clutch MAZDA PROTEGE 1992 Workshop Manual

TD TECHNICAL DATA
Spring name
2-3 accumulator
small spring Outer diameter Free length Wire diameter
mm (in) mm (in) No. of coil
mm (in) BP DOHC 11.6 (0.457)
59.7 (2.350)
16.9 1.8 (0.071)
56 SOHC
BP SOHC 10.0 (0.394) 71.8
(2.827) 24.2 1.4 (0.055)
2-3 accumulator BP DOHC 15.0
(0.591) 71.8 (2.827) 9.8
1.2 (0.047)
large spring B6 SOHC
BP SOHC 15.0 (0.591)
71.8 (2.827)
15.8 2.0 (0.079)
l-2 accumulator small spring
11.2 (0.441)
84.7 (3.335)
25.5 1.5 (0.059)
BP DOHC
- - -
-
l-2 accumulator
Accumulator large spring B6 SOHC
BP SOHC 16.0 (0.630)
84.7 (3.335) 19.5
1.9 (0.075)
B6 SOHC 10.8 (0.425) 101.2 (3.984)
28.2
1.2 (0.047)
N-D Accumulator
small spring BP SOHC
BP DOHC
10.8 (0.425) 101.2 (3.984)
28.2
1.2 (0.047)
B6 SOHC
15.0 (0.591) 94.2 (3.709)
16.5
1.6 (0.063)
N-D Accumulator
large spring BP SOHC
BP DOHC 15.0 (0.591) 94.2
(3.709) 16.5
1.6 (0.063)
N-R Accumulator small spring
9.8 (0.386)
93.2 (3.669) 31.5
1.3 (0.051)
N-R Accumulator large spring
14.0 (0.551) 106.5 (4.193)
23.0 1.7 (0.067)
3-4 clutch
Return spring
74.4 (2.929)
40.5 (1.594) 1 .o
5.0 (0.197)
Coasting clutch
Return spring
7.3 (0.287) 20.45 (0.805)
10.0 1 .o (0.039)
Low and reverse
brake Return
spring 5.55 (0.219)
14.3 (0.563)
12.0 0.75 (0.030)
Servo
Return spring
27.7 (1.091) 43.25 (1.703)
4.5
3.2 (0.126)
Vehicle Speed at Shift point Table -
lode
- -
angc
-
D Throttle condition
(Throttle sensor
voltage)
Fully opened
(4.0 volt)
Half throttle
(1.6-2.2 volt)
/ &%L) j 3 1 850-2,500 2,100-2,650 2,300-3,000 74-100 (46-62) 91-116 (56-72) 93-120 (58-74
Lock-up
[1,850-2,20011,950-2.550(2,300-2,700/74-88 (46--55)185-110 (53-68)(93-108 (58-67)1
Kir.kdnwn OD -+ DI
1,05U
%lly opened
i4.0 volt)
Half throttle
s2 -+ s3 5,000-5,45c
s3 -+ s2 2,900
S2 -+ ST 2,300-2,6OC
SI * 52
2.500-3.35C
(1.6-2.2 volt)
s2 -+ s3 v, v...
