fuel MAZDA PROTEGE 1992 Workshop Manual

CONTROL SYSTEM F
VB: Battery voltage
incorrect voltage POBSible cause
Alwvs OV’ l ROOM IOA fuse burned l Open circuit in wiring from ROOM IOA fuse to ECU terminal 1A
Always OV
l Main relay malfunction (Refer to page F-171) l Open or short circuit in wiring from main relay to ECU terminal 1B
I
Always OV (Starter turns) l Open or short circuit in wiring from starter interlock switch (USA), ignition
switch (CANADA), to ECU terminal 1C
I
Always OV
Always Vs
Always approx. 5V
l Main relay (FUEL IWJ relay) malfunction (Refer to page F-171) l Open circuit in wiring from main relay to diagnosis connector terminal +B l Open or short circuit in wiring from diagnosis connector terminal MEN to
ECU terminal 1D
l Poor connection at ECU connector l ECU malfunction
l ECU malfunction
Always below
23 MIL always ON
MIL never ON
l Short circuit in wiring from combination meter to ECU terminal 1E l ECU malfunction
l Open circuit in wiring from combination meter to ECU terminal 1E
I
Always Ve l Poor connection at ECU connector l ECU malfunction
Always below
2.5V
Always
VB
No display on Self- * Main relay (FUEL INJ relay) malfunction (Refer to page F-171)
Diagnosis Checker l Open circuit in wiring from main relay to diagnosis connector terminal +B
“88” displayed and
l Open or short circuit in wiring from diagnosis connector terminal FEN to
buzzer sounds con- ECU terminal 1F
tinuously
l Poor connectron at ECU connector l ECU malfunction
Always OV
l Short circuit in wiring from igniter to ECU terminal 1G
I -
I -
I
I -
I -
I
Always below
2.5V
Always VB AIC does not operate l A/C relay malfunction (Refer to page U-55) l Open circurt in wiring from ignition switch to A/C relay l Open circuit in wiring from A/C relay to ECU terminal 1J
A/C switch OFF but
l Short circuit in wiring from A/C relay to ECU terminal IJ
AIC operates l ECU malfunction
l Poor connection at ECU connector l ECU malfunction
Always below l.OV
l Short circuit in wiring from diagnosis connector terminal TEN to ECU termi-
nal 1K
Always Vs
l Open circuit in wiring from diagnosis connector terminal TEN to ECU termi-
nal 1K
l Open circuit in wiring from diaonosis connector terminal GND to ground
Always below
2.W
Always Va DRL ON when ignition
l Short circuit in wiring from DRL relay to ECU terminal IL
switch ON l Short circuit in wiring from DRL relay to DRL unit
DRL never ON
l Open circuit in wiring from DRL relay to ignition switch
l Parking brake switch always ON l DRL unit malfunction (Refer to page T-33)
23UOFX- 134
F-l 51

CONTROL SYSTEM
Ve: Battery voltage
Incorrect voltage
I Possible cause
4bove OV
l Poor contact at ground terminal l Open circuit in wiring from ECU to ground
Always approx. OV or approx. 2V
l Refer to Code No.02 Troubleshooting (Refer to page F-86) -
r\lways approx. OV or approx. 1.W - l Refer to Code No.03 Troubleshooting (Refer to page F-88)
Approx. 4.5-5.5V (California)
Always OV (Canada)
l Open circuit in wiring from ECU terminal 2H to ground
l Short circuit in wiring from ECU terminal 2l-i to main relay (FUEL INJ relay) - -
Approx. 4.5--55V l ECU malfunction
Always OV
l Short circuit in wiring from ECU terminal 2K to throttle sensor, or airflow
meter
Below 4.5V or above 5.5V
l Poor connection at ECU connector l ECU malfunction
1
l ECU malfunction
Always OV
l Throttle sensor malfunction (Refer to page F-169) l Short circuit in wiring from ECU terminal 2L to throttle sensor l Poor connectron at ECU connector l ECU malfunction
Always 4.5--5.W
Always constant
l Throttle sensor misadjustment (Refer to page F-169) l Open circuit in wiring from ECU terminal 2L to throttle sensor l Open circuit in wiring from ECU terminal 2L to ECU terminal 2D
l Open circuit in wiring from ECU terminal 2M to throttle sensor
l Open circuit in wiring from ECU terminal 2K to throttle sensor l Open circuit in wiring from ECU terminal 20 to throttle sensor
Always above 1V 1
l Throttle sensor misadjustment
OV after warm-up
Always approx. 1V after warm-up (
l Refer to Code No.15 Troubleshooting (Refer to page F-98)
I * Refer to Code No.1 7 Troubleshooting (Refer to page F-100)
Always OV or 4.5-5.5V
Always OV or 4.5~-5.W
I l
Refer to Code No.08 Troubleshooting (Refer to page F-90) l
Refer to Code No.10 Troubleshootrng (Refer to page F-94)
Always OV or 4.5-5.W l
Refer to Code No.09 Troubleshooting (Refer to page F-92) -
23UOFX-131
F-l 55

