1992 MAZDA PROTEGE oil

TD TECHNICAL DATA
Jl l MANUAL TRANSAXLE (FSM-R)
BB SOHC
l- BP SOHC I
F %M.R
I
1
Floor shift Item
Transmission Shift lever oosition Engine/lransaxle
First
Second
-I?-:-.4
I 0.918
I
n ‘31
I Gear ratio lllll”
Fourth
Fifth
Reverse
Grade
Oil Viscosity
Capacity liters (US qt, Imp qt) Clearance
Clearance of lever and reverse Standard
idler gear
mm (in) Wear limit
1 st-2nd
Standard 3rd-4th
Clearance of shift fork and Sth-Rev.
clutch sleeve mm (in)
1 st-2nd
Wear limit 3rd-4th
I 5th~Rev. j
Clearance of synchronizer ring and gear Standard ) mm (in)
Wear limit 3.416
1.842
1.290
ce GL-4
SW-90
I
V.I.
3.214
API servil
SAE 7t
2.68 (2.83, 2.36)
0.1 O-O.32 (0.004-o.
0.37 (0.015)
0.1 O-O.36 (0.004-o.
0.20-0.50 (0.008-O.
0.40-0.75 (0.016-O.
0.86 (0.034)
1 .oo (0.039)
i 3c /n n/la
I .L” \“.“T”,
1.12-l .88 (0,044-O.
0.8 (0.032)
0.05-0.28 (0.002-0.011)
0.33 (0.013)
0.18-0.51 (0.007-0.020)
0.56 (0.022)
0.06-0.21 (0.002-0.008)
0.26 (0.010)
0.21-0.61 (0.008-0.024)
0.66 (0.026)
0.06-0.26 (0.0024-0.0102)
0.31 (0.0122)
(0.008), 0.3 (0.012), 0.4 (0.016) Fifth Standard
Limit
0.1 (0.004) 0.2
Rnnrinn nrdnari adjust Primary shaft
0.5 (0.020) 0.6
I shim mm (in)
Secondary shaft 0.15 (0.006) 0.20 (0.008) 0.25 (0.
~-~?r;liln I Final gear
Bearing preload
I Bearing preload adjust shim
[Backlash of side gear and pinion gear
I
I
030)
,074)
I
First Standard
Limit
Second Standard
Limit
Gear thrust clearance
mm (in) Third Standard
Limit
Fourth Standard
Limit
(0.024j
OlO), 0.30 (0.012)
I
I V.“” \“‘V I .,, “.~lV \Y... VW,? “I ,-
\... 018j, 0.50 (0.020)
Helical
4.105 : 1
I 3.619 : 1
N,m (cm-kg, in-lb) 0.03-0.74 (0.3-7.6, 0.3-6.6)
n qn
mm (in)
“.L” ,“.“U mnr78), 0.25 (o.oio), 0.30 (0.012) 0.35
(0.014)
0.40 (0.01 6) 0.45 (0.018),
0.50 (0.020) 0.55 (0.022)
-~ -1
mm (in) j o-o.1 (O-0.004 --
--’
TD-12

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

TECHNICAL DATA TD
Item
Carrier hub
Sun gear drum
Small sun gear TransaxlelEngine
Clearance between pinion washer
and planet carrier mm (in) Maximum
Bushing inner diameter
mm (in) Maximum
Bushing inner diameter
mm (in) Maximum F4A-EL
B6 SOHC BP SOHC BP DOHC
0.2-0.7 (0.008-0.028)
30.425 (1.198)
21.021 (0.828)
Gear assembly
Total end play
End play adjust race
Idle gear bearing preload
Preload
adjust shims
Output gear bearing preload
Preload adjust shims
Differential
Bearing preload
Preload
adjust shims
Backlash of side gear and pinion mm (in)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
mm (in) Standard
Maximum 0.25-0.50 (0.010-0.020)
1.2 (0.047) 1.4 (0.055), 1.6 (0.063)
1.8 (0.071) 2.0 (0.079) 2.2 (0.087)
-
0.03-0.9 (0.3-9.0, 0.26-7.8)
3.80 (0.150) 3.85 (0.152) 3.90 (0.154) 3.95
(0.156)
4.00 (0.158) 4.05 (0.159) 4.10 (0.161) 4.15 (0.163)
4.20 (0.165) 4.25 (0.167) 4.30 (0.169) 4.35 (0.171)
4.40 (0.173), 4.45 (0.175) 4.50 (0.177) 4.55
(0.179)
4.60 (0.181) 4.65 (0.183) 4.70 (0.185) 4.75 (0.187)
0.03-0.9 (0.3-9.0, 0.26-7.8)
0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65
(0.026).
