1992 MAZDA PROTEGE Workshop Manual

CHARGING SYSTEM G
RUB
PRO
03UOGX-01
Terminal and cable
1. Check the tightness of the terminals to ensure good electri-
cal connections.
2. Check for corroded or frayed battery cables.
3. Check the rubber protector on the positive terminal for prop-
er coverage.
4. Clean the terminals if necessary, and coat them with grease.
Recharging
Battery
55D23L Slow charge Quick charge
(A) (4
Under 6 Max. 20
Slow charging
It is not necessary to remove the vent caps to perform a slow
charge.
Quick charging
Remove the battery from the vehicle and remove the vent caps
to perform a quick charge.
Warning
l Before performing maintenance or recharging the
battery, turn off all accessories and stop the engine.
l The negative cable must be removed first and in-
stalled last.
l Set the battery in water when quick charging to pre-
vent overheating the battery.
G-9

G
ALTERNATOR
Removal / Installation
CHARGING SYSTEM
Caution
l Be sure the battery connections are not reversed, because this will damage the rectifier.
l Do not use high-voltage testers such as a megger, because they will damage the rectifier.
l Remember that battery voltage is always applied to the alternator B terminal.
l Do not ground the L terminal while the engine is running.
l Do not start the engine while the connector is disconnected from the L and S terminals.
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary
3. Install in the reverse order of removal.
N.m (m-kg, R-lb)
OSlJOGX b20
1. Negative battery cable
2. Vacuum hose
3. Solenoid bracket (If equipped)
4. Connector
5. B terminal wire
Inspect for damage and corroston 6. Drive belt
Inspection. . . . ., ~.. ,. ,.... . , page G-l 4
Adjustment ,~, ,.,., ,. ,. ,, ,.. page G-l 4
Replacement . . . . . . . . page
G-l 4
7. Alternator
Disassembly / Assembly ,........,... page G-l 1
Inspection... ,, . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-l 2
G-10

CHARGING SYSTEM G
Disassembly / Assembly
1. Disassemble in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly.
P-105 N.m (9.5-11 m-kg, 61-79 ft.lb)
N-m (cm-kg, in-l
OBUOGX-0
1. Pulley 6. Rectifier
2. Front cover Inspection .,,,..,,,,.....,,.,.,,............. page G-13
3. Rotor 7. Brush holder assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-12 Inspection
4. Rear bracket (Brush and brush spring) . . . . . . . . . page G-13
5. Stator 8. Bearing
Inspection . . . . . . . . . . . . . . . . . . . . . . . . page G-l 2 Inspection .,.,,...,......,......,............ page G-13
G-l 1

G CHARGING SYSTEM
23UOGX-OO!
23UOGX-00
03UOGX-02,
03UOGX-02
Inspection
Rotor
1. Measure the resistance between the slip rings with an
ohmmeter.
Specification: 3.5-4.5Q [at 20°C (66OF)]
2. If not within specification, replace the rotor.
3. (1) Check continuity between each slip ring and the core
with an ohmmeter.
(2) Replace the rotor if there is continuity.
4. Check if the slip ring surface is rough. Use fine sandpaper
to repair it if necessary.
Stator
1. Check for continuity between the stator coil leads with an
ohmmeter.
2. Replace the stator it there is no continuity.
3. Check continuity between the stator coil leads and the core
with an ohmmeter.
4. Replace the stator if there is continuity.
G-12

CHARGING SYSTEM G
L
23UOGX.00
P2 I9
WEAR LIMIT
03UOGX-021
03UOGX-02C
03UOGXz
Rectifier
1. Check continuity of the diodes with an ohmmeter.
Negative
E
B
T
Pl, P2,
P3
Pl, P2, P3
Positive
PI,
P2, P3
E
B
T
Continuity
Yes
No
No
No
Yes
Yes
2. Replace the rectifier if necessary.
Brush
If a brush is worn almost to or beyond the limit, replace the
brushes.
Standard: 21Smm (0.848 in)
Minimum: 8.0mm (0.315 in)
Brush spring
1. Measure the force of the brush spring with a spring pres-
sure gauge.
2. Replace the spring if necessary.
Standard force:
3.1-4.3 N (320-440 g, 11.3-15.5 oz)
Minimum: 1.6-2.4 N (160-240 g, 5.6-8.5 oz)
Note
l Read the spring pressure with the brush tip project-
ing 2mm (0.079 in).
Bearing
1. Check for abnormal noise, looseness, or sticking
2. Replace the bearing(s) if necessary.
G-l 3

G CHARGING SYSTEM
WATER PUMP 13UOGX-00,
03UOGX-03:
I /I I III
I f 03UOGX-03:
03UOGX-034
DRIVE BELT
Inspection
1. Check the drive belt and pulley for wear, cracks, and fray-
ing. Replace if necessary.
2. Measure the drive belt tension with a tension gauge. .-A
Tension N (kg, lb)
Drive belt
Alternator
A/C and P/S New Used
383-461
304-303
(39-47, 85.8-103.4) (31-39, 68.2-85.8)
491-589 422-491
(50-60, 11 O-l 32) (43-50, 95-110)
3. Measure the deflection by applying moderate pressure (98
N, 10
kg, 22 lb) midway between the pulleys. Adjust if
necessary.
Deflection mm (in)
Drive belt
Alternator
AIC and P/S New Used
8-9 9-10
(0.31-0.35) (0.35-0.39)
8-9 9-10
(0.31-0.35) (0.35-0.39)
Adjustment
1. Loosen the alternator mounting bolt and adjusting bolt.
2. Move the alternator to set the specified deflection.
3. Tighten all bolts and recheck the tension.
Replacement
1. Remove the A/C and P/S drive belt, if equipped.
Note
l Refer to pages 61-5 and 82-5.
2. Loosen the alternator mounting bolt and adjusting bolt.
3. Remove the alternator belt.
4. Install the new alternator belt and adjust it to specification.
5. Tighten all bolts to the specified torque.
Tightening torque
Alternator bolt:
37-52 N#rn (3.8-5.3 m-kg, 27-38 ft-lb)
Adjusting bolt:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
6. Install the A/C and P/S drive belt if equipped, and adjust
to specification.
Note
l Refer to pages 61-5 and 82-5.
G-14

IGNITION SYSTEM G
IGNITION SYSTEM
PREPARATION
SST
49 NO18 001
Adapter Harness
CIRCUIT DIAGRAM
ECU
T
IGNITION SWITCH
,
I
DISTRIBUTOR
7
1 ZL BATTERY
IGNITER
03UOGX-03t
G-15

G IGNITION SYSTEM
TROUBLESHOOTING
iTEP
INSPECTION
ACTION
1
Check if MIL illuminates when engine is running Yes Check for malfunction code number
and perform troubleshooting (TEN ter-
minal grounded) c7 Section F
No Go to next step
2 Drsconnect high-tension lead from distributor and
Yes
check for strong blue spark while cranking en-
l Check distributor cap and rotor v page G-22
gine * Check high-tension lead
KP page G-19 c7 page G-17
+ Ignition system normal
No
Go to next step
3 Check if resistance of ignition coil is OK
Yes
Go to next step ~7
page G-19
Specification (at 20°C [66”9):
Primary coil winding: 0.81-0.99Q No
Replace ignition coil
Secondary coil winding: IO-16 kQ
-i
Check if resistance of high-tension leads is OK Yes Go to next step
D= page G-17
Specification: 16 kQ per 1 m (3.28 ft)
No Replace high-tension lead
5 Check if igniter is OK
m- page G-23 Yes
Replace ECU
No
Replace igniter
03UOGX-03
G-16