ignition MAZDA PROTEGE 1992 Workshop Manual

TROUBLESHOOTING GUIDE U
I 23UOUX-01
03UOUX-02
Step 5 Measure voltage at refrigerant pressure switch
No.1
Measure the voltage at the following terminal wires of the
refrigerant pressure switch No. 1 connector.
VB: Battery voltage
Wire
WV
W-) Voltage Action
V0 Repair wire (B/R)
ov Next check wire (B/L)
VB Go to Step 6
ov Repair wire (B/L)
Step 6 Measure refrigerant pressure
1. Turn the ignition switch OFF.
2. Connect the high-pressure hose of the manifold gauge to
the high-pressure gauge fitting.
3. Measure the refrigerant pressure at the high-pressure side.
High-pressure side:
Above 451 kPa (4.6 kg/cm2, 65 psi)
4. If not as specified, check the refrigerant system by refer-
ring to the troubleshooting information on page U-14.
5. If correct, replace refrigerant pressure switch No.2 with cool-
er pipe No.2. (Refer to page U-54.)
23UOUX-014
U-l 1

AIR CONDITIONER U
REFRIGERANT PRESSURE
2.0 f 0.2 kg/cm* 27 f 2 kg/cm’
4.1 f 0.5 kg/cm* 21 * 4 kg/cm*
03uoux-09
9
23UOUX-050
REFRIGERANT PRESSURE SWITCH No.1
Inspection
1. Turn the ignition switch OFF.
2. Connect the manifold gauge set and measure the high-
pressure side refrigerant pressure.
High-pressure side:
Above 451 kPa (4.6 kg/cm2, 65 psi)
3. If not as specified, check the refrigerant system, referring
to the troubleshooting information on page U-14.
4. If correct, go to the next step.
5. Disconnect the refrigerant pressure switch No.1 connector.
6. Check for continuity of the switch.
Terminals
1 Continuity
a-b
Yes I
7. If not as specified, replace the switch together with cooler
pipe No.2. (Refer to page U-54.)
Note
l If problems occur in the refrigeration system, caus-
ing abnormally high (above 2,649 SL: 196 kPa [27 f
2 kg/cm2, 384 f 28 PSI]) or low (below 196 f 20
kPa [2.0 f 0.2 kg/cm2, 28 & 2.8 psi]) pressures,
refrigerant pressure switch No.1 cuts power to the
magnetic clutch to protect the mechanical compo-
nents. If the pressure recovers to within normal
operating range (below 2,080 f 392 kPa [21 f 4
kg/cm2, 299 f 57 psi] or above 402 f. 49 kPa t4.1
f 0.5 kg/cm2, 58 f 7 psi]), the power is again re-
stored.
REFRIGERANT PRESSURE SWITCH No.2
(BP ENGINE WITH ATX)
Inspection
1. Turn the ignition switch OFF.
2. Connect the manifold gauge set and measure the high-
pressure side refrigerant pressure.
High-pressure side:
below 1,177 kPa (12 kg/cm2, 171 psi)
3. Disconnect the refrigerant pressure switch No.2 connector.
4. Check continuity of the switch.
Terminals
a-b I Continuity
No
5. If not as specified, replace the switch together with cooler
pipe No.2. (Refer to page U-54.)
6. If correct, go to next stop.
u-55

