no spark MAZDA PROTEGE 1992 Owner's Manual

OUTLINE
Component Function Remark
Engine control unit (ECU) Controls operation of the following:
(Cont’d)
1. A/C (Cut-off) 1. A/C relay
2. Fail-safe function 2. Self-Diagnosis Checker and MIL
3. Fuel injection system 3. Injector
4. idle speed control 4. Idle speed control (ISC) valve
5. Ignition timing control system 5. Igniter
6. Monitor function 6. Monitor lamp (Self-Diagnosis Checker)
7. Pressure regulator control system 7. Solenoid valve
(Pressure regulator control) (BP)
8. Purge control system 8. Purge control solenoid valve
9. VICS 9. Solenoid valve (WCS) (DOHC) Fuel filter
Filters particles from fuel Fuel pump
Provides fuel to injectors l Operates while engine running l Installed in fuel tank Igniter
Receives spark signal from ECU and gener-
ates high voltage in ignition coil Ignition switch
Engine cranking signal sent to ECU (START position)
Inhibitor switch (ATX)
Detects in-gear condition; sends signal to Switch ON in N or P range
ECU Injector
Intake air thermosensor
Idle speed control (ISC)
valve
Main relay
(FUEL INJ relay)
MIL (Malfunction
indicator lamp)
Neutral switch (MTX)
Oxygen sensor
PCV valve
P/S pressure switch
Pressure regulator
Resonance chamber
Resonance duct
Separator
Stoplight switch
Solenoid valve
(Purge control)
Shutter valve actuator
(DOHC)
Throttle body
Throttle sensor
Injects fuel into intake port l Controlled by signals from ECU
l High-ohmic injector
Detects intake air temperature; sends signal Installed on dynamic chamber
to ECU
Controls bypass air amount Controlled by duty signal from ECU
Supplies electric current to injectors, ECU,
etc.
Lamp flashes to indicate malfunction code
number of input and output devices
Detects in-gear condition; sends signal to
ECU
Detects oxygen concentration; sends signal
to ECU
Controls blowby gas introduced into engine
Detects P/S operation; sends signal to ECU
Adjusts fuel pressure supplied to injectors
Reduces intake air noise
Reduces intake air noise
Prevents fuel from flowing into charcoal
canister
Detects braking operation (deceleration),
sends signal to ECU
Controls evaporative fumes from canister to
intake manifold
Closes/opens shutter valve to improve
torque characteristics
Controls intake air quantity
l Detects throttle valve fully closed/fully
opened condition (MTX) TEN terminal grounded
Switch ON in neutral
Zirconia ceramic and platinum coating
P/S: ON when steering wheel turned right or
left
Controlled by duty signal from ECU
For Variable inertia charging system (VICS*)
Integrated throttle sensor, dashpot, and ISC
valve
l Detects throttle valve opening angle
(A-W
l Sends signals to ECU
F-l 7

F TROUBLESHOOTING GUIDE
SYMPTOM TROUBLESHOOTING
2 CRANKS NORMALLY BUT WILL NOT START (NO COMBUSTION)
l Engine cranks at normal speed but shows no sign of “firing”
DESCRIP-
*Battery in normal condition
TION
*Throttle valve not held fully open while cranking (Dechoke system not operate)
*Fuel in tank [TROUBLESHOOTING HINTS]
Because of no combustion, possibly no fuel is injected to engine or no ignition at all cylinders
:I) No spark
@I Low fuel line pressure
l Ignition control malfunction
@ Low engine compression l Ignition system component malfunction
3 No fuel injection
l Fuel pump inoperative l Injectors inoperative
TEP INSPECTION
ACTION
1 Check if strong blue spark is visible at discon-
Yes Go to Step 3
netted high-tension lead
No Go to Step 2
2 Check if “00” is displayed on Self-Diagnosis
Yes Check ignition system (Refer to
Checker with ignition switch ON
Troubleshooting “Misfire”) w page G-5
w page F-82
No Service Code No. displayed
Check for cause (Refer to specified
check sequence) w page F-83
“88” flashes
Check ECU terminal 1F voltage w page F-150
Specification: Battery voltage
(Ignition switch ON)
W: SELF TEST e If OK, replace ECU w page F-149 c3 If not OK, check wiring between
SELECT SW: A ECU and Self-Diagnosis Checker
3 Connect diagnosis connector terminals F/P and
Yes Check if engine starts in this condition
GND with jumper wire and check for fuel pump
operating sound with ignition switch ON c3 If starts, check circuit opening relay c7 page F-129
w page F-125
c3 If does not start, go to Step 5
DIAGNOSIS C
Go to next step ._-,
._. ,
F-30

