1992 MAZDA PROTEGE engine

G STARTING SYSTEM
1 03lJOGX.079
23LJOGX-011
I I OBUOGX-081
3. Place the armature on V-blocks, and measure the runout
with a dial indicator.
If the runout is not within specification, repair it with a lathe
or replace the armature.
Runout: 0.05mm (0.002 in)
Maximum: O.lmm (0.004 in)
4. Replace the armature if the outer diameter of the commu-
tator is almost at or less than the grind limit.
5. If the commutator surface is dirty, wipe it with a cloth; if it
is rough, repair it with a lathe or fine sandpaper.
Engine
Grind limit mm (in) 1 B6 1 BP (MTX) 1 BP (ATX)
31.4 (1.24) 1 28.8 (1.13)
6. Segment groove depth
If the depth of the mold between segments is almost at or
less than the minimum, undercut the grooves to the stan-
dard depth.
Depth: OS-0.8mm (0.02-0.03 in)
Minimum: 0.2mm (0.008 in)
Bearing (if equipped)
1. Check for abnormal noise, looseness, or sticking.
2. Replace the bearing(s) if necessary.
I
03UOGX-082
G-30

STARTING SYSTEM G
STARTER INTERLOCK SWITCH (MTX)
CONTACT
IGNITION SWITCH
IG2 ROD
p IG1 ‘NTERlfM$TCH
i BATTERY
I
STARTER
For operator safety, if the clutch pedal is not depressed during starting, battery power will not be supplied
to the starter and the engine will not crank.
Interlock Switch
Inspection
1. Disconnect the interlock switch connector.
2. Connect an ohmmeter to the switch.
3. Check the continuity.
Clutch pedal
----- I_
Depressed
Released 4.
Replace the switch if necessary.
Continuity
--
Yes
No
G-31

OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
-
-
Item
Clutch control Engine/Transaxle B6 SOHC BP SOHC BP DOHC
F!Wl-R GBM-R Hvdraulic
Clutch cover
Clutch disc Type
Set load Diaphragm spring
N
(kg, lb) 1 3,630 (370, 814) 1 3,826 (390, 858) 1 3,846 (392, 862)
30 17.48)
200 (7.87) 215 (8.46) Outer diameter mm (in)
Inner diameter mm (in)
Pressure plate
side mm (in)
Thickness
Flywheel side
mm lit-d
1! , I
130 (5.12) ’ ’
150 i5.91 j
3.5 (0.138) 3.8 (0.150)
3.5 (0.138)
Type Suspended
Clutch pedal
Master cylinder
Release cylinder
Clutch fluid Pedal ratio 6.55
Full stroke mm (in) 135 (5.32)
Height (With carpet)
mm (in) 196-204 (7.72-8.03)
Inner diameter mm (in) 15.87 (0.625)
Inner diameter
mm (in) 19.05 (0.750)
SAE J1703 or FMVSS116 DOT-3
23UOHX-003
TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page
Slipping
Clutch disc facing worn excessively Replace H-15, 17
Clutch disc facing surface hardened or oil on surface Repair or replace H-15
Pressure plate damaged Repair or replace H-15
Diaphragm spring damaged or weakened Replace H-15
Insufficient clutch pedal play Adjust H- 5
Clutch pedal sticking Repair or replace H- 6
Flywheel damaged Repair or replace H-15, 17 Faulty disen-
Excessive runout or damaged clutch disc Replace H-15, 17 gagement Clutch disc splines rusted or worn Remove rust or replace H-15
Oil on facing Repair or replace H-15
Diaphragm spring weakened Replace H-15
Excessive clutch pedal play Adjust H- 5
Insufficient clutch fluid
Add fluid H- 3
Leakage of clutch fluid Locate and repair or -
replace Clutch vibrates
Oil on facing Repair or replace H-15 when accelerating Torsion rubbers weakened Replace H-15
Clutch disc facing hardened or damaged Repair or replace H-15
Clutch disc facing rivets loose Replace H-15
Pressure plate damaged or excessive runout Replace H-15
Flywheel surface hardened or damaged Repair or replace H-15
Loose or worn engine mount Tighten or replace - Clutch pedal
Pedal shaft not properly lubricated Lubricate or replace H- 6 sticking
Abnormal noise
Clutch release bearing damaged Replace H-15, 17
Poor lubrication of release bearing sleeve Lubricate or replace H-15
Torsion rubbers weakened Replace H-15
Excessive crankshaft end play Repair Refer to Section E
Pilot bearing worn or damaged Replace H-15, 18
Worn pivot points of release fork Repair or replace H-15
^^. .^. I~, ^r
H-3

H CLUTCH RELEASE CYLINDER, CLUTCH UNIT
Disassembly Note
Piston and cup assembly
Caution
l Hold a rag over the release cylinder to prevent the
piston and cup assembly from suddenly popping
out.
1. Remove the piston and cup assembly by applying com-
pressed air through the clutch pipe installation hole.

