1992 MAZDA PROTEGE engine

AIR CONDITIONER U / ,
9MUOUX-13
SIGHT GLASS
Checking refrigerant charge
1. Run the engine at a fast idle.
2. Operate the air conditioner at maximum cooling for a few
minutes.
3. Determine the amount of refrigerant as shown below by ob-
serving the sight glass.
Item Symptom Amount of refrigerant Action
I Bubbles present in sight glass Insufficient refrigerant Check refrigerant pressure
2 No bubbles present in sight glass Too much or proper amount of Turn air conditioner OFF, and
refrigerant watch bubbles (Refer to Items 3
and 4)
3 Immediately after air conditioner turned Too much refrigerant Check refrigerant pressure
OFF, refrigerant in sight glass stays clear
4 When air conditioner turned OFF, refrigerant Proper amount of refrigerant Refrigerant amount normal
foams, and then sight glass becomes clear
QMUOUX-140
Checking refrigerant pressure
1. Connect the manifold gauge set. (Refer to page U--32.)
2. Operate the engine at 2,000 rpm and set the air condition-
er to maximum cooling.
3. Measure the low- and high-pressure sides.
Normal pressure
Low-pressure side: 147-294 kPa
(1.5-3.0 kg/cm2, 21-43 psi)
High-pressure side: 1 ,I 77-l ,619 kPa
(12.0-l 6.5 kg/cm2, 171-235 psi)
u-37

U AIR CONDITIONER
OFF
03UOUX-06
03UOUX-06,
03UOUX-06
On-vehicle Inspection
Thermoswitch
1. Remove the glove box.
2. Run the engine at idle.
3. Turn OFF the A/C switch and set the blower switch to the
highest position to operate the blower fan for a few minutes.
4. After a few minutes, turn OFF the blower switch and stop
the engine.
5. Disconnect the thermoswitch connector and check for con-
tinuity between terminals of the switch.
Terminals Continuity
a-b Yes
6. If not as specified, replace the thermoswitch.
Note
l The thermoswitch contacts will be open if the
evaporator temperature is below 0.4 f 0.7OC (32.7
z!z 1.3OF).
Inspection
Thermoswitch
1. Immerse the sensing bulb in a container of ice water.
2. Check continuity between terminals of the switch as
specified.
Terminals
a-b Temperature Continuity
Above 5°C Yes
Below 0% No
3. If not as specified, replace the thermoswitch
Evaporator
1. Check the evaporator fins for blockage. If the fins are
clogged, clean them with compressed air.
Caution
l Never use water to clean the evaporator.
2. Check the fittings for cracks and other damage.
Replace the evaporator if necessary.
u-40

AIR CONDITIONER U
REFRIGERANT PRESSURE
2.0 f 0.2 kg/cm* 27 f 2 kg/cm’
4.1 f 0.5 kg/cm* 21 * 4 kg/cm*
03uoux-09
9
23UOUX-050
REFRIGERANT PRESSURE SWITCH No.1
Inspection
1. Turn the ignition switch OFF.
2. Connect the manifold gauge set and measure the high-
pressure side refrigerant pressure.
High-pressure side:
Above 451 kPa (4.6 kg/cm2, 65 psi)
3. If not as specified, check the refrigerant system, referring
to the troubleshooting information on page U-14.
4. If correct, go to the next step.
5. Disconnect the refrigerant pressure switch No.1 connector.
6. Check for continuity of the switch.
Terminals
1 Continuity
a-b
Yes I
7. If not as specified, replace the switch together with cooler
pipe No.2. (Refer to page U-54.)
Note
l If problems occur in the refrigeration system, caus-
ing abnormally high (above 2,649 SL: 196 kPa [27 f
2 kg/cm2, 384 f 28 PSI]) or low (below 196 f 20
kPa [2.0 f 0.2 kg/cm2, 28 & 2.8 psi]) pressures,
refrigerant pressure switch No.1 cuts power to the
magnetic clutch to protect the mechanical compo-
nents. If the pressure recovers to within normal
operating range (below 2,080 f 392 kPa [21 f 4
kg/cm2, 299 f 57 psi] or above 402 f. 49 kPa t4.1
f 0.5 kg/cm2, 58 f 7 psi]), the power is again re-
stored.
REFRIGERANT PRESSURE SWITCH No.2
(BP ENGINE WITH ATX)
Inspection
1. Turn the ignition switch OFF.
2. Connect the manifold gauge set and measure the high-
pressure side refrigerant pressure.
High-pressure side:
below 1,177 kPa (12 kg/cm2, 171 psi)
3. Disconnect the refrigerant pressure switch No.2 connector.
4. Check continuity of the switch.
Terminals
a-b I Continuity
No
5. If not as specified, replace the switch together with cooler
pipe No.2. (Refer to page U-54.)
6. If correct, go to next stop.
u-55