TECHNICAL DATA TD
Item
Coolant Engine/Transaxle B6 SOHC BP SOHC BP DOHC
MTX 1 ATX 1 MTX 1 ATX 1 MTX 1 ATX
Capacity
liters tus qt, Imp qt) (5Z.4) (8.E.3) (5&4) (SE.3) (5.?i.4) (S.E.3)
Coolant protection Volume percentage %
Specific gravity at
Water Coolant 20% (68OF)
Antifreeze solution Above -16OC (3OF)
65 35 1.054
Above -26OC (-15OF) 55 45 1.066
I Above -4OOC (-40°F) 45 55
1.078
F. FUEL AND EMISSION CONTROL SYSTEMS Item
idle speed*‘**
Ignition timing** Fuel pump
Maximum output pressure Fuel filter Engine
B6 SOHC BP SOHC BP DOHC
vm 700-800
BTDC 6O--8O 4O---6O 90-l 10
kPa (kg/cm*, psi) 1 441-637 (4.5-6.5, 64-92) ‘Type
Low-pressure side Nylon element (in fuel pump)
High-pressure side Paper element Pressure regulator
Regulating pressure kPa (kg/cm*, psi) 1 265-314 (2.7-3.2, 38-46) Injector
Type
High-ohmic
Type of drive Electromechanical
Resistance n 12-16 Idle speed control (ISC) valve
Type
Rotary
Resistance n ] 11-13 Purge control solenoid valve
Resistance n 1 23-27 Water thermosensor
-20°C( -4OF) 14.6-17.8
Resistance k6 20°C( 68QF) 2.21-2.69
40% (104OF) 1.0-l .3
80°C(1760F) 0.29-0.35 Airflow meter
E2++Vs Fully closed 20-600 q D Fully open 20-l ,000
E~HVC 200-400
Resistance g Ez++THAA -2O%(-4OF) 13,600-18,400
(Intake air 20%( 68OF) 2,210-2,690
thermosensor)
60°C(1400F) 493-667
Eic*Fc Fully closed 00
Fully open 0 Fuel tank
Capacity liters (US gal, Imp gal) I
Hatchback 50 (13.2, 11.0) PROTEGE . . . . 55 (14.5, 12.1) Air cleaner
Element type Oil permeated Fuel
Specification Unleaded regular (RON 91 or higher)
*’ With parking brake applied (Canada)
*’ TEN terminal of diagnosis connector grounded
TD-9

TD TECHNICAL DATA
G. ENGINE ELECTRICAL SYSTEM
3attery Dark
current*’
Alternator 86 SOHC BP SOHC
I BP DOHC
MTX 1 ATX 1 MTX 1 ATX
Voltage V 12
Type and capacity (20-hour rate) 55D23L (60AH) 1 55D23L (60AH)
mA Max. 20.0
Type A.C
output V-A 12-65
Regulator type Transistorized (built-in IC regulator)
Regulated voltage V 14.1-14.7
Brush length Standard 21.5 (0.846)
mm (in) Minimum 8.0 (0.315)
Drive belt deflection
New 8-Q (0.31-0.35)
;riL’F,i Used Q-10 (0.35-0.39)
Coaxial
Type Direct Direct Coaxial
reduction Direct
reductior
Starter output V-kW 12-0.85 12-0.95 12-1.4 12-0.95 12-1.4
Brush length Standard 17 (0.67) 17 (0.67) 17.5 (0.69) 17 (0.67) 17.5 (0.69
mm (in) Minimum 11.5 (0.453) 11.5 (0.453) 10.0 (0.39) 11.5 (0.453) 10.0 (0.39
Distributor Electronic spark advance (photo diode)
Ignition timing BTDC
(TEN terminal of diagnosis connector grounded) 6O-8O 4O-6O 9”-11 O
Ignition coil Resistance Primary coil winding 0.81 -O.QQg
(at 20% [68OF]) Secondary coil winding lo-16 kg
SK&E-1 1 BKR5E-11
NGK
BKRGE-11 BKRGE-11
BKR7E-11
Spark plug Type
NIPPONDENSO KlGPR-Ull
K20PRUll KlGPR-Ull
K20PRUll
K22PRUll *:
. Plug gap
Firing order mm (in) 1.0-l .l (0.039-0.043)
l-3-4-2
---
’ Dark current is the constant flow of current while the ignition switch IS UFF.
(i.e engine control unit, audio, etc.) ..-
._*
T&l 0