I
I
13UOHX-017
CLUTCH UNIT
PREPARATION
SST
49 EOll IA0
Brake set,
ring gear
49 EOll 104
Collor
(Part of
49 EOl 1 1 AO)
49 SE01 310A
Clutch disc
centering tool
49 1285 073
Chuck
IPart of
b9 1285 071) For
prevention of
engine rotation 49 EOll 103
Shaft
(Part of
49 EOl 1 1 AO)
For 49
EOI 1 105 prevention of
engine rotation Stopper 453
(Part of
49 EOl 1 IA0
4
For
installation of
clutch disc 49 1285 071
Puller, bearing
For
removal of pilot
bearing For
prevention of
engine rotation
For
prevention of
engine rotation
23UOHX-013
For
removal of pilot
H-14

OUTLINE Jl
OUTLINE
SPECIFICATIONS
c EnginelTransaxle
B6 SOHC BP SOHC
Item FSM-R
I
Transaxle control
I Floor shift
Synchromesh system Forward: Synchromesh
Reverse: Selective sliding
1 1st
I 3.416
2nd 1.842
I
Gear ratio
4th
Final aear ratio 5th
Reverse I
0.918
0.731
3.214
4.105 3.619
Grade
I API service GL-4
Oil Viscosity
I SAE 75W-90
Capacity liters (US qt, Imp qt) 2.68 (2.83, 2.36)
13UOJl-00
Jl-3

Jl TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem
Shift lever won’t shift
smoothly or is hard
to shift
Too much play in
shift lever
I------
Difficult to shift
Won’t stay in gear
Abnormal noise
I
Possible cause
Seized shift lever ball
Seized change control rod joint
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
Worn shift lever ball bushing
Bent change rod
No grease in transaxle control
Insufficient oil
Deterioration of oil quality
Wear or play of shift fork or shift rod
Worn synchronizer ring
Worn synchronizer cone of gear
Bad contact of synchronizer ring and cone of gear
Excessive longitudinal play of gears
Worn bearing
Worn synchronizer key spring
Excessive primary shaft gear bearing preload
improperly adjusted change guide plate
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
improperly installed extension bar
Worn shift fork
Worn clutch hub
Worn clutch hub sleeve
Worn gear sliding part of both shaft gears
Worn gear sliding part of each gear
Worn steel sliding groove of control end
Weak spring pressing against steel ball
Excessive thrust clearance
Worn bearing
Improperly installed engine mount
Insufficient oil
Deterioration of oil quality
Worn bearing
Worn sliding surfaces of gears or shafts
Excessive gear backlash
Damaged gear teeth
Foreign material in gears
Damaged differential gear or excessive backlash Remedy Replace
Replace
Replace
Replace
Replace
Replace
Replace
Lubricate with grease
Add oil
Replace with oil of
specified quality
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Replace
Replace
Replace
Tighten
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Tighten
Add oil
Replace
Adjust or replace
Replace
Replace
Replace with oil of
specified quality
Replace
Adjust or replace Page Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl- 7
Jl- 7
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-36
Jl-17
Jl-56
Jl-56
Jl-56
Jl-56
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-14
Jl-14
Jl-22, 24
Jl-22, 24
Jl-48
Jl- 7
Jl- 7
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-53
03UOJl-OC --
-../
51-6

Jl TRANSAXLE
TRANSAXLE
PREPARATION
SST
19 GO17 5A0
support of engine removal of tie-rod
19 0107 680A
Hanger, transaxle
49 F401 440
49 BOO1 795
49 0839 42%
removal of gears
49 GO30 370
49 F401 366A
49 F401 3308
49 F401 335A -.,
.J

TRANSAXLE Jl
1. Wheel and tire
2. Splash shield
3. Air hose and resonance chamber
4. Battery
5. Battery carrier
6. Speedometer cable
7. Back-up light switch connector
8. Neutral switch connector
9. Ground
10. Starter
11. Extension bar
12. Control rod
13. Engine mount member
Removal Note . . . . . . . . . . . . . . . . . . . . . . 14. Exhaust pipe
15. Engine mount No.2
16. Clutch release cvlinder
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-1 1
17. Tie-rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
18. Stabilizer (BP SOHC)
19. Driveshaft
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
20. Engine mount No.4
21. Transaxle
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
page Jl-11
03UOJl-012
Removal Note
Engine mount member
1. Suspend the engine with the SST and remove the engine
mount member.
03UOJ2-015 Clutch release cylinder
Caution
l Do not damage the clutch pipe.
1. Remove the bolts shown.
2. Lay aside the clutch release cylinder and the clutch pipe
when removing the transaxle.
03UOJl-013
,Jl-11