oil MAZDA PROTEGE 1992 Workshop Manual

2L BUZZER 2A 28 2C 2D 1A 3K l--r nnmn
I I‘ I
1C 3L 2E 2G IL iG 1F 1D tB
3F 38 3G 1E 3D
l-l rt
II l-l
l-l It II l-l 1J 11 1H
1G IF 1E 1D 1C 1B 1A 2L 2K 2J 21 2H 2G 2F 2E 2D 2C 28 2A
r-l It ,I 3L 3K 3J 31 3H 3G 3F 3E 3D 3C 3B 3A
Ter- I I minal Connected to 1 1A Combination switch
1B Ground
IC Fuel tank unit
1 ID 1 EGI control unit
I
II L 1J 1
L Ter-
minal Connected to
2A Speed sensor output
28 Light switch (high beam)
2C Turn switch (L)
20 Turn switch (R)
2E Ground
2F Ground
2L 1 IGI battery Ter-
minal Connected to
3A
38 Alternator
3c
30 Oil pressure switch
3E
3F Parking brake switch, Brake fluid switch
3G Passive shoulder belt control unit
3H h
I 31
3J
3K
IG2 battery
3L Water temperature gauge unit

U TROUBLESHOOTING GUIDE
Case 1: Insufficient refrigerant
Measured pressure
Low-pressure side: Less than 78.5 kPa (0.8 kg/cm2, 11.4 psi)
High-pressure side: 785-883 kPa (8-9 kg/cm2, 114-128 psi)
Condition
l Outlet air from vents not cold.
l Bubbles seen in sight glass.
Step 1
1. Check for oil stains on the pipes, hoses and other parts, (Refer to illustration below.)
2. If oil staining is found at the connection of pipes or hoses, replace the O-ring; then, evacuate, charge,
and test the system.
3. If oil staining is not found, go to Step 2.
05UOUX-02
Step 2
1. Check for leakage from the following connections with a gas leak tester.
l Inlet and outlet of condenser.
l Inlet and outlet of receiver/drier.
l Inlet and outlet of compressor.
l Sight glass.
l Inlet and outlet of cooling unit.
2. If leakage is evident, go to Step 3.
3. If leakage cannot be found, evacuate, charge, and test the system. (System OK, but refrigerant leaked
gradually over time.)
Step 3
1. Check tightening torque of the connection where leak was detected.
2. If the connection is loose, tighten the connection to the specified torque; then evacuate, charge, and test
the system. --
3. If the connection is properly tightened, replace the O-ring; then evacuate, charge, and test the system.
U-16

U
COOLING UNIT
Removal / Installation AIR CONDITIONER
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Remove the glove box, glove box cover, undercover, and instrument panel stay. (Refer to Section S.)
3. Remove the cooling unit as shown in the figure. -
Note
l Immediately plug all open fittings to keep moisture out of system.
4. Install the cooling unit in the reverse order of removal.
Note
l Position the cooling unit so that its connections match those of the heater unit and blower unit.
l Apply clean compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fitting nuts.
l When installing a new cooling unit, add compressor oil through the high-pressure pipe port
of the compressor.
Compressor oil: 50 cc (3.05 cu in)
Tightening torque
Outlet pipe: 20-29 N*m (2.0-3.0 m-kg, 14-22 ft-lb)
lnla+ nina. Q n,7n N.m (I -0-2.0 m&a. 7,7-IA ftJh IIllcvb yap”. “.” -1 . . . . . \..’ -_- __- ..~, JII .- .I .-,
23UOUX-0: -.,
1. Cooling unit
Disassembly / Assembly.. . . . . . . . . . . . page U-39
U-38

AIR CONDITIONER U
Dlsassembly / Assembly
Disassemble and assemble as shown in the figure.
1. Evaporator 2. Expansion valve 3. Thermoswitch
Replacement
Expansion valve
Note
l Before replacement of the expansion valve, care-
fully check the refrigeration system, referring to the
troubleshooting information on page U-14.
1. Remove the cooling unit. (Refer to page U-38.)
2. Disassemble the cooling unit. Remove the evaporator and
expansion valve as an assembly.
3. Disconnect the inlet and outlet pipes.
I 4. Remove the capillary tube from the outlet pipe and remove
23UOUX-024 the expansion valve.
5. Install in the reverse order of removal, noting the following.
Note
l Apply clean compressor oil to the O-rings before
connecting the fittings.
Tightening torque
Inlet pipe:
12-15 N-m (1.2-l .5 m-kg, 8.7-l 1 ft-lb)
Outlet pipe:
29-34 Nmrn (3.0-3.5 m-kg, 22-25 ft-lb)
u-39

