check engine MAZDA PROTEGE 1992 Workshop Manual

TECHNICAL DATA
D. LUBRICATION SYSTEM
Item I I bhricatinn mothnd
Engine
B6 SOHC BP SOHC
Force-fed BP DOHC 1
Requlated pressure kPa (kg/Cm”, p
Inner rotor tooth tip to outer rotor Standard
I-‘---- -.----,
clearance mm (in) Maximum 0.20 (0.0078)
Outer rotor to body clearance mm (in) Standard 0.09-0.18 (0.0035-0.0071)
Maximum 0.22 (0.0087)
Side clearance mm (in) Standard 0.03-0.11 (O.pniq n nnn=’
Maximum n4rl ‘-
“” I r-“.““+..I,
I “. I ‘t (U.0055)
I
1
Oil filter
_ Type
Relief pressure differential
Engine oil
I
Capacity
liters (US qt, Imp qt)
Grade
I Viscosity Full-flow, paper element
kPa (kg/cm’, psi) 1 78-l 18 (0.8-I .2, 1 l-l 7) Tntal /An, nnr*inol 3.4 (3.6, 3.0) 1 4.0 (4.2, 3.5)
3.0 (3.2, 2.6) 1 3.6 (3.8, 3.2)
VII 111Lb1 0.17 (0.18, 0.15)
API Service SG Energy Conserving II (ECQ
1
SA!f InW-Xl 1~ Above -25% (-13OF _ .-.. --
I
I
number
1 Below O’C (32OF) SAE 5W-30
1
E. COOLING SYSTEM
Cooling method EnginelTransaxle
MTX ] ATX 1 MTXl
Water-cooled, forced circulation
J B6 SOHC BP SOHC BP DOHC
, ATX 1 MTX ) ATX
LThermostat
Type Opening temperature
Full-open temperature
Full-open lift
Radiator
_ Type
Cap valve opening pressure
Cooling circuit checking pressure Wax, two-stage
“C (OF) Sub: 83.5-86.5 (182--188), Main: 86.5-89.5 (188-193)
OC (OF) 100 (212)
mm (in) Sub: 1.5 (0.06) min., Main: 8.0 (0.31) min.
Corrugated fin
kPa (kg/cm2, psi) 74-103 (0.75-1.05, 11-15)
kPa (kg/cm’, psi) 103 (1.05, 15)
~..
Cooling fan
Type Electric .-
Number of blades 4
_.---- _I___-
Outer diameter mm (in) 320 (12.6)
--_ ~~-
Capacity w-v 80-12 - 160-12 80-l 2 160-12
6.6 Hi : 13.3
6.6 Hi : 13.3
Current A
Low : 8.8 Low : 8.8
_------ ._____
Water thermoswitch
“c (OF) 1
OFF-ON 97 (207)
I--.
Radiator thermoswitch
__-I____-
OFF+ON “C (OF) 1 1105 (221)( - (105 (221)
TD-8

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

SPECIAL TOOLS ST
CHECKER AND OTHER EQUIPMENT (CONT’D)
49 9200 162
Monitor, engine
49 GO18 903
Adapter harness
49 GO18 904
Sheet (Engine
49 HO18 9Al
49 B019 9AO
System selector TOOL NUMBER
L DESCRIPTION PRIORITY ILLUSTRATION
19 BO19 9Al
X-AT selector
EC-AT tester) A .
19 B019 908
larness, adapter A
;EC-AT tester)
49 FO18 002
Igniter checker A
49 NO18 001
Adapter harness A
(igniter checker)
49 0305 870A
Tool set, window A
ST-l 1

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

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)