CONTROL SYSTEM
Incorrect voltage
Always OV or VB
Always OV or VS
VB: BBttWy voltage
Possible cause
l Refer to Code No.41 Troubleshooting (Refer to page F-103)
l Refer to Code No.25 Troubleshooting (Refer to page F-102)
Always OV
l Main relay (FUEL INJ relay) malfunction (Refer to page F-172)
6 Open or short circuit in wiring from injector to ECU terminal 2U or 2V
Always Ve
l ECU malfunction
Always OV or
VB
Always OV or Va
l Refer to Code No.34 Troubleshooting (Refer to page F-103)
l Refer to Code No.26 Troubleshooting (Refer to page F-102)
23UOFX-140
F-t 57

F CONTROL SYSTEM
Terminal voltage (ATX)
VB: Battery voltage
erminal Input Output
Connection to Test condition Correct voltage Remark
IA - -
Battery Constant --- Va For backup
16 0 Main relay
lgnrtion switch OFF ov
(FUEL INJ relay) -
ON Vs
IC 0 Ignition switch While cranking Approx. 1 OV
(START) -
Ignition switch ON
ov
_
ID 0 Self-Diagnosis Test switch at “SELF-TEST” With Self-
Checker Lamp illuminated for 3 sec. after ignition 4.5-5.5v Diagnosis Check-
(Monitor lamp) switch OFF-ON er and System
Lamp not illuminated after 3 sec.
VB Selector
Test switch at “02 MONITOR” at idle
Monitor lamp illuminated 4.5-5.5v
Test switch at
“02 MONITOR” at idle
Monitor lamp not illuminated VB
1E 0 Malfunction indica- Lamp illuminated for 3 sec. after ignition
Below 2.5V With System
tor lamp (MIL) switch OFF+ON Selector test
Lamp not illuminated after 3
sec. VS switch at
“SELF-TEST”
Lamp illuminated Below 2.5V
Lamp not illuminated VR
IF 0 Self-Diagnosis Buzzer sounded for 3 sec. after ignition
Below 2.5V
l With Self-
Checker switch OFF+ON Diagnosis
(Code Number)
Buzzer not sounded after 3 sec.
VB Checker and
Buzzer sounded Below 2.5V System Selector
l With System
Buzzer not sounded
VB Selector test
switch at
“SELF-TEST”
IG 0 Igniter Ignition switch ON ov
-
Idle Approx. 0.2V
1H 0 Headlight switch Headlrghts ON VB
-
Headlights OFF Below 1 .OV
II
0 Diagnosis System Selector test switch at Ignition switch
connector
“02 MONITOR” VE
ON
(TEN terminal)
System Selector test switch at
“SELF-TEST” ov
1J 0 Rear window
defroster switch Rear window defroster switch OFF
Rear window defroster switch ON ov
VB
Ignition switch
- ON
1K 0 Ground (California) Constant ov
Main relay Ignition switch ON VB -
I
3 J
IJ- J-1
u- Fl
IJ -‘--l. r
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F-l 58

CONTROL SYSTEM F
VB: Battery voltage
Incorrect voltage Possible cause
Always OV l ROOM 10A fuse burned l Open circuit in wiring from ROOM 10A fuse to ECU terminal 1A
Always OV
l Main relay malfunction (Refer to page F-171) l Open or short circuit in wiring from main relay to ECU terminal 1B
Always OV (Starter turns)
l Open or short circuit in wiring from or inhibitor switch (ATX) to ECU termi-
nal 1C
Always OV
Always Ve
Always 4.5~5.5U
l Main relay (FUEL INJ relay) malfunction (Refer to page F-171) l Open circuit in wiring from main relay to diagnosis connector terminal +B l Open or short circuit in wiring from diagnosis connector terminal MEN to
ECU terminal 1D
l Poor connection at ECU connector l ECU malfunction
l ECU malfunction
Always below
25v
Always Va MIL always ON
MIL never ON
l Short circuit in wiring from combination meter to ECU terminal 1E l ECU malfunction
l Open circuit in wiring from combination meter to ECU terminal 1E
l Poor connection at ECU connector l ECU malfunction
Always below
2.5V
Always VB No display on Self- * Main relay (FUEL INJ relay) malfunction (Refer to page F-171)
Diagnosis Checker
l Open circuit in wiring from main relay to diagnosis connector terminal +B
“88” displayed and
l Open or short circuit in wiring from diagnosis connector terminal FEN to
buzzer sounds con- ECU terminal 1F
tinuously
l Poor connection at ECU connector l ECU malfunction
Always OV
l Short circuit in wiring from igniter to ECU terminal 1G
Always below 1 .OV (Headlights OK)
l Open or short circuit in wiring from headlight relay to ECU terminal 1H
(Refer to page F-171)
Always OV
Always VB
Always OV Illumination lamp
ON when rear
window defroster
switch ON
Illumination lamp
never ON
Approx. 5V (California)
Always OV (Canada)
l Short circuit in wiring from diagnosis connector terminal TEN to ECU termi-
nal II
l Open circuit in wiring from diagnosis connector terminal TEN to ECU termi-
nal II
l Open circuit in wiring from diagnosis connector terminal GND to ground
l Open or short circuit in wiring from rear window defroster switch to ECU
terminal 1 J
l Open circuit in wiring from ignition switch to rear window defroster switch l Rear window defroster switch malfunction (Refer to page T-21)
l Open circuit in wiring from ECU terminal 1K to ground
l Short circuit in wiring from ECU terminal 1K to main relay (FUEL INJ relay)
23UOFX-14: 2
f-1 59

