lock MAZDA PROTEGE 1992 Workshop Manual

CHARGING HOSE
CLOSED
CLOSED
23UOUX-061
CHARGING HOSE
CHARGING VALVE CLOSED 0
23UOUX.061
3. Connect high-and low-pressure side charging hoses and
stop valves to the refrigerant system service valves.
23UOUX-062
FREON (REFRIGERANT RECOVERY
ND RECYCLING
CONTAINER
VALVE
Manifold gauge set/Stop valve installation
Caution
l Connect all charging hoses via stop valves to avoid
venting the refrigerant remaining in the hoses into
the atomosphere. _A
l Do not disconnect the stop valve from the charg-
ing hose when there is refrigerant remaining in the
hose.
1. Turn the knob counterclockwise to close the stop valve.
2. Install the stop valve to the end of the charging hose of the
manifold gauge set.
Caution
l Verify that high-and low-pressure side valves of the
manifold gauge set are fully closed before connect-
ing the charging hose and stop valve to the refriger-
ant system service valve.
23UOUX-063 Evacuation/Airtiahtness test
1. Connect the manifold gauge set and stop valves to the
refrigerant system service valves.
2. Connect the center hose of the manifold gauge set to the
vacuum pump inlet.
3. Prepare as follows according to the charging method.
Charging from service container.
Connect the charging hose and service container valve to the
manifold gauge set air purge valve.
I
23UOUX-06
U-32
4
Refrigerant recovery operation.
Remove the refrigerant from the refrigerant system by using
a freon (refrigerant) recovery and recycling system.
Caution
. Never vent the refrigerant into the atomosphere.
l When using a freon recovery and recycling system,
follow the operation instructions provided by the
equipment manufacturer.
_-,

U AIR CONDITIONER
OFF
03UOUX-06
03UOUX-06,
03UOUX-06
On-vehicle Inspection
Thermoswitch
1. Remove the glove box.
2. Run the engine at idle.
3. Turn OFF the A/C switch and set the blower switch to the
highest position to operate the blower fan for a few minutes.
4. After a few minutes, turn OFF the blower switch and stop
the engine.
5. Disconnect the thermoswitch connector and check for con-
tinuity between terminals of the switch.
Terminals Continuity
a-b Yes
6. If not as specified, replace the thermoswitch.
Note
l The thermoswitch contacts will be open if the
evaporator temperature is below 0.4 f 0.7OC (32.7
z!z 1.3OF).
Inspection
Thermoswitch
1. Immerse the sensing bulb in a container of ice water.
2. Check continuity between terminals of the switch as
specified.
Terminals
a-b Temperature Continuity
Above 5°C Yes
Below 0% No
3. If not as specified, replace the thermoswitch
Evaporator
1. Check the evaporator fins for blockage. If the fins are
clogged, clean them with compressed air.
Caution
l Never use water to clean the evaporator.
2. Check the fittings for cracks and other damage.
Replace the evaporator if necessary.
u-40

AIR CONDITIONER U
r 23UOUX-036
L 23UOUX.03
I
L
23UOUX-03 7
Shaft Seal Replacement
1. Remove the armature plate.
Note
l Removal of the clutch pulley and coil is not
necessary.
2. Remove the felt seal and snap ring.
3. Remove the shim(s).
4. Insert the
SST into the compressor aligning the cutout of
the
SST with the groove of the seal plate.
5. Rotate the
SST counterclockwise to make sure that the
cutout is engaged with the seal plate.
6. Pull out the seal plate.
7. Insert the
SST into the compressor aligning the cutout of
the
SST with the metal pawl of the shaft seal.
8. Rotate the
SST counterclockwise to make sure that the cut-
off is engaged with the metal pawl.
9. Pull out the shaft seal.
u-47

