belt MAZDA PROTEGE 1992 Manual PDF

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

ENGINE TUNE-UP F
03UOFX.051
03UOFX-051
- w4TEN I
Air Cleaner Element
Inspection
1. Check the air cleaner element for excessive dirt, damage,
or oil.
Caution
l Do not use compression air to clean the element.
2. Replace the element if necessary.
ADJUSTMENT
Preparation
1. Warm up the engine to normal operating temperature.
2. Turn all electric loads OFF.
3. Connect the
SST to the diagnosis connector.
4. Connect a timing light.
5. Connect a tachometer to the diagnosis connector
IG- ter-
minal as shown.
6. Set switch @to position 1.
7. Set TEST SW to SELF-TEST.
Note
l If the SST is not used, jump across the TEN termi-
nal and the GND terminal of the diagnosis con-
nector.
Ignition Timing
1. Perform “Preparation”. (Refer to above.)
2. Check if the timing mark (yellow) on the crankshaft pulley
and the mark on the timing belt cover are aligned.
Specification:
Engine
Ignition Timing BTDC B6 BP SOHC BP DOHC
6O-8* 4O--6O go-110
SOHC DOHC
I 03UOFX-054
3. If the marks are not aligned, loosen the distributor lock bolts,
and turn the distributor to make the adjustment.
4. Tighten the distributor lock bolts to the specified torque.
Tightening torque:
19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
5. Disconnect the SST.
F-79

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

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

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

G CHARGING SYSTEM
WATER PUMP 13UOGX-00,
03UOGX-03:
I /I I III
I f 03UOGX-03:
03UOGX-034
DRIVE BELT
Inspection
1. Check the drive belt and pulley for wear, cracks, and fray-
ing. Replace if necessary.
2. Measure the drive belt tension with a tension gauge. .-A
Tension N (kg, lb)
Drive belt
Alternator
A/C and P/S New Used
383-461
304-303
(39-47, 85.8-103.4) (31-39, 68.2-85.8)
491-589 422-491
(50-60, 11 O-l 32) (43-50, 95-110)
3. Measure the deflection by applying moderate pressure (98
N, 10
kg, 22 lb) midway between the pulleys. Adjust if
necessary.
Deflection mm (in)
Drive belt
Alternator
AIC and P/S New Used
8-9 9-10
(0.31-0.35) (0.35-0.39)
8-9 9-10
(0.31-0.35) (0.35-0.39)
Adjustment
1. Loosen the alternator mounting bolt and adjusting bolt.
2. Move the alternator to set the specified deflection.
3. Tighten all bolts and recheck the tension.
Replacement
1. Remove the A/C and P/S drive belt, if equipped.
Note
l Refer to pages 61-5 and 82-5.
2. Loosen the alternator mounting bolt and adjusting bolt.
3. Remove the alternator belt.
4. Install the new alternator belt and adjust it to specification.
5. Tighten all bolts to the specified torque.
Tightening torque
Alternator bolt:
37-52 N#rn (3.8-5.3 m-kg, 27-38 ft-lb)
Adjusting bolt:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
6. Install the A/C and P/S drive belt if equipped, and adjust
to specification.
Note
l Refer to pages 61-5 and 82-5.
G-14

N
STEERING SYSTEM
INDEX ......................................................
MANUAL STEERING ............................... ;I g
ENGINE SPEED SENSING POWER
STEERING (ESPS) ................................. N- 3
OUTLINE ..................................................
SPECIFICATIONS .................................... ;I ::
MANUAL STEERING ..................................
PREPARATION ....................................... ;I ;
TROUBLESHOOTING GUIDE.. .................. N- 5
BOOT ................................................... N- 6
STEERING WHEEL AND COLUMN.. .......... N- 6
STEERING GEAR AND LINKAGE .............. N-13
ENGINE SPEED SENSING POWER
STEERING .............................................. N-23
PREPARATION ....................................... N-23
TROUBLESHOOTING GUIDE.. .................. N-25
AIR BLEEDING ....................................... N-26
STEERING WHEEL AND COLUMN.. .......... N-26
POWER STEERING FLUID.. ...................... N-27
STEERING GEAR AND LINKAGE .............. N-30
POWER STEERING OIL PUMP.. ................ N-37
DRIVE BELT ........................................... N-41
23UONX-001