alternator MAZDA PROTEGE 1992 User Guide

B2 ON-VEHICLE MAINTENANCE
TIMING BELT
Removal / Installation
1. Disconnect the negative battery cable.
2. Raise the vehicle on a lift and remove the right front wheel.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal, referring to Installation Note.
/ 7.8-11 N.m
(80-l 10 Cm-kg, 69-95 in-lb
1p1\ ’ (3.8-6.3, 2738)
, (80-l 10 cm-kg, 69-95 in-lb)
167--187 (X-17, 116-123)
/ 7.8--11 N-m
(80-110 MI-kg,
7.8-11 N-m
\-
(80-110 Cm-kg, 69-95 in-lb)

12-17 (1.25-1.75, 9-13)
N-m (m-kg, &lb
23UOl32-0
1. Under cover and side cover 11. Timing belt cover, lower
2. P/S and/or A/C drive belt 12. Pulley lock bolt
3. Alternator drive belt Removal Note . . ..*..........*.*......... page 82-13
4. Water pump pulley Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-14
5. Plate 13. Pulley boss
6. Crankshaft pully 14. Timing belt
7. Spark plugs Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 62-13
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 62-15 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-14
8. Oil dip stick 15. Tensioner and tensioner spring ..l
9. Timing belt cover, upper Installation Note ..,..................... page B2-14
10. Timing belt cover, middle 16. Idler
B2-12

ON-VEHICLE MAINTENANCE B2
1. Under cover and side cover
2. Resonance chamber
3. Air hose
4. Accelerator cable
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-21
5. Throttle cable (ATX)
Removal I Installation . . . . . . . . . . . . . . . . . . . . . Section K
6. High-tension lead
7. Hoses
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 82-21
8. Harnesses
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-18
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 82-21
9. Water bypass pipe
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-18
10. P/S and/or A/C drive belt
Removal / Installation . . . . . . . . . . . . . . . . page B2- 6
11. Alternator drive belt
Removal / Installation . . . . . . . . . . . . . . . . page B2- 6 12. Water pump pulley
13. Timing belt cover, upper
14. Timing belt cover, middle
15. Spark plug
16. Timing belt
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-l 8
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-20
17. Front exhaust pipe
18. Intake manifold bracket
19. Cylinder head cover
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 82-19
20. Cylinder head bolt
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-19
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-19
21. Cylinder head
Disassembly . . . . . . . . . . . , . . . . . . . . . . . . . page B2-45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-79
22. Cylinder head gasket
23UOB2-021
Removal / Installation note
Hoses
1. Disconnect the hoses shown in the figure.
VACUUM HOSE BRAYE VACUUM HOSE
‘-;:I::------. CAUT’oN
l COVER THE HOSE WITH A RAG BECAUSE FUEL WILL
SPRAY OUT WHEN DISCONNECTING.
- PLUG THE DISCONNECTED HOSES TO AVO!D FUEL
LEAKAGE.
OWOBX-03
82-l i

B2 ON-VEHICLE MAINTENANCE
HLA
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. install in the reverse order of removal, referring to Installation Note --- ----- -__ __-- ,‘.
11.3-14.2 N.m
(1.15-1.45 m-\g, 100-126 in-lb)
49-61
(5.0~6.2,-36-45)
4.9-6.6 N.m
(50-90 cm-kg, 43-76 in-lb)
7.6All N-m
(80-110 cm-kg, 69-95 in-lb) 1 Q’-25
(1.9-2.6, 14-19)
N.m (m-kg, ft-lb)
0311082-03
1. High-tension lead
10. Cylinder head cover
2. Distributor
Installation Note..
....................
Installation Note.. ......................
page 62-25
11. Camshaft pulley
3. P/S and/or A/C drive belt
Removal note ..........................
Removal / Installation..
.............. page E32-
6
Installation Note .......................
4. Alternator drive belt
12. Seal plate
Removal / Installation
......... . ...... page B2- 6
13. Camshaft
5. Water pump pulley
Removal Note.. ........................
6. Timing belt cover, upper
Installation Note.. .....................
7. Timing belt cover, middle
14. HLA
8. Spark plug
Removal note ..........................
9. Timing belt
Installation
Note.. .....................
Removal Note.. .........................
page B2-18 Inspection
................................
Installation Note.. ......................
page B2-20
7
page 62-19
page 82-23
page 82-24
page B2-23
page 62-23
page B2-23
page B2-23 ‘--’
page 82-60
82-22