Fully opened Ll + L2 5,150-5,75(
w-dt I7w-ln
nlf throttle 6-7 7 vnltl I Ll + L2 (2.500-3.350(2,850-3,8OOj3.300-4.300125-34 (16-21$1-41 (19-25)j33-43 (20-27)1
TD-16

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
ENGINE (CONT’D)
TOOL NUMBER
& DESCRIPTION PRIORITY
49 E301 144
Removing plate A ILLUSTRATION
CLUTCH AND MANUAL TRANSAXLE
TOOL NUMBER
8, DESCRIPTION
49 GO17 5AO
Support, engine
49 SE01 310A
Clutch disc
centering tool
49 1285 071
Puller, bearing
49 GO19 OAO
Hanger, transaxle
49 8017 001
Bolt set
(Except
BP DOHC)
49 GO30 370
Removing plate
ST-4
PRIORITY
A
A
A
A ILLUSTRATION
I
=-a==-=
TOOL NUMBER
81 DESCRIPTION PRIORITY ILLUSTRATION -
- -
TOOL NUMBER
!I DESCRIPTION PRIORITY ILLUSTRATION
19 0636 145
Uler, fan A
oulley boss
49 GO30 440
Holder, primary A
shaft (BP DOHC)
T
49 F401 440
Holder, primary
shaft (Except
BP DOHC) A
49 0187 520
Bearing puller,
rear axle shaft
(Except
BP DOHC) A
49 GO30 455
Holder,
differential
side gear A
49 0259 770B
Wrench, flare nut A

SPECIAL TOOLS ST
CLUTCH AND MANUAL TRANSAXLE (CONT’D)
49 GO30 380C
49 0839 425C
49 BOO1 795
49 GO17 1AO
49 FTOl 361
Remover, bearing
49 DO17 2A2A
Shim selector set
AUTOMATIC TRANSAXLE
TOOL NUMBER
& DESCRIPTION PRIORITY ILLUSTRATION
49 B019 007
Adapter, preload A TOOL NUMBER
& DESCRIPTION PRIORITY ILLUSTRATION
49 F401 3306
Installer set,
bearing A
49 GO30 338
Attachment E
(BP DOHC) A
49 8017 102 I I
Preload adapter A
(BP DOHC)
49 GO17 202
Preload adapter A
(BP DOHC)
49 8017 1AO
Remover set,
bearing (Except
BP DOHC)
49 FTOl 515A
Adapter, preload A
TOOL NUMBER
81 DESCRIPTION PRIORITY ILLUSTRATION
49 8092 365
Remover set,
bearing
ST-5

PARTS INDEX
‘I
A
ACCELERATOR CABLE ............................. F-l 14
ACCELERATOR PEDAL ............................. F-l 14
AIR CONDITIONER ...................................... u-30
A/C RELAY.. ........................................... U-56
A/C SWITCH ...........................................
U-57
COMPRESSOR.. ..................................... U-41
CONDENSER.. ....................................... U-53
CONDENSER FAN ................................. u-57
CONDENSER FAN RELAY .................... U-56
COOLING UNIT ..................................... U-38
MAGNETIC CLUTCH ............................. u-51
RECEIVER/DRIER .................................. U-52
REFRIGERANT PRESSURE SWITCH.. .. U-55
AIR FLOW METER ..................................... F-l 68
AIR VALVE.. ................................................ F-l 16
ALTERNATOR .............................................. G-10
ANTENNA FEEDER
AUDIO
....... .......................................................................................... T-i;
AUTOMATIC TRANSAXLE ............................. K-l
2-4 BRAKE BAND ................................ K-l 97
3-4 CLUTCH.. ....................................... K-l 87
ACCUMULATORS ................................ K-l 67
ATF ....................................................... K-135
ATF THERMOSENSOR ........................ K-142
BEARING COVER ASSEMBLY ............ K-208
CLUTCH ASSEMBLY ........................... K-l 72
CONTROL VALVE BODY.. .....
K-21 0,224,234
DIFFERENTIAL ..................................... K-236
DRIVE PLATE.. ..................................... K-267
EC-AT CONTROL UNIT ....................... K-144
HOLD SWITCH ..................................... K-140
HYDRAULIC CIRCUIT .......................... K-278
IDLER GEAR ........................................ K-203
INHIBITOR SWITCH ............................. K-l 41
LOW AND REVERSE BRAKE .............. K-192
MAIN CONTROL VALVE BODY .......... K-220
OIL COOLER.. ...................................... K-265
OIL PUMP ............................................
K-169
OIL SEAL ..............................................
K-209
ONE-WAY CLUTCH 2
CARRIER HUB ASSEMBLY ............... K-185
OUTPUT GEAR .................................... K-206
P RANGE SWITCH.. ............................. K-271
PREMAIN CONTROL VALVE BODY .a. K-218
PULSE GENERATOR ........................... K-142
SELECTOR LEVER ............................... K-272
SHIFT MECHANISM ............................. K-269
SHIFT-LOCK ACTUATOR
..................... K-271
SMALL SUN GEAR AND
ONE-WAY CLUTCH 1 ........................ K-l 82
SOLENOID VALVE.. ............................. K-l 43
SPEEDSENSOR .................................. K-l 43
THROTTLE CABLE .............................. K-l 37
TORQlJE CONVERTER.. ...................... K-l 66
TRANSAXLE UNIT. ......... K-149,153,246,261 UPPER CONTROL VALVE BODY.. ..... K-215
BACK-UP LIGHT SWITCH..
..........................
BATTERY T;4;
- .......................................................
BLOWER UNIT ............................................
