clutch MAZDA PROTEGE 1992 Owner's Manual

--
ASSEMBLY B2
2311082-06
2311082.04
1
03UO62-09!
J 2311062-063
4. Hold the flywheel with the SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
96-l 03 N.m (9.6-10.5 m-kg, 71-76 ft-lb)
Clutch Disc and Clutch Cover (MTX)
1. Install the clutch disc and clutch cover using the SST or
equivalent. (Refer to Section H.)
Tightening torque:
16-26 N.m (1.8-2.7 m-kg, 13-20 ft-lb)
Drive Plate (ATX)
1. Remove the sealant from the drive plate holes in the crank-
shaft and from the drive plate lock bolts.
Caution
l If all the previous sealant cannot be removed from
a bolt, replace the bolt.
l Do not apply sealant if a new bolt is used.
2. Set the adapter, drive plate, and backing plate onto the
crankshaft.
3. Apply sealant to the drive plate bolts and install them.
4. Hold the drive plate with the
SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
96-103 N.m (9.8-10.5 m-kg, 71-76 ft-lb)
Timing Belt Pulley
1, Reverse the direction of the SST or equivalent on the
flywheel.
2311082.064
B2-77

B2 INSTALLATION
L I I
03UOBZ-132
03UOB2-1 34
Engine and transaxle assembly
1. Suspend the engine and transaxle assembly.
Caution
l Do not damage any components in the engine com-
partment.
2. Install the engine and transaxle assembly in the engine
3. ii?the engine mounts with the engine mount member
mounting holes.
Engine mount
1. Install the engine mount nuts of the No.2 and No.3 mounts
and tighten them.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
2. Install the No.3 engine mount rubber.
Tightening torque
@j: 74-103 N-m (7.5-10.5 m-kg, 54-76 ft-lb)
@: 67-93 N-m (6.8-9.5 m-kg, 49-69 ft-lb)
3. Install the dynamic damper.
Tightening torque:
55-80 N-m (5.6-8.2 m-kg, 41-59 ft-lb)
Caution
l Before installing the engine support bracket, ar-
range the clutch release cylinder and pipe assembly.
4. Install the engine support bracket (MTX).
Tightening torque:
55-80 N-m (5.6-8.2 m-kg, 41-59 ft-lb)
5. Install the No.4 engine mount rubber and bracket, and
loosely tighten nuts @
6. Install bolts @ on the body side, and tighten them in two
or three steps in the order shown.
Tightening torque:
43-61 N-m (4.4-6.2 m-kg, 32-45 ft-lb)
7. Tighten nuts @.
Tightening torque:
67-93 N-m (6.8-9.5 m-kg, 49-69 ft-lb)

B2 INSTALLATION
I 1
OBUOEP-138
I
J 13UOB2-024
Tie-rod end
1. Install the tie-rod end to the knuckle.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
2. Install the new split pin.
Stabilizer
1. Install and adjust the stabilizer.
Dimension A: 17-19mm (0.87-0.75 in)
Extension bar (MTX)
1. Install the extension bar to the transaxle.
Tightening torque:
31-48 N#m (3.2-4.7 m-kg, 23-34 ft-lb)
Shift control rod (MTX)
1 Install the shift control rod to the transaxle.
Tightening torque:
18-23 N-m (1.8-2.3 m-kg, 12-17 ft-lb)
Clutch release cylinder (MTX)
1. Install the clutch release cylinder.
Tightening torque:
16-23 N#m (1.6-2.3 m-kg, 12-17 ft-lb)
2. Set the pipe bracket in position.
Tightening torque:
18-23 N-m (1.6-2.3 m-kg, 12-17 ft-lb)
Shift control cable (ATX)
1. Install the shift control cable to the transaxle.
Tightening torque:
6.9-9.8 N-m (70-100 cm-kg, 61-87 in-lb)
03UOB2-142
B2-98

