1992 MAZDA PROTEGE heater

HEATER U
4. Verify that the mode lever is in the defrost position.
5. Set the mode wire to clip A as shown, Keep natural tension
of the mode wire. (It is all right if the mode wire is slightly
pulled to the direction a) Push areas b and c simultaneous-
ly when setting the wire to the clip.
Note
l Do not push the inner wire of the mode wire when
setting, if pushed, it may result in deformation of
the wire and prevent the corret setting.
6. Check the function of the mode lever. If the result is not
good, pull the mode wire 2mm (0.08 in) in direction a.
7. Confirm the function of the mode lever.
8. Remove the set pin.
u-29

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

TD
TECHNICAL DATA
MEASUREMENTS .................................... TD- 2
ENGINE (B6 AND BP SOHC)
ENGINE (BP DOHC) ... .................................................. ;;- f
LUBRICATION SYSTEM ........................... TDI 6
COOLING SYSTEM .................................. TD- 6
FUEL AND EMISSION CONTROL
SYSTEMS ............................................. TD- 9
ENGINE ELECTRICAL SYSTEM ................ TD-10
CLUTCH ................................................. TD-11
MANUAL TRANSAXLE (F5M-R) ................ TD-12
MANUAL TRANSAXLE (GSM-R) ................ TD-13
AUTOMATIC TRANSAXLE ....................... TD-14
FRONT AND REAR AXLES.. .....................
STEERING SYSTEM ................................ ;;-;;
-
BRAKING SYSTEM .................................. TD-16
WHEELS AND TIRES ............................... TD-19
SUSPENSION ......................................... TD-19
BODY ELECTRICAL SYSTEM ................... TD-20
HEATER AND AIR CONDITIONER
SYSTEMS ............................................. TD-21
STANDARD BOLT AND NUT TIGHTENING
TORQUE .............................................. TD-21
23UTDX-001

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

SPECIAL TOOLS
GENERAL INFORMATION ........................
ENGINE .................................................. i;-
- ‘3
CLUTCH AND MANUAL TRANSAXLE.. ...... ST- 4
AUTOMATIC TRANSAXLE.. ...................... ST- 5
FRONT AND REAR AXLES.. ..................... ST- 7
STEERING SYSTEM ................................ ST- 8
BRAKING SYSTEM .................................. ST- 9
FRONT AND REAR SUSPENSIONS.. ......... ST-10
HEATER AND AIR CONDITIONER
SYSTEMS ............................................. ST-l 0
CHECKER AND OTHER EQUIPMENT.. ....... ST-10
23USTX-001

ST SPECIAL TOOLS
FRONT AND REAR SUSPENSIONS
TOOL NUMBER
& DESCRIPTION PRIORITY ILLUSTRATION
49 8034 2A0
Replacer set,
rubber bush A
49 1243 785
Installer, dust
boot A TOOL NUMBER
81 DESCRIPTION PRIORITY ILLUSTRATION
49 GO34 1AO
Compressor, coil A
spring
49 0208 701A
Air-out tool, boot B
HEATER AND AIR CONDITIONER SYSTEMS
TOOL NUMBER
PRIORITY ILLUSTRATION TOOL NUMBER
i? DESCRIPTION & DESCRIPTION PRIORITY ILLUSTRATION
49 BO61 005
Replacer, seal
plate A 0000-41-0809-06
Remover &
installer, seal
CHECKER AND OTHER EQUIPMENT
TOOL NUMBER
81 DESCRIPTION
49 0839 285
Checker, fuel &
thermometer
49 GO19 901A
EC-AT tester
49 BO19 904
Panel
(EC-AT tester) PRIORITY
A
A ILLUSTRATION
49 GO19 901
EC-AT tester
49 HO19 902
(EC-AT tester)
49 BO19 905
ST-10