PARTS INDEX
I
CRANKSHAFT.. ....................................
I31 -64
CYLINDER BLOCK .............................. 61-60
CYLINDER HEAD..
............................... 81-54
CYLINDER HEAD GASKET .................
Bl-16
DRIVE BELT(S). ...................................... 81-5
FRONT OIL SEAL ................................ 81-23
HLA .............................................. Bl-7,20,60
OIL JET ................................................ 81-61
PISTON.. ...............................................
Bl-62
PISTON PIN..
........................................ 81-62
PISTON RING
....................................... 81-62
REAR
OIL SEAL..
................................. 81-25
TENSIONER, IDLER ............................. Bl-65
TENSIONER
SPRING ...........................
Bl-65
TIMING BELT ..................................
Bl-12,65
TIMING BELT PULLEY ........................
Bl-65
VALVE MECHANISM ........................... Bl-55
ENGINE
(BP DOHC) .................................... B2-2
CAMSHAFT ..........................................
82-58
CAMSHAFT PULLEY ...........................
B2-65
CONNECTING ROD..
........................... 82-63
CRANKSHAFT ......................................
B2-64
CYLINDER BLOCK ..............................
82-60
CYLINDER
HEAD.. ............................... B2-54
CYLINDER HEAD GASKET .................
82-16
DRIVE
BELTS.. .......................................
B2-5
FRONT
OIL SEAL ................................
82-26
H LA ..............................................
OIL JET .......................... B2-7iyL;;
......................
PISTON .................................................
B2-62
PISTON PIN ..........................................
82-62
PISTON RING..
..................................... 82-62
REAR OIL SEAL ................................... B2-28
TENSIONER, IDLER ............................. B2-65
TENSIONER SPRING ........................... B2-65
TIMING
BELT.. ................................
B2-12,65
TIMING BELT PULLEY ........................ 82-65
VALVE MECHANISM ........................... 82-55
ENGINE CONTROL UNIT (ECU) ............... F-149
ENGINE COOLANT
........................................ E-5
ENGINE OIL.. .................................................
D-7
ENGINE OIL FILTER.. .................................... D-8
’ EXHAUST SYSTEM. ...................................
F-136
EXTRACTOR CHAMBER .............................. S-53
F
FAN MOTOR (COOLING FAN). ................... E-14
FAN RELAY (COOLING FAN). ..................... E-18
FLASHER UNIT ............................................
T-17
FLOORMAT ..................................................
S-99
FLYWHEEL ..................................................
H-18
FRONT AXLE .................................................
M-4
FRONT BRAKE ............................................
P-l 8
FRONT BUMPER ......................................... S-39
FRONT DOOR ................................................
S-8
FRONT DOOR LOCK AND OPENER ..........
S-13
PI-2
FRONT FENDER PANEL ............................... S-7
FRONT LOWER ARM .................................. R-16
FRONT SHOCK ABSORBER AND SPRING R-11
FRONT SIDE WINDOW REGULATOR AND
GLASS ........................................................ S-10
FRONT STABILIZER..
................................... R-l 8
FRONT SUSPENSION .................................. R-l 0
FUEL FILLER LID AND OPENER..
.............. S-37
FUEL FILTER .............................................. F-l 24
FUEL GAUGE SENDER UNIT ..................... T-73
FUEL PUMP ............................................... F-125
FUEL TANK
................................................ F-123
FUSE AND JOINT BOX.. .............................. T-12
H
HEADLIGHT AND
FRONT COMBINATION LIGHT..
................ T-41
HEADLIGHT RELAY ..................................... T-l 8
HEADLINER ................................................. S-89
HEATER CONTROL UNIT.. ......................... U-26
HEATER UNIT
.............................................. U-21
HIGH-MOUNT STOPLIGHT
.......................... T-45
HIGH-TENSION LEAD ................................. G-l 7
HOOD ............................................................. S-5
HORN T-88
...........................................................
HORN RELAY
.......................................... T-18,88
.__. ’
I I
IGNITER .......................................................
G-23
IGNITION COIL.. .......................................... G-19
INJECTOR .................................................. F-l 31
INSTRUMENT CLUSTER
AND SPEEDOMETER CABLE
.................... T-69
INTAKE MANIFOLD ................................... F-113
INTERIOR LAMP ..................................... T-52,53
ISC VALVE.. ................................................ F-l 16
J
JOINT SHAFT (FRONT AXLE) .................... M-18
L
LATERAL LINK AND TRAILING LINK.. ....... R-26
LICENSE PLATE LIGHT.. ............................. T-47
i
M
I
---
MAIN RELAY (FUEL INJ. RELAY). ............ F-172
MANUAL STEERING ..................................... N-4
MANUAL TRANSAXLE (F5M-R). .................. Jl-2