F
FUEL AND EMISSION
CONTROL SYSTEM
INDEX ...........................................
OUTLINE ...................................... ;: 2
SYSTEM DIAGRAM ...................... F-
:
VACUUM HOSE ROUTING
DIAGRAM .................................
WIRING DIAGRAM ....................... F- 6
- 7
ENGINE CONTROL UNIT (ATX) ...... F- 13
SPECIFICATIONS.. ....................... F- 15
COMPONENT DESCRIPTIONS.
...... F- 16
TROUBLESHOOTING GUIDE.. ......... F- 20
ENGINE CONTROL OPERATION
CHART
..................................... F- 20
RELATIONSHIP CHART.. .............. F- 24
USING THIS SECTION .................. F- 25
DIAGNOSTIC INDEX .................... F- 27
PRECAUTION ............................. F- 29
SYMPTOM TROUBLESHOOTING .... F- 30
ENGINE TUNE-UP
.......................... F- 76
PREPARATION ............................
F- 76
BASIC INSPECTION ..................... F- 78
ADJUSTMENT .............................
F- 79
SELF-DIAGNOSIS FUNCTION .......... F- 82
DESCRIPTION .............................
F- 82
PREPARATION
............................
F- 83
SERVISE CODE NUMBER.. ........... F- 83
SWITCH MONITOR FUNCTION ...... F-105
INTAKE AIR SYSTEM.. ................... F-109
COMPONENT PARTS.. ................. F-109
THROTTLE BODY ........................ F-l 12
DYNAMIC CHAMBER ................... F-l 12
INTAKE MANIFOLD ..................... F-l 13
ACCELERATOR PEDAL ................ F-l 14
ACCELERATOR CABLE ................ F-l 14
IDLE SPEED CONTROL (ISC)
SYSTEM ......................................
F-115
DESCRIPTION ............................. F-115
PREPARATION
............................ F-116
SYSTEM OPERATION.. ................. F-l 16
ISC VALVE ................................. F-116
AIR VALVE
................................. F-116
VARIABLE INERTIA CHARGING
SYSTEM (VICS) [DOHC] ................ F-l 17
DESCRIPTION ............................. F-117
SYSTEM OPERATION ................... F-l 18
SHUTTER VALVE ACTUATOR.. ...... F-l 18
SOLENOID VALVE (VICS). ............. F-118
VACUUM CHAMBER.. .................. F-119
FUELSYSTEM .............................. F-l 20
DESCRIPTION
............................. F-l 20
PRECAUTION ............................. F-121
SYSTEM OPERATION.. ................. F-121
FUEL TANK ................................
F-l 23
FUEL FILTER .............................. F-l 24 FUEL PUMP ............................... F-l 25
CIRCUIT OPENING RELAY.. .......... F-129
PRESSURE REGULATOR.. ............ F-129
INJECTOR .................................. F-l 31
PRESSURE REGULATOR
CONTROL SYSTEM.. .................... F-l 34
SOLENOID VALVE (PRESSURE
REGULATOR CONTROL). ............ F-l 35
EXHAUST SYSTEM ........................ F-l 36
COMPONENT PARTS.. ................. F-136
OUTLINE OF EMISSION
CONTROL SYSTEM.. .................... F-l 37
STRUCTURAL VIEW.. ................... F-l 37
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM.. ..... F-138
DESCRIPTION .............................
F-l 38
PCV VALVE ................................ F-l 38
EVAPORATIVE EMISSION
CONTROL SYSTEM.. .................... F-l 39
DESCRIPTION ............................. F-l 39
SYSTEM OPERATION.. ................. F-140
SOLENOID VALVE
(PURGE CONTROL) ................... F-140
SEPARATOR ............................... F-l 40
CHECK VALVE (TWO-WAY) ........... F-140
CHECK-AND-CUT VALVE.. ............ F-141
CHARCOAL CANISTER.. ............... F-141
DECELERATION CONTROL
SYSTEM ...................................... F-l 42
DESCRIPTION ............................. F-l 42
DASHPOT .................................. F-142
FUEL CUT CONTROL SYSTEM ....... F-143
DESCRIPTION ............................. F-l 43
PREPARATION ............................ F-l 43
SYSTEM OPERATION.. ................. F-143
DECHOKE CONTROL SYSTEM.. ...... F-145
DESCRIPTION ............................. F-l 45
SYSTEM OPERATION ................... F-l 45
CONTROL SYSTEM ....................... F-l 47
PREPARATION ............................ F-147
STRUCTURAL VIEW.. ................... F-l 48
ENGINE CONTROL UNIT (ECU) ..... F-149
AIRFLOW METER (WITH INTAKE AIR
THERMOSENSOR) ..................... F-168
WATER THERMOSENSOR.. ........... F-168
THROTTLE SENSOR .................... F-l 69
OXYGEN SENSOR.. ..................... F-171
MAIN RELAY (FUEL INJ RELAY) .... F-172
CLUTCH SWITCH (MTX) ............... F-172
NEUTRAL SWITCH (MTX). ............. F-173
POWER STEERING PRESSURE
SWITCH .................................... F-173
WJOFX-001

