fuel MAZDA PROTEGE 1992 Owner's Manual

INDEX F
1. Resonance duct
Inspection / Replacement.. ........ page F-l 09
2. Air cleaner element
Inspection ................................. page F- 79
Replacement.. ........................... page F-l 09
3. Airflow meter
(With intake air thermosensor)
Inspection
................................. page F-l 68
Replacement.. ........................... page F-l 09
4. Resonance chamber
Inspection I Replacement.. ........ page F-l 09
5. Throttle body
Inspection .................................
page F-l 12
Replacement.. ...........................
page F-l 09
6. Throttle sensor
inspection ................................. page F-l 69
Adjustment..
.............................. page F-l 69
Replacement.. ........................... page F-l 71
7. ISC valve
Inspection ................................. page F-l 16
Replacement..
........................... page F-l 09
8. Dashpot
Inspection ................................. page F-l 42
9. Dynamic chamber
Removal / Installation ................
page F-109
Inspection [DOHC] ................... page F-l 12
10. Air valve
Inspection
................................. page F-l 16
Removal / Installation ................ page F-109
11. Shutter valve actuator
Inspection ................................. page F-l 18
12. Vacuum chamber [DOHC]
Inspection ................................. page F-l 19
13. Intake manifold
Removal / Installation ................ page F-l 09
14. Injector
Inspection .................................
page F-l 31
Removal .................................... page F-131
Installation.. ............................... page F-l 33 15. Pressure regulator
Inspection ................................. page F-l 29
Replacement ............................. page F-l 30
16. Solenoid valve (Pressure regulator control)
[BP1
Inspection ................................. page F-l 35
17. Solenoid valve (VICS) [DOHC]
Inspection ................................. page F-l 18
18. Charcoal canister
Inspection ................................. page F-l 41
19. Solenoid valve (Purge control)
Inspection ................................. page F-l 40
20. Circuit opening relay
Inspection ................................. page F-l 29
Replacement ............................. page F-l 29
21. Engine control unit (ECU)
Removal / Installation ................ page F-l 49
Inspection ................................. page F-149
22. Clutch switch (MTX)
Inspection ................................. page F-l 72
Replacement.. ........................... page F-l 72
23. PCV valve
Inspection ................................. page F-l 38
24. Water thermosensor
Removal / Inspection /
Installation ............................... page F-l 68
25. Fuel filter (High-pressure side)
Replacement.. ........................... page F-l 24
26. Main relay (FUEL INJ relay)
Inspection ................................. page F-l 72
27. Neutral switch (MTX)
inspection ................................. page F-l 73
Replacement.. ........................... page F-l 73
28. Oxygen sensor
Inspection ................................. page F-l 71
Replacement ............................. page F-l 72
29. Power steering pressure switch
Inspection ................................. page F-l 73
Replacement.. ........................... page F-l 73
23UOFX-002
F-3

F INDEX
23UOFX-01
1. Fuel pump 4. Check valve (Two-way)
Inspection.. .............................. page F-l 25 Removal I Inspection ............... page F-128
Replacement ........................... page F-l 27 Inspection ................................ page F-140
Disassembly / Assembly.. ........ page F-l 28 5. Check-and-cut valve
2. Fuel tank Inspection ................................ page F-141
Removal I Inspection I 6. Exhaust system
Installation.. ............................ page F-l 23 Removal / Inspection /
3. Separator Installation.. ............................ page F-l 36
Removal I Inspection I 7. Catalytic converter
Installation.. ............................ page F-l 28 Removal / Inspection /
Installation .............................. page F-136
F-4

RESONANCE DUCT
SOLENOID VALVE’1
AIR CLEANER
ix
%
4.L VACUUM
CHAMBER-1
RESONANCE
CHAMBER DASHPOT
w/r) --CHECK VALVE
(TWO-WAY)
I II 14 J--CHECK-AND-
II l/%x II/ II _ \,\, _.-.,I CUT VALVE
TH
?z% ---{ IGNITER 1
~ Ne-SIGNAL 1/
G-SIGNAL’IU
DISTRIBUTOR AIR VA’LVE
/ WATER
THERMOSENSOR
SHUTTER 7
VALVE * 1 s%
SOHC
% TO ENGINE CONTROL UNIT
‘1 DOHC
‘2 BP
I CATALYTIC CONVERTER /
FU’EL PUMP
FUEL FILTER
(LOW-PRESSURE SIDE)

