1992 MAZDA PROTEGE oil pressure

OIL PUMP D
OIL PUMP
DISASSEMBLY / ASSEMBLY
1 Disassemble in the order shown in the figure, referring to Disassembly Note.
2: Assemble in the reverse order of disassembly, referring to Assembly Note.
FACE THE DIMPLE
TOWARD THE PUMP COVER
WHEN ASSEMBLING
O-90 cm-kg, 52-78 in-lb)
-8
23UODX-014
1. Oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
Assembly Note .,,..,.....,..,............ page D-14
2. Pump cover
Inspect for distortion or damage 6. Spring seat
7. Pressure spring
Inspection ..,..,.....,..,..,..,.............. page D-l 4
8. Control plunger
Inspect for wear or damage
9. Pump body
3. Outer rotor
4. Inner rotor
5. Roll pin
PROTECT PUMP
BODY WITH RAG
x9 05UODX-OC IO
Inspect for distortion or damage
Disassembly Note
Oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
D-13

OIL PUMP
OWODX-032
r----‘---I ----
L-
---- 05UODX-033
r- __I_.__^--
_- .-.. --.-.__-----^---
---7--l
L-.-.LlLd-..- ..-.---A OWODX-034
___ll_--_l___-----------
___I- 1
.i
5
INSPECTION
Pressure Spring
1 Inspect the spring for weakness or breakage.
2. Measure the free length. Replace the spring if necessary.
Free length: 45.5mm (1.791 in) -
Rotor Clearance
1. Measure the following clearances. Replace the rotor if
necessary.
Tooth tip clearance: 0.20mm (0.0079 in) max.
Outer rotor to pump body clearance:
0.22mm (0.0087 in) max.
Side clearance: 0.14mm (0.0055 in) max.
Assembly 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,
Caution
l The oil seal must be pressed in until it is flush with
the edge of the oil pump body.
-’
3. Press the oil seal in evenly with a suitable pipe.
Oil seal outer diameter: 44mm (1.73 in)

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

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

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

F TROUBLESHOOTING GUIDE
I 24 I EXHAUST SULFUR SMELL I
DESCRIP-
l Exhaust gas smells abnormally
TION
[TROUBLESHOOTING HINTS]
High sulfur content fuel used
STEP INSPECTION
1
Change fuel to another brand ACTION
03UOFX-039
25 HIGH OIL CONSUMPTION
DESCRIP-
l Oil consumption excessive
TION
[TROUBLESHOOTING HINTS]
@ PCV system malfunction
@ Engine malfunction (Oil working up, working down, or leakage)
iTEP
INSPECTION
1 Check if PCV hose, ventilation hose or their at- Yes Repair or replace
taching nipples are separated, damaged,
clogged, or restricted
w page F-138 No Go to next step
2 Check if air pressure or oil is present at ventila- Yes Go to next step
tion hose ACTION
No Check engine condition w page 81-3
82-3
l Oil leakage
*Worn valve seal
*Worn valve stem
*Worn valve guide
3 Check if vacuum is felt at PCV valve at idle Yes Check engine condition w page 91-3
w page F-138 82-3
*Worn piston ring groove
*Stuck piston rings l
Worn piston or cylinder
No Replace PCV valve
23UOFX-040 /-.
F-74

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