0.70 (0.028) 0.75 (0.030) 0.80 (0.032) 0.85
(0.034)
0.90 (0.035) 0.95 (0.037) 1.00 (0.039) 1.05 (0.041)
1.10 (0.043) 1.15 (0.045) 1.20 (0.047) 1.25 (0.049)
1.30 (0.051), 1.35 (0.053) 1.40 (0.055) 1.45
(0.057)
2.9-3.9 (30-40, 26-35)
0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65
(0.026)
0.70 (0.028) 0.75 (0.030) 0.80 (0.032) 0.85 (0.034)
0.90 (0.035) 0.95 (0.037) 1.00 (0.039), 1.05 (0.041)
1.10 (0.043) 1.15 (0.045) 1.20 (0.047). 1.25 (0.049)
1.30 (0.051) 1.35 (0.053) 1.40 (0.055), 1.45 (0.057)
0.025-0.1 (0.001-0.004)
0.5 (0.020)
Torque converter
Bushing inner diameter mm (in) Standard 1 53.030-53.075 (2.088-2.090)
Maximum 1 53.075 (2.090)
Spring Specification
Spring name Outer diameter Free length
No. of coil Wire diameter
mm (in) mm (in) mm (in)
Throttle modulator 8.1 I I--.._ ^^^1-^1 1 spring 1 (0.319)
1 43.4 (1.709) 1 10.5 1 0.8 (0.031)
1
” cJIJtz:I li”I IL, “I
valve body Throttle spring
Throttle assist spring 1 5.4 (0.213) 46.2 (1.819) 1 29.0
0.88 (0.035)
1 5.15 (0.203)
26.88 (1.058) 1 16.2 0.6 (0.024)
,
^ -- ,^ ^^^
Mnin contrnl I Low reducina sprina I 7.9 (0.311) .._... __.._. -
valve body
-. .- \“---I 29.98 (1.180) 10.0
0.8 (0.03lj
1 3-4
shift spring / 7.4 (0.291) I 36.6 (1.441)
12.0 0.8 (0.031)
B6 SOHC
23.0
Bypass spring BP
SOHC 4.9 (0.193) 27.6 (1.087) 0.55 (0.022)
Premain control BP
DOHC 4.9 (0.193) 30.5 (1.201) 23.0
0.55 (0.022)
valve body
2-3 shift spring 7.4 (0.291) 36.6 (1.441)
12.0 0.8 (0.031)
Converter relief spring
8.6 (0.339) 68.4 (2.693) 27.5
1.2 (0.057)
Lockup control spring
5.0 (0.197) 30.1 (1.185) 21.5 0.55 (0.022)
Control valve body Throttle relief spring
6.6 (0.260) 21.6 (0.850) 11.5
0.8 (0.031)
Oil
pump Spring
13.0 (0.512) 53.0 (2.087)
12.0 1.2 (0.047)
TD-15

TD TECHNICAL DATA
Spring name
2-3 accumulator
small spring Outer diameter Free length Wire diameter
mm (in) mm (in) No. of coil
mm (in) BP DOHC 11.6 (0.457)
59.7 (2.350)
16.9 1.8 (0.071)
56 SOHC
BP SOHC 10.0 (0.394) 71.8
(2.827) 24.2 1.4 (0.055)
2-3 accumulator BP DOHC 15.0
(0.591) 71.8 (2.827) 9.8
1.2 (0.047)
large spring B6 SOHC
BP SOHC 15.0 (0.591)
71.8 (2.827)
15.8 2.0 (0.079)
l-2 accumulator small spring
11.2 (0.441)
84.7 (3.335)
25.5 1.5 (0.059)
BP DOHC
- - -
-
l-2 accumulator
Accumulator large spring B6 SOHC
BP SOHC 16.0 (0.630)