AIR CONDITIONER U
COMPRESSOR
Removal / Installation
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Remove the undercover.
3. Remove the compressor as shown in the figure, referring to
Removal Note.
4. Install the compressor in the reverse order of removal, referring to Installation Note.
5. Install the undercover.
6. Charge the refrigeration system. (Refer to page U-33.)
u
24-35 (2.4-3.6, 17-26)
N.m (m-kg, ft-it
23UOUX-0
1. Suction hose
2. Discharge hose 3. Compressor
Note
l Immediately plug any open fittings to keep moisture out of the system.
l Apply new compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fittings.
l Tightening torque Compressor inlet and outlet: 9.8-l 8 N.m (1.0-l .8 m-kg, 8-l 2 ft-lb)
l Adjust the belt tension to specification.
lb-41

U AIR CONDITIONER
23UOUX-02
Thermal Protector Replacement
1. Removal of discharge valve body
Remove the bolts and carefully remove the discharge valve
body. .-
2. Removal of snap ring and thermal protector
Note
l When removing the thermal protector, do not pull
the harness wires but push the protector out from
its back side.
23UOUX-028 3. Installation of thermal protector
1) Check that the O-ring groove is free from foreign matter.
Apply compressor oil to the O-ring and properly fit it in
the groove.
2) Before installing the thermal protector, check it for con-
tinuity.
23uoux-029 _/”

THERMAL PROTECTOR
23UOUX-03
TH
PR
3) Install the snap ring so that its chamfered edge side faces
the thermal protector (the non-chamfered side faces out-
ward) as shown left.
Make sure the snap ring is seated securely in its groove.
Note
l Install the thermal protector so that its two lead wire
outlet sections are horizontal as shown left.

AIR CONDITIONER U
23UOUX-031 DISCHARGE
VALVE BODY
CYLINDER
1
23UOUX-03
4. Installation of discharge valve body
1) Replace the O-ring and gasket with new ones.
Apply compressor oil to the new O-ring and gasket and
properly assemble them.
Note
l Fit the gasket as shown left while checking that its
top side faces upward.
2) Carefully install the discharge valve body on the com-
pressor and finger tighten the six M6 bolts.
Note
Bolt torquing sequence
l Torque the two socket head bolts (A) to the specifi-
cation.
l Torque the four bolts (B) in a diagonal manner to
the specification.
Tightening torgue: 9.8 N,rn (100 cm-kg, 87 in-lb)
u-45

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

U AIR CONDITIONER
23UOUX.04
IO. Lay down the compressor and clean the shaft seal contact-
ing face of the compressor with cleaning solvent.
Caution
l Keep the cleaning solvent and dirt out of the com-
pressor.
l Do not use any cloth for cleaning.
Clean only by rinsing with the solvent.
l Do not spill the refrigerant oil from the compressor.
Refill the same amount of the oil if the oil is spilled
out.
23uoux-039
11. Clean the new shaft seal throughly with cleaning solvent.
12. Lubricate the shaft seal with refrigerant oil (SUNISO 5GS
or equivalent) and install it on the
SST.
Note
l Use only clean refrigerant oil.
l Do not touch the sealing surfaces of the shaft seal
after lubricated.
23UOUX-040
13. Liberally lubricate the compressor shaft with refrigerant oil.
14. Install the shaft seal onto the compressor shaft aligning the
seal case flats with the shaft flats.
U-48

AIR CONDITIONER U
15. Clean the seal plate with cleaning solvent.
Lubricate the seal plate with refrigerant oil (SUNISO 5GS
or equivalent).
Note
l Use only clean refrigerant oil.
l Do not touch the sealing surface of the seal plate
after lubricated.
23lJoux-042
SHAFT SEAL PLATE
14
16. First, slide the seal plate into the compressor by hand as
far as possible.
17. Press the seal plate with grip side of the
SST.
18. Install the snap ring with its chamfered edge inside.
19. Press the snap ring with the grip side of the
SST, then in-
stall the felt seal.
20. Make sure the snap ring is seated correctly in its groove.
21. Install the shim(s).
22. Install the armature plate.
Measure the clearance between the pulley and armature
plate all the way around.
If the clearance is not as specified, add or remove the shim
as required.
Clearance: 0.4-0.5mm (0.016-0.020 in)
Shim
Part number Thickness mm (in)
B455 61 L15 0.2 (0.008)
8456 61 L15 0.5 (0.020)
u-49