U-23
BRAKE FLUID.. .............................................. P-8
BRAKE MASTER CYLINDER. ...................... P-10
BRAKE PEDAL ...............................................
P-8
C
CALIPER .................................................. P-21,26
CARGO COMPARTMENT LAMP ................. T-54
CENTRAL PROCESSING UNIT..
.................. T-55
CHARCOAL CANISTER ............................. F-l 41
CHECK VALVE (TWO-WAY) .......................
CHECK-AND-CUT VALVE - .......................... ;-;b$
CIRCUIT OPENING RELAY.. ...................... F-129
CLUTCH COVER ......................................... H-l 7
CLUTCH DISC ............................................. H-l 7
CLUTCH FLUID ............................................. H-4
CLUTCH MASTER CYLINDER.. .................... H-7
CLUTCH PEDAL ............................................ H-5
CLUTCH RELEASE CYLINDER..
................. H-12
CLUTCH SWITCH (MTX) ............................ F-l 72
COMBINATION SWITCH .............................. T-23
COWL GRILLE ............................................. S-53
CRUISE CONTROL UNIT.. ...................... T-78,85
D
DASHBOARD ............................................... S-94
DASHPOT ................................................... F-l 42
DISTRIBUTOR .............................................. G-20
DOOR LOCK TIMER UNIT ........................... T-17
DOOR MIRROR ............................................ S-54
REMOTE CONTROL MIRROR ............... S-56
REMOTE CONTROL MIRROR SWITCH. S-55
DOOR SPEAKER .......................................... T-98
DRIVE SHAFT.. ....................................... M-l 7,21
DRL RELAY.. ................................................ T-18
DRL RESISTOR ............................................ T-46
DUAL PROPORTIONING VALVE..
............... P-l 6
DYNAMIC CHAMBER ................................ F-l 12
E
ELECTRIC COOLING FAN SYSTEM ........... E-13
ENGINE (B6 & BP SOHC) ........................... Bl-2
CAMSHAFT ..........................................
Bl-58
CAMSHAFT PULLEY ...........................
Bl-65
CONNECTING ROD ............................. 81-63
PI-I

PARTS
DIFFERENTIAL ..................................... Jl-52
SHIFT MECHANISM ............................. Jl-56
TRANSAXLE ............................................ Jl-8
TRANSAXLE OIL .................................... Jl-7
MANUAL TRANSAXLE (G5M-R) .................. J2-2
DIFFERENTIAL ..................................... J2-43
SHIFT MECHANISM ............................. J2-46
TRANSAXLE.. .......................................... J2-8
TRANSAXLE OIL .................................... J2-7
MOLDING, PROTECTOR, GARNISH ...........
S-42
BELTLINE MOLDING ............................. S-48
REAR WINDOW MOLDING.. ............. S-43,44
ROOF MOLDING.. .................................. S-46
SIDE PROTECTOR ................................. S-49
UPPER WINDSHIELD MOLDING,
A-PILLAR GARNISH ............................ S-42
NEUTRAL SWITCH (MTX) . . . . . . . . . . . . . . . . . . . . . . . . . . F-l 73
0
1
\_ OIL COOLER (ENGINE). ................................ D-8
OIL PAN (ENGINE) ........................................ D-9
OIL PUMP (ENGINE) ................................... D-l 3
..................................... F-l 71
OXYGEN SENSOR
P
PARKING BRAKE ......................................... P-31
PARKING BRAKE CABLE ............................ P-32
PARKING BRAKE LEVER ............................ P-33
PARKING BRAKE SHOE ............................. P-31
PASSIVE SHOULDER BELT SYSTEM.. ..... S-103
DOOR CATCH SWITCH ....................... S-l 07
LIMIT SWITCH ...................................... S-l 07
PASSIVE SHOULDER BELT MOTOR.. S-106
SPEED SENSOR ................................... S-l 07
WARNING SWITCH .............................. S-l 07
PCV VALVE ................................................
POWER BRAKE UNIT ‘;--=I;;
..................................
POWER DOOR LOCK SYSTEM ................... S-23
DOOR LOCK CONTROL.. ...................... S-26
DOOR LOCK SWITCH.. .......................... S-26
DOOR LOCK TIMER AND RELAY.. ....... S-26
POWER STEERING.. .................................... N-23
POWER STEERING FLUID .......................... N-27
POWER STEERING OIL PUMP.. ................. N-37
POWER STEERING PRESSURE SWITCH . . F-l 73
POWER WINDOW SYSTEM.. .......................