84.7 (3.335) 19.5
1.9 (0.075)
B6 SOHC 10.8 (0.425) 101.2 (3.984)
28.2
1.2 (0.047)
N-D Accumulator
small spring BP SOHC
BP DOHC
10.8 (0.425) 101.2 (3.984)
28.2
1.2 (0.047)
B6 SOHC
15.0 (0.591) 94.2 (3.709)
16.5
1.6 (0.063)
N-D Accumulator
large spring BP SOHC
BP DOHC 15.0 (0.591) 94.2
(3.709) 16.5
1.6 (0.063)
N-R Accumulator small spring
9.8 (0.386)
93.2 (3.669) 31.5
1.3 (0.051)
N-R Accumulator large spring
14.0 (0.551) 106.5 (4.193)
23.0 1.7 (0.067)
3-4 clutch
Return spring
74.4 (2.929)
40.5 (1.594) 1 .o
5.0 (0.197)
Coasting clutch
Return spring
7.3 (0.287) 20.45 (0.805)
10.0 1 .o (0.039)
Low and reverse
brake Return
spring 5.55 (0.219)
14.3 (0.563)
12.0 0.75 (0.030)
Servo
Return spring
27.7 (1.091) 43.25 (1.703)
4.5
3.2 (0.126)
Vehicle Speed at Shift point Table -
lode
- -
angc
-
D Throttle condition
(Throttle sensor
voltage)
Fully opened
(4.0 volt)
Half throttle
(1.6-2.2 volt)
/ &%L) j 3 1 850-2,500 2,100-2,650 2,300-3,000 74-100 (46-62) 91-116 (56-72) 93-120 (58-74
Lock-up
[1,850-2,20011,950-2.550(2,300-2,700/74-88 (46--55)185-110 (53-68)(93-108 (58-67)1
Kir.kdnwn OD -+ DI
1,05U
%lly opened
i4.0 volt)
Half throttle
s2 -+ s3 5,000-5,45c
s3 -+ s2 2,900
S2 -+ ST 2,300-2,6OC
SI * 52
2.500-3.35C
(1.6-2.2 volt)
s2 -+ s3 v, v...
Fully opened Ll + L2 5,150-5,75(
w-dt I7w-ln
nlf throttle 6-7 7 vnltl I Ll + L2 (2.500-3.350(2,850-3,8OOj3.300-4.300125-34 (16-21$1-41 (19-25)j33-43 (20-27)1
TD-16

TECHNICAL DATA TD
1 Throttle condition 1
nrllm pn-t
Mode Rr _ me/ flhrottle sensor 1 Shift 1 -.- -*r2d rpm
Vehicle speed I km/h (mohl , . ,
I
ioltage) 1 B6 sot
iC 1 BP SOHC 1 BP DOHC
66 SOHC 1 BP SOHC 1 BP
I I I
’ ni - n9 I’) 7nn-1 “50 2,500-3,05012,700-3.3001 I I DOHC
Fully opened 27-33 (17-201
3 D (4.0 volt) 50 2,050-2,55012,200-2,750]
40-50 i25-31 j
e I 300-500 1 450-650 / Q-15 16-9) 112-18 (7-111
00 3,250-3,45013,550-3.800~91-97 f56-60&G10’4 (61-64)hOO-106;62-&\I
s
i- f Fully closed
(0.5 volt)
YI -l&c
L, r vv-“,L
Dz + D3 2,150-2,7
D3 -+ DI 300--5O(
S3 -+ S2 3,200-3,4
’ L2 -+ LI 2,350-2,65012,200-2,50012,350-2.7001
43-49 ;27--3b1 ’ ‘I
M. FRONT AND REAR AXLES -
Item
Driveshaft Engine/Transaxle BP SOHC BP DOHC
Joint type
Length of shaft
Shaft diameter Front axle
Bearing play axial direction Rear axle
Bearing play axial direction Inside Tripod joint
