check oil 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

ENGINE COOLANT E
ENGINE COOLANT
PREPARATION
SST
49 9200 145
For 49 9200 146
For
inspection of inspection of
cooling system Adapter A cooling system
pressure (Part of pressure
49 9200 145)
05UOEX-00
INSPECTION
Warning
l Never remove the radiator cap while the engine is
hot.
l Wrap a thick cloth around the cap when removing it.
l When removing the radiator cap, loosen it slowly
to the first stop until the pressure in the radiator is
released, and then remove it.
03UOEX~006
Coolant Level (Engine cold)
1. Verify that the coolant level is near the radiator filler neck.
2. Remove the coolant level gauge and check the coolant level.
Coolant Quality
1. Verify that there is no buildup of rust or scale around the
radiator cap or radiator filler neck.
2. Verify that coolant is free of oil. Replace the coolant if
necessary.
Coolant Leakage
1. Connect a radiator tester (commercially available) and the
SST to the radiator filler neck.
2. Apply
103 kPa (1.05 kg/cm2, 15 psi) pressure to the
system.
3. Verify that the pressure is held.
If not, check for coolant leakage.
E-5

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

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

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

TROUBLESHOOTING GUIDE
DIAGNOSTIC INDEX
No. TROUBLESHOOTING ITEM DESCRIPTION
1 Will not crank or cranks slowly Refer to Engine Electrical System PAGE
G- 4
Engine cranks at normal speed but shows no sign of 1 F-30
Engine cranks at normal speed but shows only par-
I
tial combustion and will not continue to run
Engine starts normally when cold, but will not start af-
After warm-up
5 Cranks normally but
Always
hard to start Engine cranks at normal speed but requires exces-
sive cranking time before starting F-36
F-38
I----
F-40 Same condition as No.5 when engine cold
Restarts normally after warm-up
Same cond;ion as No.5 after running and hot
soaked
Starts normally when cold
8
H
Rough idle
9 (Low idle speed)/
Engine stalls at idle Enaine stalls or vibrates excessivelv at idle
Engine stalls or vibrates excessively at idle during
warm-up 1 F-42
F-44
Engine runs normally at idle during warm-up but
vibrates excessively or stalls after warm-up
Engine stalls or vibrates excessively at idle when
A/C, P/S, or E/L ON F-46
F-46
starting (acceleration from idle)
l---- Engine stalls or vibrates excessively only just after
Idle speed excessive after warm-up 1 F-50 F-49 12 Rough idle/Engine stalls just after starting
13 High idle speed after warm-up
1 14 1 Idle moves up and down/Idle hunting Engine speeds up and down periodically at idle
1 F-52
I l5 I Engine stalls on deceleration
Engine unexpectedly stops running while decelerat-
ing or after deceleration F-54
Engine intermittently stops running
Flat spot occurs just after accelerator depressed or
mild jerkrng occurs during acceleration
Unexpected change in engine speed which is usually
repetitive F-56
F-57
F-59 16 Engine stalls suddenly (Intermittent)
17 Hesitates/Stumbles on acceleration
1 18 1 Surges while cruising
19
I I
Lack of power Performance poor under load when throttle valve F-61
wide open
Maximum speed reduced
Performance poor-while accelerating
-I- F-65 20 Poor acceleration
21 Runs rough on deceleration/Backfire Engine runs rough while decelerating and abnormal
combustion occurs in exhaust system F-69
Abnormal combustion accompanied by audible
“pinging” noise
Gasoline odor in cabin 22 Knocking
23 Fuel odor
24 Exhaust sulfur smell
26 High oil consumption Exhaust gas smells abnormal
Oil consumption excessive
Fuel economy unsatisfactory 1 26 1 Poor fuel economy 1 F-75
Self-Diagnosis Checker does not indicate malfunction
23UOFX~O’
F-27

