1992 MAZDA PROTEGE ESP

IMPORTANT INFORMATION
IMPORTANT INFORMATION
BASIC ASSUMPTIONS
This workshop manual assumes that you have certain special tools that are necessary for the safe and effi-
cient performance of service operations on Mazda vehicles and that you know how to use them properly.
It also assumes that you are familiar with automobile systems and basic service and repair procedures. You
should not attempt to use this manual unless these assumptions are correct and you understand the conse-
quences described below.
SAFETY RISK
This manual contains certain notes, warnings, and other precautionary information that you should carefully
read and follow to reduce the risk of personal injury to yourself or others and the risk of improper service
that may damage the vehicle or render it unsafe. If there is no such information in regard to any specific
service method, this does not mean there is no possibility that personal safety or vehicle safety will be
jeopardized by the use of incorrect methods or tools.
POSSIBLE LOSS OF WARRANTY
The manufacturer’s warranty on Mazda vehicles and engines can be voided if improper service or repairs
are performed by persons other than those at an Authorized Mazda Dealer.
WARNING ON LUBRICANTS AND GREASES
Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated
during service (e.g., engine sump oils) are more irritating and more likely to cause serious effects, including
skin cancer, in the event of gross and prolonged skin contact.
Wash skin thoroughly after work involving oil.
Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not
use gasoline, paraffin, or other solvents to remove oil from the skin.
Lubricants and greases may be slightly irritating to the eyes.
Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particu-
lar care should be taken with used oils and greases containing lead. Do not allow work clothing to be con-
taminated with oil. Dry clean or launder such clothing at regular intervals.
9MUGIX-002
GI-2

HOW TO USE THIS MANUAL/FUNDAMENTAL PROCEDURES
SYMBOLS
There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such
materials during service.
Symbol Meaning Kind
Apply oil New engine oil or gear oil as appropriate
aI i . Apply brake fluid Only brake fluid
Apply automatic transaxle fluid Only ATF
Apply grease Appropriate grease
amal Apply sealant Appropriate sealant
0 Apply petroleum jelly Appropriate petroleum jelly
23UGIX-001
Note
l When special oil or grease is needed, this is shown in the illustration.
NOTES, CAUTIONS, AND WARNINGS
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each
one is there for a specific purpose.
NOTES give you added information that will help you to complete a
particular procedure.
CAUTIONS are given to prevent you from making an error that could damage the
vehicle. WARNINGS
remind you to be especially careful in those areas where carelessness can cause per-
sonal injury.
The following list contains some general WARNINGS you should follow when you work on
a vehicle.
9MUGIX-036
SMUGIX-037
a-4 FUNDAMENTAL PROCEDURES
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas be-
fore starting work.

ENGINE STAND MOUNTING Bl
OBUOBX-Ot
OWOBX-0; 36
ENGINE
NlJ/ WkSHER b&i THAP
2Omm (0.79 il
OWOBX-0
I
-I n)
80
OWOBX-089
1. Install the SST (arms) to the holes as shown in the figure,
and loosely tighten the SST (bolts).
2. Assemble the SST (bolts and plate) in the specified po-
sition.
3. Assemble the SST (nuts, hooks, and bolts).
4. Install the SST to the respective arms.
Note
l Adjust the SST (bolts) so that less than 20mm (0.79
in) of thread is exposed.
l Make the SST (plate and arms) parallel by adjust-
ing the SST (bolts and nuts).
5. Tighten the SST (bolts and nuts) to affix the SST firmly.
6. Mount the engine on the SST (engine stand).
81-37

