battery MAZDA PROTEGE 1992 Owner's Guide

OIL PAN
I 03UODX.02
05UOBX.20
1
05UODX-021
56 SOHC
03UODX-02
3P s
03UODX-02!
1. Remove all foreign material from the contact surfaces.
2. Apply silicone sealant to the contact surfaces of a new oil
pan gasket, shown in the figure.
3. Install new gaskets onto the oil pump body and the rear
cover with the projections in the notches shown in the figure.
4. Apply a continuous bead of silicone sealant to the oil pan
along the inside of the bolt holes and overlap the ends.
5. Install the oil pan.
B6 SOHC
Tightening torque:
7.6-11 N-m (80-110 cm-kg, 69-95 in-lb)
BP SOHC
Tightening torque
A : 7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
8 B : 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Steps After Installation
1. Install the under cover and side cover.
2. Fill with the specified amount and type of engine oil.
3. Connect the negative battery cable.
4. Start the engine and check for leaks.
5. Check the oil level and add oil if necessary.
D-12

E RADIATOR
RADIATOR
REMOVAL / INSTALLATION
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
-...__--- --- i
771 InFu.nnc; cvyILII ..,.,..
6. Oil cooler hose (ATX)
7. Radiator bracket
8. Radiator
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E-9
9. Cooling fan and radiator cowling assembly 1. Resonance chamber
2. Cooling fan connector
3. Radiator thermoswitch connector (BP ATX)
4. Coolant reservoir hose
5. Radiator hose i
Y’
E-8

RADIATOR, THERMOSTAT t
THERMOSTAT
REMOVAL / INSTALLATION INSPECTION
Check for the following and repair or replace as necessary.
1. Cracks, damage, and water leakage.
2. Bent fins (repair with a screwdriver).
3. Distorted or bent radiator inlet.
Steps After Installation
1. Fill the radiator with the specified amount and type of en-
gine coolant. (Refer to page E-6.)
2. Connect the negative battery cable.
3. Start the engine and check for leaks.
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
SOHC AND BP SOHC : \,
19-26 N&6.9-2.6 m-kg, 14-19 ft-lb) 19-26 N-m (l.S--2&m-kg, 14-Wft-lb)
23UOEX-006
1. Water thermoswitch connector
2. Radiator hose upper
3. Thermostat cover
4. Thermostat gasket 5. Thermostat
Inspection . . . . .., .., ,.. ,.. . . . ,.. . . . . . . . . . . . . . . . . . . . . . . below
Installation Note ..,....................... page E-10
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page E-10
INSPECTION
1. Visually check that the thermostat valve is airtight.
2. Place the thermostat and a thermometer in water.
3. Heat the water and check the following:
Initial-opening temperature
Main: 86.5-89.5°C (188-193OF)
Sub : 83.5-86.5OC (182-188OF)
Full-open temperature: 1 OOOC (212OF)
Full-open lift
OSUOEX-019
Main: 8.0mm (0.31 In) min.
Sub : 1.5mm (0.06 in) min.
E-9

E THERMOSTAT
Installation Note JIGGLE PIN Thermostat
6 8 8
1. Install the thermostat into the cylinder head with the jiggle
pin at the top. ..__
Thermostat gasket
1. Install a new gasket with the seal print side facing the cylin-
der head.
03UOEX-014
Steps After Installation
1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E-6.)
2. Connect the negative battery cable,
3. Start the engine and check for leaks.
03UOEX-015
.-
E-IO

WATER PUMP WATER PUMP
E
REMOVAL / INSTALLATION
Caution
l Do not disassemble the water pump. If a problem is found, replace the pump as a Unit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal.
B6 SOHC AND BP SOHC
83, t B6, BP SOHC
I
I
L-----------------_-- ------- -1
/ \/
19-26 (1.9-2.6, 14-19) LVVVLI. YY,
1. Timing belt 4. Water pump assembly
Service ., . . .., ,, ., . . . . . ,. ,.,. ., ,., . . ,,.... . . . . , Section Bl Inspect for cracks, damaged mounting
2. Water inlet pipe
and gasket surface, bearing condition, and leakage
3. Water bypass pipe and O-ring 5. Water pump gasket
E-l 1

BP DOHC
L 7.8-11 N-m (60-110 cm-kg, 69-95 in-lb)
E WATER PUMP
157-167
I
(W-17, 116-123) I
I
/
I
I
I
---N-w------
---------------
----_---_
-I
N.m (m-kg, ft-lb) 1
^^, *--., ^^^
1. Timing belt
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5. Water pump assembly
B2
2. Water inlet pipe and gasket Inspect for cracks, damaged mounting
3. Water bypass pipe and O-ring surface, bearing condition, and leakage
4. Oil dip stick pipe bracket 6. Water pump gasket
Steps After Installation
1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E-6.)
2. Connect the negative battery cable,
3. Start the engine and check for leaks.
03UOEX-018
E-12

E ELECTRIC COOLING FAN SYSTEM, FAN MOTOR
03UOEX-02
I
1
I
‘4
.

