MAZDA PROTEGE 1992 Workshop Manual

U
L
ENGINE STARTED
*-ENGINE STARTED
23UOUX.071
6. Close the low-pressure side valve.
7. Stop the engine.
8. Close the stop valves and the service container valve.
Caution
l Do not disconnect the stop valves or the service
container valve from the charging hoses when there
is refrigerant remaining in the hoses.
Refilling
Caution
l Do not overcharge the system.
l Note the sight glass during refilling the refrigerant.
Stop charging when no bubbles are observed in the
glass.
(Refer to page U-40).
l Care must be taken when the ambient temperature
is low. The bubbles may not be present even if the
refrigerant amount is insufficient.
1. Connect the manifold gauge set to the refrigerant system
charging valve.
(Refer to page U-32).
2. Start the engine.
3. Open the low-pressure side valve of the manifold gauge set
and charge the system as necessary.
4. Note the sight glass, and when no bubbles can be seen,
close the low-pressure side valve.
5. Stop the engine.
6. Close the stop valve and service container valve. Discon-
nect the stop valves quickly.
u-35

U AIR CONDITIONER
DRY AND WET THERMOMETER
13uoux-014
Performance test
After finishing repairs, conduct a performance test of the air
conditioning system as follows.
1. Connect the manifold gauge set. (Refer to page U-32.)
2. Start the engine and keep the engine speed at
1,500 rpm.
3. Operate the air conditioner at maximum cooling.
4. Open all windows and doors.
5. Place a dry-bulb thermometer in the center ventilator outlet.
6. Place a dry and wet thermometer close to the blower inlet.
7. Wait until the air conditioner outlet temperature stabilizes.
Stabilized condition
Blower inlet temperature: 25-35*C (77-95*F)
High-pressure side:
1,177-1,619 kPa (12.0-16.6 kg/cm’, 171-235 psi)
Note
l If the high-pressure side becomes too high, pour
cool water on the condenser. If It is too low, cover
the front of the condenser.
8. After the air conditioner stabilizes, read the dry and wet ther-
mometer at the air inlet.
9. Calculate the relative humidity from the chart below by com-
paring the wet- and dry-bulb readings.
05uoux-051
‘C ‘F
26
24
22
20
18
16
14
12
10
U
--k----
RELATIVE HUMIDITY ‘%’
I 96U16X.103
IO. Read the dry thermometer at the air outlet, and calculate
the difference between the inlet dry-bulb and outlet dry-bulb
temperatures.
11. Verify that the intersection of the relative humidity and tem-
perature difference is in the shaded zone.
U-36

AIR CONDITIONER U / ,
9MUOUX-13
SIGHT GLASS
Checking refrigerant charge
1. Run the engine at a fast idle.
2. Operate the air conditioner at maximum cooling for a few
minutes.
3. Determine the amount of refrigerant as shown below by ob-
serving the sight glass.
Item Symptom Amount of refrigerant Action
I Bubbles present in sight glass Insufficient refrigerant Check refrigerant pressure
2 No bubbles present in sight glass Too much or proper amount of Turn air conditioner OFF, and
refrigerant watch bubbles (Refer to Items 3
and 4)
3 Immediately after air conditioner turned Too much refrigerant Check refrigerant pressure
OFF, refrigerant in sight glass stays clear
4 When air conditioner turned OFF, refrigerant Proper amount of refrigerant Refrigerant amount normal
foams, and then sight glass becomes clear
QMUOUX-140
Checking refrigerant pressure
1. Connect the manifold gauge set. (Refer to page U--32.)
2. Operate the engine at 2,000 rpm and set the air condition-
er to maximum cooling.
3. Measure the low- and high-pressure sides.
Normal pressure
Low-pressure side: 147-294 kPa
(1.5-3.0 kg/cm2, 21-43 psi)
High-pressure side: 1 ,I 77-l ,619 kPa
(12.0-l 6.5 kg/cm2, 171-235 psi)
u-37

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

AIR CONDITIONER U
Dlsassembly / Assembly
Disassemble and assemble as shown in the figure.
1. Evaporator 2. Expansion valve 3. Thermoswitch
Replacement
Expansion valve
Note
l Before replacement of the expansion valve, care-
fully check the refrigeration system, referring to the
troubleshooting information on page U-14.
1. Remove the cooling unit. (Refer to page U-38.)
2. Disassemble the cooling unit. Remove the evaporator and
expansion valve as an assembly.
3. Disconnect the inlet and outlet pipes.
I 4. Remove the capillary tube from the outlet pipe and remove
23UOUX-024 the expansion valve.
5. Install in the reverse order of removal, noting the following.
Note
l Apply clean compressor oil to the O-rings before
connecting the fittings.
Tightening torque
Inlet pipe:
12-15 N-m (1.2-l .5 m-kg, 8.7-l 1 ft-lb)
Outlet pipe:
29-34 Nmrn (3.0-3.5 m-kg, 22-25 ft-lb)
u-39