Z
SYSTEM INDEX
System Section System Section
AUDIO SYSTEM ......................................................... J
BACK-UP LIGHTS ...................................................
F-3
CHARGING SYSTEM ............................................... A-2
CIGARETTE LIGHTER ............................................... I-1
COMMON CONNECTOR LIST ..................................... X
COOLING FAN SYSTEM ....................................... B-3.4
COURTESY LAMPS .................................................. l-3
CRUISE CONTROL SYSTEM ...................................... Q
DAYTIME RUNNING UGHTS .................................... E-3
DIAGNOSIS CONNECTOR .......................................... U
DIGITAL CLOCK ....................................................... l-l
ELECTRICAL WIRING SCHEMATIC ............................. W
ENGINE CONTROL SYSTEM (MT) ................. B-l a, 1 b, 1 c
ENGINE 8 EC-AT CONTROL
SYSTEM (EC-AT) ...................................... B-2a,2b,2c
GENERAL INFORMATION .......................................... GI
GROUND POINT ........................................................ Y
HEADLIGHTS ....................................................... E-l ,2
HEATER 8 AIR CONDITIONER .................................... G
HORN .................................................................... F-3
IGNITION KEY CYLINDER LAMP ............................... l-2
ILLUMINATION LAMPS .............................................
l-4
INSTRUMENT CLUSTER . WARNING LAMPS .............. C INTER CONNECTING OF JOINT BOX ......................... JB
INTERIOR LAMP ...................................................... l-2
JOINT BOX .............................................................. JB
LICENSE PLATE UGHTS ......................................... E-4
PARTS INDEX ........................................................... PI
PARTS LOCATION ................................................... PL
PASSIVE SHOULDER BELT CONTROL SYSTEM .......... S
POSITION LIGHTS ................................................... E-4
POWER DOOR LOCK ............................................. K-2
POWER OUTSIDE MIRROR ......................................... L
POWER WINDOW ................................................... K-l
REAR SIDE MARKER LIGHTS.. ................................. E-4
REAR WINDOW DEFROSTER .................................... I-1
REAR WIPER 8 WASHER ........................................ D-3
SHIFT-LOCK SYSTEM ................................................ H
SLIDING SUNROOF ................................................... M
SOUND WARNING SYSTEM ...................................... l-2
STARTING SYSTEM ................................................ A-l
STOPLIGHTS .......................................................... F-2
TAILLIGHTS ............................................................ E-4
TRUNK COMPARTMENT LAMP ................................. l-3
TURN 8 HAZARD FLASHER UGHTS ......................... F-l
WINDSHIELD WIPER 8 WASHER .......................... D-l ,2

Z-Gl-4 Reading Wiring Diagrams
System circuit diagram/connector diagram
l These show the circuits for each system, from the power supply to the ground. The power supply side
is on the upper part of the page, the ground side on the lower part. The diagrams describe circuits with
the ignition switch off.
Below is an explanation of the various points in the diagram.
) Indicates operating conditions for switches.
The prefix letter indicates the system in which
:he connector is used.
JB: Joint box connections
X : Common connectors
A : Charging system/starting system
connectors
B : Engine control system connectors
C : Gauge control system connectors
D : Wiper system connectors
E : Lighting system connectors
F : Signal system connectors
G : Air-conditioning system connectors
H : Transmission control system
connectors
I : Interior lamp system connectors
J : Audio/radio connectors
K : Power window/power door lock system
connectors
L : Remote control mirror system
connectors
M : Sliding sunroof system connectors
N : Power steering/4-wheel steering
system connectors
0 : Anti-lock brake system connectors
P : Power seat/seat heater system
connectors
Cl : Auto cruise control system connectors
R : Auto adjusting suspension system
connectors
S : Passive shoulder belt control/air bag
system connectors
T : Others
Y : Ground connector
- .
1