AIR CONDITIONER
23UOUX-051
23UOUX-05
23UOUX-05
U-56
Caution
l While testing refrigerant pressure switch No.2, care-
fully note the high-pressure side refrigerant pres-
sure. If the pressure increases above 1,766 kPa (18
kg/cm2, 256 psi), stop the testing. _,
7. Disconnect the condenser fan connector.
8. Run the engine at 2,000 rpm, and operate the air condi-
tioner at maximum cooling position.
9. Check that the refrigerant pressure switch turns on when
the high-pressure side refrigerant pressure increases above
1,570 f 98 kPa (16 f 1 kg/cm2, 228 f 14 psi).
IO. If not as specified, replace the switch together with cooler
pipe No.2. (Refer to page U-54.)
A/C RELAY
Inspection
1. Disconnect the A/C relay connector.
2. Check continuity between terminals of the switch.
Terminals
Tester probe: + 1 Tester probe: -
a b Continuity
Yes
3. If not as specified, replace the relay.
4. If correct, go to the next step.
5. Apply battery voltage to terminal d and ground terminal a.
6. Check for continuity between terminals a and d.
Terminals
a-d Continuity
Yes
7. If not as specified, replace the relay.
CONDENSER FAN RELAY
Inspection
1. Disconnect the condenser fan relay connector.
2. Check continuity between terminals of the relay.
Terminals Continuity
I a-b Yes I
2
I c-d I No I
A 3. If not as specified, replace the relay.
4. If correct, go to the next step.
5. Apply battery voltage to terminal a and ground terminal b.
6. Check for continuity between terminals c and d.
Terminals Continuity
c-d Yes
7. If not as specified, replace the relay.

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

TD TECHNICAL DATA
MEASUREMENTS
I ._.____2_ nem
Overall length
Overall width
Overall height
Wheel base
Front tread
Rear tread Body ) mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in) PRfWFr.f! . . ..s .-VW Hatchback 4,355 (171.5) 4,155 (163.6)
1,675 (65.9) 1,670 (65.7)
1,375 (54.1) 1,380 (54.3)
2,500 (98.4) 2,450 (96.5)
1,430 (56.3)
1,435 (56.5)
Bl. ENGINE (B6 AND BP SOHC)
1 Type
1 Cylinder arrangement and number Engine
86 SOHC BP SOHC
^ . . _
,?
I
uasollne, 4-cyw
. . *. 4
in-line 4-cyrinaer
Pentroof
1
I Combustion chamber I Multispherical
J Valve system OHC, belt-driven OHC, belt-driven 16 valves
. , I (3.07 x 3.29) 83.0 x 85.0 (3.27 x 3.35)
Total piston displacement cc (cu in) 1,597 (97.4) 1,839 (112.2)
Compression ratio 9.3 8.9
) Standard 1,236 (12.6, 179)-300 1,197 (12.2, 173)300
I
863 (8.8, 125)-300 834 (8.5, 121)300 1 Bore x Stroke
mm (in) I 78.0 x 83.6
Compression pressure
kPa (kg/cm’, psi)-rpm
E cvlinders 1 Maximum difference
196 (2.0, 28)
I
, ------- ---- -J - IN Open BTDC 14O 2O
Close ABDC 50°
Valve timing
Open BBDC 52O 55O
EX
Close ATDC 12O 8O
IN 0 Maintenance-free I \/AIo &-in --
Valve clearance EX 0 Maintenance-free
(Warm engine) mm (in) / ,,syi: 1
IN 0 Maintenance-free
I , EX 0 Maintenance-free
I Cylinder head
Height
Distortion
Grinding Valve and T _
Valve head diameter
Valve head margin thickness
Valve face angle IN mm (in) EX
IN
mm b-4 Fx mm (in) 107.4-107.6 (4.228-4.236)
mm (in) 0.15 (0.006) max. 0.10 (0.004) max.
mm (in) 0.20 (0.008) max. 0.10 (0.004) max.
37.9-38.1 (1.492-l ,500) 29.9-30.1 (1.177-1.185)
31 .Q-32.1 (1.256-l ,264) 24.85-25.15 (0.978-0.990)
0.8 (0.031) 0.9 (0.035)
1.1 10.043) 1 .o (0.039)
-, ,
\- I
IN 45O
EX 45O
I I Standard
IN
Minimum
Valve length mm (in)
EX Standard
Minimum I”L. I, \*.“cL
Valve stem diameter IN
mm On) EX 6.970-6.985 (0.2744-
6.965-6.980 (0.2742-
Guide inner diameter
I Valve stem-to-guide clearance mm (in) lTj7---- ,
Maximum 103.77 (4,085) 101.77 (4.007)
103.27 (4.066) 101.27 (3.987)
102.67 (4.042) 102.97 (4.054)
,n+ 47 IA noo
1 102.47 (4.034)
-0.2750) 5.970-5.985 (0.2350-0.2356)
-0.2748) 5.965-5.980 (0.2348-0.2354)
3.2760-0.2768) 6.01-6.03 (0.2366-0.2374)
0.025-0.060 (0.001 O-0.0024)
0.030-0.065 (0.001 l-0.0026)
-.
I
mm (in) 1 7.01-7.03 (r ‘
1 IN
Guide projection (Height “A”) IN
mm (in) Ex 13.2-l 3.8 (0.520-
13.2-13.8 (0.520-
TD-2

