no spark MAZDA PROTEGE 1992 Owner's Guide

F FUEL SYSTEM
MIN. 35mm (1..4 in) -/
23UOFX-10
NJ
23UOFX-l(
OBUOFX-1:
Installation Note
Fuel hoses
1. Push the ends of the main fuel hose, fuel return hose, and
evaporative hoses onto the fuel tank fittings at least 25mm
(1.0 in).
2. Push the fuel filler hose onto the fuel tank pipe and filler pipe
at least 35mm (1.4 in).
FUEL FILTER
Replacement
Low-pressure side (In-tank filter)
(Refer to page F-128.)
High-pressure side
The fuel filter must be replaced at the intervals outlined in the
maintenance schedule.
Warning
l Always work away from sparks or open flames.
1. Disconnect the fuel hoses from the fuel filter.
2. Remove the fuel filter and bracket.
3. Install in the reverse order of removal.
Note
l When installing the filter, push the fuel hoses fully
onto the fuel filter.
F-l 24

FUEL SYSTEM F
DISCONNECT CONNECTOR
TO RELEASE FU5L PRESSURE
REAR SEAT C
23UOFX-11:
REPLACE
03UOFX-14s Replacement
Warning
l Before performing the following procedures, release
the fuel pressure from the fuel system to reduce the
possibility of injury or fire. (Refer to page F-121 .)
l When replacing the fuel system parts, keep sparks,
cigarettes, and open flames away from the fuel.
1. Push the rear seat cushion buttons and remove the cushion.
2. Remove the fuel pump cover.
3. Disconnect the fuel pump connector.
4. Disconnect the fuel hoses.
5. Remove the fuel pump and fuel tank gauge sender unit as-
sembly.
Caution
l Secure the fuel hoses tightly.
+ Use a new seal rubber.
6. Install in the reverse order of removal.
F-l 27

F FUELSYSTEM
DISCONNECT CONNECTOR
TO RELEASE FlJ$L PRESSURE
REAR SEAT C
23UOFX-11
INSTALL CLAMPS 7
03UOFX.I 59
F-l 30
DIAGNOSl&OJNECTOR
/ K
1 SUOFX-10
DISCONNECT CONNECTOR
TO RELEASE
FlJl$L PRESSURE
23UOFX-11
I
Hold pressure
Perform this inspection if the fuel pressure hold inspection is
not as specified. (Refer to page F-121 .)
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 .) ,-
1. Disconnect the negative battery terminal.
2. Connect a fuel pressure gauge between the fuel filter and
the fuel main hose. (Install clamps as shown.)
3. Connect the negative battery terminal.
4. Connect the diagnosis connector terminals
F/P and GND
with a jumper wire.
5. Turn the ignition switch ON
for 10 seconds to operate the
fuel pump.
6. Turn the ignition switch OFF and disconnect the jumper wire.
7. Pinch the fuel return hose with pliers.
8. Observe the fuel pressure
for 5 minutes.
Fuel pressure:
More than 147 kPa (1.5 kg/cm2, 21 psi)
9. If not as specified, replace the pressure regulator.
Replacement
Warning
l Before performing the followlng operation, release
the fuel pressure from the fuel system to reduce the
possibility of injury or flre. (Refer to page F-l 21.)
l When replacing fuel system components, keep
sparks, cigarettes, and open flames away from the
fuel.
1. Disconnect the vacuum hose.
2. Disconnect the fuel return hose.
3. Remove the pressure regulator.
Tightening torque:
7.8-11 N#m (80-110 cm-kg, 89-95 In-lb)
4. Install a new O-ring.
5. Install in the reverse order of removal.

231JOFX-1
FUEL SYSTEM F
INJECTOR
Inspection
Operation check
1. Warm up the engine and run it at idle.
2. Listen for operational sound of each injector with a screw-
driver or a sound scope.
3. If no sound is heard, measure injector resistance.
4. If the injector resistance is OK, check wiring to the injector
and the voltages of the ECU terminals MTX (2A, 2U and
2V) ATX (3A, 3U and 3V).
(Refer to page F-152.)
Injector resistance
1. Disconnect the injector harness.
2. Measure resistance of the injector with an ohmmeter.
Resistance: 12-l 6Q
3. If not as specified, replace the injector.
03UOFX-1
DISCONNECT CONNECTOR
TO RELEASE FU5L PRESSUR
REAR SEAT C
23UOFX-1
OBUOFX-
GRQMMET
INSULATOR
c5
OSUOFX-
Removal
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 system components, keep
sparks, cigarettes, and open flames away from the
fuel.
1. Disconnect the connectors from the injectors.
2. Remove the injector harness from the delivery pipe.
3. Remove the bolts from the intake manifold.
4. Remove the delivery pipe with the injectors and the pres-
sure regulator.
5. Remove the injectors, grommets, and insulators.
F-131