S-27
MAIN POWER WINDOW SWITCH.. .......
S-31
POWER WINDOW MOTOR.. ..................
S-32
POWER WINDOW SUB-SWITCH ........... S-32
PRESSURE REGULATOR (FUEL). ............. F-l 29 . . . . . . . . , . . . . . , . RADIATOR CAP .............................................
E-7
RADIATOR GRILLE,
I
LOWER GRILLE MOLDING ....................... S-51 fl
RADIATOR THERMOSWITCH ...................... E-17 t
REAR AXLE ................................................. M-10
REAR BRAKE (DISC) ................................... P-23
REAR BRAKE (DRUM) ................................. P-28
REAR BUMPER ............................................ s-40
REAR COMBINATION LIGHT.. ....
REAR CROSSMEMBER ............................... R-29
REAR DOOR ................................................ S-l 5
REAR DOOR LOCK AND OPENER.. .
REAR FINISHER ........................................... s-52
REAR HATCH ............................................... s-20
REAR HATCH LOCK AND OPENER.. ......... S-22
REAR SHOCK ABSORBER AND SPRING.. R-21
REAR SIDE MARKER LIGHT ....................... T-48
REAR SIDE WINDOW REGULATOR AND . . . . . . . . .
AI .,.n
INDEX
Q
QUARTER WINDOW GLASS . . . . . . . . . . . . ..a........ S-62
R
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kiLA33 ........................................................ a-- I I
REAR SPEAKER ........................................... T-99
REAR SPOILER ............................................ s-41
REAR STABILIZER.. ..................................... R-27
REAR SUSPENSION .................................... R-20
REAR WINDOW GLASS ............................... S-63
REAR WINDOW DEFROSTER.. .................... T-74
REAR WINDOW DEFROSTER SWITCH ....... T-77
REAR WIPER AND WASHER ...................... S-74
REAR WASHER MOTOF
REAR WIPER AND WASHER SWITCH . . S-77
REAR WIPER MOTOR ............................ s-77
RELEASE BEARING (CLUTCH). . . . . . . . . . ..s..... H-17 I . . . . . . . . ...*. .*......*..
SEAT BELT.. ........................................ S-100,102
BUCKLE SWITCH.. ............................... S-l 02
SEAT ........................................................... s-110
SEPARATOR (FUEL) .................................. F-l 40
SHUTTER VALVE ACTUATOR (VICS) ........ F-l 18
SLIDING SUNROOF ..................................... S-80
MOTOR ASSEMBLY ............................... S-81
SUNROOF RELAY.. ................................ S-82
SUNROOF SWITCH.. .............................. S-82
SOLENOID VALVE
(PRESSURE REGULATOR CONTROL) .... F-135
SOLENOID VALVE (PURGE CONTROL). .. F-140
SOLENOID VALVE (VICS) .......................... F-l 18
SPARK PLUGS ............................................ G-18
-II__

(SECTION I-41
4
I31
81 -01 ENGINE CONTROL UNITIEM)
1" IS 10 10 1M 1K 11 1G 1E 1C 1A 2Y 2W 2U 25 2Q 20 2M 2K 21 26 2E 2C 2A
R/0 O/L G/0 G Y LG/Y * G/W Y/B
v L/R * L/O Y y%/W R Y LG/R X ’ + ‘IL’ W B/L B/O
BR/Y B/L B/G L/Y R/W ‘BRp’ L/B * W/B W/V W/R x W/L ‘f/B G/O * R/B R/L LG/W * (Bc) * B/B B/O
1” 1T 1R 1P 1N 1L 1J 1H IF 10 IB 22 2X 2V 2T 2R 2P 2N 2L 23 2H 2F 20 28
-20 THROTTLE SE%;: 81-21 CLUTCH SWITCH(F) 81-22 NEUTRAL SWITCH (EM)
z-30