INDEX F
1. Resonance duct
Inspection / Replacement.. ........ page F-l 09
2. Air cleaner element
Inspection ................................. page F- 79
Replacement.. ........................... page F-l 09
3. Airflow meter
(With intake air thermosensor)
Inspection
................................. page F-l 68
Replacement.. ........................... page F-l 09
4. Resonance chamber
Inspection I Replacement.. ........ page F-l 09
5. Throttle body
Inspection .................................
page F-l 12
Replacement.. ...........................
page F-l 09
6. Throttle sensor
inspection ................................. page F-l 69
Adjustment..
.............................. page F-l 69
Replacement.. ........................... page F-l 71
7. ISC valve
Inspection ................................. page F-l 16
Replacement..
........................... page F-l 09
8. Dashpot
Inspection ................................. page F-l 42
9. Dynamic chamber
Removal / Installation ................
page F-109
Inspection [DOHC] ................... page F-l 12
10. Air valve
Inspection
................................. page F-l 16
Removal / Installation ................ page F-109
11. Shutter valve actuator
Inspection ................................. page F-l 18
12. Vacuum chamber [DOHC]
Inspection ................................. page F-l 19
13. Intake manifold
Removal / Installation ................ page F-l 09
14. Injector
Inspection .................................
page F-l 31
Removal .................................... page F-131
Installation.. ............................... page F-l 33 15. Pressure regulator
Inspection ................................. page F-l 29
Replacement ............................. page F-l 30
16. Solenoid valve (Pressure regulator control)
[BP1
Inspection ................................. page F-l 35
17. Solenoid valve (VICS) [DOHC]
Inspection ................................. page F-l 18
18. Charcoal canister
Inspection ................................. page F-l 41
19. Solenoid valve (Purge control)
Inspection ................................. page F-l 40
20. Circuit opening relay
Inspection ................................. page F-l 29
Replacement ............................. page F-l 29
21. Engine control unit (ECU)
Removal / Installation ................ page F-l 49
Inspection ................................. page F-149
22. Clutch switch (MTX)
Inspection ................................. page F-l 72
Replacement.. ........................... page F-l 72
23. PCV valve
Inspection ................................. page F-l 38
24. Water thermosensor
Removal / Inspection /
Installation ............................... page F-l 68
25. Fuel filter (High-pressure side)
Replacement.. ........................... page F-l 24
26. Main relay (FUEL INJ relay)
Inspection ................................. page F-l 72
27. Neutral switch (MTX)
inspection ................................. page F-l 73
Replacement.. ........................... page F-l 73
28. Oxygen sensor
Inspection ................................. page F-l 71
Replacement ............................. page F-l 72
29. Power steering pressure switch
Inspection ................................. page F-l 73
Replacement.. ........................... page F-l 73
23UOFX-002
F-3

