relay MAZDA PROTEGE 1992 Workshop Manual

GI CAUTION
/
_____--__.. -I
OWGIX-028
2. Check the terminals of waterproof connectors from the con-
nector side, as they cannot be accessed from the wire har-
ness side.
Caution
l Use fine wire to prevent damage to the terminal.
l Do not damage the terminal when inserting the
tester lead.
.- - 9MUGIX-027
9MUGIX-028
Same as the female type.
I
9MUGK031
Terminals
Inspection
Pull lightly on individual wires to check that they are secured
in the terminal.
Replacement of terminals
Use the appropriate tools to remove the terminal as shown.
When installing the terminal, be sure to insert it until it locks
securely.
< Female >
Insert a thin piece of metal from the terminal side of the con-
nectar, and then, with the terminal locking tab pressed down,
pull the terminal out from the connector.
< Male >
Sensors, Switches, and Relays
Handle sensors, switches, and relays carefully. Do not drop
them or strike them against other parts.
GI-14

E
COOLING SYSTEM
INDEX ...................................................... E- 2
OUTLINE .................................................. E- 4
SPECIFICATIONS .................................... E- 4
TROUBLESHOOTING GUIDE ...................... E- 4
ENGINE COOLANT .................................... E- 5
PREPARATION ....................................... E- 5
INSPECTION ..........................................
REPLACEMENT ...................................... :z ;
RADIATOR CAP ........................................
PREPARATION ....................................... ;I ;
INSPECTION .......................................... E- 7
RADIATOR ............................................... E- 8
REMOVAL / INSTALLATION ...................... E- 8
INSPECTION .......................................... E- 9
THERMOSTAT .......................................... E- 9
REMOVAL / INSTALLATION ...................... E- 9
INSPECTION .......................................... E- 9
WATER PUMP .......................................... E-l 1
REMOVAL / INSTALLATION ...................... E-l 1
ELECTRIC COOLING FAN SYSTEM ............ E-13
SYSTEM CIRCUIT .................................... E-l 3
SYSTEM INSPECTION .............................. E-14
FAN MOTOR ............................................. E-14
INSPECTION .......................................... E-l 4
REPLACEMENT ...................................... E-l 5
WATER THERMOSWITCH .......................... E-l 8
REMOVAL / INSTALLATION ...................... E-18
INSPECTION .......................................... E-l 8
RADIATOR THERMOSWITCH ..................... E-l 7
REMOVAL I INSTALLATION ...................... E-17
INSPECTION .......................................... E-l 7
FAN RELAY .............................................. E-l 8
REMOVAL I INSPECTION .......................... E-l 8
INSPECTION .......................................... E-l 8
23UOEX-001

INDEX
B6 SOHC AND BP SOHC
COOLANT RESERVOIR
@ ENGINE COOLANT
TOTAL CAPACITY
MTX: 5.0 liters (5.3 US qt, 4.4 Imp qt)
ATX: 6.0 liters (6.3 US qt, 5.3 Imp qt)
1. Engine coolant 6. Electric cooling fan system
23UOEX-00
inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E- 5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E-
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
page E- 2. Radiator cap
7
3. Radiator
Removal I Installation . . . . . . . ,.......... page E- 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E- 9
4. Thermostat
Removal / Installation . . . . . . . . . . . . . . . . . . page E- 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E- 9
5. Water pump
Removal / Installation ....t___.......... page E-i 1
System
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Water thermoswitch
Removal / Installation . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Radiator thermoswitch (BP ATX) System
Removal I Installation . . . . . . . . . . . . . . . . . inspection . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IO. Fan relay
7. Fan motor
Removal / Inspection . . . . . . . . . . . . . . . . . page E-13
page E-14
page E-14
page E-15
page E-16
page E-16
page E-17
page E-l 7
page E-18 ..--’
E-2