TECHNICAL DATA TD
Item Engine
B6 SOHC BP SOHC
Valve seat
IN
45O
Seat angle
EX 45O
Seat contact width IN
mm 04 EX 1.1-l .7 (0.043-0.067) 0.8-l .4 (0.031-0.055)
1.1-l .7 (0.043-0.067) 0.8-l .4 (0.031-0.055)
IN Standard 39 (1.5354) 42.5 (1.673)
Seat sinking mm (in) Maximum 40.5 (1.594) 44.0 (1.732)
EX Standard 39 (1.5354) 41.0 (1.614)
Maximum 40.5 (1.594) 42.5 (1.673) Valve spring
Standard mm (in) 43.66 (1.7188) 46.12 (1.8157)
IN
Minimum N (kg, Ib)/mm (in) 224-253 (22.8-25.8, 205-231 (20.9-4X3.5,
Free length 50--57)/35.5 (1.398) 46-52)/39 (1.535)
Standard mm (in) 43.66 (1.7188) 43.61 (1.7169)
EX
Minimum N (kg, Ib)/mm (in) 224-253 (22.8-25.8, 129-147 (13.1-15.0,
50-57)/35.5 (1.398) 29-33)/37.5 (1.476)
Out-of-square mm (in) 1 Maximum 1.52 (0.060) IN...l.61 (0.063) EX...1.52 (0.060)
Lobe height mm (in) IN
EX Standard 36.451 (1.4351) 35.993 (1.4170)
Wear limit 36.251 (1.4272) 35.793 (1.4092)
Standard 36.451 (1.4351) 36.273 (1.4281)
Wear limit 36.251 (1.4272) 36.073 (1.4202)
Front 43.440-43 ,460 No.1 & 43.440-43.460
(1.7102-l .7 ‘110) No.5 (1.7102-1.7110)
43.430-43 ,445 No.2 & 43.425-43.450
mm (in) Center
(1.7098-l .7 ‘108) No.4 (1.7096-l .7106)
. , L
Rear 43.440-43.460 No’3 43.41 o-43.435
(1.7102-l .7110) (1.7091-1.7100)
1 Out-of-round 0.05 (0.002) max.
Front 0.055-0.095 No.1 & 0.040-0.075
(0.0021-0.0037) No.5 (0.0016-0.0030)
e--I-.. 0.060-O. 105 No.2 84 0.035-0.080
1041) No.4
“.“-.-..“” (O.OOi 4-0.0031)
Rear 0.055-0.095 0.050-0.095
(0.0021-0.0037) No.3
(0.0020-0.0037)
1 Maximum
0.15 (0.006)
0.01 (0.0004)
0.03 (0.0012)
0.05-0.18 (0.0020-0.0071) 0.06-0.19 (0.0024-0.0075)
n ‘1 m *no Journal diameter
Camshaft hearinn nil cIewanr.F? mm tin I b,er’Ler I (0.0023--0.c
Camshaft runout mm (in) Maximum
Camshaft end play mm (in) Standard
Maximum
I Rocker arm and rocker arm shaft
Rocker arm inner diameter mm (in) 18.000-18.027 (
Rocker arm shaft diameter mm (in)
17 9.59-17 981) I “.L ~“.““O,
lN...19.000--19.027 (0.7480-0.7491)
o.7087-o’70g7) EX...19.000-19.033 (0.7480-0.7493)
I .““” -- -
0 7070-0.7079) 18.959-18.980 (0.7464-0.7472)
lN...0.020-0.068 (0.0008-0.0027)
Rnrkx arm tn shaft clearance
mm (in Standard
I .Y”,.VG 11.,, .” -,,-.. “,“-.“, .I”
““” ,“‘I o.020-o.068 (“~ooo8-o~oo27) EX...O.020-0.074 (0.0008-0.0029)
Maximum 0.10 (0.004) Cylinder block
Height mm (in) 221.5 (8.720)
Distortion mm (in) 0.15 (0.006) max.
Grinding mm (in) 0.20 (0.008) max.
^. , ,
78.006-78.013 (3.0711-3.0714) 183.006-83.013 (3.2679-3.2682)
-.n nr,. -,n fin,% ,n nnnr
” nn’n’ ’ “- T)cc 83.263 (3.2778-3.2781) Cylinder bore diameter stanaara size
mm (in) 0.25 (0.010) oversize IU.L3cl-/U.dDJ (J.uouu-J.uo IL) 1 OJ.LJU--
0.50 (0.020) oversize 78.506-78.513 (3.0908-3.0911) ) 83.506-
Cylinder bore taper and out-of-round mm (in) 0.019 (0.0007) ma: 83.513 i3.2876-3.2879)
I(.
TD-3