__ __-_- -- - -- ---
EGI MT mENGINE CONTROL SYSTEM(3/3)
;;FlTCONTROL
(SECTION E-3) @+ER/W (F) qBR,W (EM1 - INSTRUMENT
CLUSTER
(SECTION c) @& Y/B (F) -Y/B (EM) -
,e~~=~~TI~=T==JT~~=======~==========~=====~~-----~-----
_.____~--- 53Bl-01
ENGINE CONTROL UNIT
EXCEPT
CANAOA
CONTROL UNIT
(SECTION 0)
81-19 AIRFLOW METER (EM)
R/B R /0 CWR /L 0 LG

HARNESS COLOR : FRONT- ENGINE m
5
P
/ !%%!,E SENSOR
Bl-20
// I WIRING DIAGRAM
81-21
CLUTCH SWITCH
@LACK)
ENGINE CONTROL
“NIT

T.&condition
-t
Off
IQ”&” switch
ON
Whik cranking
lgnitlon switch ON
Test switch at “SELF-TEST”
Lamp illuminated for 3 sec. after ignition
SwiIch OFF-KIN
Lamp not illuminated after 3 sec. collect vdtaQe
ReRlar*
ve
For backup
ov
-
V%
Approx. tov
ov
4 5--5.5v With Self-
D&Q”& Check-
er and system
Vi3 st?lt?ctor Input &PJ
- -
0
0
0
0
0
0
- -
- -
0
0
c
- -
0 connectkfl to mnina
Connection to
Stoplight swtch Test condition
-L 1A
Bake pedal released
IEI
IC Main relay
(FUEL INJ relay) Brake pedal depressed
lQ”ih0” switch ON
___-- P/S Qrc?ss"re
switch
Ignition switch
(START) P/S ON at idle
P/S OFF at idle
A/C switch ON
A/C switch OFF
Cwlng fan operatng (Engine coolant tem-
perature over 97°C (207°F) or dlagnosls
connector terminal TFA grounded) (IG ON)
Fan not ooeralmg (Idle) 1D .self-mag”osls
Checker
(Monitor lamp) A!C switch
coohng fan swtctl
Test switch at “02 MONITOR” at idle
Monitor lamp ilfummated
Test switch at “02 MONITOR” at idle
Monitor lamp not illuminated
Lamp illuminated for 3 sec. after ignition
switch OFF&N
Lamp not illuminated after 3 ser.
Lamp illuminated
Lamp not #lluminated VB
Below 2.w With System
Selector test
VB swtch at
“SELF-TEST”
Eelow 2.5v
VS Blower Control
swttch Blower control switch OFF or 1 st posihon
Blower control swtch 2nd or htgher
position 1E
Malfunction indicator
lamp
NJ
Rear window defroster swtch OFF Rear wmdow
defroster switch
Headkght switch Rear window defroster Switch ON
-2-A - I
tieadlghts ON
Headlights OFF
Neutral positton or clutch pedal
depressed
OlhWS l Wiih Self-
DkQnosls
Checker and
Svstem Selector Self- Diaanosis Buzzer sounded for 3 sec. after ignition
switch OFF-ON
Buzzer not sounded after 3 set 6&w 2.5v
V8 Checke;
(Cede Number) I
ov Ignition swtch
ON NeulraliClutch
switches
. ‘.&h System
Selector test
switch at Buzzer sou”ded
1 Below 2.5V 1
VB
ov -
ov -
ov -
ov -
APprox. ov
or 4 5-5 5v
-
Approx. 2V
-
-
AQWOX. Ov
or 4 5-5 5v
-
APQ~OX 1.5V Buzzer not sounded
I VE
I
Ground (Injector)
Ground
(OUtQUt)
Ground (CPU)
Grou”d (Input)
constant
lgnlti swtch ON
klk “SELF-TEST”
ov
-
Ap~rox O.2V
- - Constant
Co”stant lgnller
1H
Constant
Igntho” swdch ON -
- D&ribulor
(Ne-sIgnal) II
1J
1K
1L
1M
1N -
fgnition switch ON
AX switch ON al idle
NC switch OFF at Idle
System Selector lest switch at
“0-z MONITOR” I -
- VB
5&w 2.w -
Vi3
VB Ignition switch
ON
System Selector test swatch at
“SELF-TEST”
ParkIng brake pulled wth lgndlon swtch ON
(DRL OFF) ov
VB
l DRL: oaytime Running tigms
Idle (DFtL ON) Below 2.5v A/C relay
Idle
-
Ignition swtch ON
-
Distributor
(G-stgnal) [DOHC]
3ignosis
x”“ec1or
,TEN terminal) Idle
3RL relay (canada)
-
Accelerator pedal released
Accelerafor pedal depressed
-
ov
VB
-
Ignition switch
ON rhr0ttte sensor
‘Idle switch)