E
BP DOHC
-a TO HEATER
&$ No.1 RELAY
COOLANT ~~ESERVOI~~
@ ENGINE COOLANT
TOTAL CAPACITY
MTX: 5.0
liters (5.3 US qt, 4.4 Imp qt)
ATX: 6.0 liters (6.3 US qt, 5.3 Imp qt)
23UOEX-00
1. Engine coolant
6. Electric cooling fan system
Inspection ...................................
page E- 5 System circuit
.............................
page E-l 3
Replacement ...............................
page E-
6 System inspection
....................... page E-14
2. Radiator cap
7. Fan motor
Inspection ................................... page E- 7
Inspection ...................................
page E-14
3. Radiator
Replacement..
............................. page E-i 5
Removal / Installation..
................
page E-
8 8. Water thermoswitch
Inspection
.................. ................................... page E- 9 Removal / Installation
page E-16
4. Thermostat
Inspection ...................................
page E-l 6
Removal I Installation
.................. page E- 9 9. Radiator thermoswitch (ATX)
Inspection
.................. ...................................
page E- 9 Removal I Installation
page E-l 7
5. Water pump
Inspection
...................................
page E-l 7
Removal / Installation ..................
page E-i 1 10. Fan relay
Inspection ...................................
page E-l 8
E-3

ELECTRIC COOLING FAN SYSTEM E
ELECTRIC COOLING FAN SYSTEM
SYSTEM CIRCUIT
I
SINGLE-SPEED TYPE
WITH A/C
r __________ -------- ------..---- i
I
I
I -
I
I
r,
, II
I 1
P ’
iI
:”
IGZ
b CONNECTOR
WATER
THERMOSWITCH
ABOVE 97% (207OF): ON WO-SPEED TYPE
WITH AK
r--------
l
I
I
I
I
I
I I
I
I
I
L-
No.2
FAN
RELAY
ADDITIONAL
FAN
MOTOR - -_-_---
A-- 1- A/C SWITCH
_________ - -.--- -- _ .- .- - LDIAGNOSIS
CONNECTOR
WATER
THERMOSWITCH
ELAY ABOVE 97% (207“F): ON
RADIATOR SWITCH
ABOVE 105-Z (221°F): ON
03UOEX-019
E-13

t FAN RELAY
FAN RELAY
REMOVAL / INSPECTION
1. Disconnect the negative battery cable.
2. Remove the fan relay in a place shown in the figure.
FAN RELAY
BP ATX)
l o... . ,. . . . . . . . . . TYPE 1 @ No.2 FAN RELAY
(FOR !3P ATX)
@AND @ . . . ..TYPE 2
03UOEX-029
[TYPE l] [TYPE 21
INSPECTION
1. Check continuity as shown with an ohmmeter.
Contir
No
Yes Terminal
m-0
OS-@
2. Apply 12V between terminals @ and @.
Check for continuity between terminals @ and 0.
3. If not as specified, replace the fan relay. .-
._/ ’