TD TECHNICAL DATA
Item Engine
BP DOHC
Guide projection (Height “A”) IN
mm (in) EX 18.3-l 8.9 (0.720-0.744)
_-j
18.3-l 8.9 (0.720-0.744)
Valve seat
Seat angle
Seat contact width IN 45O
EX 45O
IN
mm (in) EX 0.8-l .4 (0.031-0.055)
0.8-l .4 (0.031-0.055)
Seat sinking
Valve spring
Free length
Out-of-square
Camshaft IN Standard 45.0 (1.7716)
mm (in) Maximum 46.5 (1.831)
EX Standard 45.0 (1.7716)
Maximum 46.5 (1.831)
Standard mm (in) 46.26 (1.821)
Minimum N (kg, Ib)/mm (in) 224-253 (22.8-25.8, 50--57)/39.5 (1.555)
mm (in) 1.62 (0.064) max.
I C+^~rl^.A
44.094 (1.7360)
43.894 (1.7281)
44.600 (1.7560)
44.400 (1.7480) IN 3Ldl l”dl u
Cam height mm (in) Wear limit
EX Standard
Wear limit
Standard
Journal diameter mm (in) (No.l-No.5) 25.940-25.965 (1.0213-l .0222)
Out-of-round 0.03 (0.001) max.
Standard
Camshaft bearing oil clearance mm (in) (No-1-No.5) 0.035-0.081 (0.0014-0.0032)
Maximum 0.15 (0.006)
Camshaft runout mm (in) 0.03 (0.0012) ma
IX.
Camshaft end play mm (in) ’ Standard 0.07-O. 19 (0.0028-0.0075)
Maximum I
I n 9 m mm “.L \“.“““,
Cylinder block
Height
Distortion
Grinding mm (in) 221.5 (8.720)
mm (in) 0.15 (0.006) max.
mm (in) 0.20 (0.008) max.
Cylinder bore diameter Standard size 83.006-83.013 (3.2679-3.2682)
mm (in) 0.25 (0.010) c oversize 83.256-83.263 (3.2778-3.2781)
n.vl IO0701 I -.--
\-----I Jversize 83.506-83.513 (3.2876-3.2879)
Cylinder bore taper and out-of-round mm (in) 0.019 (0.0007) max.
Piston
I
I I
Piston diameter 82.954-82.974 (3.2659-3.2667)
Measured at 90” to pin
bore axis and 16.5mm
83.21 l-83.21 7 (3.2760-3.2763)
(0.650 in) below oil ring
groove
mm fin) 0.50 (0.020) oversize 83.461-83.467 (3.2859-3.2861)
r~ Piston to cylinder clearance
mm On) (Standaid 0.039-0.052 (0.0015-0.0020)
Piston ring
Thickness
End gap
(Measured in the cylinder) mm (in) ‘W
Second
Top
Second
mm (in) Oil (rail)
Maximum
Too I .‘t, - I .ct3 (“.“a, 3-u
1.47-l .49 (0.0579-C
0.1%0:30 (0.006--C
0.15-0.30 (0.006-C
I I.01 2)
0.20-0.70 (0.008-0.028)
1.0 (0.039)
1,520-l
,535 (0.0598-0.0604)
1.52-l .54 (0.0598-0.0606)
3.02-3.04 (0.1189-O. 1197)
I Ring groove width in piston mm (In) n
;_A
TD-6