REMOVAL
0311082-046
Removal note
P/S oil pump and bracket
Caution
l Do not damage the hoses.
1. Remove the P/S oil pump and bracket with the hoses still
connected.
2. Position the pump away from the engine and affix it with wire.
A/C compressor (if equipped)
Caution
l Do not damage the hoses.
1. Remove the A/C compressor with the hoses still connected.
2. Position the compressor away from the engine and affix it
with wire.
Step 2
1. Disconnect the harness connectors shown in the figure.
OIL PRESSURE SWITCH ATX
THROTTLE INHIBITOR SWITCH
ALTERNATOR
I SENSOR 1
II
rl (MTX)
-03UOB2-05( .-,’

B2 DISASSEMBLY
AUXILIARY PARTS
1, Drain the engine oil.
2. Disassemble in the order shown in the figure
GASKET, REPLACE ..______-.
-___ -
03UOB2-064
1. Distributor and high-tension lead 7. Oil cooler
2. Intake manifold assembly 8. Oil pressure switch
3. Injector and distribution pipe assembly 9. Spark plug
4. Alternator and drive belt 10. Oil level gauge
5. No.3 engine mount bracket 11. Oil level gauge pipe stay
6. Oil filter 12. Engine hanger
82-42

ASSEMBLY B2
03UOB2-111
03UOB2-ill
03UOB2-119
No.3 Engine Mount Bracket
1. Install the No.3 engine mount bracket.
Tightening torque:
93-l 17 N-m (9.5-l 1.9 m-kg, 69-86 ft-lb)
Alternator and Drive Belt
1. Install the alternator and loosely tighten the mounting bolts.
2. Install the alternator drive belt.
3. Adjust the drive belt deflections. (Refer to page B2-6.)
Injector and Distribution Pipe Assembly
1. Install the new injector insulators to the cylinder head.
2. Install the injector and distribution pipe assembly to the cyl-
inder head.
Tightening torque:
19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
Intake Manifold Assembly
1. Remove all foreign material from the intake manifold con-
tact surface.
2. Install a new gasket and the intake manifold assembly.
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-l 9 ft-lb)
82-89

G
ENGINE ELECTRICAL SYSTEM
INDEX ......................................................
OUTLINE ..................................................
SPECIFICATIONS .................................... G- 3
TROUBLESHOOTING
GUIDE.. .................... G-
4
DIAGNOSTIC INDEX ................................
SYMPTOM TROUBLESHOOTING..
............. :- t
-
CHARGING SYSTEM ................................. G- 6
PREPARATION .......................................
CIRCUIT DIAGRAM ................................. :I ;
TROUBLESHOOTING .............................. G- 7
BATTERY ............................................... G- 6
ALTERNATOR ........................................ G-10
DRIVE BELT ........................................... G-14
IGNITION SYSTEM .................................... G-15
PREPARATION ....................................... G-15
CIRCUIT DIAGRAM ................................. G-15
TROUBLESHOOTING .............................. G-16
IGNITION TIMING ................................... G-17
HIGH-TENSION LEAD .............................. G-17
SPARK PLUGS ....................................... G-16
IGNITION COIL ....................................... G-19
DISTRIBUTOR ........................................ G-20
IGNITER ................................................ G-23
STARTING SYSTEM .................................. G-24
PREPARATION ....................................... G-24
CIRCUIT DIAGRAM ................................. G-24
STARTER ...............................................
G-25
STARTER INTERLOCK SWITCH (MTX)
........ G-31
03UOGX-001

