engine coolant MAZDA PROTEGE 1992 Owner's Guide

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)

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 OUTLINE
I Component
I Function
I Remark
I
Three-way
solenoid
valve vIcs*
Pressure
regulator
control
Controls vacuum to shutter valve actuator
Controls vacuum to pressure regulator Cuts vacuum when engine speed above
5.000 ram
Cuts vacuum just after starting when engine
hot starting Vacuum chamber
(DOHC)
Water thermosensor
Stores vacuum for use during wide open For WCS*
throttle
Detects coolant temperature; sends signal to
ECU
l WCS: Variable Inertia Charging System 23UOFX-013
F-l 8

F TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
ENGINE CONTROL OPERATION CHART
Note
Input Device and Engine Conditions
l The data in this chart is for reference only.
INPUT DEVICES APPROX,- SENSORS
MATE TIME G& THROTTLE SENSOR
(BASED ON TRIBUTOR
WATER INTAKE
10-16°C, (G. OXYGEN AIRFLOW AIR
VT
POW
.50-6OOF
SIGNAL)” ;;;;;f- SENSOR METER
AMBIENT) (Ne-SIGNAL) THERMO- TERMINAL TERMINAL yE\MINAL
CONDITIONS SENSOR (ATX)
WX)
A
c
CRANKING
-COLD ENGINE Signal has Signal has Signal has Signal has Slgnal has Slgnal has
l COLD AIR zero no affect no effect no effect no effect no effect
no effect
. COLD COOLANT on ECU on ECU on ECU on ECU on ECU
on ECU
Cool to A A
COLD START
warm: Low volume Closed Closed
Closed
-FAST IDLE
One
Medium airflow: throttle: throttle:
l COLD AIR
minute
voltage High volt-
Low volt- Low volt- throttle.
Low volt-
* COLD COOLANT
(3.5” and :zo:o, ,,Pbove 1’,“,“$; a(ogi-O,8”) ;149&“) we W)
dropping) to high
(68OF)]:
COLD DRIVEAWAY voltage A
Above
-PART THROTTLE Two (O-0.9”) 2.3”
l COLD AIR minutes
l COLD COOLANT
v v ,,
Warm: Medi- Sensor Moderate II
WARM DRIVEAWAY
volume air-
-PART THROTTLE Three N&IGNAL um voitage hot:
flow: Low
l WARM AIR minutes Sends all Vvwrox switching l WARM COOLANT cylinders 0.7V and
from high to medium
Part Part
TDC signal dropping) voltage voltage
throttle: throttle.
)
A (0.9V) (1 .o-3.5”)
to ECU
.“~ Medium Medium
HOT CRUISE
s voltage voltage
Open
l WARM AIR G-
SIGNAL”’ to low (0.8-3.0”) (4.5-5.5”) throttle:
l WARM COOLANT High
Sends No. voltage
1 cylinder (0.1”) voltage
1 (battery
TDC (com-
1 I voltage)
HOT ACCELERATION pression)
-60% THROTTLE signal to
Moderate
ECU
to strong
High Cool lo warm
voltage ;$,“,” Of j-20-4OT
f t
HOT ACCELERATION
More’ than Hot: Low (0.9”) Low (-4-‘04”F)l: W,ds open
voltage 1.5-4.3v
throttle: Wide open
-WIDE OPEN
four voltage
High volt- throttle
THROTTLE (0.5-1.5V)
minutes (Below High
0.5”) age (Above
voltage (OV)
t 1 3.OV)
I,
A 1. /I
DECELERATION
-CLOSED THROTTLE
HOT CURB IDLE
-EXTENDED
HOT ENGINE
SHUTDOWN Low
voltage
(0”) Low Closed Closed
Closed
volume throttle: throttle.
throttle.
of airflow:
~~~~!$$ (Above Low Low
Low
voltage voltage
voltage
to low 3.OV) (0.2-0.N) (4.5-5 5V) (OV)
voltage
(0.75%
t t 1 0.25”)
r v 1 I I
Sensor
hot: Low
OFF OFF voltage
-
(0.1”) until OFF OFF OFF OFF
OFF
sensw
COOIS
._-

F TROUBLESHOOTING GUIDE
Output Devices and Engine Conditions
Note
. The data in this chart is for reference only.
INJECTOR
CONDITIONS
CRANKING
-COLD ENGINE
l COLD AIR l COLD COOLANT
COLD START
-FAST IDLE
l COLD AIR l COLD COOLANT
COLD DRIVEAWAY
-PART THROTTLE
l COLD AIR l COLD COOLANT
WARM DRIVEAWAY
-PART THROTTLE
. WARM AIR
l WARM COOLANT
HOT CRUISE
l WARM AIR l WARM COOLANT Zero
One
mrnute
Two
minutes
Three
minutes
I AIR
INJECTION “AL”E
INJECTION TlMlNG
A
All A
cylinders
each
ignition
pulse
1
Rich Open:
coolant
tem-
perature:
Below
40%
(104OF)
,
I/
Rich and
2-group” 1’
lean l-group” /I
,
i
HOT ACCELERATION
-60% THROTTLE
-lOT ACCELERATION
-WIDE OPEN
THROTTLE
Closed ISC
VALVE
1, THREE-WAY
SOLENOID SOLENOID
VALVE VALVE
(PURGE
(PRESSURE
CONTROL) REGULATOR
CONTROL)‘3
c
OFF
(Purge
cut)
Large
1
, AK
RELAY
amount or
bypass air
OFF
(Vacuum
to
pressure
regulator)
After start-
rng: ON dur-
ing hot start