\\‘
IGNITION SYSTEM l ENGINE CONTROL 9 harness ground is represented differently
:han a unit ground.
Types of grounds Symbol
Harness
I
-
-
-
-
‘“G:
si-
P
7:’
.I
I
I
.i
-
-
-
f
9
Tiii
zs
LL
Y
a
EE
-

Reading Wiring Diagrams Z-GI-9
Symbol ‘ Meaning Symbol Meaning
Horn l Generates sound when current flows. Switch (1) l Allows or breaks current flow by
opening and closing circuits.
Speaker
w
Heater l Generates heat when current flows. Normally open (NO)
Switch (2)
Normally closed (NC)
Harness l Unconnected intersecting harness.
Speed sensor l Movement of magnet in speedometer
set turns contact within sensor on and
Off. (Not connected)
l Connected intersecting harness.
Ignition switch @Turning ignition key operates switch
contacts to complete various circuits.
(Connected)
rlormally open (NO)
Relay (1) l Current flowing through coil produces electromagnetic force causing contact to open or close.
____- .~.~~
Open Closed
--.--.-m.---------,
Relay (2) Normally open relay (NO)
- Ri i No flow ’ ni 1 Closed
Normally closed relay (NC) Flow
ormally closed (NC)
Sensor (variable) l Resistor whose resistance changes Diode
l Known as a semiconductor rectifier.
--3p6G- with operation of other components. diode allows current flow in one
direction only
--T- IA
IY Calhode(K)+- Anode(A)
* Flow of electric current
K-1 KD, he>:
-
ensor (thermistor)
l Resistor whose resistance changes Light emitting diode 0 Diode that lights when current flows
with temperature.
(LED)
l Unlike ordinary light bulbs, diode does
not generate heat when lit
Capacitor
l Component that temporarily stores “2, Cathode(K) --&---Anode(A)
I7
Cathode(K)
electrical charge.
c Anode(A)
----il---- .
Flow of electric current
Solenoid
l Current flowing through co11 generates Reference(zener) l Allows current to flow In one dlrectlon
electromagnetic force to operate diode up to a certain voltage. allows current
plungers, etc. cd to flow In other dIrectron once that
J-
voltage IS exceeded.
z-9