TECHNICAL DATA TD
Item Engine
B6 SOHC BP SOHC
Valve seat
IN
45O
Seat angle
EX 45O
Seat contact width IN
mm 04 EX 1.1-l .7 (0.043-0.067) 0.8-l .4 (0.031-0.055)
1.1-l .7 (0.043-0.067) 0.8-l .4 (0.031-0.055)
IN Standard 39 (1.5354) 42.5 (1.673)
Seat sinking mm (in) Maximum 40.5 (1.594) 44.0 (1.732)
EX Standard 39 (1.5354) 41.0 (1.614)
Maximum 40.5 (1.594) 42.5 (1.673) Valve spring
Standard mm (in) 43.66 (1.7188) 46.12 (1.8157)
IN
Minimum N (kg, Ib)/mm (in) 224-253 (22.8-25.8, 205-231 (20.9-4X3.5,
Free length 50--57)/35.5 (1.398) 46-52)/39 (1.535)
Standard mm (in) 43.66 (1.7188) 43.61 (1.7169)
EX
Minimum N (kg, Ib)/mm (in) 224-253 (22.8-25.8, 129-147 (13.1-15.0,
50-57)/35.5 (1.398) 29-33)/37.5 (1.476)
Out-of-square mm (in) 1 Maximum 1.52 (0.060) IN...l.61 (0.063) EX...1.52 (0.060)
Lobe height mm (in) IN
EX Standard 36.451 (1.4351) 35.993 (1.4170)
Wear limit 36.251 (1.4272) 35.793 (1.4092)
Standard 36.451 (1.4351) 36.273 (1.4281)
Wear limit 36.251 (1.4272) 36.073 (1.4202)
Front 43.440-43 ,460 No.1 & 43.440-43.460
(1.7102-l .7 ‘110) No.5 (1.7102-1.7110)
43.430-43 ,445 No.2 & 43.425-43.450
mm (in) Center
(1.7098-l .7 ‘108) No.4 (1.7096-l .7106)
. , L
Rear 43.440-43.460 No’3 43.41 o-43.435
(1.7102-l .7110) (1.7091-1.7100)
1 Out-of-round 0.05 (0.002) max.
Front 0.055-0.095 No.1 & 0.040-0.075
(0.0021-0.0037) No.5 (0.0016-0.0030)
e--I-.. 0.060-O. 105 No.2 84 0.035-0.080
1041) No.4
“.“-.-..“” (O.OOi 4-0.0031)
Rear 0.055-0.095 0.050-0.095
(0.0021-0.0037) No.3
(0.0020-0.0037)
1 Maximum
0.15 (0.006)
0.01 (0.0004)
0.03 (0.0012)
0.05-0.18 (0.0020-0.0071) 0.06-0.19 (0.0024-0.0075)
n ‘1 m *no Journal diameter
Camshaft hearinn nil cIewanr.F? mm tin I b,er’Ler I (0.0023--0.c
Camshaft runout mm (in) Maximum
Camshaft end play mm (in) Standard
Maximum
I Rocker arm and rocker arm shaft
Rocker arm inner diameter mm (in) 18.000-18.027 (
Rocker arm shaft diameter mm (in)
17 9.59-17 981) I “.L ~“.““O,
lN...19.000--19.027 (0.7480-0.7491)
o.7087-o’70g7) EX...19.000-19.033 (0.7480-0.7493)
I .““” -- -
0 7070-0.7079) 18.959-18.980 (0.7464-0.7472)
lN...0.020-0.068 (0.0008-0.0027)
Rnrkx arm tn shaft clearance
mm (in Standard
I .Y”,.VG 11.,, .” -,,-.. “,“-.“, .I”
““” ,“‘I o.020-o.068 (“~ooo8-o~oo27) EX...O.020-0.074 (0.0008-0.0029)
Maximum 0.10 (0.004) Cylinder block
Height mm (in) 221.5 (8.720)
Distortion mm (in) 0.15 (0.006) max.
Grinding mm (in) 0.20 (0.008) max.
^. , ,
78.006-78.013 (3.0711-3.0714) 183.006-83.013 (3.2679-3.2682)
-.n nr,. -,n fin,% ,n nnnr
” nn’n’ ’ “- T)cc 83.263 (3.2778-3.2781) Cylinder bore diameter stanaara size
mm (in) 0.25 (0.010) oversize IU.L3cl-/U.dDJ (J.uouu-J.uo IL) 1 OJ.LJU--
0.50 (0.020) oversize 78.506-78.513 (3.0908-3.0911) ) 83.506-
Cylinder bore taper and out-of-round mm (in) 0.019 (0.0007) ma: 83.513 i3.2876-3.2879)
I(.
TD-3