CONTROL SYSTEM
Ve: Betterv voltaae
Incorrect voltage Possible csuse
Always OV l Main relay (FUEL INJ relay) malfunction (Refer to page F-172) l Open or short circuit in wiring from injector to ECU terminal 3U or 3V
Always Ve
l ECU malfunction
Always OV
Always Ve
l 1-2 shift solenoid valve malfunction (Refer to page K-143) l Short circuit in wiring from solenoid valve to ECU terminal 3W
I
l l-2 shift solenoid valve malfunction (Refer to page K-143) l Ooen circuit in wiring from solenoid valve to ECU terminal 3W
Always OV
l 2-3 shift solenoid valve malfunction (Refer to page K-143) l Short circuit in wirino from solenoid valve to ECU terminal 3X
Always VB
Always OV
l 2-3 shift solenoid valve malfunction (Refer to page K-143) l Open circuit in wiring from solenoid valve to ECU terminal 3X
l 3-4 shift solenoid valve malfunction (Refer to page K-143) l Short circuit in wiring from solenoid valve to ECU terminal 3Y
Always
VB l 3-4 shift solenoid valve malfunction (Refer to page K-143) l Open circuit in wiring from solenoid valve to ECU terminal 3Y
Always OV
l Lockup solenoid valve malfunction (Refer to page K-143) l Short circuit in wiring from solenoid valve to ECU terminal 32
Always Ve
l Lockup solenoid valve malfunction (Refer to page K-143) l Open circuit in wiring from solenoid valve to ECU terminal 32
23UOFX-1 E i0
F-l 67

F CONTROL SYSTEM
23UOFX-15
23UOFX-15
23UOFX-15
LOCK
4
I
13UOFX-oc
F-l 72
6. Turn the ignition switch OFF.
7. Disconnect the negative battery terminal for
at least 20 sec.
to eliminate the malfunction code that was created during
inspection from the control unit memory.
Replacetnent
1. Disconnect the oxygen sensor connector.
2. Remove the oxygen sensor.
3. Install in the reverse order of removal.
Tightening torque:
29-49 N-m (3-5 m-kg, 22-36 ft-lb)
MAIN RELAY (FUEL INJ RELAY)
Inspection
1. Verify that the main relay clicks when turning the ignition
switch ON and OFF.
2. Apply battery voltage to terminal A and ground terminal E3
of the main relay.
3. Check continuity of the terminals as shown.
VB: Battery voltage
Terminals 1 Ve not applied VB applied
C-D No continuity Continuity
4. If not as specified, replace the main relay.
CLUTCH SWITCH (MTX)
Inspection
1, Disconnect the clutch switch connector.
2. Connect an ohmmeter to the switch.
3. Check continuity of the switch.
Pedal Continuity
Depressed Yes
Released No
4. If not as specified, replace the clutch switch. ,
Replacement
1. Disconnect the clutch switch connector.
2. Loosen the locknuts.
3. Remove the clutch switch.
4. Install in the reverse order of removal.
5. Adjust the pedal height. (Refer to page H-6.)