2
.:
)
SYSTEM INSPECTION
1. Jump across the fan test (TFA) terminal and the ground
(GND) terminal of the diagnosis connector.
2. Turn the ignition switch ON and verify that the fan operates.
If the fan does not operate, inspect the cooling fan system
components and wire harness. -.-
3. Remove the radiator cap and place a thermometer in the
radiator filler neck.
4. Start the engine.
5. Verify that the fan operates when the coolant temperature
reaches approx. 97OC (207OF).
If it does, check the water thermoswitch.
(Refer to page E-16.)
FAN MOTOR
INSPECTION
Single-Speed Type
1. Check that the battery is fully charged.
2. Disconnect the fan motor connector.
3. Connect the battery and an ammeter to the fan motor con-
nectar.
4. Verify that current is as specified.
Current (A)
B6 SOHC
BP SOHC
BP DOHC MTX ATX
6.6 f 1 6.6 f 1
6.6 f 1 -
6.6 f 1 -
5. If current is not within specification and/or the fan does not
turn smoothly, replace the fan motor.
Two-Speed Type
1. Check that the battery is fully charged.
2. Disconnect the fan motor connector.
3. Connect the battery and an ammeter to the fan motor con-
nectors for low-speed inspection. 4. Verify that the fan motor operates smoothly at the standard
current.
Current (A): 8.8 + 10% MAX

I
03UOEX-022
E-14

FAN MOTOR E
I-
i.- 5. Connect the battery, an ammeter, and switch to the fan mo-
tor connectors for high-speed inspection.
6. Verify that the fan motor operates smoothly at the standard
current or less with the switch ON.
Current (A): 13.3 + 10% MAX
7. If the fan motor is faulty, replace it.
---“-. --
REPLACEMENT
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
7.8-11 N.m
7.8-11 N.m
(80-110 cm-kg,
1. Resonance chamber
4. Radiator cowling
2. Cooling fan connector
5.
Cooling fan
3. Radiator hose upper
6. Fan motor
E-l 5

E WATER THERMOSWITCH
WATER THERMOSWITCH
REMOVAL / INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
3. Install in the reverse order of removal, referring to
Installation Note.
2. Water thermoswitch
23UOEX-OO!
1. Water thermoswitch connector
05UOEX-031
05UOEX.03
E-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
INSPECTION
1. Place the switch and a thermometer in water.
2. Heat the water gradually and check continuity of the switch
with an ohmmeter.
I Coolant temDerature
OC PF) 1 Continuity
I
More than 97 (207) Yes
Less than 90 (194) No
3. If not as specified, replace the water thermoswitch.
Installation Note
Water thermoswitch
1. Apply a small amount of engine coolant to the new O-ring.
Caution
l Do not use an impact wrench for Installation.
2. Install the water thermoswitch.
Tightening torque:
5.9-8.8 N#m (69-90 cm-kg, 52-78 in-lb)

RADIATOR THERMOSWITCH E
RADIATOR THERMOSWITCH
REMOVAL / INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
3. Install in the reverse order of removal. referrina to
Installation Note.
(80-110 cm-kg,
69-95 in-lb)
GAdKET,
REPLACE (60-120 cm-kg, 52-104 In-lb)
1. Resonance chamber
2. Radiator cowling installation bolts
3. Radiator thermoswitch connector 4. Radiator thermoswitch
Inspection . . . . . . . . . . . . . . . ..*...,..,..................* below
Installation Note ..,.,........,.......,........,... below
1. Place the switch and a thermometer in engine oil.
03UOEX-02
INSPECTION
Warning
l Do not heat the engine oil above 120°C (248OF)
2. Heat the engine oil gradually and check continuity of the
switch with an ohmmeter.
Engine oil temperature OC (OF) Continuity
More than 105 (221)
Yes
Less than 96 (205) No
3. If not as specified, replace the radiator thermoswitch.
lnstallatlon Note
Radiator thermoswitch
Caution
l Do not use an impact wrench for installation.
1. Install the radiator thermoswitch along with a new gasket.
Tightening torque:
5.9-12 N#m (60-l 20 cm-kg, 52-104 in-lb)
13UOEX-005
E-17