIATOR CAP E
RADIATOR CAP
PREPARATION
I I 05UOEX-014
INSPECTION
Radiator Cap Valve
1. Remove foreign material (such as water residue) from be-
tween the radiator cap valve and the valve seat.
2. Attach the radiator cap to a radiator cap tester (commer-
cially available) with the
SST. Apply pressure gradually to
74-103 kPa (0.75-l .05 kg/cm , 11-15 PSI).
3. Wait about 10 seconds. Verify that the pressure has not
decreased.
Negative Pressure Valve
1. Pull the negative pressure valve to open it. Verify that it
closes completely when released.
2. Check for damage on the contact surfaces and for cracked
or deformed seal packing.
3. Replace the radiator cap if necessary.
E-7

E RADIATOR
RADIATOR
REMOVAL / INSTALLATION
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.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
-...__--- --- i
771 InFu.nnc; cvyILII ..,.,..
6. Oil cooler hose (ATX)
7. Radiator bracket
8. Radiator
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E-9
9. Cooling fan and radiator cowling assembly 1. Resonance chamber
2. Cooling fan connector
3. Radiator thermoswitch connector (BP ATX)
4. Coolant reservoir hose
5. Radiator hose i
Y’
E-8