1992 MAZDA PROTEGE ignition

ON-VEHICLE MAINTENANCE B2
05UOBX-05
BLA-DE 0-dlNG
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page 82-8.) 3. Install the camshaft pulley lock bolts.
4. Hold the camshaft with a wrench.
5. Tighten the camshaft pulley lock bolt.
Tightening torque:
49-61 N-m (5.0-6.2 m-kg, 36-45 ft-lb)
Distributor
1. Apply grease to a new O-ring and the blade.
2. Install the distributor and loosely tighten the installation bolt.
3. Connect the distributor connector.
0311082-039
B2-25

ON-VEHICLE MAINTENANCE
I 05UOBX-063
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
13EOB2-02
ALIGN.KEY GRCi&E
13EOB2-02
23UOB2-025
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page 92-8.)
3
Installation Note
Oil seal
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly with a suitable pipe and a ham-
mer until it is about flush with the face of the oil pump body.
Oil seal outer diameter: 50.5mm (1.98 in)
Timing belt pulley
1. Install the timing belt pulley.
2. Install the pulley Woodruff key with the tapered side toward
the oil pump body.
Pulley lock bolt
1. Hold the crankshaft with the SST and tighten the pulley lock
bolt.
Tightening torque:
157-187 N.m (18-17 m-kg, 116-123 ft-lb)
23UOB2-026
82-27

92 INSTALLATION
RESOiANCE CHAMBER
03UOBZ-154
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut A.
Deflection: 1-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 Nlm (80-l 10 cm-kg, 69-96 In-lb)
2. Install the battery carrier.
Tightening torque:
7.8-l 1 N*m (80-l 10 cm-kg, 69-96 in-lb)
3. Install the battery and the battery bracket.
Tightening torque:
2.9-5.9 N*m (30-60 cm-kg, 26-52 in-lb)
Air cleaner assembly
1. Install the air cleaner assembly.
Tightening torque
@: 19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N*m (80-l 10 cm-kg, 69-95 In-lb)
2. Connect the air flow sensor connector.
Resonance chamber
I, Install the resonance chamber.
Tightening torque:
7.8-l 1 N#m (80-l 10 cm-kg, 69-95 In-lb)
Under cover and side cover
1. Install the under cover and side cover.
Steps After Installation
1. If the engine oil was drained, fill with the specified amount and type of engine oil.
(Refer to Section D.)
2. Fill the radiator with the specified amount and type of engine coolant.
(Refer to Section E.)
3. If the transaxle oil was drained, fill with the specified amount and type of transaxle oil.
(Refer to Sections J2, K.)
4. Connect the negative battery cable.
5. Start the engine and check the following:
(1) Engine oil, transaxle oil, and engine coolant leakage.
(2) ignition timing, idle speed. (Refer to page 82-8.)
(3) Operation of emission control system.
6. Perform a road test.
7. Recheck the engine oil and engine coolant levels.
B2-102
2311082.047

E ELECTRIC COOLING FAN SYSTEM, FAN MOTOR
03UOEX-02
I
1
I
‘4
.

2
.:
)
SYSTEM INSPECTION
1. Jump across the fan test (TFA) terminal and the ground
(GND) terminal of the diagnosis connector.
2. Turn the ignition switch ON and verify that the fan operates.
If the fan does not operate, inspect the cooling fan system
components and wire harness. -.-
3. Remove the radiator cap and place a thermometer in the
radiator filler neck.
4. Start the engine.
5. Verify that the fan operates when the coolant temperature
reaches approx. 97OC (207OF).
If it does, check the water thermoswitch.
(Refer to page E-16.)
FAN MOTOR
INSPECTION
Single-Speed Type
1. Check that the battery is fully charged.
2. Disconnect the fan motor connector.
3. Connect the battery and an ammeter to the fan motor con-
nectar.
4. Verify that current is as specified.
Current (A)
B6 SOHC
BP SOHC
BP DOHC MTX ATX
6.6 f 1 6.6 f 1
6.6 f 1 -
6.6 f 1 -
5. If current is not within specification and/or the fan does not
turn smoothly, replace the fan motor.
Two-Speed Type
1. Check that the battery is fully charged.
2. Disconnect the fan motor connector.
3. Connect the battery and an ammeter to the fan motor con-
nectors for low-speed inspection. 4. Verify that the fan motor operates smoothly at the standard
current.
Current (A): 8.8 + 10% MAX