TECHNICAL DATA TD
Item
Carrier hub
Sun gear drum
Small sun gear TransaxlelEngine
Clearance between pinion washer
and planet carrier mm (in) Maximum
Bushing inner diameter
mm (in) Maximum
Bushing inner diameter
mm (in) Maximum F4A-EL
B6 SOHC BP SOHC BP DOHC
0.2-0.7 (0.008-0.028)
30.425 (1.198)
21.021 (0.828)
Gear assembly
Total end play
End play adjust race
Idle gear bearing preload
Preload
adjust shims
Output gear bearing preload
Preload adjust shims
Differential
Bearing preload
Preload
adjust shims
Backlash of side gear and pinion mm (in)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
mm (in) Standard
Maximum 0.25-0.50 (0.010-0.020)
1.2 (0.047) 1.4 (0.055), 1.6 (0.063)
1.8 (0.071) 2.0 (0.079) 2.2 (0.087)
-
0.03-0.9 (0.3-9.0, 0.26-7.8)
3.80 (0.150) 3.85 (0.152) 3.90 (0.154) 3.95
(0.156)
4.00 (0.158) 4.05 (0.159) 4.10 (0.161) 4.15 (0.163)
4.20 (0.165) 4.25 (0.167) 4.30 (0.169) 4.35 (0.171)
4.40 (0.173), 4.45 (0.175) 4.50 (0.177) 4.55
(0.179)
4.60 (0.181) 4.65 (0.183) 4.70 (0.185) 4.75 (0.187)
0.03-0.9 (0.3-9.0, 0.26-7.8)
0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65
(0.026).
0.70 (0.028) 0.75 (0.030) 0.80 (0.032) 0.85
(0.034)
0.90 (0.035) 0.95 (0.037) 1.00 (0.039) 1.05 (0.041)
1.10 (0.043) 1.15 (0.045) 1.20 (0.047) 1.25 (0.049)
1.30 (0.051), 1.35 (0.053) 1.40 (0.055) 1.45
(0.057)
2.9-3.9 (30-40, 26-35)
0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65
(0.026)
0.70 (0.028) 0.75 (0.030) 0.80 (0.032) 0.85 (0.034)
0.90 (0.035) 0.95 (0.037) 1.00 (0.039), 1.05 (0.041)
1.10 (0.043) 1.15 (0.045) 1.20 (0.047). 1.25 (0.049)
1.30 (0.051) 1.35 (0.053) 1.40 (0.055), 1.45 (0.057)
0.025-0.1 (0.001-0.004)
0.5 (0.020)
Torque converter
Bushing inner diameter mm (in) Standard 1 53.030-53.075 (2.088-2.090)
Maximum 1 53.075 (2.090)
Spring Specification
Spring name Outer diameter Free length
No. of coil Wire diameter
mm (in) mm (in) mm (in)
Throttle modulator 8.1 I I--.._ ^^^1-^1 1 spring 1 (0.319)
1 43.4 (1.709) 1 10.5 1 0.8 (0.031)
1
” cJIJtz:I li”I IL, “I
valve body Throttle spring
Throttle assist spring 1 5.4 (0.213) 46.2 (1.819) 1 29.0
0.88 (0.035)
1 5.15 (0.203)
26.88 (1.058) 1 16.2 0.6 (0.024)
,
^ -- ,^ ^^^
Mnin contrnl I Low reducina sprina I 7.9 (0.311) .._... __.._. -
valve body
-. .- \“---I 29.98 (1.180) 10.0
0.8 (0.03lj
1 3-4
shift spring / 7.4 (0.291) I 36.6 (1.441)
12.0 0.8 (0.031)
B6 SOHC
23.0
Bypass spring BP
SOHC 4.9 (0.193) 27.6 (1.087) 0.55 (0.022)
Premain control BP
DOHC 4.9 (0.193) 30.5 (1.201) 23.0
0.55 (0.022)
valve body
2-3 shift spring 7.4 (0.291) 36.6 (1.441)
12.0 0.8 (0.031)
Converter relief spring
8.6 (0.339) 68.4 (2.693) 27.5
1.2 (0.057)
Lockup control spring
5.0 (0.197) 30.1 (1.185) 21.5 0.55 (0.022)
Control valve body Throttle relief spring
6.6 (0.260) 21.6 (0.850) 11.5
0.8 (0.031)
Oil
pump Spring
13.0 (0.512) 53.0 (2.087)
12.0 1.2 (0.047)
TD-15