EGI MT n ENGINE CONTROL SYSTEM (i/3) CD.. OOHC 0 . ..CANAOA 3-l
MAIN
lOA @
HERMOSWITCW
SECTION B-3)
l-01 ENGINE CONTROL UNIT (EM)
iU 1s
IQ IO it4 1K 11 16 IE 1C ,A 61-02 MAIN RELAY (~1 2Y 2W 2U 25 28 20 2M 2K 21 26 2E 2C 24 81-03 CIRCUIT OPENING
(FUEL INJ)
R/0 O/L G/B G * -G/Y )c G/W Y/B
pL/W R
l -G/ x “y W 3/LG 0/O

<>. .DOHC EGI EC-AT l ENGINE CONTROL SYSTEM 6, EC-AT CONTROL SYSTEM(1/3)
(SECTION n-i)
DIAGNOSIS CONNECTOR
(SECTION U)
SHIELD WIRE
TACHOMETER
2-01 ENGINE CONTROL UNIT(EM) 82-02 MAIN RELAY (E)
,IJ 23 113 10 1” 1K 11 1G 1E 1C 1A _
20 2M 2K 21 26 2E 2C 2A 3~ 3W 3” 35 30 30 3M 3K 31 36 3E 3C 3A (FUEL INJ)
* w G G/B G/A (‘c) G/ G/W Y/B V L/R
W/L W/L R/E G/ W/B L/W R/L W 0 L/O Y * L/O X G/O X kBc Y/W Y /L E/O

EGI EC-AT eENGINE CONTROL SYSTEM &i EC-AT CONTROL SYSTEM(2/3)
DISTRI8UTOR -W/R IEM) ::
MAIN RELAY [FUEL INJI
(SECTION B-2d
I-4)
F-2)
@
t-01 ENGINE CONTROL UNIT (EM) 82-09 DISTRIBUTOR (EM)
X L/O x G/O
!-17 INJECTOR N0,4(INJ) 82-18 WATER THERMOS:NSyFB2-25 SOLENOID VALVE
(vIcs) (INJ)

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

F OUTLINE
COMPONENT DESCRIPTIONS
Component
Air cleaner
Airflow meter
Mr valve
Atmospheric pressure
Sensor
Catalytic converter Function Remark
Filters air entering throttle body
Detects amount of intake air; sends signal to intake air thermosensor and fuel pump
ECU switch included
Supplies bypass air into dynamic chamber
l Engine speed increased to shorten
when engine is cold warm-up period
l Thermowax type l Installed in dynamic chamber
Detects atmospheric pressure; sends signal Built in ECU
to ECU
Reduces HC, CO, and NOx by chemical Monolith type
reaction Charcoal canister
Stores fuel tank fumes while engine stopped Check valve
Controls pressure in fuel tank Two-way type Circuit opening relay
Voltage for fuel pump while engine running Clutch switch (MTX)
Detects clutch condition; sends signal to Switch OFF when clutch pedal released
ECU Diagnosis connector
Concentrated service connector 25pin (located near left suspension mount-
Concentrated terminals: ing block)
1. EGI self-diagnostic terminal
2. EC-AT self-diagnostic terminal
3. Test terminal
4. Fuel pump check terminal
5. Cooling fan check terminal
6. Engine rpm output terminal Dynamic chamber
Interconnects all cylinders Engine control unit (ECU) Detects the following:
1. A/C operation 1. A/C switch
2. Air/fuel ratio (Oxygen concentration) 2. Oxygen sensor
3. ATF thermosensor
4. Atmospheric pressure 4. Atmospheric pressure sensor
5. Braking signal 5. Stoplight switch (MTX)
6. Cranking signal 6. Ignition switch (START Position)
7. DRL (Daytime Running Light) operation 7. DRL relay (Canada)
8. E/L operation 8. Blower motor switch, cooling fan relay,
headlight switch, and rear window
defroster switch
9. Engine coolant temperature 9. Water thermosensor
10. Engine speed 10. Distributor (Ne-signal)
11. Ignition ON signal 11. Ignition switch
12. In-gear condition 12. Neutral and clutch switches (MTX)
13. Inhibitor switch (ATX) 13. N range, D range, S range, L range
switch
14. Intake air amount 14. Airflow meter
15. Intake air temperature 15. Intake air thermosensor
(In airflow meter)
16. No.1 piston TDC of compression
17. P/S operation
18. Shift solenoid (ATX)
19. Test signal (Ignition timing, idle speed,
Malfunction code No.)
20. Throttle valve fully closed/fully open
condition 16. Distributor (G-signal) DOHC)
17. P/S pressure switch
18. 1-2, 2-3, 3-4, Lockup solenoid
19. Diagnosis connector
(TEN terminal)
20. Throttle sensor (MTX)
21. Throttle valve opening angle
22. Turbine sensor 21. Throttle sensor (ATX) .__r
F-10

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

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