INSPECTION / REPAIR Bl
1
I
0311082-007
STEM TIP
MARGIN
THICKNESS
23UOBl-072
2311091.04:
2311091.04.
II- VALVE STEM
VALVE
CLEARANCE
J 05UOBX-125
4. Measure the manifold contact surface distortion in the six
directions shown in the figure.
Distortion: 0.15mm (0.006 in) max.
5. If distortion exceeds specification, grind the surface or re-
place the cylinder head.
VALVE MECHANISM
Valve and Valve Guide
1. Inspect each valve for the following. Replace or resurface
the valve if necessary.
(1) Damaged or bent stem.
(2) Rough or damaged face.
(3) Damaged or unevenly worn stem tip.
2. Measure the valve head margin thickness of each valve.
Replace the valve if necessary.
Margin thickness min.
mm (in)
B6 SOHC BP SOHC
IN 0.8 (0.031) 0.9 (0.035)
EX 1.1 (0.043)
1 .o (0.039)
3. Measure the length of each valve.
Length
mm (in)
4. Measure the stem diameter of each valve at the points
shown.
Diameter
IN
EX B6 SOHC
6.970-6.985
(0.2744-0.2750)
6.965-6.980
(0.2742-0.2748) mm (in)
BP SOHC
5.970-5.985
(0.2350-0.2356)
5.965-5.980
(0.2348-0.2354)
5. Measure the inner diameter of each valve guide at the points
shown.
Inner diameter
mm (in)
66 SOHC BP SOHC
IN 7.01-7.03 6.01-6.03
(0.2760-0.2768) (0.2366-0.2374)
EX 7.01-7.03 6.01-6.03
(0.2760-0.2768) (0.2366-0.2374)
6. Calculate the valve stem to guide clearance.
Subtract the outer diameter of the valve stem from the in-
ner diameter of the corresponding valve guide.
Clearance
IN : 0.025-0.060mm (0.0010-0.0024 in)
EX: 0.030-0.065mm (0.0012-0.0026 in)
Maximum: 0.20mm (0.008 in)
7. If the clearance exceeds specification, replace the valve
and/or valve guide.
Bl-55

B2 ENGINE STAND MOUNTING
051JOBX-08
05UOBX.086
20mm (0.79 in 20mm (0.79 in
05UOEX-OE
05UOBX-01
1. Install the SST (arms) to the holes as shown in the figure,
and loosely tighten the
SST (bolts).
2. Assemble the SST (bolts and plate) in the specified po-
sition.
3. Assemble the
SST (nuts, hooks, and bolts).
4. Install the SST to the respective arms.
Note
l Adjust the SST (bolts) so that less than 20mm (0.79
in) of thread is exposed.
l Make the SST (plate and arms) parallel by adjust-
ing the SST (bolts and nuts).
5. Tighten the SST (bolts and nuts) to affix the SST firmly.
6. Mount the engine on the
SST (engine stand).
82-40

INSPECTION / REPAIR B2
0311082-007
I!!?
STEM TIP
23UOBZ03f
23UOW03i
IL VALVE STEM
OWOBX-125 CLEARANCE
4. Measure the manifold contact surface distortion in the four
directions shown in the figure.
Distortion: 0.15mm (0.006 In) max.
5. If distortion exceeds specification, grind the surface or re-
place the cylinder head.
VALVE MECHANISM
Valve and Valve Guide
1. inspect each valve for the following. Replace or resurface
the valve if necessary.
(1) Damaged or bent stem.
(2) Rough or damaged face.
(3) Damaged or unevenly worn stem tip.
2. Measure the valve head margin thickness of each valve.
Replace the valve if necessary.
Margin thickness
IN : 0.9mm (0.0354 in)
EX: l.Omm (0.0394 in)
3. Measure the length of each valve.
Length
Standard
IN : 101.34mm (3.9696 in)
EX: 101.44mm (3.9937 in)
Minimum
IN : 100.64mm (3.9701 in)
EX: 100.94mm (3.9740 in)
4. Measure the stem diameter of each valve at the points
shown.
Diameter
IN : 5.970-5965mm (0.2350-0.2356 in)
EX: 5.965-5960mm (0.2346-0.2354 in)
5. Measure the inner diameter of each valve guide at the points
shown.
Inner diameter
IN : 6.01-6.03mm (0.2366-0.2374 in)
EX: 6.01-6.03mm (0.2366-0.2374 in)
6. Calculate the valve stem to guide clearance.
Subtract the outer diameter of the valve stem from the in-
ner diameter of the corresponding valve guide.
Clearance
IN : 0.025-0.060mm (0.0010-0.0024 in)
EX: 0.030-0.065mm (0.0012-0.0026 in)
Maximum: 0.20mm (0.006 in)
7. If the clearance exceeds specification, replace the valve
and/or valve guide.
B2-55