R OUTLINE
OUTLINE
SPECIFICATIONS
Suspension type Item Specification Strut
Shock absorber Double-acting, oil-filled
Coil spring
Stabilizer Type Front Taper wound
Rear Straight wound
Dimension See coil spring specification below
Type Torsion bar
BP SOHC Front 19.1 (0.75) (Hollow type)
Rear 20.0 (0.79) (Hollow type)
Diameter 22.0 (0.87) (Solid type)
mm (in) BP DOHC ;eTrt
21 .O (0.83) (Solid type)
P ,
-
66 SOHC rronr
Rear 20.0 (0.79) (Hollow type)
Maximum Inner 400 f 20
steering angle
Outer 330 f 20
Total mm (in) 2 f 3 (0.08 f 0.12)
Front toe-in
degree 0.2O f 0.3O
Wheel alignment
(*‘Unladen) Camber angle -0005’ f 45’
Caster angle 1055 * 55’
Kingpin angle 12O25’
Total mm (in) 2 f 3 (0.08 * 0.12)
Rear toe-in
degree 0.2O f 0.3O
Camber angle -0°20’ f 45’
*’ Fuel tank full; radiator coolant and engine oil at specified levels; and spare tire, jack, and tools in designated positions.
23UORX.004
Coil Spring Specifications (See next page for coil spring applications)
I Item Wire diameter Coil center Free lel.=-. .
mm iin1 rliamotor mm [in mm (in 1 coil numbs
Front
nath
1 _ . . *St Identification mark color +l
., . . . . I...,
-*.....-.“, * . . . . . ,..-, -....- I--‘, M iA*=
A 13.1 (0.52) 133.5-159.5 (5.26-6.28)
294.5 (11.59) 3.22 Light green
B 13.3 (0.52) 133.7-159.9 (5.26-6.30) 300.5 (11.83)
3.43 Purple Yellow
C 13.4 (0.53)
132.6-158.6 (5.22-6.24) 301.5 (11.87) 3.49
Light blue
D 13.7 (0.54)
132.9-158.9 (5.23-6.26) 302.0 (11.89) 3.52
Pink White
I F I 12f3 Kl5Al I 1.17 A-l!% 8 f!i PR-Fi 751
I RrIl .5 II 1 6x71 I 3.56 Orange
Blue
3 83 Pink -
Brown - .“._ \“.- .,
. “W.., ~ - -. - \-. -- -. - -, -- .-
\’ .‘-‘I t
F 11 .o (0.43) 129.0 (5.08)
335.0 (13.19) -.--
G 11.2 (0.44) 128.8 (5.07)
334.0 (13.15) 3.94
Rnnr l-4
1 I ? 07 AA 1387 /5n7
.?m !i 113 1% 3 an Blue - I I I I .” \v.-7, I&V., \V.“., ---.., \.-. .-, I 11.5 (0.45) 128.5 (5.06)
333.0 (13.11) i:oi Gray
-
J 11.6 (0.46) 128.4 (5.06)
332.5 (13.09) 4.00 Orange
-
l ’ Main identification mark color: Indicated on second coil from bottom.
*’ Auxiliary identification mark color: Indicated on third coil from bottom. 23UORX-005
R-4

WHEEL ALIGNMENT
WHEEL ALIGNMENT
PRE-INSPECTION
1. Check the tire inflations and set to the recommended pressure, if necessary.
2. Inspect the front wheel bearing play; replace the bearing if necessary.
3. inspect the wheel and tire runout.
4. Inspect the ball joints and steering linkage for any excessive looseness.
5. The vehicle must be on level ground and have no luggage or passenger load.
6. The difference in height between the left and right sides from the center of the wheel to the fender brim
must not exceed
10mm (0.39 in).
7. Shake the vehicle to check operation of the shock absorbers.
03UORX.007
FRONT WHEEL ALIGNMENT
Specifications
item
Specifications
Maximum Inner 4o” f: 2O
steering angle Outer
33O f 2O
Total mm (in) 2 f 3 (0.08 f 0.12)
toe-in dearee 0.20 f 0.30 Wheel alignment
(*‘Unladen) Front
*I Fuel tank full; radiator coolant and Camber angle -0005 * 45’
Caster angle 1°55’ f 55’
Kingpin angle 12O25’
engine oil at specified level; and spare tire, jack, and tools in designated positions.
23UORX-008
I
I 23UORX-023
Adjustments
Maximum steering angle
1. Loosen the left and right tie rod locknuts, then turn the tie
rods equally.
Maximum left/right difference: 3mm (0.12 in)
2. Tighten the tie rod locknuts.
Tightening torque:
34-50 N-m (3.5-5.1 m-kg, 25-37 ft-lb)
3. Adjust the toe-in after adjusting the steering angle.
4. Inspect and adjust the toe-in after adjusting the turning angle.
I 23UORX-024
R-7

WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT
Specifications
kern Specifications
Total mm (in) 2 f 3 (0.08 f 0.12)
Wheel alignment
(*‘Unladen) Rear toe-in
degree 0.2O f 0.3O
Camber angle -0020’ f 45’
*I Fuel tank full; radiator coolant and engine oil at specified level; and spare tire, jack, and tools in designated positions.
13UORX-012
Adjustment
Total toe-in
1. Loosen the lateral link locknuts.
2. Turn the lateral link adjustment link to adjust.
Note
l One turn of the link changes 11.3mm (0.44 in).
3. Tighten the lateral link locknuts to the specified torque.
Tightening torque:
55-64 N,m (5.6-6.5 m-kg, 41-47 ft-lb)
R-9