battery MAZDA PROTEGE 1992 Workshop Manual

G
ALTERNATOR
Removal / Installation
CHARGING SYSTEM
Caution
l Be sure the battery connections are not reversed, because this will damage the rectifier.
l Do not use high-voltage testers such as a megger, because they will damage the rectifier.
l Remember that battery voltage is always applied to the alternator B terminal.
l Do not ground the L terminal while the engine is running.
l Do not start the engine while the connector is disconnected from the L and S terminals.
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary
3. Install in the reverse order of removal.
N.m (m-kg, R-lb)
OSlJOGX b20
1. Negative battery cable
2. Vacuum hose
3. Solenoid bracket (If equipped)
4. Connector
5. B terminal wire
Inspect for damage and corroston 6. Drive belt
Inspection. . . . ., ~.. ,. ,.... . , page G-l 4
Adjustment ,~, ,.,., ,. ,. ,, ,.. page G-l 4
Replacement . . . . . . . . page
G-l 4
7. Alternator
Disassembly / Assembly ,........,... page G-l 1
Inspection... ,, . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-l 2
G-10

IGNITION SYSTEM G
IGNITION SYSTEM
PREPARATION
SST
49 NO18 001
Adapter Harness
CIRCUIT DIAGRAM
ECU
T
IGNITION SWITCH
,
I
DISTRIBUTOR
7
1 ZL BATTERY
IGNITER
03UOGX-03t
G-15

IGNITION SYSTEM . . . ._,
03UOGX-04
Lszl /
P
0 V
- 23UOGX-OC
03UOGX-048
03UOGX-04
03UOGX-0%
IGNITION COIL
Inspection
Spark test
1. Disconnect the high-tension lead from the distributor.
2. Hold it with insulated pliers 5-l
Omm (0.20-0.39 in) from
a ground.
3. Crank the engine and verify that a strong blue spark is
visible.
4. If there is no spark, disconnect the connector from the igni-
tion coil and check for voltage at the positive (+) terminal
of the connector with the ignition switch in the ON position.
Specification: Battery voltage
5. If there is no voltage, check the main fuse, ignition switch,
and wire harness.
Primary coil winding
1. Use an ohmmeter and measure resistance of the primary
coil winding. If not within specification, replace the coil.
Prlmary coil resistance: 0.81-0.99112 (at 2O*C [88*F])
Secondary coil winding
1. Use an ohmmeter and measure resistance of the secon-
dary coil winding. If not within specification replace the coil.
Secondary coil resistance: lo-18 kQ (at 20°C [68*F])
Insulation of case
1. Use a 500V megger tester to measure the insulation resis-
tance between each terminal and the case.
Speclficatlon: 10 MS1 min.
G-19

IGNITION SYSTEM G
03UOGX-05
03UOGX-05t 3
03UOGX-059
03UOGX-06
VOLTMETER 0
03UOGX-06
IGNITER
Inspection
1. Disconnect the igniter connector.
2. Connect the
SST between the igniter and the wire harness.
3. Connect the connector (4-pin) of the Igniter Checker to the
adapter harness.
4. Connect the power leads of the
SST (Igniter Checker) to
the battery.
Spark test
1. Turn the ignition switch ON.
2. Disconnect the high-tension coil lead from the distributor
and hold it
5--10mm (0.20-0.39in) from a ground.
Caution
l Hold the SW2 ON for no longer than one second.
3. Flip the SW2 ON and OFF, and verify that strong blue sparks
are discharged from the high-tension lead.
Voltage test
1. Turn the ignition switch ON.
2. Connect a voltmeter to the terminal of the black wire of the
adapter harness.
Caution
l Hold the SW2 ON for no longer than one second.
3. Flip the SW2 ON and OFF, and verify that the voltmeter
pointer fluctuates.
G-23