G INDEX
NDEX
- 03UOGX-00:
6. Ignition coil 1. Battery
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page G- 8
Recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..t page G- 9
2. Alternator
Removal / Installation . . . . . . . . . . . . . . . . . .
page G-l 0
Disassembly / Assembly . . . . . . . . . . . . . page G-l 1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-l 2
3. Drive belt
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-l 4
Adjustment . . . . . . . . page G-l 4
Replacement . . . . . . . . . . . . . .
page G-l 4
4. High-tension lead
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-l 7
5. Spark plugs
Removal / Installation . . . . . . . . . . page G-1 0
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-l 8
G-2
Inspection .,.. . . . . . . . . . . . . . . . . I . . . . . page
G-l 9
7. Distributor
Spark test ., . . . . . . . . . . ,... . . . . . . . .
page G,-20
Electronic advance inspection page G-20
Removal / Installation ,................. page G-21
Disassembly / Assembly.. , . . page
G-22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-22
8. Igniter
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-23
9. Starter
Removal / Installation .;...........,.... page G-25
Disassembly ! Assembly . . . . . . . . . . . . . page G-26
Inspection . . . . ...‘........................,,,
page G-28 .--
10. Starter interluck switch
Inspection... . . . . . . . . . . . . . . . . . . . . ,.., ,...,
page G-31

TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
DIAGNOSTIC INDEX
No. Troubleshooting items
Page
1
Will not crank-starter motor does not operate G-4
2
Will not crank-starter motor spins G-4
3
Cranks slowly G-5 4
Alternator warning lamp illuminates when engine running
G-5
5 Discharged battery G-5
6
Misfire
G-5
03UOGX-004
SYMPTOM TROUBLESHOOTING -
1
iTEl
1
2
3 Will not crank-Starter motor does not operate
INSPECTION
T
Check if engine cranks with fully charged battery
Check if battery voltage is applied at B terminal
TERMINAL
battery voltaae is aoolied at S terminal
when clutch pedal depressed (MTX) and ignition
switch in START position
S TERMINAL
Yes
No
Yes ACTION Check charging system CT- page G-7
Go to next step
Go to next step
No Check wire harness
Yes
l Check magnetic switch l Check field coil l Check armature
No
l Check starter interlock switch (MTX) ccp: page G-31 l Check inhibitor switch (ATX) c=p Section K l Check ignition switch CI Section T l Check wire harness
1 L-T page G-28
CT- page G-29
CT- page G-29
23UOGX.001
03UOGX-006
G-4

TROUBLESHOOTING GUIDE G
3 Cranks slowly
STEP INSPECTION ACTION
1 Check if engine cranks normally with fully Yes Check charging system CT page G-7
charged battery
No Go to next step
2 Check starter cable connection for looseness Yes Repair or replace connection
and corrosion
OBUOGX-OC
I 1 4
.
Alternator warning lamp illuminates when engine running
STEP INSPECTION ACTION
1 Check for correct battery voltage at idle Yes Check wire harness between alternator L terminal and aI*
Specification: 14.1--14.7V ternator warning lamp
No Check charging system w page G-7
03UOGX-008
5 I Discharged battery I 1TEP INSPECTION
f Check charging system w page G-7 -
6
TEF
1
r
--
Yes
03UOGX-009
ACTION
Turn ignition switch ON and check dark current as shown
Dark current: Below 20mA
No Repair or replace parts as necessary 1
Misfire
INSPECTION
-
Disconnect high-tension lead from each spark
plug and check for strong blue spark while
cranking
, i
Yes
No T-
I
ACTION
- Check spark plug w page G-f8
~3 If OK, engine electrical system normal
~3 If not OK, clean or replace spark plug
Check ignition system ci’ page G-16
1 03UOGX-010
G-5