EGI MT l ENGINE CONTROL SYSTEM(3/3) <>. .DOHC
INSTRUMENT
(SECTION E-3)
EXCEPT
SECTION G) LAMPS
(SECTION 1-4)
-01 ENGINE CONTROL UNIT(EM1
1” is 10 10 iw 1K 11 1G 1E ic 1A 61-19 AIRFLOW METER (EM)
2Y 2w 2” 25 20 20 2M 2K 21 26 2E
2c 2A
X G/W Y/B V L/R * i/o Y G/ x ‘I;’ W /L B/O
L/B * W/B W/Y W/R * W/L Y/B G/O X R/B R/L G/ * “F’ P /0 B/O
1.l 1H IF ID IS
22 2x 2v 2T 2R 2P 2N 2L 2J 2H 2F 20 26
-20 THROTTLE SENSOR 81-21 CLUTCH SWITCH fF)
(EM) El-22 NEUTRAL SWITCH (EM1

F OUTLINE
COMPONENT DESCRIPTIONS
Component
Air cleaner
Airflow meter
Mr valve
Atmospheric pressure
Sensor
Catalytic converter Function Remark
Filters air entering throttle body
Detects amount of intake air; sends signal to intake air thermosensor and fuel pump
ECU switch included
Supplies bypass air into dynamic chamber
l Engine speed increased to shorten
when engine is cold warm-up period
l Thermowax type l Installed in dynamic chamber
Detects atmospheric pressure; sends signal Built in ECU
to ECU
Reduces HC, CO, and NOx by chemical Monolith type
reaction Charcoal canister
Stores fuel tank fumes while engine stopped Check valve
Controls pressure in fuel tank Two-way type Circuit opening relay
Voltage for fuel pump while engine running Clutch switch (MTX)
Detects clutch condition; sends signal to Switch OFF when clutch pedal released
ECU Diagnosis connector
Concentrated service connector 25pin (located near left suspension mount-
Concentrated terminals: ing block)
1. EGI self-diagnostic terminal
2. EC-AT self-diagnostic terminal
3. Test terminal
4. Fuel pump check terminal
5. Cooling fan check terminal
6. Engine rpm output terminal Dynamic chamber
Interconnects all cylinders Engine control unit (ECU) Detects the following:
1. A/C operation 1. A/C switch
2. Air/fuel ratio (Oxygen concentration) 2. Oxygen sensor
3. ATF thermosensor
4. Atmospheric pressure 4. Atmospheric pressure sensor
5. Braking signal 5. Stoplight switch (MTX)
6. Cranking signal 6. Ignition switch (START Position)
7. DRL (Daytime Running Light) operation 7. DRL relay (Canada)
8. E/L operation 8. Blower motor switch, cooling fan relay,
headlight switch, and rear window
defroster switch
9. Engine coolant temperature 9. Water thermosensor
10. Engine speed 10. Distributor (Ne-signal)
11. Ignition ON signal 11. Ignition switch
12. In-gear condition 12. Neutral and clutch switches (MTX)
13. Inhibitor switch (ATX) 13. N range, D range, S range, L range
switch
14. Intake air amount 14. Airflow meter
15. Intake air temperature 15. Intake air thermosensor
(In airflow meter)
16. No.1 piston TDC of compression
17. P/S operation
18. Shift solenoid (ATX)
19. Test signal (Ignition timing, idle speed,
Malfunction code No.)
20. Throttle valve fully closed/fully open
condition 16. Distributor (G-signal) DOHC)
17. P/S pressure switch
18. 1-2, 2-3, 3-4, Lockup solenoid
19. Diagnosis connector
(TEN terminal)
20. Throttle sensor (MTX)
21. Throttle valve opening angle
22. Turbine sensor 21. Throttle sensor (ATX) .__r
F-10