TROUBLESHOOTING GUIDE F
USING THIS SECTION
Introduction
Most of the fuel and emission control system is electrically controlled, often making it difficult to diagnose
problems in the system, especially intermittent problems, Before undertaking actual checks, take a few minutes
to talk with a customer who approaches with a drivability complaint. The customer is often a good source
of information on such problems, especially intermittent ones. Through talks with the customer, one can find
out what the symptoms are and under what conditions they occur.
Work flow
CHECK IN
LISTEN TO CUSTOMER COMPLAINTS
REFER TO TROUBLESHOOTING PAGE THAT - - - - - - - - - - - DIAGNOSTIC INDEX
CORRESPONDS TO ACTUAL SYMPTOM (Refer to page F-23)
CHECK FOR WHAT IS BAD IN SYSTEM - - - - - - - - - - - - - INSPECTION
1
CHECK FOR WHAT PART IS BAD - - - - - - -,- - - - - - - ACTION
i I
REPAIR/REPLACEMENT - - - - - - - - 1
I
DETERMINE IF TROUBLE HAS BEEN ELIMINATED
1 Yes
CHECK OUT
13lJOFX-008
Diagnostic index
No.:
Each troubleshooting item is
assigned a number.
TROUBLESHOOTING ITEM: There are 29 troubleshooting
items. Choose the item that
most closely
corresponds to
the actual symptom.
TROUBLESHOOTING GUIDE
‘ROUBLESHOOTINl3 ITEM
f H
DESCRIPTION
iE
7
-
DESCRIPTION:
Describes each troubleshooting
item.
/
PAGE:
Shows the reference page.
OWOFX-014
F-25

F TROUBLESHOOTING GUIDE
Troubleshooting chart
6 I
CRANKS NORMALLY BUT HARD TO START - WHEN ENGINE COLD
*Engine cranks at normal speed but requires excessive crankmg time before starting
IESCRIP-
l Batterv in normal condition
llON l Restans OK after warmup l Engine runs normally at idle [If Idle condrtron is not OK, refer to “Rough idle” (Nos. S-12)]
TROUBLESHOOTING HINTS]
B Air/Fuel mrxture too rrch @Air/Fuel mixture too lean
l Arrflow meter stickrng l Fuel iniectron control malfunction
l Aw cleaner element clogged
*Idle weed control malfunction (Correction for coolant temperature)
0 Poor atomizatron
- ~~ ~~ *Low RVP (summer) fuel is used rn cold weather >
f INSPECTION T Check If “00” is displayed on Self-Diagnosis
Checker wth Ignition switch ON -
Yes
No CT page F-73
SYSTEM SELECT: 1
“SELECT SW: A
Check if ECU terminal voltages are OK
(Especially 1C. 2D. and 2Q)
cc page F-144
Check If engine starts easily when throttle valve -
Yes
-
NO
-
Yes ACTION
Go to next step
Malfunctlon Code No. dlsplayed
Check for cause (Refer to specified
check sequence)
“58” flashes CT- page F-79
Check ECU terminal 1F voltage
Speciflcetlon: Battery voltage CT page F-144
(Ignition ewltch ON)
+ If OK, replace ECU CT page F-143
e If. not OK, check wrring between
ECU and Self-Diagnoos Checker
Go to next step
Check for cause CI page F-145
(-!hnrlr ,‘ ICP ..-I..- .^ nv
c+ page F-103
13UOFX-009
DESCRIPTION:
Further describes the symptom. Confirm that the chart addresses the actual symptom before beginning
troubleshooting.
TROUBLESHOOTING HINTS:
This describes the possible point of malfunction.
STEP:
This shows the order of troubleshooting. Proceed with troubleshooting as indicated.
INSPECTION:
This describes an inspection to quickly determine the malfunction of parts. If a detailed procedure is necessary
to perform the INSPECTION, refer to the page shown by the “~7” mark.
ACTION:
This recommends the appropriate action to take as a result (Yes/No) of the INSPECTION. How to perform
the action is described on the reference page shown by the “~7” mark.
OWOFX-016
F-26