F
FUEL AND EMISSION
CONTROL SYSTEM
INDEX ...........................................
OUTLINE ...................................... ;: 2
SYSTEM DIAGRAM ...................... F-
:
VACUUM HOSE ROUTING
DIAGRAM .................................
WIRING DIAGRAM ....................... F- 6
- 7
ENGINE CONTROL UNIT (ATX) ...... F- 13
SPECIFICATIONS.. ....................... F- 15
COMPONENT DESCRIPTIONS.
...... F- 16
TROUBLESHOOTING GUIDE.. ......... F- 20
ENGINE CONTROL OPERATION
CHART
..................................... F- 20
RELATIONSHIP CHART.. .............. F- 24
USING THIS SECTION .................. F- 25
DIAGNOSTIC INDEX .................... F- 27
PRECAUTION ............................. F- 29
SYMPTOM TROUBLESHOOTING .... F- 30
ENGINE TUNE-UP
.......................... F- 76
PREPARATION ............................
F- 76
BASIC INSPECTION ..................... F- 78
ADJUSTMENT .............................
F- 79
SELF-DIAGNOSIS FUNCTION .......... F- 82
DESCRIPTION .............................
F- 82
PREPARATION
............................
F- 83
SERVISE CODE NUMBER.. ........... F- 83
SWITCH MONITOR FUNCTION ...... F-105
INTAKE AIR SYSTEM.. ................... F-109
COMPONENT PARTS.. ................. F-109
THROTTLE BODY ........................ F-l 12
DYNAMIC CHAMBER ................... F-l 12
INTAKE MANIFOLD ..................... F-l 13
ACCELERATOR PEDAL ................ F-l 14
ACCELERATOR CABLE ................ F-l 14
IDLE SPEED CONTROL (ISC)
SYSTEM ......................................
F-115
DESCRIPTION ............................. F-115
PREPARATION
............................ F-116
SYSTEM OPERATION.. ................. F-l 16
ISC VALVE ................................. F-116
AIR VALVE
................................. F-116
VARIABLE INERTIA CHARGING
SYSTEM (VICS) [DOHC] ................ F-l 17
DESCRIPTION ............................. F-117
SYSTEM OPERATION ................... F-l 18
SHUTTER VALVE ACTUATOR.. ...... F-l 18
SOLENOID VALVE (VICS). ............. F-118
VACUUM CHAMBER.. .................. F-119
FUELSYSTEM .............................. F-l 20
DESCRIPTION
............................. F-l 20
PRECAUTION ............................. F-121
SYSTEM OPERATION.. ................. F-121
FUEL TANK ................................
F-l 23
FUEL FILTER .............................. F-l 24 FUEL PUMP ............................... F-l 25
CIRCUIT OPENING RELAY.. .......... F-129
PRESSURE REGULATOR.. ............ F-129
INJECTOR .................................. F-l 31
PRESSURE REGULATOR
CONTROL SYSTEM.. .................... F-l 34
SOLENOID VALVE (PRESSURE
REGULATOR CONTROL). ............ F-l 35
EXHAUST SYSTEM ........................ F-l 36
COMPONENT PARTS.. ................. F-136
OUTLINE OF EMISSION
CONTROL SYSTEM.. .................... F-l 37
STRUCTURAL VIEW.. ................... F-l 37
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM.. ..... F-138
DESCRIPTION .............................
F-l 38
PCV VALVE ................................ F-l 38
EVAPORATIVE EMISSION
CONTROL SYSTEM.. .................... F-l 39
DESCRIPTION ............................. F-l 39
SYSTEM OPERATION.. ................. F-140
SOLENOID VALVE
(PURGE CONTROL) ................... F-140
SEPARATOR ............................... F-l 40
CHECK VALVE (TWO-WAY) ........... F-140
CHECK-AND-CUT VALVE.. ............ F-141
CHARCOAL CANISTER.. ............... F-141
DECELERATION CONTROL
SYSTEM ...................................... F-l 42
DESCRIPTION ............................. F-l 42
DASHPOT .................................. F-142
FUEL CUT CONTROL SYSTEM ....... F-143
DESCRIPTION ............................. F-l 43
PREPARATION ............................ F-l 43
SYSTEM OPERATION.. ................. F-143
DECHOKE CONTROL SYSTEM.. ...... F-145
DESCRIPTION ............................. F-l 45
SYSTEM OPERATION ................... F-l 45
CONTROL SYSTEM ....................... F-l 47
PREPARATION ............................ F-147
STRUCTURAL VIEW.. ................... F-l 48
ENGINE CONTROL UNIT (ECU) ..... F-149
AIRFLOW METER (WITH INTAKE AIR
THERMOSENSOR) ..................... F-168
WATER THERMOSENSOR.. ........... F-168
THROTTLE SENSOR .................... F-l 69
OXYGEN SENSOR.. ..................... F-171
MAIN RELAY (FUEL INJ RELAY) .... F-172
CLUTCH SWITCH (MTX) ............... F-172
NEUTRAL SWITCH (MTX). ............. F-173
POWER STEERING PRESSURE
SWITCH .................................... F-173
WJOFX-001