I
03UOEX-022
E-14

OUTLINE F
SPECIFICATIONS
Item
Idle speed*1 *2
Ignition timing*2
Fuel pump
Maximum outout Dressure Engine
rpm B6 SOHC
6O--80 BTDC 1
kPa (ka/cm’. osi1 1 BP SOHC
700-800
4O---6O BP DOHC
90-l 1 O
441-637 (4.5-6.5. 64-92) I
I Fuel filter I
Type Low-pressure side Nylon element (in fuel pump)
High-pressure side Paper element
Pressure reaulator
Regulating pressure kPa (kg/cm’, psi) 1 265-314 (2.7-3.2, 38-46)
I lniector I
Type Type of drive
Resistance
Idle speed control (ISC) valve
TvDe , ,
t Resistance
Purge control solenoid valve
Resistance
Water thermosensor n High-ohmic
Electromechanical
12-16
Rotarv
n I II-13 I
n 1 23-27
1 -20% I -4OFj 1 14.6-17.8
Resistance k62 2ooc i 68OF) 2.21-2.69
40°C (104OF) 1.0-l .3
80°C (176OF) 0.29-0.35
Airflow meter
E2++Vs
E2-Vc Fully closed
Fully open 20-600
20-l ,000
200-400
Capacity liters (US gal, Imp gal) 1 Hatchback 50 (13.2, ll.O), PROTEGE ,... 55 (14.5, 12.1)
I Air cleaner I
Element type
Fuel
Specification l
l Wlth parking brake applied (Canada)
‘2 TEN terminal of diagnosis connector grounded Oil permeated
Unleaded regular (RON 91 or higher) 23UOFX-012
F-l 5

F OUTLINE
COMPONENT DESCRIPTIONS
Component
Air cleaner
Airflow meter
Mr valve
Atmospheric pressure
Sensor
Catalytic converter Function Remark
Filters air entering throttle body
Detects amount of intake air; sends signal to intake air thermosensor and fuel pump
ECU switch included
Supplies bypass air into dynamic chamber
l Engine speed increased to shorten
when engine is cold warm-up period
l Thermowax type l Installed in dynamic chamber
Detects atmospheric pressure; sends signal Built in ECU
to ECU
Reduces HC, CO, and NOx by chemical Monolith type
reaction Charcoal canister
Stores fuel tank fumes while engine stopped Check valve
Controls pressure in fuel tank Two-way type Circuit opening relay
Voltage for fuel pump while engine running Clutch switch (MTX)
Detects clutch condition; sends signal to Switch OFF when clutch pedal released
ECU Diagnosis connector
Concentrated service connector 25pin (located near left suspension mount-
Concentrated terminals: ing block)
1. EGI self-diagnostic terminal
2. EC-AT self-diagnostic terminal
3. Test terminal
4. Fuel pump check terminal
5. Cooling fan check terminal
6. Engine rpm output terminal Dynamic chamber
Interconnects all cylinders Engine control unit (ECU) Detects the following:
1. A/C operation 1. A/C switch
2. Air/fuel ratio (Oxygen concentration) 2. Oxygen sensor
3. ATF thermosensor
4. Atmospheric pressure 4. Atmospheric pressure sensor
5. Braking signal 5. Stoplight switch (MTX)
6. Cranking signal 6. Ignition switch (START Position)
7. DRL (Daytime Running Light) operation 7. DRL relay (Canada)
8. E/L operation 8. Blower motor switch, cooling fan relay,
headlight switch, and rear window
defroster switch
9. Engine coolant temperature 9. Water thermosensor
10. Engine speed 10. Distributor (Ne-signal)
11. Ignition ON signal 11. Ignition switch
12. In-gear condition 12. Neutral and clutch switches (MTX)
13. Inhibitor switch (ATX) 13. N range, D range, S range, L range
switch
14. Intake air amount 14. Airflow meter
15. Intake air temperature 15. Intake air thermosensor
(In airflow meter)
16. No.1 piston TDC of compression
17. P/S operation
18. Shift solenoid (ATX)
19. Test signal (Ignition timing, idle speed,
Malfunction code No.)
20. Throttle valve fully closed/fully open
condition 16. Distributor (G-signal) DOHC)
17. P/S pressure switch
18. 1-2, 2-3, 3-4, Lockup solenoid
19. Diagnosis connector
(TEN terminal)
20. Throttle sensor (MTX)
21. Throttle valve opening angle
22. Turbine sensor 21. Throttle sensor (ATX) .__r
F-10