l Be extremely careful when working with fuel. I
23UOFX.121 Always work away from sparks or open flames.
3. Connect the diagnosis connector terminals F/P and GND
with a jumper wire.
FUEL SYSTEM
Fuel leakage test
1. Remove the injectors with the delivery pipe.
(Refer to page F-l 31.)
2. Affix the injectors to the delivery pipe with wire.
Caution
l Affix the injectors firmly to the delivery pipe so that
no movement of the injectors is possible.
-
Warning
4. Turn the ignition switch ON.
03UOFX-16’
23UOFX-12 9 5. Tilt the injectors approx. 60 degrees and verify that no fuel
leaks from the injector nozzles.
6. If fuel leaks from an injector, replace it.
Note
l After 1 minute a small amount of fuel leakage from
the injector Is acceptable.
7. Turn the ignition switch OFF and remove the jumper wire.
-i
F-l 32

DECHOKE CONTROL SYSTEM t-
DECHOKE CONTROL SYSTEM
DESCRIPTION
To facilitate starting the engine when the spark plugs become fouled, such as when the engine is flooded,
fuel injection is cut if the throttle valve is held wide open while cranking and the engine coolant temperature
is O°C (32OF) or below. This allows the spark oluas to drv and purges excess fuel from the cylinders.
f-- ECU _
. IGNITION SWITCH (START)
l ENGINE SPEED BELOW 500 rpm ’
l THROTTLE VALVE FULLY OPEN
l ENGINE COOLANT TEMPERATURE ;
BELOW
0% (32°F) I FUEL CUT
OBUOFX-19
I / / ‘ I
SYSTEM OPERATION
1.
2. Check if the engine coolant temperature is below O°C
(32OF).
If the engine coolant temperature is above O°C (32OF), dis-
connect the water thermosensor connector and connect an
approx. 10 kB resistor to the connector.
03UOFX.198 3. Turn the ignition switch to START and verify that the injec-
OBUOFX-19! 3
tor operating sound is heard.
4. Depress the accelerator pedal fully and turn the ignition
switch START. Verify that no injector operating sound is
heard.
F-l 45

G
ENGINE ELECTRICAL SYSTEM
INDEX ......................................................
OUTLINE ..................................................
SPECIFICATIONS .................................... G- 3
TROUBLESHOOTING
GUIDE.. .................... G-
4
DIAGNOSTIC INDEX ................................
SYMPTOM TROUBLESHOOTING..
............. :- t
-
CHARGING SYSTEM ................................. G- 6
PREPARATION .......................................
CIRCUIT DIAGRAM ................................. :I ;
TROUBLESHOOTING .............................. G- 7
BATTERY ............................................... G- 6
ALTERNATOR ........................................ G-10
DRIVE BELT ........................................... G-14
IGNITION SYSTEM .................................... G-15
PREPARATION ....................................... G-15
CIRCUIT DIAGRAM ................................. G-15
TROUBLESHOOTING .............................. G-16
IGNITION TIMING ................................... G-17
HIGH-TENSION LEAD .............................. G-17
SPARK PLUGS ....................................... G-16
IGNITION COIL ....................................... G-19
DISTRIBUTOR ........................................ G-20
IGNITER ................................................ G-23
STARTING SYSTEM .................................. G-24
PREPARATION ....................................... G-24
CIRCUIT DIAGRAM ................................. G-24
STARTER ...............................................
G-25
STARTER INTERLOCK SWITCH (MTX)
........ G-31
03UOGX-001