INDEX F
1. Resonance duct
Inspection / Replacement.. ........ page F-l 09
2. Air cleaner element
Inspection ................................. page F- 79
Replacement.. ........................... page F-l 09
3. Airflow meter
(With intake air thermosensor)
Inspection
................................. page F-l 68
Replacement.. ........................... page F-l 09
4. Resonance chamber
Inspection I Replacement.. ........ page F-l 09
5. Throttle body
Inspection .................................
page F-l 12
Replacement.. ...........................
page F-l 09
6. Throttle sensor
inspection ................................. page F-l 69
Adjustment..
.............................. page F-l 69
Replacement.. ........................... page F-l 71
7. ISC valve
Inspection ................................. page F-l 16
Replacement..
........................... page F-l 09
8. Dashpot
Inspection ................................. page F-l 42
9. Dynamic chamber
Removal / Installation ................
page F-109
Inspection [DOHC] ................... page F-l 12
10. Air valve
Inspection
................................. page F-l 16
Removal / Installation ................ page F-109
11. Shutter valve actuator
Inspection ................................. page F-l 18
12. Vacuum chamber [DOHC]
Inspection ................................. page F-l 19
13. Intake manifold
Removal / Installation ................ page F-l 09
14. Injector
Inspection .................................
page F-l 31
Removal .................................... page F-131
Installation.. ............................... page F-l 33 15. Pressure regulator
Inspection ................................. page F-l 29
Replacement ............................. page F-l 30
16. Solenoid valve (Pressure regulator control)
[BP1
Inspection ................................. page F-l 35
17. Solenoid valve (VICS) [DOHC]
Inspection ................................. page F-l 18
18. Charcoal canister
Inspection ................................. page F-l 41
19. Solenoid valve (Purge control)
Inspection ................................. page F-l 40
20. Circuit opening relay
Inspection ................................. page F-l 29
Replacement ............................. page F-l 29
21. Engine control unit (ECU)
Removal / Installation ................ page F-l 49
Inspection ................................. page F-149
22. Clutch switch (MTX)
Inspection ................................. page F-l 72
Replacement.. ........................... page F-l 72
23. PCV valve
Inspection ................................. page F-l 38
24. Water thermosensor
Removal / Inspection /
Installation ............................... page F-l 68
25. Fuel filter (High-pressure side)
Replacement.. ........................... page F-l 24
26. Main relay (FUEL INJ relay)
Inspection ................................. page F-l 72
27. Neutral switch (MTX)
inspection ................................. page F-l 73
Replacement.. ........................... page F-l 73
28. Oxygen sensor
Inspection ................................. page F-l 71
Replacement ............................. page F-l 72
29. Power steering pressure switch
Inspection ................................. page F-l 73
Replacement.. ........................... page F-l 73
23UOFX-002
F-3

EGI MT n ENGINE CONTROL SYSTEM (i/3) CD.. OOHC 0 . ..CANAOA 3-l
MAIN
lOA @
HERMOSWITCW
SECTION B-3)
l-01 ENGINE CONTROL UNIT (EM)
iU 1s
IQ IO it4 1K 11 16 IE 1C ,A 61-02 MAIN RELAY (~1 2Y 2W 2U 25 28 20 2M 2K 21 26 2E 2C 24 81-03 CIRCUIT OPENING
(FUEL INJ)
R/0 O/L G/B G * -G/Y )c G/W Y/B
pL/W R
l -G/ x “y W 3/LG 0/O

<>. .DOHC EGI EC-AT l ENGINE CONTROL SYSTEM 6, EC-AT CONTROL SYSTEM(1/3)
(SECTION n-i)
DIAGNOSIS CONNECTOR
(SECTION U)
SHIELD WIRE
TACHOMETER
2-01 ENGINE CONTROL UNIT(EM) 82-02 MAIN RELAY (E)
,IJ 23 113 10 1” 1K 11 1G 1E 1C 1A _
20 2M 2K 21 26 2E 2C 2A 3~ 3W 3” 35 30 30 3M 3K 31 36 3E 3C 3A (FUEL INJ)
* w G G/B G/A (‘c) G/ G/W Y/B V L/R
W/L W/L R/E G/ W/B L/W R/L W 0 L/O Y * L/O X G/O X kBc Y/W Y /L E/O