fuel MAZDA PROTEGE 1992 User Guide

REMOVAL
REMOVAL
Warning
l Release the fuel pressure. (Refer to Section F.)
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil.
3. Remove in the order shown in the figure, referring to Removal Note,
Step 1
1. Undercover and side cover
2. Air cleaner assembly 10. Cooling fan connector
3. Battery and battery cover 11. Oil cooler hose (ATX)
4. Battery carrier 12. Radiator and cooling fan assembly
13. P/S and/or A/C drive belt
5. Battery duct
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Accelerator cable page Bl- 6
7. Resonance chamber 14. P/S oil pump and bracket
8. Radiator hose Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
9. Coolant reservoir hose 15. A/C compressor (if equipped)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
81-28

Bl REMOVAL
Step 3
1. Disconnect the hoses shown in the figure.
BP SOHC
1. Brake vacuum hose
2. Fuel hose
Removal
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bl-30
05UOBX-078
03UOBi -050
below 3. Vacuum hose (Purge control)
4. Vacuum hose (Cruise control)
5. Heater hose
Removal Note ..,,,................................ below
Removal note
Fuel hose
Warning
l Keep sparks and open flame away from the fuel
area.
Caution
l Cover the hose with a rag because fuel will spray
out when disconnecting.
l Plug the disconnected hoses to avoid fuel leakage.
1. Disconnect the fuel hoses.
Heater hose
Caution
l Heater hose joint has O-rings and spacer.
l Do not lose them when removing.
1. Push the heater hose retainer and remove the heater hose.

OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
ItC- Engine
BP DOHC
Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4 cylinders
Combustion chamber Pentroof
Valve svstem DOHC, belt-driven 16 valves
Displacement
Bore and stroke cc (cu in) 1,839 (112.2)
mm (in) I 83.0 x 85.0 (3.27 x 3.35)
Compression ratio
Compression pressure
IN
Valve timing
EX kPa (kg/cm*, psi)-rpm
BTDC Open
Close ABDC
Open BBDC
Close ATDC 9.0
1,256 (12.8, 182)300
!zJ”
48O
56O
140
Valve clearance IN 0: Maintenance-free
mm (in)
EX 0: Marntenance-free
Idle speed *’ *’ MTX
rpm
ATX
Ignition timing*2
Firing order
::...With parking brake applied. (Canada)
. ..TEN terminal of diagnosis connector grounded BTDC 700-800
700-800 (P range)
90-l 1 O
l-3-4-2
P3UOBZ003
TROUBLESHOOTING GUIDE
Problem
Difficult starting
Poor idling
Excessive oil
consumption Possible Cause
Malfunction of engine-related components
Burned valve
Worn piston, piston ring, or cylinder
Failed cylinder head gasket
Malfunction of fuel system
Malfunction of ignition system
Malfunction of engine-related components
Malfunction of HLA*
Poor valve-to-valve seat contact
Failed cylinder head gasket
Malfunction of fuel system
Malfunction of ignition system
Oil working up
Worn piston ring groove or sticking piston ring
Worn oiston or cvlinder
Oil working down
Worn valve seal
Worn valve stem or auide
Oil leakaae i
Replace 82-55
Replace or repair 92-60, 62
Reolace B2-16
Refer to Section F
I
Replace 82-47, 79
Replace 82-55
Refer to Section 0 I
82-3