Outside Ball joint
Right
919.3 (36.19) 918.7 (36.17) 630.7 (24.83)
mm (in) Left
637.8 (25.11) 640.2 (25.20) 621.2
637.1
(24.46) (25.08)
21.5 (0.85) 23.0 (0.91)
mm (in) 1 0.05 (0.002)
mm (in) I 0.05 (0.002)
N. STEERING SYSTEM Steering wheel
Outer diameter Item Specifications 370 (14.57)
Lock-to-lock I Steering gear
--
Type
Steering gear ratio
Backlash between rack and pinion mm (in)
N.r ’ ’ ” ’ n (cm-Kg, in-01
Preload measured by torque
*rrv~rrdl Rack and pinion
Infinite (00)
0 (0)
M/S : 0.9-l .3 (Q-13, 7.8-l 1.3)
P/S : 1.0-1.3 (10-14, 8.7-12)
Pinion preload ““l~jll~,,
9 (0.4
Preload measured by pull
scale with attachment
Limit of rack housing movement mm (in)
Distance between left and right brackets mm (in)
Rack stroke mm (in M/S : 900-l ,300 (31.8-45.9)
P/S : l,OOO-1,400 (35.3-49.4)
1.5 (0.06)
298.5 (11.75)
140 (5.511
Lubricant type (power steering)
Oil capacity (power steering) Drive belt
liter (US qt, Imp qt) I ATF: M-III or DexronW
0.8 (0.85, 0.70)
I New belt: 8-Q (0.31-0.35)
Deflection with force of 98 N (10 kg, 22 lb) mm (in) Used belt: 9-10 (0.35-0.39)
I imit: 11.5 (0.461
TD-17

TECHNICAL DATA
Q. WHEELS AND TIRES
Item Specifications
Wheel
Size
Off set Standard: 13x5-J, 14x5 l/2-JJ
Temporary
mm (in) 1 _ spare: 14x4-T
45 (1.77)
I Diameter of oitch circle
mm (in) I 100 (3.94)
r I Pl
-
Inflation pressure kPa (kg/cm*, psi) Front 1 8
I 9
Runout limit
Unbalance limit mm (in) ;lii.raltLa’
a (02) ’
13 inch wheel: 11 (0.
R. SUSPENSION Item Specifications
Suspension type Strut
)e Double-acting, oil-filled
I Shock absorber tyf
Coil spring
Type
Dimension
Type Front Taper wound
Rear Straight wound
See next page
Torsion bar
I
I C.rrn,
19.1 (0.75)
20.0 (0.79)
22.0 (0.87)
21 .O f0.83)
Wheel alignment
(“‘Unladened) BP SOHC ;;a;
Diameter
mm (in) BP DOHC - ;la;t
Front -
B6 SOHC
Rear 20.0 (0.79)
Maximum Inner 4o” f 2O
steering angle Outer
Total mm (in) 2 f 3 (0.08 j
Front toe-in
dearee
.-.._
Rear
.--. I --- ~~
Camber angle
Caster angle
Kingpin angle
I Total
I mm OnI I I toe-in
1 dearee I , --U’-- 1
Camber angle
I 33O * 2O
: 0.12)
0.2O f 0.3O
-0OO5’ * 45’
1055’ * 55’
12O25’
2 f 3 (0.08 f 0.12)
0.2O f 0.3O
-0°20’ f 45’
l ’ Fuel tank full; radiator coolant and engine ail at specified level; and spare tire, jack, and tools in designated posmons.