TROUBLESHOOTING GUIDE
TEP INSPECTION ACTION
4 Check if ECU terminal voltages are OK Yes Go to next step
MTX...Especially IC, 20 and 2Q
ATX... Especially lC, 2E and 3D v page F-150
No Check for cause ~3‘ page F-151
5
Check for air leakage of intake air system com- Yes Repair or replace
ponents
No Go to next step
6 Check if engine starts when water thermosensor Yes Check water thermosensor c7 page F-158 is disconnected
Check for correct engine compression 82-10 ’ No
Check engine condition CIP page Bl-10
Engine compression: 82-10
l BP SOHC l Worn piston, piston rings or cylinder 834 kPa (8.5 kg/cm*, 121 psi)300 rpm
wall
l BP DOHC l Defective cylinder head gasket 883 kPa (9.0 kg/cm*, 128 psi)-300 rpm l Distorted cylinder head
l B8 l Improper valve seating 932 kPa (9.5 kg/cm*, 135 psi)300 rpm *Valve sticking in guide
9 Check if spark plugs are OK Yes Go to next step CT- page G-18
1.0-l .l mm
(0.039-0.043 in) DAMAGE AND
DETERIORATION No Clean, or replace c7 page G-18
10 Try known good ECU and check if condition
improves CT- page F-149
23UOFX-01 I
F-33

F TROUBLESHOOTING GUIDE
5
CRANKS NORMALLY BUT HARD TO START - ALWAYS
DESCRIP- l Engine cranks at normal speed but requires excessive cranking time before starting
TION l Battery in normal condition
*Engine runs normally at idle [If idle condition not OK, refer to “Rough idle” (Nos. 8-12)J [TROUBLESHOOTING HINTS]
@ Air/Fuel mixture too lean
@ Air/Fuel mixture too rich l Fuel injection control malfunction
(Correction for coolant temperature) *Air cleaner element clogged
l Airflow meter stuck
*Low fuel line pressure
l Air leakage @ Poor ignition spark
;TEP INSPECTION ACTION
1
Check if “00” is displayed on Self-Diagnosis Yes Go to next step
Checker with ignition switch ON W page F-82 No
Service Code No. displayed
Check for cause (Refer to specified SYSTEM SELECT: 1 check sequence) w page F-83
“88” flashes
Check ECU terminal 1F voltage w page F-150
Specification: Battery voltage
(Ignitlon switch ON)
* If OK, replace ECU w page F-149
W: SELF TEST c3 If not OK, check wiring between
ECU and Self-Diagnosis Checker
2 Check for correct intake manifold vacuum at idle
Yes Go to next step
VsCUUm: More than 450 mmHg (17.7 inHg) No Check for air leakage of intake air sys-
tem components
3 Check if air cleaner element is clean
Yes Go to next step w page F-79
No
Replace air cleaner element
4 Check if engine starts easily when throttle valve Yes Check throttle valve for carbon deposit
quarter open and then go to Step 6 Fuel line pressure:
265-314 kPa (2.7-3.2 kg/cm*, 38-46 psi)
(Vacuum hose to pressure regulator dis-
pressure while pinching
c3 If fuel line pressure quickly in-
creases, check pressure regulator w page F-129
c3 If fuel line pressure gradually in-
creases, check for clogging be-
tween fuel pump and pressure
If not clogged, check fuel pump
maximum pressure W- page F-126
F-36

F TROUBLESHOOTING GUIDE
8 ROUGH IDLE/ENGINE STALLS AT IDLE - ALWAYS
bESCRIP- l Engine starts normally but stalls or vibrates excessively at idle in every condition
‘ION TROUBLESHOOTING HINTS]
D Air/Fuel mixture too lean @ Incorrect idle speed
l Air leakage l Idle speed misadjustment l Fuel injection control malfunction l Idle speed control malfunction
*Low fuel line pressure @ One or more spark plugs not firing
3 One or more injectors clogged or not operating @ Low engine compression
3 Low intake air amount @ Airflow meter stuck INSPECTION
1
1
2
3
4
5
6
- Check if “00” is displayed on Self-Diagnosis
Checker with ignition switch ON w page F-82
SYSTEM2ELECT: 1
M v’SELECT SW: A TEST
Check if ECU terminal voltages are OK
MTX...Especially 2D, 20 and 2Q
ATX... Especially 2B, 2E and 3D CT page F-150
Disconnect high-tension lead at idle and check if
engine speed decreases equally at each cylinder
Check for injector operating sound at idle
Check if battery voltage exists at injector connec-
tor (W/R) wire
Check if strong blue spark is visible at discon-
nected high-tension lead
, Yes No Service Code No. displayed
Check for cause (Refer to specified
:heck sequence) “88” flashes
Check ECU terminal IF voltage CT page F-150
Specification: Battery voltage
(Ignition switch ON)
3 If OK, replace ECU w page F-149 3 If not OK, check wiring between
ECU and Self-Diaanosis Checker Yes
Go to next step No
Check for cause Yes
Go to Step 8 No
Go to next step
Go to Step 6
Go to Step 5 Yes
No
Yes
No
Yes
No I-
30 to next step w page F-83
0 page F-151
Check if injector resistance is OK c7 page F-131
Resistance: Approx. 12-l 852
c3 If OK, check wiring between ECU
and injector
c3 If not OK, replace injector w page F-131
Check wiring between ECU and injector
Go to next step
Check high-tension lead w page G-17
Q If OK, check distributor cap and
rotor w page G-22
c3 If not OK, replace high-tension lead
F-42

