ignition MAZDA PROTEGE 1992 Workshop Manual

Troubleshooting Z-Gl-13
el
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31
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Usina electrical test eaubment -----w - I - Equipment Use Operation Handling precautions
Test lamp Test for locating open or shorted l Connect the test lamp
0 Test lamps use 12V 1.4 or
R circuits. between the circuit being
3.4W bulbs or light- emitting
measured and a ground.
diodes (LED). Using a large
*The
lamp will light if the circuit
capacity bulb may damage the
is energized to the point
CPU.
,.WD,.l
b tested.
Jumper wire
Used to create a temporary l Connect the jumper wire 0 Do not connect the power side
circuit. between the terminals of a directly to a ground as this
circuit to bypass a switch, etc. may burn the harness or
damage electrical
/d<;>‘-
d components.
I
n
Voltmeter
Used for measuring the voltage
l Connect the positive (+) lead l Connect the voltmeter In
of a circuit to locate possible to where voltage is to be parallel with the circuit.
opens or shorts. measured and the negative
0 Set the range to the desired
(- ) lead to a ground. voltage.
l Use the service hole when
measuring the voltage at the
diagnosis connector.
~Tie a thin wire to the posrtive
(+) lead to access narrow
terminals.
Ohmmeter
Ammeter Used for locating opens and
l Zero the ohmmeter. *Zero the meter after switching
shorts in the circuit, confirming
I to the measuring range.
continuity of switches and
checking sensor resistance. &.--
l Before using the ohmmeter,
make sure that the ignition
l Verify that current is not switch is OFF or the negative
flowing through the circuit. (- ) battery cable is
0 Touch the leads to the check disconnected to prevent
points.* burning the ohmmeter.
Used for checking alternator
l Connect the ammeter in l Set the range to the desired
output, current supplied to the series with the circuit by
voltage.
starter, and dark current within a touching the positive (+) lead
l Connect the ammeter in series
circuit. to the power side terminal and
with the circuit. The ammeter
the negative (- ) lead to the
may be burned If it is
Note ground- side terminal.
connected in parallel.
Dark current is the current
flowing through the circuit when
the Ignition switch is OFF.

Z-GM 4 Troubleshooting
Measuring voltage
, ’
Battery
(positive te;minal) lgnitipn switch
Voltmeter
Fuse
Motor Therm0
switch
+ r-
Ground 2 Ground 1
I
!I4 aD
0 0
Test lamp
or
f
“J-
1. Use a Voltmeter or &St lamp to ascertain voltage at the
measuring points.
Circuit operation
Measur-
ing points Ignitio&Gtch: Ignition switch:ON
Thermo switch: Thermo switch:
OFF ON
@ ov x 12v ‘6 12v
‘6
a ov x 12v ~6 ov
X
c ov x ov x ov X
B: 12v ‘6 12v ‘6 12v ~‘. 0
cc ov x ov X 12v .’ 0
@ ov x ov x ov X
‘b’ : Test lamp ON
x : Test lamp OFF
neasuring voltage of connectors Poor contact
A voltmeter lead may momentarily connect a terminal when
inserted into the connector and give an erroneous reading
when checking for rmproperly engaged connectors, poor
terminal contacts, or loose terminals.
Voltmeter lead
Measuring voltage of ground unit
Touch the voltmeter lead to the ground wire when checking
the ground circuit.
Poor contact

II-GM6 Troubleshooting
Finding short circuits
Shorts occur between the power(positive) and ground(negative) sides of a circuit.
Therefore, finding a shdit circuit requires determining how the circuit is routed.
Circuits not connected to control unit
Examples
Indication
0 Fuse melts. Finding short circuit
0
Test lamp 1. Remove the fuse and
main fuse of the circurt.
2. Disconnect all connectors
of electrical components
in the circuit.
3. Attach a voltmeter or test
lamp to the fuse box and
reconnect each
connector, beginning
nearest the power
source.
4. Check the voltmeter or
see if the test lamp lights
as the connectors are
connected. Finding short circuit
,,{:““o
1. Remove the fuse and main
fuse of the circuit.
2. Disconnect all connectors of
/ electrical components in the
circuit.
Test lamp 3. Attach a voltmeter or test
lamp to the fuse box and
reconnect each connector,
beginning nearest the power
4. Check the voltmeter or see
if the test lamp lights as the
connectors are connected.
Sensor/switch
1. Attach the test lamp or
voltmeter to the CPU
connector.
2. Connect to the swrtch/
sensor connector.
3. Check the voltmeter or see
if the test lamp lights.