Terminal vdt
wminal lrput
1A -
1B 0
-
1C 0
1D e (ATX) ve: aattefy voltage
1
Connected to
I Test wndition ~cwrect rc4t.gej F&W*
-
0
-
-
3attery
Uain r&y
:FUEL INJ relay) Constant
tgnition swdch V% For backt@
OFF ov
ON V6
Ignition swtch
(START)
Self-Diagnosis
Checker
[monitor lamp)
3 - White crankii npprox 1ov
fgnition switch ON ov
Test swtch at “SELF-TEST’ With Self-
Lamp illuminated for 3 sec. after igmtmn 4.5-5.w Diagnosis Check-
switch OFF-+ON er and System
Selector
Lamp net illuminated after 3 Sec. VS
Test swtch at “02 MONITOR” at idle
i Monitor lamp illuminated 4.5-55v
Test switch at “02 MONtTOR” at idfe
Monitor lamp not illuminated
Malfunction indicator
lamp illuminated for 3 sec. after ignition
Below 2 5v With System
lalllp switch OFF+ON selector test
WLI switch at
Lamp not luminated after 3 sec. VE
“SELF-TEST”
lamp ifluminated BelOW 2.w
Lamp not illuminated VS
Self-Diagnosis Buzzer sounded for 3 sec. after ignrtion
l With Self-
Checker switch OFF-+ON Below 2.5V
Diagm!3s
(code number) Checker and
Buzzer not sounded after 3 set VB
system
Select0 Buzzer sou&?d Below 2 5v l With System
Selector test
I Buzzer not sounded
tgmter Ignition switch ON ov
Idle Appror 0 2v -
Headlight switch Headlights ON
f VB
-
Headlbhts OFF ! ov
Diagnosis
connector
, System Selector test switch at
VS Ignition witch
“02 MONITOR” ON
(TEN terminal)
Rear window
defroster switch
Ground Icalifornia) System Selector tesf switch at
“SELF-TEST”
Rear window defroster watch OFF
Rear window de!roster watch ON
ConSlant QV
ov lgmhon switch
__ ON
VO
ov
- Main relay (canadal fgmtion switch ON VB
AC relay Ignitiin switch ON VB
A/C switch ON at Idle Below 2.5% -
Vehicle speed A/C switch OFF at Gle
/ Vehicle stopped
P/S pressure
switch lgmhon switch ON
P/S ON at idle Iturnino)
I.
P/S OFF at idle I VB Terminal voltage v‘s: Battery vottage
I I
1
Terminal input Output Connected to Test condition comcl voltage Remark
10
0 A/C swatch AIC switch ON Befow25V ignition switch
ON and blower
A/C switch OFF VB I
motor ON
IP
ii Blower control Blower control swtch OFF or 1 St poSItion VB tgnibon switch
switch ON
Blower control switch 2nd or higher
ov
position
1Q
0 Stopltght switch Brake pedal released Below 1 ov
-
IT <; Brake pedal depressed VE
lnhtbitor switch N or P range ov Ignition switch
(P N range) ON
Other ranges VB
Cruise control man Set or Resume swtch ON or vehicle speed lgmhon swtch
switch 8kmih &mph) lower than preset speed &tow 1 5~ ON
(Drwng vehcfe crwse cantrol
OperatiOn)
Fk
z 1v -
3A ’ Throttle Sensor
(Idle switch) Normal conditions
Accelerator pedal released
Accelerator pedal depressed “8
Bebw 1 ov lgnihon swatch
ON
VS
I -
-
- - -
-
-
- - -
D&rib&r
-‘. / b / / (Ne-signal) lgmtion swtch ON
/ ,,,, Approx. OV
or 5v
-
Approx 2v
I ._.
/
28 1
AdlOw meter lgmhon switch ON
Approx 3 BV .,
-
Idle Approx 3 3V
2c j r:
I \’ oxygen sensor fgmtson switch ON ov
1
20 Idle (cold englIIei
Idle (after warn-up)
lncreasma enwe speed (after warm-up) ov
O-l ov -
0 w-1 .ov
_ -
,
Deceleration o-o 4v
Coolmg fan swtch Fan operahng (engine coolant temperature
over 97°C (207’F) or diagnosis connector DV
termmat TFA grounded) -
Fan not operatmg (idle)
Water thermosensor Engine codant temperature L” %, I”” I , ‘Y”8’.“” . . . ...-1.
After warm-up
I
Thrnttb SP”SOi 1 Accelerator pedal released Approx 0.5V
2G .._..._ --..--
-
Accelerator pedal fully depressed Approx. 4 OV
0 ATF thermosensor -XPC (-2o”~)--1x1~c (302°F) aprxox as5-~m lgmhon swtch
ON
ATF temp 20°C (68°F) Approx. 4.6V
13OOC (266°F) Aporox 1.54V
I I I I I I
2H / i, I / Hold switch Hold mode Below 2V Ingbhon switch
Normal mode