U AIR CONDITIONER
OFF
03UOUX-06
03UOUX-06,
03UOUX-06
On-vehicle Inspection
Thermoswitch
1. Remove the glove box.
2. Run the engine at idle.
3. Turn OFF the A/C switch and set the blower switch to the
highest position to operate the blower fan for a few minutes.
4. After a few minutes, turn OFF the blower switch and stop
the engine.
5. Disconnect the thermoswitch connector and check for con-
tinuity between terminals of the switch.
Terminals Continuity
a-b Yes
6. If not as specified, replace the thermoswitch.
Note
l The thermoswitch contacts will be open if the
evaporator temperature is below 0.4 f 0.7OC (32.7
z!z 1.3OF).
Inspection
Thermoswitch
1. Immerse the sensing bulb in a container of ice water.
2. Check continuity between terminals of the switch as
specified.
Terminals
a-b Temperature Continuity
Above 5°C Yes
Below 0% No
3. If not as specified, replace the thermoswitch
Evaporator
1. Check the evaporator fins for blockage. If the fins are
clogged, clean them with compressed air.
Caution
l Never use water to clean the evaporator.
2. Check the fittings for cracks and other damage.
Replace the evaporator if necessary.
u-40

AIR CONDITIONER U
COMPRESSOR
Removal / Installation
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Remove the undercover.
3. Remove the compressor as shown in the figure, referring to
Removal Note.
4. Install the compressor in the reverse order of removal, referring to Installation Note.
5. Install the undercover.
6. Charge the refrigeration system. (Refer to page U-33.)
u
24-35 (2.4-3.6, 17-26)
N.m (m-kg, ft-it
23UOUX-0
1. Suction hose
2. Discharge hose 3. Compressor
Note
l Immediately plug any open fittings to keep moisture out of the system.
l Apply new compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fittings.
l Tightening torque Compressor inlet and outlet: 9.8-l 8 N.m (1.0-l .8 m-kg, 8-l 2 ft-lb)
l Adjust the belt tension to specification.
lb-41

U AIR CONDITIONER
-0
1 03UOUX-066
23UOUX-02 16
1 13UOUX-027
.ECTION
Removal note
Drive belt
Remove the drive belt as follows.
Vehicle with power steering.
1) Loosen bolt A.
2) Loosen nut C.
3) Loosen nut B.
4) Loosen bolt D.
5) Remove the drive belt.
Vehicle without power steering
1) Loosen nut A.
2) Loosen bolt B.
3) Remove the drive belt.
Installation note
Vehicle with power steering
Drive belt
Adjust the deflection of the drive belt as follows.
Vehicle with power steering
1) Loosen bolt A and nuts B and C.
2) Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.
Belt Deflection: When applying moderate pressure 98 N (IO kg, 22 lb)
New 8-Qmm (0.31-0.35 in)
Used Q-IOmm (0.35-0.39 in)
3) Tighten bolt A and nuts B and C.
Tightening torque
Bolt A: 36-54 N.m (3.7-5.5 m-kg, 27-40 ft-lb)
Nut B : 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
Nut C : 32-46 N,m (3.2-4.7 m-kg, 24-34 ft-lb)
Vehicle without power steering
1) Loosen nut A.
2) Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.
Belt Deflection: When applying moderate pressure 98 N (10 kg, 22 lb)
New 8-Qmm (0.31-0.35 in)
Used Q-10mm (0.35-0.39 in)
3) Tighten nut A. Tightening torque
Nut A: 31-34 N.m (3.2-3.6 m-kg, 23-25 ft-lb)
U-42

AIR CONDITIONER U
Disassembly / Assembly
Preparation
SST
49 B061 005
Replacer,
seal plate For
replacement of
shaft seal plate 0000-4 l-0809-06
Remover &
installer, seal For
replacement of
shaft seal
03uoux-07
Structural view
I
1. Compressor body 4. Discharge valve body 6. Discharge valve plate
2. Shaft seal plate 5. Thermal protector 7. Discharge valve
3. Shaft seal
u-43

U AIR CONDITIONER
23UOUX-02
Thermal Protector Replacement
1. Removal of discharge valve body
Remove the bolts and carefully remove the discharge valve
body. .-
2. Removal of snap ring and thermal protector
Note
l When removing the thermal protector, do not pull
the harness wires but push the protector out from
its back side.
23UOUX-028 3. Installation of thermal protector
1) Check that the O-ring groove is free from foreign matter.
Apply compressor oil to the O-ring and properly fit it in
the groove.
2) Before installing the thermal protector, check it for con-
tinuity.
23uoux-029 _/”

THERMAL PROTECTOR
23UOUX-03
TH
PR
3) Install the snap ring so that its chamfered edge side faces
the thermal protector (the non-chamfered side faces out-
ward) as shown left.
Make sure the snap ring is seated securely in its groove.
Note
l Install the thermal protector so that its two lead wire
outlet sections are horizontal as shown left.