A short has occurred where voltmeter
reads OV or the test lamp goes out,
- Short location
Battery Short (A)
l Main fuse melts.
L* Short(B)
0 The motor operates regardless
of whether thermoswitch ON
or OFF when the ignition
switch is ON. Short (C)
lotor
M
P The-
tmo-
switc *The fuse is not melted.
@The main fuse melts when the
ignition switch and thermo-
switch are ON and the relay is
operating. Short (D)
Circuits connected to control unit
-T Examples
Indication
l Fuse melts.
- Short locatior
I
ignition switch
I
Fuse R-l Short (A)
J+L--l
Short (A) l Solenoid A operates normally
when the ignition switch is
ON.
9enold m rfr solenok
;<
A) u a(B) ’ Short (6)
l The CPU transistor burns out
when the ignition switch is
turned ON. Short (C)
l The CPU thinks the switch is
ON because the same
conditions exist as when the
switch is ON.
*The CPU senses the sensor
to be 0 R because the
conditions exist as when
resistance value is 0 R
*The CPU equipped with the
self-diagnosis function output
the malfunctron code. Short (0)
Swltcl1 ml
Short (E) Z-16

kll?lNQ MAQRAY
EGI MT l ENGINE CONTROL SYSTEM (l/3)
30A
STARTING
SYSTEM
(SECTION A-
MAIN
RELAY
[FUEL
INJ)
: 1
Ix-181
-W/R [EM) ENGINE CONTRO- UNIT
v (EM) --------+ lc
1G
IB
- LG (EM) 81-01 ~~=~~~===~T-~-~~~---~~--------------------------~--
I I I
FL% A
a
I SHIELD I
WIRE :
/ 1 WATFJ
DIAGNOSIS CONNECTOR
(SECTION u)
!I-01 ENGINE CONTROL UNIT (EM) 81-02 MAIN RELAY iE) 81-03 CIRCUIT OPENING
1” IS 10 ID ,M 1K II IG 1E IC IA 2~ 2~ 2~ 25 20 20 2~ 2K 21 2G 2E 2C 2A (FUEL INJ) RELAY (EM)
)t LG/Y X G/W Y/0 v L/R * L/O Y < x LG/R * x /LG B/O
R/Y B/L B/G L/y R/W (‘;“’ L/B t W/B W/Y W/R x W/L Y/B G/O * R/B R/L LG/W * “;’ * /BP B/O
I” IT 1R IP IN IL lJ 1H IF ID 16 2L 2X 2” 27 2R 2P 2N 2L 2J 2H 2F 20 28
II -04 FUEL TANK UNIT [RI Bl-05 IGNITER (EM) Bl-06 CONDENSER (EM) 81-07 IGNITION COIL (EM) ~1-08 OXYGEN SENSOR (EM)
~~~ (w] (jj (JJD @
Z-26

“.w- MIM . FRONT- ENGINE - REAR - - __._ -._.- -.~ -~ ~.. .-_.--_* . . . . . -...-- --
- WIRING DIAGRAM
IGNITION COIL
IA-VI/ FUSE BOX FUSE BOX
Bl-02
MAIN RELAY
(FUEL INJ)
JOINT BOX
I h
(_an&=y “t Ix-16j
I- 323 HATCHBACH
h-s* A,- (WW
JB-06 DI-U3 . dl, u=nE)
I
IGNITER (GRAY) 4b

s/JB-04 B&M
FUEL TANK “NIT
JOINT
CONNECTOR
A - Bl-01
\W\“ A Bl -03 /
JO& BOX
(F)-o /x-o! (BucI() (F)-(EM) w PROTEGii
Z-27

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)

VE Batmy voltage
1 Ve: Battery vm
i
Remark
Termfnal Input Output Connection lo
Test conditkm
colmct voltage Remark
2W
0 Iscvalve lgmtian swdch ON
Approx. iv
-
Idle Appror. 9v
2x
0 Solenoid valve
lgnitlon switch ON
VS
(Purge control) -
IUk
VB
2Y - - -
-
-
@i switch
)N le
I!
