heater MAZDA PROTEGE 1992 Owner's Manual

HEATER U
23UOUX-01
23uoux-02
Inspection
Blower motor
1, Remove the glove box. (Refer to Section S.)
2. Disconnect the blower motor connectors.
3. Verify that the blower motor runs when connecting battery
voltage to terminal a and grounding terminal b.
4. If not as specified, replace the blower motor.
Resistor assembly
1. Remove the glove box. (Refer to Section S.)
2. Disconnect the resistor assembly connectors.
3. Check continuity between terminals.
G-O: Indicates continuity
4. If not as specified, replace the resistor assembly.
u-25

U HEATER
HEATER CONTROL UNIT
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
3. Install in the reverse order of removal.
Note
l After installing the Mix, Mode, and Ret-Fresh wires. verifv that each lever moves its full stroke.
1. Side panel
2. Lower panel (R.H.)
3. Lower panel (Center)
4. Meter hood 5. Glove box
6. Glove box cover
7. Mode wire
8. Mix wire
9. Ret-Fresh wire
IO. Heater control assembly
U-26

Disassembly / Assembly
HEATER U
Disassemble and assemble the heater control unit as shown in the figure.
--
03uoux-041
1. Knob
5. Mode wire 7. Ret-Fresh lever
2. Switch panel Adjustment . . . . . . . page U-28
8. Mode lever
3. Switch body 6~ Mix wire 9. Mix lever
4. Ret-Fresh wire
Adjustment....... page U-28 10. Blower switch
Adjustment . . . . . . . page U-28
Inspection . . . . page U-28
U-27

HEATER
Inspection
Blower switch
1. Check continuity between terminals of the blower switch.
Terminals
SW’TCH a b c d e f g h
OFF 0 0
0 0
-
03uoux-01
U-28
mm (in)
I - I I I ” I I I 7- I
m: Indicates continuity
2. If not as specified, replace the blower switch.
Adjustment
Ret-fresh wire
1. Set the Fiec-Fresh lever to fresh position.
2. Connect the Ret-Fresh wire to the Ret-Fresh door.
3. Set the door to fresh position and clamp the wire into place.
4. Verify that the Ret-Fresh lever moves its full stroke.
Mix wire
1, Set the Mix lever to cold position.
2. Connect the Mix wire to the Mix door.
3. Set the door to cold position and clamp the wire into place.
4. Verify that the Mix lever moves its full stroke.
Mode wire
1. Set the mode lever at defrost position.
2. Remove the mode wire from clip A.
3. Align the set pin hole at B of the link with the matching hole
of the heater unit. If a pin (0.24 in in diameter) is available,
insert it to fix the link to the correct position.

HEATER U
4. Verify that the mode lever is in the defrost position.
5. Set the mode wire to clip A as shown, Keep natural tension
of the mode wire. (It is all right if the mode wire is slightly
pulled to the direction a) Push areas b and c simultaneous-
ly when setting the wire to the clip.
Note
l Do not push the inner wire of the mode wire when
setting, if pushed, it may result in deformation of
the wire and prevent the corret setting.
6. Check the function of the mode lever. If the result is not
good, pull the mode wire 2mm (0.08 in) in direction a.
7. Confirm the function of the mode lever.
8. Remove the set pin.
u-29

U
COOLING UNIT
Removal / Installation AIR CONDITIONER
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Remove the glove box, glove box cover, undercover, and instrument panel stay. (Refer to Section S.)
3. Remove the cooling unit as shown in the figure. -
Note
l Immediately plug all open fittings to keep moisture out of system.
4. Install the cooling unit in the reverse order of removal.
Note
l Position the cooling unit so that its connections match those of the heater unit and blower unit.
l Apply clean compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fitting nuts.
l When installing a new cooling unit, add compressor oil through the high-pressure pipe port
of the compressor.
Compressor oil: 50 cc (3.05 cu in)
Tightening torque
Outlet pipe: 20-29 N*m (2.0-3.0 m-kg, 14-22 ft-lb)
lnla+ nina. Q n,7n N.m (I -0-2.0 m&a. 7,7-IA ftJh IIllcvb yap”. “.” -1 . . . . . \..’ -_- __- ..~, JII .- .I .-,
23UOUX-0: -.,
1. Cooling unit
Disassembly / Assembly.. . . . . . . . . . . . page U-39
U-38