F TROUBLESHOOTING GUIDE
RELATIONSHIP CHART
OUTPUT DEVICE
INPUT DEVICE
DIAGNOSIS CONNECTOR
[TEN TERMINAL) 0 0 0 0
IGNITION SWITCH (START POSITION) 0 0 0 0 0 0
E/L SIGNALg4 0
0
P/S PRESSURE SWITCH 0 0
B/C SWITCH 0 0 0
INHIBITOR SWITCH (ATX) 0 0 0 0 0 0 0
NEUTRALANDCLUTCH
SWITCHES (MTX) 0 0 0 0 0 0 0
STOPLIGHT SWITCH 0
0
&TMOSPHERIC PRESSURE SENSOR
[IN ECU) o 0 0 0 0
rHROTTLE SENSOR 0 0 0 0 0 0 0
INTAKE AIR THERMOSENSOR 0 0 0 0 0
MRFLOW METER 0 0 0 0 0
3XYGEN SENSOR 0 0 0 0
JVATERTHERMOSENSOR 0 0 0 0 0 0 0
G-SIGNAL*’ 0 0
3ISTRIBUTOR
Ne-SIGNAL 0 0 0 0 0 0 0 0
-- ,.-, ,--., ,.*
+z
*3 &HC
MIL: Malfunction Indicator Lamp
r.9u”rn-” I
*’ E/L SIGNAL: Blower fan control switch second position or higher, cooling fan operating, headlights ON, or rear win-
dow defroster switch ON
F-24

TROUBLESHOOTING GUIDE F
9 LACK OF POWER
_-- --
L L -
ESCRIP- *Performance poor under load when throttle valve wide open
ION *Reduced maximum speed
* Idle condition normal
VtOUBLESHOOTlNG HINTS]
) Factors other than engine malfunction
*Clutch slipping
* ATX slipping
l Brake dragging l Low tire pressure
l Incorrect We size l Overloaded
‘, Low intake air amount @ Air/Fuel mixture too lean
l Fuel line pressure decreases l Fuel injection malfunction
@ Poor ignition
@ Low engine compression
@ Alcohol blended fuel used
l Throttle valve not open fully
*Clogged intake air system
l Low tire pressure CY Section H
CY Section K
cz7 Section P
c7 Section Q
w page F-l 14
CT= page F-l 12
Checker with ignition switch ON
w page F-83
rminal 1F voltage CT page F-150
Specification: Battery voltage
(Ignition switch ON)
* If OK, replace ECU w page F-149
c3 If not OK, check wiring between
ECU and Self-Diagnosis Checker
Ignition timing (BTDC)
l BP DOHC : 9*-l lo l BP SOHC
: 4O-8O 4 If advances, go to next step
* If not advance, check ECU terminal
w page F-150
F-61

TROUBLESHOOTING GUIDE F
20 POOR ACCELERATION
DESCRIP- l Performance poor while accelerating
TION l idle condition normal [TROUBLESHOOTING HINTS)
3 Factors other than engine malfunction @ Air/Fuel mixture too lean
*Clutch slipping l Fuel line pressure decreases l ATX slipping l Fuel injection malfunction
l Brake dragging @ Poor ignition l Low tire pressure
@ Low engine compression
l Incorrect tire size @ Alcohol blended fuel used l Over-loaded
3 Low intake arr amount
*Throttle valve not open fully
*Clogging in intake air system
Check factors other than engine CT Section H
c7 Section
P
ing accelerator fully w page F-l 14
w page F-l 12
Checker with ignition switch ON w page F-83
rminal 1 F voltage w page F-150
Specification: Battery voltage
(Ignition switch ON)
W: SELF TEST c3 If OK, replace ECU w page F-149 r;3 If not OK, check wiring between
ECU and Self-Diagnosis Checker
Clearance between throttle
lever and stopper
0.1 mm (0.004 in)
l.Omm (0.039 in)
O.lmm (0.004 in)
0.6mm (0.024 in)