G STARTING SYSTEM
STARTING SYSTEM
PREPARATION
SST
49 E301 144
Removing plate
I I 03UOGX-062
CIRCUIT DIAGRAM
I --II /l--f--I1 I It------t--r/
INHIBITER SWITCH-ATX 1 It---f-l/
SWITCH STARTER IF
SWFCH-MTX
II
BATTERY V 0
FIELD COIL
BRUSH
S TERMIN
M TERMINAL
““““.“I “1 Note
l BP ATX vehicles use a coaxial reduction starter.
G-24

STARTING SYSTEM G
STARTER
Removal / Installation
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal.
37-52 (3.8-5.3, 27-38)
I 9.8-12 N-m (100-120 cm-kg, 87-104 in-lb)
9 I
1 1 ~ /;’ (1.9-2.6, 14-19)
I
9.8-12 N.m /
(100-120 cm-ka. 87-104 In-lb) (3.8-5.3, 27-38)
L-
\\ 37-52 ,d-5.3. 27-38
REMOVE THE STARTER
AS SHOWN IN THE FIGURE
N-m Im-ka. ft.lb 1
I
031JOGX.06
1. Battery 5. Starter
2. intake manifold bracket Disassembly I Assembly.. . . . . . . . . . . . page G-26
3. S terminal wire Inspection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-28
4. B terminal wire 6. Starter bracket
G-25

STARTING SYSTEM G
STARTER INTERLOCK SWITCH (MTX)
CONTACT
IGNITION SWITCH
IG2 ROD
p IG1 ‘NTERlfM$TCH
i BATTERY
I
STARTER
For operator safety, if the clutch pedal is not depressed during starting, battery power will not be supplied
to the starter and the engine will not crank.
Interlock Switch
Inspection
1. Disconnect the interlock switch connector.
2. Connect an ohmmeter to the switch.
3. Check the continuity.
Clutch pedal
----- I_
Depressed
Released 4.
Replace the switch if necessary.
Continuity
--
Yes
No
G-31

CLUTCH MASTER CYLINDER H
CLUTCH MASTER CYLINDER
PREPARATION
SST
49 0259 770B
Wrench, flare nut For
disconnecting
and connecting
clutch pipe
I I 03UOHX-01
REMOVAL / INSPECTION / INSTALLATION
Caution
l Clutch fluid will damage painted surfaces. Be sure to use a container or rags to collect it. If
fluid gets on a painted surface, wipe it off immediately with a rag.
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
N.m (m-kg, R-lb
23UOHX-007
1. Battery
2. Diagnosis connector
3. Clutch pipe
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page H- 8
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page H-
8
4. Clip
5. Nut
6. Clutch master cylinder
Check for fluid leakage from the cylinder
bore
Overhaul . . . . . . . ..*........*................ page H-10
Air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H- 8
7. Gasket
H-7

Jl TRANSAXLE
REMOVAL
1. Disconnect the negative battery cable.
2. Raise the vehicle and support it with safety stands.
3. Drain the transaxle oil into a suitable container.
A D~.MP,~,~ in +hn nr,-4ar chnln,n in the finlIre re!fe,rrino to Removal Note,
4.
51-10

TRANSAXLE Jl
1. Wheel and tire
2. Splash shield
3. Air hose and resonance chamber
4. Battery
5. Battery carrier
6. Speedometer cable
7. Back-up light switch connector
8. Neutral switch connector
9. Ground
10. Starter
11. Extension bar
12. Control rod
13. Engine mount member
Removal Note . . . . . . . . . . . . . . . . . . . . . . 14. Exhaust pipe
15. Engine mount No.2
16. Clutch release cvlinder
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-1 1
17. Tie-rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
18. Stabilizer (BP SOHC)
19. Driveshaft
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
20. Engine mount No.4
21. Transaxle
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Jl-12
page Jl-11
03UOJl-012
Removal Note
Engine mount member
1. Suspend the engine with the SST and remove the engine
mount member.
03UOJ2-015 Clutch release cylinder
Caution
l Do not damage the clutch pipe.
1. Remove the bolts shown.
2. Lay aside the clutch release cylinder and the clutch pipe
when removing the transaxle.
03UOJl-013
,Jl-11