C
4
-C
,
,
e
”
3
-C
.
f
-
-
-
)nition switch
)N I I I
I I
I -
22 - - -
- -
-
-
-
luilt in airflow
1eter
lnition swttch
)N
-
VICS: Vata&
Inertia charging
SYStem loaHCl
-
Engine Signal
Monitor: Green
and red lamps
flash
mnin
2H
- I Main relay (w=w I Ignition switch ON
VB
_/I/ - I -
I - 21
25
-7 I - I -
I - , I t 0 Air-flow meter constant
4.5-5.5v 2K
I I I
I
0 I 1 Thr0tlle sensor Accekrator pedal r&eased
4.5-5-W
I I (Power switch)
Accelerator pedal fuUy depessed ov
2M
l-l - I -
-
I -
0 oxygen sensw Ignitia switch ON
ov
Idle (Cold engine) ov
Idle (After “ram-up)
O-l .ov
Increasing engine speed (After warm-up) 0.5v-1 .ov
oeceleratlon
0-0.4v
0 Airflow meter Ignition switch ON
Ap~rox 3 8L
ldk Approx. 3.3 2N
20
2P
0 Intake air ther- Ambient air temperature 20°C (68” F)
mosensor
W W Ap&xox 2 5V
0 water thermosensor Enaine coolant temperature 20°C (68°F)
ADDTOX 2.5\( 20
2R
2s
,.
After “am-up B&w 0 5v
I I I I
- - - - -
0 Sdenoid valve Engine speed below 5.000 rpm Below 1 5v
ww
Engine speed above 5.000 rpm VB
2T I 0 lsolertoid valve
I60 jDOHCl/l20 ISOHCI seconds after en- 1
/ I--
temperature abo& 56°C (136 o F)
(OOHC]/SO”C (122°F) (SOHC]
0 Injector (Nos. 1.3) Other condition at idle VB
Ignition switch ON
Vt7
Idle
VB‘ 2u
2v Engine speed above 2.000 rpm on
decderation (After warm-up) Ve
0 Injector (NOS. 2. 4) Ignition swatch at id& VB
idle
VS.
Engine speed above 2,000 rpm on
deceteratiin (After warm-up) VS

L WIRINQ DIAQRAM
EGI EC-AT HENGINE CONTROL SYSTEM 6 EC-AT CONTROL SYSTEM(1/3) <>. .DoHC 0 .ChNADh b-2
THERMOSWITCH
(SECTION 8-41 MAIN
- -
INSTRUMENT CLUSTER
+ Y/L (EM)
I I I I
Q
I
DIAGNOSIS CONNECTOR
(SECTION u)
II R/L
(EM)
1 ;
2-01 ENGINE CONTROL UNIT (EM)
162-02 MAIN RELAY (ET
1” IS 10 10 IM 1K 31 IG 1E IC 1A
x w G G/B G/R “,$%G,‘Y G/W Y/B V L/R
x R/W 0/L O/L L/Y C/B B/L R/B W/B w/y W/R
,” ,T 117 ,P IN 3L IJ 1H IF 10 16 20 2M 2K 21 26 2E 2C 2A
/L W/L R/B -G/ W/E L/W R/L W
R/Y Y/L * “t R/%-G/k B/G R
2P 2N 2L 2J 2H 2F 2D 28 3Y 3W 3U 35 30 30 3M 3K 31 36 3E 3C 3A (FUEL INJ)
0 L/O Y 3c L/O * G/O *
BpJY/W Y 3/L B/O
L L/Y Y/B * x * * *
* Y/R yp’ 3/B B/O
32 3X 3V 3T 3R 3P 3N 3lL 3J 3H 3F 30 38
2-03 CIRCUIT OPENING 82-04 FUEL TANK UNIT(R) 82-05 IGNITER (EM1 82-06 CONDENSER (EM) 82-07 IGNITION COIL (EM)
RELAY iEM)
B/G
B 82-08 OXYGEN SENSOR (EM)
z-34

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

fgnltio” switch ON Ve Battery von%ge
rrmin%l Inpu( Output
Connected to
3u
0 Injector (Nos 1, 3)
I Test condition curact von%ge Remmk r 1 lon~tii switch ON I
I
VB 1 ‘Enaine S~anal
Idle
Engine speed above 2.000 rpm on deceler-
atton (after warm-up) V%
VB Monitor: Green
and red lamps
fksh
3v
3w
3x 0 Injector (Nos. 2. 4) Ignition switch ON VB
tdk VS
Engine speed above 2,000 rpm on dec%kr-
atlo” (after warm-up) VS
ci 1-2 shift soknold Solenoid valve ON V%
whtk during
valve
Soknold valve OFF ov
0 2-3 shrft solenoid Soknold valve ON
V% wh6k during
valve
Solenoid valve OFF ov
3Y
32 0 3-4 shift solenoid Solenoid valve ON
vs while during
valve
Solenoid valve OFF ov
0 Lock up solenoid Solenoid valve ON
V% while during
valve
Soknoad valve OFF ov
i