B2 TROUBLESHOOTING GUIDE
Problem
Insufficient power
Abnormal
combustion
Engine noise -
I
I
f
,
I
I
,
I
I Possible Cause Action Page
Insufficient compression
Malfunction of HLA*
Compression leakage from valve seat
Seized valve stem
Ueak or broken valve spring
Failed cylinder head
gasket Cracked or distorted cylinder head
Sticking, damaged, or worn piston ring
Cracked or worn piston Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section F 82-22
82-57
02-55
B2-58
82-16
82-54
82-62
82-62 Malfunction of fuel system
Malfunction of ianition svstem
Others
Slipping clutch
Dragging brakes
Wrong size tires Malfunction of engine-related components
Malfunction of HLA*
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber Malfunction of fuel system
Malfunction of ignition system
Crankshaft- or bearing-related parts
Excessive main bearing oil clearance
Main bearing seized or heat-damaged
Excessive crankshaft end play
Excessive connecting rod bearing oil clearance
Connecting rod bearing seized or heat-damaged Piston-related parts
Worn cylinder
Worn piston or piston pin
Seized piston
Damaged piston ring
Bent connecting rod Valves or timing-related parts
Malfunction of HLA*
Broken valve spring
Excessive valve guide clearance Malfunction of cooling system
Malfunction of fuel svstem
Others
Malfunction of water pump bearing Refer to Section E
Improper drive belt tension Adjust
Malfunction of alternator bearing Refer to Section G
Exhaust gas leakage Refer to Section F
Malfunction of timing belt tensioner Replace Refer to Section G
Refer to Section H
Refer to Section P
Refer to Section C!
Replace B2-22
Replace 82-55
Replace 82-58
Eliminate carbon -
Refer to Section F
Refer to Section G
Replace or repair B2-70
Replace 82-64
Replace or repair 82-7 1
Replace or repair B2-72
Replace B2-64
Replace or repair
82-60
Replace 82-63
Replace 82-62
Replace 82-62
Replace 82-63
Replace
Replace
Replace
Refer to Section E
Refer to Section F 82-22
82-58
82-55
B2- 6
82-12
23UOB2-00,
..J
.-,
l
Tappet noise may occur if the engine has set idle for an extended period. The noise should dissipate after the engine has reached
normal operating temperature. (HLA troubleshooting: Refer to page 82-7.)
82-4

B2 COMPRESSION
COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor idle, check the following:
1, Ignition system (Refer to Section G.)
2. Compression
3. Fuel system (Refer to Section F.)
23UOB2-013
13UOl32.004
2311087-014
-_
B2-10
2311082-012
INSPECTION
1. Check that the battery is fully charged. Recharge it if neces-
sary. (Refer to Section G.)
2. Warm up the engine to normal operating temperature.
3. Turn the engine OFF.
4. Remove all spark plugs.
5, Disconnect the ignition coil connector.
6. Connect a compression gauge to the No.1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder.
Compression:
1,256 kPa (12.6 kg/cm’, 182 psi)-300 rpm
Minimum:
883 kPa (9.0 kg/cm2, 128 psi)-300 rpm
Max. difference between cylinders:
196 kPa (2.0 kg/cm2, 28 psi)
10. If the compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder wall may be worn.
(2) If the compression stays low, the valve may be stuck
or seating improperly.
(3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be defective or the cylinder
head distorted.
Il. Connect the ignition coil connector.
12. Install the spark plugs.
05UOBX-020
Tightening torque:
15-23 N*m (1.5-2.3 m-kg, 11-17 ft-lb)

82 ON-VEHICLE MAINTENANCE
CYLINDER HEAD GASKET
Replacement
Warning
l Release the fuel pressure. (Refer to Section F.)
l Keep sparks and open flame away from the fuel area.
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. install in the reverse order of removal, referrina to Installation Note.
BOLT THREADS ?&d 4.9-8.8 N.m
fsn-an om.h 41-‘71( ir
AND SEAT FACES ,-- -- -... ..=, _” . _ ..I-lb)
78-81 - /
(7.7-8.3, 58-60)
7.8-11 N.m
(80-l 10 cm-ka, 69-95
, . . . . . . (80-l 10 cm-kg, 69-9: in-lb) (j-$15-23 (1.5-2.3, 11-17)
82-l 6
7.8-11 N.m
(80-110 cm-k?, 69-95 In-lb) 180-110 cm-ka. 69-95 in-lb
-37-52
(3.8-5.3, 27-38)
’
nl MTX:?64-69 (6.6-9.1,
PTX: 55-60 (6.6-8.2, 69-95 in. .Ib)
47-86)
41-69)
7.8-11 N./n (3.2-4.7, 23-34)
37-52
(80-110 cm-kg, 69-95 in-lb) (3.8-5.3, 27-38)
N-m (m-kg, N-lb)
^^. .^_^ __

