MAZDA PROTEGE 1992 Workshop Manual

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
TROUBLESHOOTING GUIDE
DIAGNOSTIC INDEX
No. Troubleshooting items
Page
1
Will not crank-starter motor does not operate G-4
2
Will not crank-starter motor spins G-4
3
Cranks slowly G-5 4
Alternator warning lamp illuminates when engine running
G-5
5 Discharged battery G-5
6
Misfire
G-5
03UOGX-004
SYMPTOM TROUBLESHOOTING -
1
iTEl
1
2
3 Will not crank-Starter motor does not operate
INSPECTION
T
Check if engine cranks with fully charged battery
Check if battery voltage is applied at B terminal
TERMINAL
battery voltaae is aoolied at S terminal
when clutch pedal depressed (MTX) and ignition
switch in START position
S TERMINAL
Yes
No
Yes ACTION Check charging system CT- page G-7
Go to next step
Go to next step
No Check wire harness
Yes
l Check magnetic switch l Check field coil l Check armature
No
l Check starter interlock switch (MTX) ccp: page G-31 l Check inhibitor switch (ATX) c=p Section K l Check ignition switch CI Section T l Check wire harness
1 L-T page G-28
CT- page G-29
CT- page G-29
23UOGX.001
03UOGX-006
G-4

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

G CHARGING SYSTEM
03UOGX-011
CIRCUIT DIAGRAM
CHARGING SYSTEM
PREPARATION
SST
I I
49 9200 020
Tension gauge,
V-ribbed belt For
inspection of
drive belt tension
STATOR
1 DIODE TRIO
T l-f-l /
-I J
WARNING
t
I --.- I I I I 15A
e I
I I -L
-E-
I IC REGULATOR
0
-
BATTERY = IGNITION
SWITCH
03u0tix-012
The alternator has a self-diagnostic function to warn of the following
If a problem arises, the alternator warning lamp illuminates. problems in the charging system.
1. S terminal circtiit open
2. No voltage output
3. Field coil circuit open
4. B terminal circuit open
5. Voltage output too high
G-6

CHARGING SYSTEM G
TROUBLESHOOTING
INSPlhdN
ACTION
1
Check battery voltage Yes Go to next step Specification: Above 12.4V
No
Check battery ri-page G-8
2 Start engine and check if alternator warning
Yes Go to Step 4
lamp goes out
No Go to next step
3 Check if voltages at alternator terminals are Yes Check wire harness between battery and terminal B
3. Turn all electrical loads ON and depress
2,500-3,000 rpm
l Do not ground terminal B
G-7

G CHARGING SYSTEM
INDICATOR
NG POINT
OSUOGX-Ol!
BATTERY
Inspection
Indicator sign (If equipped)
1. Check that the indicator is blue.
2. If the indicator is not blue, check if the electrolyte level lies
between the upper and lower lines.
3. If low, add distilled water, being careful not to overfill.
4. If the electrolyte level is acceptable and yet the indicator
is not blue, the battery must be recharged.
Specific gravity of electrolyte
Measure the specific gravity with a hydrometer.
Specification: 1.27-l .29 (at 20°C [66OF])
Note
l If the battery charge indicator is not blue when the
specific gravity is normal, the indicator could be
defective.
Battery discharge test
I I Measure open circuit voltage of battery with a digital voltmeter capable of
reading O.OlV
I
I I
1 Below i 2.4V
Abo”;t 12.4V
I 1 I
Quick charge for 2 hours
and recheck voltage
c Below 12.4V Above 12.4V
l Apply test load (see test load chart) to the battery
using a battery load tester
l Record battery voltage at the end of 15 seconds; is
voltage more than specification? YES
Measure open circuit Below 12.4V Above 12.4V
Charge battery J Test load
Battery
] Load (A)
55D23L 180
Battery voltage with load
Approximate Minimum
battery temp. voltage (V)
21 OC (70°F) 9.6
15OC (60%) 9.5
10°C (50°F) 9.4
4% (40°F) 9.3
-1 ‘C (30°F) 9.1
-7OC (20°F) 8.9
-12OC (lOoF) 8.7
-18% ( 0“F)
8.5
23UOGX-003 /
L_,*
G-8

CHARGING SYSTEM G
RUB
PRO
03UOGX-01
Terminal and cable
1. Check the tightness of the terminals to ensure good electri-
cal connections.
2. Check for corroded or frayed battery cables.
3. Check the rubber protector on the positive terminal for prop-
er coverage.
4. Clean the terminals if necessary, and coat them with grease.
Recharging
Battery
55D23L Slow charge Quick charge
(A) (4
Under 6 Max. 20
Slow charging
It is not necessary to remove the vent caps to perform a slow
charge.
Quick charging
Remove the battery from the vehicle and remove the vent caps
to perform a quick charge.
Warning
l Before performing maintenance or recharging the
battery, turn off all accessories and stop the engine.
l The negative cable must be removed first and in-
stalled last.
l Set the battery in water when quick charging to pre-
vent overheating the battery.
G-9

G
ALTERNATOR
Removal / Installation
CHARGING SYSTEM
Caution
l Be sure the battery connections are not reversed, because this will damage the rectifier.
l Do not use high-voltage testers such as a megger, because they will damage the rectifier.
l Remember that battery voltage is always applied to the alternator B terminal.
l Do not ground the L terminal while the engine is running.
l Do not start the engine while the connector is disconnected from the L and S terminals.
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary
3. Install in the reverse order of removal.
N.m (m-kg, R-lb)
OSlJOGX b20
1. Negative battery cable
2. Vacuum hose
3. Solenoid bracket (If equipped)
4. Connector
5. B terminal wire
Inspect for damage and corroston 6. Drive belt
Inspection. . . . ., ~.. ,. ,.... . , page G-l 4
Adjustment ,~, ,.,., ,. ,. ,, ,.. page G-l 4
Replacement . . . . . . . . page
G-l 4
7. Alternator
Disassembly / Assembly ,........,... page G-l 1
Inspection... ,, . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-l 2
G-10