TECHNICAL DATA TD
r-
RP sm.lc: I Item
Crankpin bearing Engine
86 SOHC
I -. VW.._
Crankpin bearing oil clearance mm (in) Standard 0.028-0.068 (0.001 l-0.0027)
Maximum 0.10 (0.004)
Available undersized bearing mm (in)
0.25 (O.OlO), 0.50 (0.020) 0.75 (0.030) Thrust bearing
Crankshaft end play mm (in) Standard 0.080-0.282 (0.0031-0.0111)
Maximum 0.30 (0.012)
Standard size 2.500-2.550 (0.0984-0.1004)
Bearing width mm (in) 0.25 (0.010) oversize 2.625-2.675 (0.1033-0.1053)
0.50 (0.020) oversize 2.750-2.800 (0.1083-0.1102)
0.75 (0.030) oversize 2.875-2.925 (0.1132-0.1152)
1 Timing belt
Belt deflection mm (in)/98 N (10 kg, 22 lb) 1 11 .o-13.0 (0.43-0.51) 82.
ENGINE (BP DOHC) Item
Type
Cylinder arrangement and number BP DOHC
Gasoline, 4-cycle
In-line 4-cylinders
-. I
Combustion chamber
Valve svstem DOHC, belt-d
Bore x Stroke
Total piston displacement ventroot
riven
(3.2:
mm (in) 1 83.0 x 85.0
cc (cu in) ]
7x3.35)1 1,839 (112.2)
I 16 valves I 9.0
-300
mn Compression ratio
Standard 1,256 (12.8, 182)
Compression pressure Minimum 883 (9.0, 128)-Z kPa (kglcm2,
Psi)-rPm
Maximum dif
‘ference
between eat -, h cvlinder 196 (2.0, 28)
IN Open BTDC 5O
Valve timing Close ABDC 48’
EX Open BBDC 56O
Close ATDC .4 In
IY-
IN
mm (in) EX 0 Maintenance-l
Valve clearance
0 Maintenance-i ‘ree
‘me Cylinder head
Height mm (in)
Distortion mm (in)
Grinding mm (in)
Standard
Cylinder head-to-HLA clearance mm (in) Maximum Valve and valve guide 133.8-134.0 (5.268-5.276)
0.10 (0.004) max.
0.10 (0.004) max.
0.025-0.066 (0.0010-0.0026)
0.18 (0.0071)
Valve head diameter IN
mm (in) EX 32.9-33,l (1.295-l ,303)
27.85-28.15 (1.096-1.108)
Valve head margin thickness IN
mm On) Fx 0.9 (0.0354)
1 .o fO.0393)
1 Valve face angle . .
I
FX I I
Valve length IN
Standard 101.34 (3.9898)
mm (in) Minimum 100.84 (3.9701)
Standard 101.44 (3.9937) I -, .
I
Valve stem diameter EX
Minimum loo.94 i3.974oj
IN
mm (in) - EX 5.970-5.985 (0.2350-0.2356)
5.965-5.980 (0.2348-0.2354)
mm (in) I
. , , 6.01-6.03 (0.23 166-0.2374)
1 IN
I 0.025-0.060 (0.0010-0.0024)
3.0012-0.0026)
( Maximum 0.20 (0.008)
I
TD-5