ON-VEHICLE MAINTENANCE B2
1. Under cover and side cover
2. Resonance chamber
3. Air hose
4. Accelerator cable
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-21
5. Throttle cable (ATX)
Removal I Installation . . . . . . . . . . . . . . . . . . . . . Section K
6. High-tension lead
7. Hoses
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 82-21
8. Harnesses
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-18
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 82-21
9. Water bypass pipe
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-18
10. P/S and/or A/C drive belt
Removal / Installation . . . . . . . . . . . . . . . . page B2- 6
11. Alternator drive belt
Removal / Installation . . . . . . . . . . . . . . . . page B2- 6 12. Water pump pulley
13. Timing belt cover, upper
14. Timing belt cover, middle
15. Spark plug
16. Timing belt
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-l 8
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-20
17. Front exhaust pipe
18. Intake manifold bracket
19. Cylinder head cover
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 82-19
20. Cylinder head bolt
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-19
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-19
21. Cylinder head
Disassembly . . . . . . . . . . . , . . . . . . . . . . . . . page B2-45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-79
22. Cylinder head gasket
23UOB2-021
Removal / Installation note
Hoses
1. Disconnect the hoses shown in the figure.
VACUUM HOSE BRAYE VACUUM HOSE
‘-;:I::------. CAUT’oN
l COVER THE HOSE WITH A RAG BECAUSE FUEL WILL
SPRAY OUT WHEN DISCONNECTING.
- PLUG THE DISCONNECTED HOSES TO AVO!D FUEL
LEAKAGE.
OWOBX-03
82-l i

REMOVAL
REMOVAL
Warning
l Release the fuel pressure. (Refer to Section F.)
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil,.
3. Remove in the order shown in the figure, referring to
Removal Note.
Step
1
1. Undercover and side cover 12. Oil cooler hose (ATX)
2. Resonance chamber 13. Cooling fan connector
3. Air cleaner assembly 14. Radiator switch connector (ATX)
4. Battery bracket 15. Radiator bracket
5. Battery cover 16. Radiator and cooling fan assembly
6. Battery
17. P/S and/or A/C drive belt
7. Battery carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2- 6
8. Battery duct 18. P/S oil pump and bracket
9. Accelerator cable Removal Note . . . . . . . . . . . . . . . . . . . . + . . . . . . page 82-32
10. Radiator hose 19. A/C compressor (if equipped)
11. Coolant reservoir hose Removal Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page 82-32
B2-31

REMOVAL
Step 3
1. Disconnect the hoses shown in the figure.
J”“DC-” I I
1. Fuel hose
3. Brake vacuum hose
Removal
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
below
4. Vacuum hose (Purge control)
2. Heater hose
Removal Note . . . . . . . . . . . . . , . . . . . . . . . . . .
05UOBX-078
0311082-052
. . . . .
below 5. Vacuum hose (Cruise control)
Removal note
Fuel hose
Warning
l Keep sparks and open flame away from the fuel
area.
Caution
l Cover the hose with a rag because fuel will spray
out when disconnecting.
l Plug the disconnected hoses to avoid fuel leakage.
1. Disconnect the fuel hoses.
Heater hose
Caution
l Heater hose joint has O-rings and spacer.
l Do not lose them when removing.
1. Push the heater hose retainer and remove the heater hose.
82-33