TROUBLESHOOTING GUIDE F
No Replace airflow meter
9
Check for injector operating sound at idle Yes Go to Step 11
No Go to next Step
10 Check if battery voltage exists at injector connec- Yes Check if injector resistance is OK CT page F-131
tor (W/R) wire Resistance: 12-l 6fi
c3 If OK, check wiring between ECU
and injector
c3 If not OK, replace injector CT page F-131
No
Check wiring between ECU and injector
11 Check if strong blue spark is visible at discon-
Yes Go to next step
netted high-tension lead
No Check high-tension lead
+ If OK, check distributor cap and
rotor w page G-22
* If not OK, replace high-tension lead
12
Check if spark plugs are OK Yes Check for correct engine compression CT page Bl-10
w page G-16 82-10
Compression (Minimum):
. BP SOHC
834 kPa (8.5 kg/cm2, 121 psi)300 rpm
BON BUILDUP l BP DOHC
883 kPa (9.0 kg/cm*, 128 psi)-300 rpm
l.O-l.lmm ’ B6 DAMAGE AND 932 kPa (9.5 kg/cm’, 135 psi)-300 rpm DETERIORATION
c3 If OK, go to next step
c13 If not OK, check for cause CT page Bl-10
B2-10
No
Clean or replace w page G-18
13
Check for injector leakage Yes Replace injector CT page F-131
w page F-132
No Go
to next step
14 Try known good ECU and check if condition im-
proves cc7 page F-149
23UOFX-030
F-53

TROUBLESHOOTING GUIDE
16 ENGINE STALLS SUDDENLY (INTERMITTENT)
DESCRIP- l Engine intermittently stops running
TION l Before stalling, engine condition OK [TROUBLESHOOTING HINTS]
@ Intermittently no spark or no-fuel injection caused by ve-
hicle vibration, acceleration, or deceleration
*Poor connection in wire harness
3 INSPECTION
Check if “00” is displayed on Self-Diagnosis
Checker with ignition switch ON c7 page F-82
g
-%ELECT SW: A
Check for poor connection of following parts l ignition coil
l igniter l Distributor l High-tension lead l lniector
l Ci;cuit opening relay l ECU
Check if ECU terminal voltages are OK
MTX...Especially lB, 2A, 28 and 2C
ATX... Especially lB, 3A, 38 and 3C w page F-150
Note
l When checking voltages, tap, move, and
wiggle harness and connector to recreate
problem
Yes
No Service Code No. displayed
Check for cause (Refer to specified
check sequence) Note
l When checking wiring harness and
connectors, tap, move, and wiggle
suspect sensor and/or harness to
recreate problem
“88” flashes
Check ECU terminal IF voltage w page F-150
Specification: Battery voltage
(Ignition switch ON)
c3 If OK, replace ECU CT= page F-149
+ If not OK, check wiring between
ECU and Self-Diagnosis Checker
Yes
Repair or replace
No Go to next step
Yes
No
T ACTION
Go to next step w page F-83
Go to Troubleshooting No.2
‘CRANKS NORMALLY BUT WILL NOT
START (NO COMBUSTION)” CT- page F-30
Check for cause D page F-151
F-56