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
1 Throttle condition 1
nrllm pn-t
Mode Rr _ me/ flhrottle sensor 1 Shift 1 -.- -*r2d rpm
Vehicle speed I km/h (mohl , . ,
I
ioltage) 1 B6 sot
iC 1 BP SOHC 1 BP DOHC
66 SOHC 1 BP SOHC 1 BP
I I I
’ ni - n9 I’) 7nn-1 “50 2,500-3,05012,700-3.3001 I I DOHC
Fully opened 27-33 (17-201
3 D (4.0 volt) 50 2,050-2,55012,200-2,750]
40-50 i25-31 j
e I 300-500 1 450-650 / Q-15 16-9) 112-18 (7-111
00 3,250-3,45013,550-3.800~91-97 f56-60&G10’4 (61-64)hOO-106;62-&\I
s
i- f Fully closed
(0.5 volt)
YI -l&c
L, r vv-“,L
Dz + D3 2,150-2,7
D3 -+ DI 300--5O(
S3 -+ S2 3,200-3,4
’ L2 -+ LI 2,350-2,65012,200-2,50012,350-2.7001
43-49 ;27--3b1 ’ ‘I
M. FRONT AND REAR AXLES -
Item
Driveshaft Engine/Transaxle BP SOHC BP DOHC
Joint type
Length of shaft
Shaft diameter Front axle
Bearing play axial direction Rear axle
Bearing play axial direction Inside Tripod joint
Outside Ball joint
Right
919.3 (36.19) 918.7 (36.17) 630.7 (24.83)
mm (in) Left
637.8 (25.11) 640.2 (25.20) 621.2
637.1
(24.46) (25.08)
21.5 (0.85) 23.0 (0.91)
mm (in) 1 0.05 (0.002)
mm (in) I 0.05 (0.002)
N. STEERING SYSTEM Steering wheel
Outer diameter Item Specifications 370 (14.57)
Lock-to-lock I Steering gear
--
Type
Steering gear ratio
Backlash between rack and pinion mm (in)
N.r ’ ’ ” ’ n (cm-Kg, in-01
Preload measured by torque
*rrv~rrdl Rack and pinion
Infinite (00)
0 (0)
M/S : 0.9-l .3 (Q-13, 7.8-l 1.3)
P/S : 1.0-1.3 (10-14, 8.7-12)
Pinion preload ““l~jll~,,
9 (0.4
Preload measured by pull
scale with attachment
Limit of rack housing movement mm (in)
Distance between left and right brackets mm (in)
Rack stroke mm (in M/S : 900-l ,300 (31.8-45.9)
P/S : l,OOO-1,400 (35.3-49.4)
1.5 (0.06)
298.5 (11.75)
140 (5.511
Lubricant type (power steering)
Oil capacity (power steering) Drive belt
liter (US qt, Imp qt) I ATF: M-III or DexronW
0.8 (0.85, 0.70)
I New belt: 8-Q (0.31-0.35)
Deflection with force of 98 N (10 kg, 22 lb) mm (in) Used belt: 9-10 (0.35-0.39)
I imit: 11.5 (0.461
TD-17

TD TECHNICAL DATA
Coil Spring Specifications (See page R-5 for coil spring applications)
*’ Main identification mark color: Indicated on second coil from bottom. l * Auxiliary identification mark color: Indicated on third coil from bottom.
T. BODY ELECTRICAL SYSTEM
Item
Headlight
Frnnt tl wn sinnnl/Pnrkinn linht
Specification (W) (Bulb Trade number)
65145 (9004)
2718 II I 571
I
“‘VW, I u”“y’ 1. I” \’ ‘V’,
uinh mount stoplight 18.4 (1141)
turn single light 27 (1156)
Y-,-~p light 27 (1156)
Rear side marker light (Sedan) 3.8 (194)
License plate light 7.5 (89) [PROTEGE], 5 (168) [3HBl
Interior 10
Interior and spot lamp
spot 6
Interior lamp 10
‘i--” Spot lamp (in overhead console)
8 (67)
Cargo room lamp 5 (168)
Trunk room lamp 5 (168)
I I
ntminr Iamnc
I
Curtesy lamp
High beam
Turn light
Brake
Hold
) Charge 5 (168)
3.4
3.4
3
3 (158)
i
Oil pressure
Washer
Seat belt
Malfunction
Fuel
illumination 3 (158)
3 (158)
3 (158)
3 (158)
3 (158)
3 (158)
3.4 Indicator and
warning lamps
Check 3 (158)
Dif. lock
I 3 (158) .-
,
-.-’
I
I
TD-20

SPECIAL TOOLS ST
.._ ENGINE
9 LO10 1AO
,9 0636 100A
19 B012 OA2
19 LO12 OAO
nstaller set,
/alve seal &
$9 0249 OlOA
3emover &
nstaller, valve
49 8012 005
Remover &
installer, valve
49 0187 280
Oil pressure ‘OOL NUMBER
: DESCRIPTION PRIORITY ILLUSTRATION
9 0221 061A
:emover & B
Istaller, piston
in (BP DOHC)
4 9 HO11 OOlA
s iupport block
h lead (Except
E )P DOHC)
.9 LO1 1 OAO
‘iston pin setting A
DOI set (Except
3P DOHC) 4
F
tl
E
L
(
II
1
I
I I9 DO11 102
;rankshaft
ock tool
19 EOI 1 1AO
3rake, ring gear
49 s120 170
Remover,
valve seal A
@ 0
A
49 9200 145
Adapter set,
radiator cap A cl3JQ
tester
49 9200 020
Tension gauge,
V-ribbed belt A
ST-3