PARTS INDEX
I
CRANKSHAFT.. ....................................
I31 -64
CYLINDER BLOCK .............................. 61-60
CYLINDER HEAD..
............................... 81-54
CYLINDER HEAD GASKET .................
Bl-16
DRIVE BELT(S). ...................................... 81-5
FRONT OIL SEAL ................................ 81-23
HLA .............................................. Bl-7,20,60
OIL JET ................................................ 81-61
PISTON.. ...............................................
Bl-62
PISTON PIN..
........................................ 81-62
PISTON RING
....................................... 81-62
REAR
OIL SEAL..
................................. 81-25
TENSIONER, IDLER ............................. Bl-65
TENSIONER
SPRING ...........................
Bl-65
TIMING BELT ..................................
Bl-12,65
TIMING BELT PULLEY ........................
Bl-65
VALVE MECHANISM ........................... Bl-55
ENGINE
(BP DOHC) .................................... B2-2
CAMSHAFT ..........................................
82-58
CAMSHAFT PULLEY ...........................
B2-65
CONNECTING ROD..
........................... 82-63
CRANKSHAFT ......................................
B2-64
CYLINDER BLOCK ..............................
82-60
CYLINDER
HEAD.. ............................... B2-54
CYLINDER HEAD GASKET .................
82-16
DRIVE
BELTS.. .......................................
B2-5
FRONT
OIL SEAL ................................
82-26
H LA ..............................................
OIL JET .......................... B2-7iyL;;
......................
PISTON .................................................
B2-62
PISTON PIN ..........................................
82-62
PISTON RING..
..................................... 82-62
REAR OIL SEAL ................................... B2-28
TENSIONER, IDLER ............................. B2-65
TENSIONER SPRING ........................... B2-65
TIMING
BELT.. ................................
B2-12,65
TIMING BELT PULLEY ........................ 82-65
VALVE MECHANISM ........................... 82-55
ENGINE CONTROL UNIT (ECU) ............... F-149
ENGINE COOLANT
........................................ E-5
ENGINE OIL.. .................................................
D-7
ENGINE OIL FILTER.. .................................... D-8
’ EXHAUST SYSTEM. ...................................
F-136
EXTRACTOR CHAMBER .............................. S-53
F
FAN MOTOR (COOLING FAN). ................... E-14
FAN RELAY (COOLING FAN). ..................... E-18
FLASHER UNIT ............................................
T-17
FLOORMAT ..................................................
S-99
FLYWHEEL ..................................................
H-18
FRONT AXLE .................................................
M-4
FRONT BRAKE ............................................
P-l 8
FRONT BUMPER ......................................... S-39
FRONT DOOR ................................................
S-8
FRONT DOOR LOCK AND OPENER ..........
S-13
PI-2
FRONT FENDER PANEL ............................... S-7
FRONT LOWER ARM .................................. R-16
FRONT SHOCK ABSORBER AND SPRING R-11
FRONT SIDE WINDOW REGULATOR AND
GLASS ........................................................ S-10
FRONT STABILIZER..
................................... R-l 8
FRONT SUSPENSION .................................. R-l 0
FUEL FILLER LID AND OPENER..
.............. S-37
FUEL FILTER .............................................. F-l 24
FUEL GAUGE SENDER UNIT ..................... T-73
FUEL PUMP ............................................... F-125
FUEL TANK
................................................ F-123
FUSE AND JOINT BOX.. .............................. T-12
H
HEADLIGHT AND
FRONT COMBINATION LIGHT..
................ T-41
HEADLIGHT RELAY ..................................... T-l 8
HEADLINER ................................................. S-89
HEATER CONTROL UNIT.. ......................... U-26
HEATER UNIT
.............................................. U-21
HIGH-MOUNT STOPLIGHT
.......................... T-45
HIGH-TENSION LEAD ................................. G-l 7
HOOD ............................................................. S-5
HORN T-88
...........................................................
HORN RELAY
.......................................... T-18,88
.__. ’
I I
IGNITER .......................................................
G-23
IGNITION COIL.. .......................................... G-19
INJECTOR .................................................. F-l 31
INSTRUMENT CLUSTER
AND SPEEDOMETER CABLE
.................... T-69
INTAKE MANIFOLD ................................... F-113
INTERIOR LAMP ..................................... T-52,53
ISC VALVE.. ................................................ F-l 16
J
JOINT SHAFT (FRONT AXLE) .................... M-18
L
LATERAL LINK AND TRAILING LINK.. ....... R-26
LICENSE PLATE LIGHT.. ............................. T-47
i
M
I
---
MAIN RELAY (FUEL INJ. RELAY). ............ F-172
MANUAL STEERING ..................................... N-4
MANUAL TRANSAXLE (F5M-R). .................. Jl-2

Z
SYSTEM INDEX
System Section System Section
AUDIO SYSTEM ......................................................... J
BACK-UP LIGHTS ...................................................
F-3
CHARGING SYSTEM ............................................... A-2
CIGARETTE LIGHTER ............................................... I-1
COMMON CONNECTOR LIST ..................................... X
COOLING FAN SYSTEM ....................................... B-3.4
COURTESY LAMPS .................................................. l-3
CRUISE CONTROL SYSTEM ...................................... Q
DAYTIME RUNNING UGHTS .................................... E-3
DIAGNOSIS CONNECTOR .......................................... U
DIGITAL CLOCK ....................................................... l-l
ELECTRICAL WIRING SCHEMATIC ............................. W
ENGINE CONTROL SYSTEM (MT) ................. B-l a, 1 b, 1 c
ENGINE 8 EC-AT CONTROL
SYSTEM (EC-AT) ...................................... B-2a,2b,2c
GENERAL INFORMATION .......................................... GI
GROUND POINT ........................................................ Y
HEADLIGHTS ....................................................... E-l ,2
HEATER 8 AIR CONDITIONER .................................... G
HORN .................................................................... F-3
IGNITION KEY CYLINDER LAMP ............................... l-2
ILLUMINATION LAMPS .............................................
l-4
INSTRUMENT CLUSTER . WARNING LAMPS .............. C INTER CONNECTING OF JOINT BOX ......................... JB
INTERIOR LAMP ...................................................... l-2
JOINT BOX .............................................................. JB
LICENSE PLATE UGHTS ......................................... E-4
PARTS INDEX ........................................................... PI
PARTS LOCATION ................................................... PL
PASSIVE SHOULDER BELT CONTROL SYSTEM .......... S
POSITION LIGHTS ................................................... E-4
POWER DOOR LOCK ............................................. K-2
POWER OUTSIDE MIRROR ......................................... L
POWER WINDOW ................................................... K-l
REAR SIDE MARKER LIGHTS.. ................................. E-4
REAR WINDOW DEFROSTER .................................... I-1
REAR WIPER 8 WASHER ........................................ D-3
SHIFT-LOCK SYSTEM ................................................ H
SLIDING SUNROOF ................................................... M
SOUND WARNING SYSTEM ...................................... l-2
STARTING SYSTEM ................................................ A-l
STOPLIGHTS .......................................................... F-2
TAILLIGHTS ............................................................ E-4
TRUNK COMPARTMENT LAMP ................................. l-3
TURN 8 HAZARD FLASHER UGHTS ......................... F-l
WINDSHIELD WIPER 8 WASHER .......................... D-l ,2