Z-GI-10 Reading Wiring Diagrams
Logic symbols
‘ypes of logic symbols Operation Expressing output Simple relay circuits
OR Input to A or 6 will Low electrical potential (L) at A and B --,
produce output at C No output (L) at C
High electrical potential (H) at A or B -+ A
A
ID- C Output (H) at C
EB Q-f2 c
B B
AND Input to A and B will High electrical potential (H) at A and B -+
produce output at C Output (H) at C
A _
A
El-- Low electrical potential (L) at A or B -+
B C
No output (L) at C
B
II!I3 Q-00-Q
C
INV No input to A will produce Low electrical potential (L) at A +
an output at B
Ungrounds (H) B
-b- Input to A will not produce High electrical potential (H) at A +
A B
any output at B Grounds (L) B A-
El
PROCESS Simplified representation of complex functions within circuit Describes (Examples)
main function
Breakerless transistor
---
-I- 1 1 Signal detector for emission control unit, cooling unit and
I igniters
- ~._..._...._._..._._..__,
--L--A tachometer
P.Signal converter for turn and hazard flasher unit,breakerless : siinalcon”elter :
i..-.--...-.........---i
transistor igniter unit, etc. --j CoIlsignal ConVerted e
--I. .‘p. Y?YT?!!9’. . _ i
Abbreviations used in this booklet
A
%J Ampere
Auto Stop
Air Supply Valve
A/C AAS
Air Conditioner Auto Adjusting Suspension
A/F Air Fuel ABS
AIR Anti-lock Brake System
Auto Reverse
A/T ACV
Automatic Transmission
ACC Air Control Vafve
Acc%K4tIory
ACCEL Accelerator
ADD AE
Additional Acoustic Equilibration
ALT Alternator
EP AIS
Amplitude Modulation Air Injection System
Amplifier ALL
ANT Antenna Automatic Load Levelino
ATP Atmospheric Pressure
ATX Automatic Tmnsaxle FR Fmnt Right ELI?
FIB Feedback
F/I Fuel Injector Emergency Locking Retractor
EN ELEC Electric
Frequency Modulation
Generator
HEI Electronic Tuner
Hiih Energy lgnitiin
HID K!
Heat/Defmster
HEAT Heater Exhaust
HI Hiih F
ISC Front
Idk Speed Contml
IG Ignition
ILLUMI Illumination FICB
INT Intermittent FL Fast Idle Cam Breaker
Fmnt Left
JB
LH Joint Box
Left Hand
:AC Battery
Bypass Air Control Valve
B/L Ei-Level
CPU Central Pmcessing Unit
CSD COM start Device
CARB Carburator
CCT Circuit
CIGAR Cigarette
COMBI Combination
CON Conditioner
CONT Control
DOHC Double Overhead Camshaft
DEF Defroster
ECPS Electronicalfy Controlfed Power
Steering
EGI Electronic Gasoline Injection
EGR Exhaust Gas Recirculation LCD Liquid Crystal Display
:i Low
Low Wave
/IL Motor
MaWunction Indicator Lamp
MTR Mechanical Tuning Radio
Mrr Manual Transmission
MID Mkfdk,
MIN Minute
MIX
MiXtUt MPX Mukiplex
MTX Manual Transaxte
K Middle Wave
Normalty Closed
too Normally Open
Over Drive
OFF Switch Off ON
FRCV
PTC
P/S
PRG
ass
ii:
RPM
EC
SOL
ST
Et TCV
TICS
TEMP
ES
V
VRIS
VENT
VOL
W Switch On
Power
Pressure Regulator Control
Solenoid Valve
Positiie Temperature
Coefficiint Heater
Power Steering
Purge Solenoid Vahe
Quick Start System
Rear
Riiht Hand
Rear Left
Revolution Per Minute
Rear Right
Recirculation
Solenoid
Start
Short Wave
Switch
~;eScml Turbocharger Solenoid
Triple Induction Control System
Temperature
Transistor
Total Wiring System
volt
Variable Resonance Induction
System
Ventilation
Volume
Wan

Troubleshootina Z-GM 1
Precautions when servicing electrical system
l Note the following items when servicing the electrical system.
l Do not alter the wiring or electrical equipment in any way as this may damage the vehicle or cause a fire
due to shorting or overcapacity of a circuit.
l Always disconnect the negative (- ) battery cable first and 0 Replace blown fuses with ones having the same designated
reconnect It last when disconnecting the battery. capacity.
1OA
15A
Zaution
l Be sure that the ignition and other switches are OFF
before disconnecting or connecting the battery
terminals.
Failure to do so may damage the semi-conductor
components. Caution l Replacing a fuse with one of a larger capacity than
designated may damage components or cause an electrical
fire.
l Secure harnesses with a clamp when provided to take Up l Tape areas of the
a Be sure that the harness
any slack. harness that may rub or
is not caught or damaged
bump against sharp
when mounting
edges to protect it from
components.
damage.
Caution
l Clamp all harnesses near vibrating components(e.g.
the engine) to remove any slack and prevent Contact
due to vibration.
l Do not handle roughly or drop electrical components.
l Disconnect heat sensitive
parts (e.g. relays, ECU)
when performing
maintenance where
temperatures may exceed l Make sure that the
connectors are securely
connected when
installed.
80°C (176°F) (i.e.welding).
oid