TD-19

TD TECHNICAL DATA
Coil Spring Specifications (See page R-5 for coil spring applications)
*’ Main identification mark color: Indicated on second coil from bottom. l * Auxiliary identification mark color: Indicated on third coil from bottom.
T. BODY ELECTRICAL SYSTEM
Item
Headlight
Frnnt tl wn sinnnl/Pnrkinn linht
Specification (W) (Bulb Trade number)
65145 (9004)
2718 II I 571
I
“‘VW, I u”“y’ 1. I” \’ ‘V’,
uinh mount stoplight 18.4 (1141)
turn single light 27 (1156)
Y-,-~p light 27 (1156)
Rear side marker light (Sedan) 3.8 (194)
License plate light 7.5 (89) [PROTEGE], 5 (168) [3HBl
Interior 10
Interior and spot lamp
spot 6
Interior lamp 10
‘i--” Spot lamp (in overhead console)
8 (67)
Cargo room lamp 5 (168)
Trunk room lamp 5 (168)
I I
ntminr Iamnc
I
Curtesy lamp
High beam
Turn light
Brake
Hold
) Charge 5 (168)
3.4
3.4
3
3 (158)
i
Oil pressure
Washer
Seat belt
Malfunction
Fuel
illumination 3 (158)
3 (158)
3 (158)
3 (158)
3 (158)
3 (158)
3.4 Indicator and
warning lamps
Check 3 (158)
Dif. lock
I 3 (158) .-
,
-.-’
I
I
TD-20

TECHNICAL DATA TD
U. HEATER AND AIR CONDITIONER SYSTEMS
Item Specifications
Refrigerant amount
g (04
Refrigerant pressure kPa (kg/cm2, psi) 750-800 (26.5-28.2)
High: 1,177-1,619 (12.0-16.5, 171-235)
Low: 147-294 (1.5-3.0, 21-43)
Compressor
Magnetic clutch
Condenser fan
Recerver/Drier Capacity cc (cu in)
Compressor oil amount cc (cu in)
Electrical load w
Electrical load w
Capacity cc (cu in) 115 (7.0)
loo---120 (6.1-7.3)
31
77
330 (20.1)
STANDARD BOLT AND NUT TIGHTENING TORQUE
Diameter Pitch 4T 6T 8T
mm (in) mm (in) N-m m-kg ft-lb N.m m-kg ft-lb N.m m-kg ft-lb
6 (0.236) 1 (0.039) 4.2-6.2 0.43-0.63 3.1-4.6 6.9-9.8 0.7-1.0 5.0-7.2 7.8-11.8 0.8-1.2 5.8-8.8
8 (0.315) 1.25 (0.049) 9.8-14.7 1.0-1.5
7.2-10.8 16-23 1.6-2.3 12-17 18-26 1.8-2.7 13-20
10 (0.394) 1.25 (0.049) 20-28 2.0-2.9
14-21 31-46 3.2-4.7 23-34 36-54 3.7-5.5 27-40
12 (0.472) 1.5 (0.059) 34-50 3.5-5.1 25-37 55-80 5.6-8.2
41-59 63-93 6.4-9.5 46-69
14 (0,551) 1.5 (0.059)
- - - 75-103 7.7-10.5 56-76 102-137
lo-14 75-101
1 16 (0.630) 1 1.5 iO.059j 1 - 1 - - 116-157 12-16 85-116 156-211 16-22 115-156
1 18 ;0.709j Il.5 iO.O59 1 - 1 -
167
1 20 i0.787; Il.5 iO.059i 1 - 1 - 1 - 12:
31 _..
22 (0.866) 1 1.5 io.059j 1 - 1 - 1 - 1314-423 __ ._ ,--. -._,
1 I
24 (0.945) 1 1.5
(0.059) 1 -
- 1475-546 41-56 (298-4031536-7261 55-74 1396-536 -2251 17-23 123-166 221-299 23-31 163-221
-3141 24-32 171-231 308-417 31-43 227-307
37-43 331-312 417-564 43-58 307-416
TD-21