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

TROUBLESHOOTING GUIDE F
r
- SENSORS
z-----
‘RES-
‘URE
‘WITCH FRL (Dsy
ime Run-
ling
.ight)
:ONTROL
INIT
CANADA]
)FF
3attery
oltage)
T- IEUTRAL
rND
:LUTCH
iWITCHES
MTX) IIAGNOSIS
:ONNEC-
‘OR TEN
‘ERMINAL
rEST
‘ERMINAL) IGNITION SWITCH
s kgnal has
r IO effect
C In ECU
I neutral:
.ow volt-
rge signal
II ECU
w
-
f
I
Iriving in
iny gear:
iigh volt-
ige signal
o ECU
Battery TOP-
IGHT
WITCH UHIBITOR
iWITCH
4TX) L/C
;WITCH
5
IL
IGNAL
Sl ignal has
nl 3 effect
01 n ECU
H
0
F-f
S
C
VI
si
E
te
VI
C
VI
si
i
1 T
eadlight
r rear
‘indow
efroster
Nitch
IN: High
pltage
gnal to
CU (Bat-
try
sltage)
IFF: Low
altage
gnal to
cu
3elow
.5V)
B
S'
0
C,
C
L
E
E
II
(
\i
c
E
t’
I lower
Nitch**
r Electri-
al fan
IN: Low
foltage
signal to
iCU (Be-
3w 1.W)
IFF: High
loltage
rignal to
ICU (Bat-
ev
voltage)
I
OFF ITART
‘OSITION IN
OSITION
‘ends sig
al to
CU (Bat-
?ry
oltage) #ignal has
0 effect
#n ECU ignal has
0 effect
n ECU ignal has
0 effect
n ECU ;ignal has
IO effect
rn ECU ignal has
0 effect
n ECU
rake pedal Ggnal has
IQ effect
In ECU
1NorP
ange: No
ignal to
.cu
w
-
7D
ange: No
#ignal to
.cu
Battery
foltage)
- - - - -
ends sig-
31 to ECU
jattr ?ry
Atac
-2
/heel -
Jrned:
ow volt-
ge signal
I ECU
3elow
.5V)
teering
/heel
traight
head:
ligh volt-
ge signal
) ECU
dattery .erminal
lot
Irounded:
iigh volt-
tge Signal
3 ECU
Battery
roltage)
‘erminal
Irounded:
.ow volt-
rge signal
3 ECU
Below lo signal
ent to
cu
3elow
5V) r/C switch
IN:
iends sig-
ial to
CU (Be-
IW 1.5V)
r/C switch
IFF: No
ignal to
CU (Bat-
3ry
‘oltage) )RL ON:
w ends sig-
al to
CU (Bat-
2ry
oltage) lo signal
3 ECU
3elow
.5V) )RL OFF:
3attery
oltage)
I .5V’
medal
Sends
signal to
KU
Battery
voltage)
- -
In N or P
range:
Sends sig-
nal to ECU
PV In neutral:
Low volt-
age stgnal
to ECU
(W
I -
- - -
OFF OFF OFF OFF OFF OFF OFF
OFF OFF
23UOFX-0’
+’ Blower switch: 2nd position or more
F-21