TROUBLESHOOTING GUIDE
17 HESITATES/STUMBLES ON ACCELERATION
bESCRIP-
*Flat spot occurs just after accelerator depressed or mild jerking occurs during acceleration
‘ION TROUBLESHOOTING HINTS]
0 Air/Fuel mixture becomes lean when depressing accelerator l Fuel injection control malfunction
(Correction for accelerating condition)
*Air leakage
l Fuel line pressure decreases l Spark advance control malfunction TEP INSPECTION ACTION
1 Check if “00” is displayed on Self-Diagnosis Yes Go to next step
Checker with ignition switch ON W page F-82 ’ No
Service Code No. displayed
SYSTEM SELECT: 1 Check for cause (Refer to specified
check sequence) w page F-83
“88” flashes
W: SELF TEST Check ECU terminal IF voltage CT= page F-150
Specification: Battery voltage
(Ignition switch ON) c3 If OK, replace ECU c? page F-149 * If not OK, check wiring between
ECU and Self-Diagnosis Checker Vacuum: More than 450 mmHg (17.7 InHg)
tern components
Replace air cleaner element 4
Check if ECU terminal voltages are OK
Yes Go to next step
MTX...Especiaily 2L
ATX... Especially lT, 2F, and 21 w page F-150
No Check for cause cp page F-151
5
Check if throttle linkage is correctly installed and
Yes Go to next step
operates freely w page F-l 14 ~~
Correct, clean, or replace as required
any binding or damaged linkage and
adjust cable deflection at throttle body w page F-l 14
6
Check continuity between throttle sensor termi- Yes Go to next step
nals IDL and E w page F-189
MTX
A-I-X 1
J E
IDL
Clearance between throttle
lever and stopper Continuity
MTX 0.1 mm (0.004 in) Yes
1 .Omm (0.039 in) No
ATX 0.1 mm (0.004 in)
Yes
0.6mm (0.024 in) No
No Adjust w page F-189
F-57

TROUBLESHOOTING GUIDE F
26 POOR FUEL ECONOMY
DESCRIP-
l Fuel economy unsatisfactory TION
[TROUBLESHOOTING HINTS]
While fuel consumption is drastically increased by city driving, short-run operation, stop and go driving, extended winter
warm-up periods, etc., as opposed to “trip” mileage, an attempt should be made to determine these factors when con-
fronted with “poor mileage” conditions. However, since the operator is not always at fault, the following is offered.
@II Operator depressing accelerator more than usual due to
@ Air/Fuel mixture too rich
low engine power
l Poor ignition *High fuel line pressure
@ Alcohol blended fuel used
*Low intake air amount
l Electronic spark advance control system malfunction @ High vehicle load l Low tire pressure
*Clutch slipping/ATX slipping l Incorrect tire size l Exhaust component restricted l Brake dragging ;TEP
INSPECTION ACTION
1
Check factors other than engine Yes
Go to next step
l Low tire pressure = Section Q 9 Unrecommended tire srze v Section Q l Clutch slipping w Section H l Brake dragging No
0 Section P Repair
l Exhaust component restricted cz= page F-136
2
Check if air hoses are connected correctly - Yes
Go to next step CI page F-109
No
Repair 3
Check if “00” IS displayed on Self-Diagnosis
Yes
Checker with ignition switch ON Go to next step W page F-82 No
SYSTEM SELECT: 1 Service Code No. displayed Check for cause (Refer to specified
check sequence) w page F-63
“88” flashes
Check ECU terminal 1F voltage w page F-150
Specification: Battery voltage
(Ignition switch ON)
* If OK, replace ECU CT= page F-149 e If not OK, check wiring between
ECU and Self-Diagnosis Checker 4
Check for correct intake manifold vacuum at idle
Yes Go to next step Vacuum: More than 450 mmHg (17.7 inHg) No
Check for air leakage at intake air sys-
tem components 5
Check if air cleaner element is clean Yes
Go to next step CT= page F-79
No
Replace air cleaner element
F-75

FUEL SYSTEM F
FUEL TANK
Removal / Inspection / Installation
Warning
l Before performing the following operation, release the fuel pressure from the fuel system to
reduce the possibility of injury or fire. (Refer to page F-121 .)
l When removing the fuel tank, keep sparks, cigarettes, and open flames away from it.
l Before repair the fuel tank, clean it throughly with steam to remove all explosive gas.
1. Remove in the order shown in the figure.
2. Inspect the fuel tank components visually and repair or replace if necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
7.8-l 1 N.m (80-l 10 cm-kg,
7.8-i 1 N-m (80-I 10 cm-kg, 89-95 in-lb) 69-95 in-lb)
N.m (m-kg, ft-lb]
23UOFX-107
Note
l Drain the fuel from the fuel tank before removing the tank.
1. Fuel pump cover 7. Fuel tank
2. Fuel pump connector Inspect for cracks and corrosion
3. Fuel hoses 8. Separator
Installation Note . ..., I .I,,,,I,I,.,.I.,,. page F-l 24 Inspect for cracks and corrosion
4. Evaporative hoses 9. Check valve (Two-way)
Installation Note ,..,..,................. page F-l 24 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page F-140
5. Insulator 10. Check-and-cut valve
6. Fuel tank straps Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . page F-141
F--l 23