G INDEX
NDEX
- 03UOGX-00:
6. Ignition coil 1. Battery
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page G- 8
Recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..t page G- 9
2. Alternator
Removal / Installation . . . . . . . . . . . . . . . . . .
page G-l 0
Disassembly / Assembly . . . . . . . . . . . . . page G-l 1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-l 2
3. Drive belt
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-l 4
Adjustment . . . . . . . . page G-l 4
Replacement . . . . . . . . . . . . . .
page G-l 4
4. High-tension lead
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-l 7
5. Spark plugs
Removal / Installation . . . . . . . . . . page G-1 0
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-l 8
G-2
Inspection .,.. . . . . . . . . . . . . . . . . I . . . . . page
G-l 9
7. Distributor
Spark test ., . . . . . . . . . . ,... . . . . . . . .
page G,-20
Electronic advance inspection page G-20
Removal / Installation ,................. page G-21
Disassembly / Assembly.. , . . page
G-22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-22
8. Igniter
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-23
9. Starter
Removal / Installation .;...........,.... page G-25
Disassembly ! Assembly . . . . . . . . . . . . . page G-26
Inspection . . . . ...‘........................,,,
page G-28 .--
10. Starter interluck switch
Inspection... . . . . . . . . . . . . . . . . . . . . ,.., ,...,
page G-31

OUTLINE G
OUTLINE
SPECIFICATIONS
Item EnginelTransaxle
‘-2, B6 SOHC BP SOHC BP DOHC
MTX 1 ATX MTX ( ATX
Voltage v 1 12
I
3attery
Dark current*’ Type and capacity
(20-hour rate)
mA 55D23L (60AH) 55D23L (60AH)
Max. 20.0
L\lternator
Starter
Type AC
output V-A 12-65
Regulator type Transistorized (built-in IC regulator)
Regulated voltage V 14.1-14.7
Brush length Standard 21.5 (0.846)
mm (in) Minimum 8.0 (0.315)
Drive belt deflection
New
98 N (10 kg, 22 lb)
mm (in) Used 8-Q (0.31-0.35)
Q-10 (0.35-0.39)
Type
I Direct Direct
I Coaxial
Direct Coaxial
reduction reduction I
output V-kW 12-0.95 12-0.95 12-1.4
12-0.95 12-1.4
Brush length Standard 17 (0.67) 17 (0.67) 17.5 (0.69) 17 (0.67)
17.5 (0.69)
mm (in) Minimum 11.5 (0.453) 11.5 (0.453) 10.0 (0.39) 11.5 (0.453) 10.0 (0.39)
Distributor
Ignition timing BTDC
(TEN terminal of diagnosis connector grounded) Electronic spark advance (photo diode)
6O--8O 4O-6O Q”-1 1 o
Ignition coil
Spark plug Resistance
(at 20% [68OF]) Primary
coil winding 0.81-O.QQg
Secondary
coil winding IO-16 kg
BKR5E-11 BKR5Ell BKR5Ell
NGK
BKR6E-11 BKRGEl 1 BKRGEli
BKR7Ell
Type NIPPON-
DENSON Kl GPR-Ul l
K20PRU 11 KIGPR-Ull
K20PR-Ul l KIGPR-Ull
K20PRUll
K22PR-Ul l
I Plua aao mm (in) I 1.0-l .l (0.039-0.043)
Firing order
’ Dark current is the constant flow of current while the ignition switch is OFF.
(i.e. engine control unit, audio, etc.) l-3-4-2
23lJOGX-00
G-3

TROUBLESHOOTING GUIDE G
3 Cranks slowly
STEP INSPECTION ACTION
1 Check if engine cranks normally with fully Yes Check charging system CT page G-7
charged battery
No Go to next step
2 Check starter cable connection for looseness Yes Repair or replace connection
and corrosion
OBUOGX-OC
I 1 4
.
Alternator warning lamp illuminates when engine running
STEP INSPECTION ACTION
1 Check for correct battery voltage at idle Yes Check wire harness between alternator L terminal and aI*
Specification: 14.1--14.7V ternator warning lamp
No Check charging system w page G-7
03UOGX-008
5 I Discharged battery I 1TEP INSPECTION
f Check charging system w page G-7 -
6
TEF
1
r
--
Yes
03UOGX-009
ACTION
Turn ignition switch ON and check dark current as shown
Dark current: Below 20mA
No Repair or replace parts as necessary 1
Misfire
INSPECTION
-
Disconnect high-tension lead from each spark
plug and check for strong blue spark while
cranking
, i
Yes
No T-
I
ACTION
- Check spark plug w page G-f8
~3 If OK, engine electrical system normal
~3 If not OK, clean or replace spark plug
Check ignition system ci’ page G-16
1 03UOGX-010
G-5