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

TECHNICAL DATA TD
U. HEATER AND AIR CONDITIONER SYSTEMS
Item Specifications
Refrigerant amount
g (04
Refrigerant pressure kPa (kg/cm2, psi) 750-800 (26.5-28.2)
High: 1,177-1,619 (12.0-16.5, 171-235)
Low: 147-294 (1.5-3.0, 21-43)
Compressor
Magnetic clutch
Condenser fan
Recerver/Drier Capacity cc (cu in)
Compressor oil amount cc (cu in)
Electrical load w
Electrical load w
Capacity cc (cu in) 115 (7.0)
loo---120 (6.1-7.3)
31
77
330 (20.1)
STANDARD BOLT AND NUT TIGHTENING TORQUE
Diameter Pitch 4T 6T 8T
mm (in) mm (in) N-m m-kg ft-lb N.m m-kg ft-lb N.m m-kg ft-lb
6 (0.236) 1 (0.039) 4.2-6.2 0.43-0.63 3.1-4.6 6.9-9.8 0.7-1.0 5.0-7.2 7.8-11.8 0.8-1.2 5.8-8.8
8 (0.315) 1.25 (0.049) 9.8-14.7 1.0-1.5
7.2-10.8 16-23 1.6-2.3 12-17 18-26 1.8-2.7 13-20
10 (0.394) 1.25 (0.049) 20-28 2.0-2.9
14-21 31-46 3.2-4.7 23-34 36-54 3.7-5.5 27-40
12 (0.472) 1.5 (0.059) 34-50 3.5-5.1 25-37 55-80 5.6-8.2
41-59 63-93 6.4-9.5 46-69
14 (0,551) 1.5 (0.059)
- - - 75-103 7.7-10.5 56-76 102-137
lo-14 75-101
1 16 (0.630) 1 1.5 iO.059j 1 - 1 - - 116-157 12-16 85-116 156-211 16-22 115-156
1 18 ;0.709j Il.5 iO.O59 1 - 1 -
167
1 20 i0.787; Il.5 iO.059i 1 - 1 - 1 - 12:
31 _..
22 (0.866) 1 1.5 io.059j 1 - 1 - 1 - 1314-423 __ ._ ,--. -._,
1 I
24 (0.945) 1 1.5
(0.059) 1 -
- 1475-546 41-56 (298-4031536-7261 55-74 1396-536 -2251 17-23 123-166 221-299 23-31 163-221
-3141 24-32 171-231 308-417 31-43 227-307
37-43 331-312 417-564 43-58 307-416
TD-21

SPECIAL TOOLS
GENERAL INFORMATION ........................
ENGINE .................................................. i;-
- ‘3
CLUTCH AND MANUAL TRANSAXLE.. ...... ST- 4
AUTOMATIC TRANSAXLE.. ...................... ST- 5
FRONT AND REAR AXLES.. ..................... ST- 7
STEERING SYSTEM ................................ ST- 8
BRAKING SYSTEM .................................. ST- 9
FRONT AND REAR SUSPENSIONS.. ......... ST-10
HEATER AND AIR CONDITIONER
SYSTEMS ............................................. ST-l 0
CHECKER AND OTHER EQUIPMENT.. ....... ST-10
23USTX-001

ST SPECIAL TOOLS
FRONT AND REAR SUSPENSIONS
TOOL NUMBER
& DESCRIPTION PRIORITY ILLUSTRATION
49 8034 2A0
Replacer set,
rubber bush A
49 1243 785
Installer, dust
boot A TOOL NUMBER
81 DESCRIPTION PRIORITY ILLUSTRATION
49 GO34 1AO
Compressor, coil A
spring
49 0208 701A
Air-out tool, boot B
HEATER AND AIR CONDITIONER SYSTEMS
TOOL NUMBER
PRIORITY ILLUSTRATION TOOL NUMBER
i? DESCRIPTION & DESCRIPTION PRIORITY ILLUSTRATION
49 BO61 005
Replacer, seal
plate A 0000-41-0809-06
Remover &
installer, seal
CHECKER AND OTHER EQUIPMENT
TOOL NUMBER
81 DESCRIPTION
49 0839 285
Checker, fuel &
thermometer
49 GO19 901A
EC-AT tester
49 BO19 904
Panel
(EC-AT tester) PRIORITY
A
A ILLUSTRATION
49 GO19 901
EC-AT tester
49 HO19 902
(EC-AT tester)
49 BO19 905
ST-10