F TROUBLESHOOTING GUIDE
15
ENGINE STALLS ON DECELERATION
DESCRIP-
l Engine unexpectedly stops running while decelerating or after deceleration
TION l Idle condition normal
[TROUBLESHOOTING HINTS]
Engine speed drops too much when releasing accelerator or poor connector connection disconnected by deceleration
force
3 Idle speed control malfunction
3 Fuel cut control malfunction @ Idle speed misadjustment
TEP INSPECTION
ACTION
1
Check if idle condition is normal Yes
Go to next step
No Adjust or perform troubleshooting
Nos. 8-11 “ROUGH IDLE” v page F-42
F-48
--
2
Check if “00” is displayed on Self-Diagnosis Yes Go to next step
Checker with ignition switch ON
W page F-82 No
SYSTEM SELECT: 1 Service Code No. displayed
Check for cause (Refer to specified
check sequence) w page F-83
“88” flashes
Check ECU terminal IF voltage LIT= page F-150
Specification: Battery voltage
(Ignition switch ON)
W: SELF TEST + If OK, replace ECU w page F-149
Q If not OK, check wiring between
ECU and Self-Diagnosis Checker
3 Check switches for correct operation with Self-
Yes Go to next step
Diagnosis Checker Monitor Lamp with ignition
switch ON
w page F-105 No
Lamp not ON or OFF with specified
switch
Check for cause (Refer to specified
check sequence) CT page F-106
-,-y/
,’ Lamp always ON
Check wiring between ECU terminal 1 D
and Self-Diagnosis Checker
W: SELF
TEST
4 Check if ECU terminal voltages are OK
Yes Go to next step
MTX...Especially IV, 2D, 20, 2U, 2V and 2Q
ATX... Especially 28, 2E, 30, 3U, and 3V
w page F-150 No Check for cause w page F-151
5
Check for poor connection of following parts
Yes Repair or replace
. Ignition coil
l Igniter l Distributor
-- l High-tension lead
No l Injector Go to next step l Circuit opening relay l ECU
F-54

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 F
DAMAGE AND
DETERIORATION
Check if resistance of high-tension leads are OK Resistance: 16 kQ per 1 m (3.26 ft)
li;;g
‘&
d No
Replace
.
12 Check if resistance of ignition coil is OK Yes Go to next step c7 page G-19
Resistance (at 20°C [6SaF]):
Primary coil winding . . . . . . . . 0.61-0.99n
Secondary coil winding.... lo-16 kdl
PRIMARY COIL SECONDARY COIL
WINDING
WINDING
No
Replace
13 Check for correct engine compression Yes Go to next step u page Bl-10
92-10 No
Check engine condition ~7 page 81-10
Engine compression: 82-l 0
. BP DOHC
*Worn piston, piston rings or cylinder 663 kPa (9.0 kg/cm2, 126 psi)-300 rpm wall
l BP SOHC l Defective cylinder head gasket 634 kPa (6.5 kg/cm2, 121 psi)-300 rpm l Distorted cylinder head
l 66 l improper valve seating 932 kPa (9.5 kg/cm2, 136 psi)300 rpm *Valve sticking in guide
14 Change fuel and check if condition improves Yes Change fuel to another brand
No SOHC
Go to Step 16 DOHC
Go to next step
F-63

TROUBLESHOOTING GUIDE F
TEP INSPECTION ACTION
9 Check if airflow meter is OK Yes Go to next step
CT page F-168
I. Check if measuring plate moves smoothly
II. Check resistance No Repair or replace
Fc Ei Vc Ez Vs THA
WEAR AND CARBON BUILDUP
DAMAGE AND
DETERIORATION
Resistance (at 20% [68OF]):
Primary coil winding . . . . . . . . 0.81-0.99Q
Secondary coil winding.... IO-16 kQ
PRIMARY COIL SECONDARY COIL
cc;i’ page 81-10
Engine compression (Minimum):
883 kPa (9.0 kg/cm*, 128 psi)-300 rpm
834 kPa (8.5 kg/cm*, 121 psi)-300 rpm
932 kPa (9.5 kg/cm2, 135 psi)-300 rpm *Worn piston, piston rings or cylinder
l Defective cylinder head gasket l Distorted cylinder head
l improper valve seating
*Valve sticking in guide
F-67