only (Vacu-
um cut)
OFF
l 2 SOHC, *’ BP
F-22

F TROUBLESHOOTING GUIDE
Troubleshooting chart
6 I
CRANKS NORMALLY BUT HARD TO START - WHEN ENGINE COLD
*Engine cranks at normal speed but requires excessive crankmg time before starting
IESCRIP-
l Batterv in normal condition
llON l Restans OK after warmup l Engine runs normally at idle [If Idle condrtron is not OK, refer to “Rough idle” (Nos. S-12)]
TROUBLESHOOTING HINTS]
B Air/Fuel mrxture too rrch @Air/Fuel mixture too lean
l Arrflow meter stickrng l Fuel iniectron control malfunction
l Aw cleaner element clogged
*Idle weed control malfunction (Correction for coolant temperature)
0 Poor atomizatron
- ~~ ~~ *Low RVP (summer) fuel is used rn cold weather >
f INSPECTION T Check If “00” is displayed on Self-Diagnosis
Checker wth Ignition switch ON -
Yes
No CT page F-73
SYSTEM SELECT: 1
“SELECT SW: A
Check if ECU terminal voltages are OK
(Especially 1C. 2D. and 2Q)
cc page F-144
Check If engine starts easily when throttle valve -
Yes
-
NO
-
Yes ACTION
Go to next step
Malfunctlon Code No. dlsplayed
Check for cause (Refer to specified
check sequence)
“58” flashes CT- page F-79
Check ECU terminal 1F voltage
Speciflcetlon: Battery voltage CT page F-144
(Ignition ewltch ON)
+ If OK, replace ECU CT page F-143
e If. not OK, check wrring between
ECU and Self-Diagnoos Checker
Go to next step
Check for cause CI page F-145
(-!hnrlr ,‘ ICP ..-I..- .^ nv
c+ page F-103
13UOFX-009
DESCRIPTION:
Further describes the symptom. Confirm that the chart addresses the actual symptom before beginning
troubleshooting.
TROUBLESHOOTING HINTS:
This describes the possible point of malfunction.
STEP:
This shows the order of troubleshooting. Proceed with troubleshooting as indicated.
INSPECTION:
This describes an inspection to quickly determine the malfunction of parts. If a detailed procedure is necessary
to perform the INSPECTION, refer to the page shown by the “~7” mark.
ACTION:
This recommends the appropriate action to take as a result (Yes/No) of the INSPECTION. How to perform
the action is described on the reference page shown by the “~7” mark.
OWOFX-016
F-26

F TROUBLESHOOTING GUIDE
3 CRANKS NORMALLY BUT WILL NOT START (PARTIAL COMBUSTION) - WHEN ENGINE COLD
DESCRIP- *Engine cranks at normal speed but shows only partial combustion and will not continue to run
TION
l Battery in normal condition
*Fuel in tank
[TROUBLESHOOTING HINTS]
0 Air/Fuel mixture too rich
*Air cleaner element clogged
l Airflow meter stuck @ Low engine compression
@ Air/Fuel mixture too lean
l Fuel injection control malfunction
(Correction for coolant temperature)
*Low fuel line pressure
*Air leakage of intake air system
Checker with ignition switch ON
CT page F-83
w page F-150
Specification: Battery voltage
(Ignition switch ON)
W: SELF TEST w page F-149
Fuel line pressure:
285-314 kPa (2.7-3.2 kg/cm’, 38-48 psi) If fuel line pressure quickly in-
creases, check pressure regulator CF- page F-129
d If fuel line pressure gradually in-
creases check for clogging be-
I pump and pressure
Check if fuel return hose is clogged or
F-32

F TROUBLESHOOTING GUIDE
4
CRANKS NORMALLY BUT WILL NOT START (PARTIAL COMBUSTION) - AFTER WARM-UP *Engine cranks at normal speed and shows partial combustion but will not continue to run after running and
DESCRIP- hot soaked
TION *Battery in normal condition
*Engine starts normally when cold
[TROUBLESHOOTING HINTS] 3 Air/Fuel mixture too rich
@ Vapor lock
l Insufficient fuel injection control
*Fuel pressure not held in fuel line after engine stopped
(Correction for coolant temperature)
*High RVP (winter) fuel used in warm weather
l Injector fuel leakage @ Pressure regulator control system malfunction [BP]
switch ON, then check if en
D‘ page F-134
Fuel line pressure:
265-314 kPa (2.7-3.2 kg/cm’, 36-46 psi) ne pressure w
+ If fuel line pressure quickly in-
if fuel return hose is clogged
or
F-=34