F
FUEL AND EMISSION
CONTROL SYSTEM
INDEX ...........................................
OUTLINE ...................................... ;: 2
SYSTEM DIAGRAM ...................... F-
:
VACUUM HOSE ROUTING
DIAGRAM .................................
WIRING DIAGRAM ....................... F- 6
- 7
ENGINE CONTROL UNIT (ATX) ...... F- 13
SPECIFICATIONS.. ....................... F- 15
COMPONENT DESCRIPTIONS.
...... F- 16
TROUBLESHOOTING GUIDE.. ......... F- 20
ENGINE CONTROL OPERATION
CHART
..................................... F- 20
RELATIONSHIP CHART.. .............. F- 24
USING THIS SECTION .................. F- 25
DIAGNOSTIC INDEX .................... F- 27
PRECAUTION ............................. F- 29
SYMPTOM TROUBLESHOOTING .... F- 30
ENGINE TUNE-UP
.......................... F- 76
PREPARATION ............................
F- 76
BASIC INSPECTION ..................... F- 78
ADJUSTMENT .............................
F- 79
SELF-DIAGNOSIS FUNCTION .......... F- 82
DESCRIPTION .............................
F- 82
PREPARATION
............................
F- 83
SERVISE CODE NUMBER.. ........... F- 83
SWITCH MONITOR FUNCTION ...... F-105
INTAKE AIR SYSTEM.. ................... F-109
COMPONENT PARTS.. ................. F-109
THROTTLE BODY ........................ F-l 12
DYNAMIC CHAMBER ................... F-l 12
INTAKE MANIFOLD ..................... F-l 13
ACCELERATOR PEDAL ................ F-l 14
ACCELERATOR CABLE ................ F-l 14
IDLE SPEED CONTROL (ISC)
SYSTEM ......................................
F-115
DESCRIPTION ............................. F-115
PREPARATION
............................ F-116
SYSTEM OPERATION.. ................. F-l 16
ISC VALVE ................................. F-116
AIR VALVE
................................. F-116
VARIABLE INERTIA CHARGING
SYSTEM (VICS) [DOHC] ................ F-l 17
DESCRIPTION ............................. F-117
SYSTEM OPERATION ................... F-l 18
SHUTTER VALVE ACTUATOR.. ...... F-l 18
SOLENOID VALVE (VICS). ............. F-118
VACUUM CHAMBER.. .................. F-119
FUELSYSTEM .............................. F-l 20
DESCRIPTION
............................. F-l 20
PRECAUTION ............................. F-121
SYSTEM OPERATION.. ................. F-121
FUEL TANK ................................
F-l 23
FUEL FILTER .............................. F-l 24 FUEL PUMP ............................... F-l 25
CIRCUIT OPENING RELAY.. .......... F-129
PRESSURE REGULATOR.. ............ F-129
INJECTOR .................................. F-l 31
PRESSURE REGULATOR
CONTROL SYSTEM.. .................... F-l 34
SOLENOID VALVE (PRESSURE
REGULATOR CONTROL). ............ F-l 35
EXHAUST SYSTEM ........................ F-l 36
COMPONENT PARTS.. ................. F-136
OUTLINE OF EMISSION
CONTROL SYSTEM.. .................... F-l 37
STRUCTURAL VIEW.. ................... F-l 37
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM.. ..... F-138
DESCRIPTION .............................
F-l 38
PCV VALVE ................................ F-l 38
EVAPORATIVE EMISSION
CONTROL SYSTEM.. .................... F-l 39
DESCRIPTION ............................. F-l 39
SYSTEM OPERATION.. ................. F-140
SOLENOID VALVE
(PURGE CONTROL) ................... F-140
SEPARATOR ............................... F-l 40
CHECK VALVE (TWO-WAY) ........... F-140
CHECK-AND-CUT VALVE.. ............ F-141
CHARCOAL CANISTER.. ............... F-141
DECELERATION CONTROL
SYSTEM ...................................... F-l 42
DESCRIPTION ............................. F-l 42
DASHPOT .................................. F-142
FUEL CUT CONTROL SYSTEM ....... F-143
DESCRIPTION ............................. F-l 43
PREPARATION ............................ F-l 43
SYSTEM OPERATION.. ................. F-143
DECHOKE CONTROL SYSTEM.. ...... F-145
DESCRIPTION ............................. F-l 45
SYSTEM OPERATION ................... F-l 45
CONTROL SYSTEM ....................... F-l 47
PREPARATION ............................ F-147
STRUCTURAL VIEW.. ................... F-l 48
ENGINE CONTROL UNIT (ECU) ..... F-149
AIRFLOW METER (WITH INTAKE AIR
THERMOSENSOR) ..................... F-168
WATER THERMOSENSOR.. ........... F-168
THROTTLE SENSOR .................... F-l 69
OXYGEN SENSOR.. ..................... F-171
MAIN RELAY (FUEL INJ RELAY) .... F-172
CLUTCH SWITCH (MTX) ............... F-172
NEUTRAL SWITCH (MTX). ............. F-173
POWER STEERING PRESSURE
SWITCH .................................... F-173
WJOFX-001