stop start MAZDA PROTEGE 1992 Workshop Manual

PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Following items may be done at any time prior to delivery to your customer.
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Glass, exterior bright metal and paint for damage
Cl Wheel lug nuts, and locks (if equipped)
88-118 N.m (9-12 m-kg, 65-87 ft-lb)
q All weatherstrips for damage or detachment
0 Operation of hood release and lock
0 Operation of trunk lid, rear hatch, and fuel lid opener
Cl With trunk open, check for spare jack, tire, tools, and
fasteners securing these items in place.
Cl Door operation and alignment
Cl Headlight aim
INSTALL the following parts:
Cl Wheel caps or rings (if equipped)
q Outside rearview mirror(s)
1 UNDER HOOD-ENGINE OFF )
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Fuel, coolant and hydraulic lines, fittings, connections and
components for leaks
Cl Engine oil level
0 Power steering fluid level
0 Brake and clutch master cylinder fluid level
El Windshield washer reservoir fluid level
Cl Radiator coolant level
Cl Tightness of battery terminals
Cl Manual transaxle oil level
riizmiq
INSTALL the following parts:
Cl Rubber stopper for inside rearview mirror
CHECK operation of the following items:
0 Seat controls (sliding and reclining) and head restraint
Cl Folding rear seat
0 Door locks, including childproof door locks (if equipped)
Seat belts and warning system
Cl Ignition switch and steering lock
0 Inhibitor switch (ATX only)
U Starter interlock switch (clutch pedal, MTX only)
Cl All lights, including warning and indicator lamps
Cl Sound warning system
Cl Horn, wipers and washers (front and rear, if equipped)
0 Audio system (if equipped) 0 Cigarette lighter and clock
0 Sunroof (if equipped)
II Remote control outside rearview mirrors (if equipped)
Cl Power windows (if equipped)
q Heater, defroster and air conditioner at various mode
selections (if equipped)
CHECK the following items:
Cl Presence of spare fuse
0 Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
0 Pedal height and free play of brake and clutch pedal
Pedal height mm (in) Free play mm (in)
0 Parking brake
5-7 notches/98 N (10 kg, 22lb)
UNDER HOOD-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
q Automatic transaxle fluid level
[I
CHECK the following items:
Cl Underside fuel, coolant and hydraulic lines, fittings, con-
nections and components for leaks
0 Tires for cuts or bruises
0 Steering linkage, suspension, exhaust system and all un-
derside hardware for looseness or damage
[I
CHECK the following items:
0 Brake operation
0 Clutch operation
Cl Steering control
Cl Operation of gauges
q Squeaks, rattles or unusual noise
Cl Emergency locking retractors
0 Cruise control system (if equipped)
1 AFTER ROAD TEST (
CHECK for necessary owner information materials.
Following items must be done just before the delivery to your customer.
q Load test battery and charge if necessary
1 Volts 1 0 Install fuses for accessories
i.. _
0 Adjust tire pressure to the specification
Load test result cl Remove seat and floor mat protective covers
(Refer to door label) 0 Vacuum and clean interior of vehicle
0 Clean outside of vehicle q Inspect installation of option parts with invoice
23UOAX-002
A-2

ENGINE TUNE-UP PROCEDURE Bl
Tightening torque
@ : 37-52 N,m (3.8-5.3 m-kg, 27-38 ft-lb)
@ : 19-25 Nsm (1.9-2.6 m-kg, 14-19 ft-lb)
23UOBl-OC
P/S belt, P/S + A/C belt
If necessary, loosen the P/S oil pump bolts @and nut @and
Oand adjust the belt deflection by turning the adjusting bolt
0.
Tightening torque
@I : 36-54 N.m (3.7-5.5 m-kg, 27-40 ft-lb)
@ : 19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
0: 31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
A/C belt
If necessary, loosen the locknut @and adjust rhe belt deflec-
tion by turning the adjusting bolt @.
Tightening torque:
31-34 N-m (3.2-3.5 m-kg, 23-25 ft-lb)
1
HLA
Problem Possible Cause Action
1. Noise when engine is started immedi- Oil leakage in oil passage Run engine 2000-3000 rpm.
ately after oil is changed. If noise stops after 2 second-10
2. Noise when engine is started after set- minutes(*), HLA is normal.
ting approx. one day. If not, replace HLA.
3. Noise when engine is started after Oil leakage in HLA - * Time required for engine oil to circu-
cranking for 3 seconds or more. late within engine, includes tolerance
4. Noise when engine is started after for engine oil condition and ambient
new HLA is installed. temperature.
5. Noise continues more than 10 minutes Insufficient oil pressure Check oil pressure.
If lower than specification, check for
cause.
Oil pressure; 294-392 kPa
(3.0-4.0 kg/cm*, 43-57 psi)-3000 rpm
(Refer to page 81-60)
Press down HLA by hand.
If it does not move,. HLA is normal.
If it moves, replace HLA.
t
I
Measure valve clearance.
If more than Omm (0 in), replace HLA.
5. Noise occurs durning idle after high-
speed running Incorrect oil amount
Deteriorated oil Check oil level.
Drain or add oil as necessary.
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
23UOBl-01
Bl-7

ENGINE TUNE-UP PROCEDURE 92
23UOB2-OC
DRIVE PULLEY
I I
2311082.010
HLA
I Problem
1. Noise when engine is started immedi-
ately after oil is changed.
2. Noise when engine is started after set-
tina aporox. one dav.
3. Noise when engine is started after
cranking for 3 seconds or more.
4. Noise when engine is started after
new HLA is installed.
5. Noise continues more than 10 minutes
6. Noise occurs durning idle after high-
“”
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-16 ft-lb)
(4) Tighten mounting bolt @.
Tightening torque:
37-52 N#rn (3.6-5.3 m-kg, 27-36 ft-lb)
(5) Recheck the belt tension or deflection.
2. P/S belt, P/S + A/C belt
(1) Loosen the P/S oil pump bolt @and nuts @, 0.
(2) Adjust the belt tension and deflection by turning the ad-
justing belt 0.
(3) Tighten the adjusting lock nut @J and the P/S oil pump
bolt @ and nut 0.
Tightening torque
@: 36-54 N-m (3.7-5.5 m-kg, 27-40 ft-lb)
@ : 19-25 N*m (1.9-2.6 m-kg, 14-19 ft-lb)
0: 31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb) Possible Cause
Oil leakage in oil passage
Oil leakage in HLA
Insufficient oil pressure
Faulty HLA
Incorrect oil amount
Deteriorated oil Action Run engine 2000-3000 rpm.
If noise stops after 2 second-10
minutes(*), HLA is normal.
If not, replace HLA.
* Time required for engine oil to circu-
late within engine, includes tolerance
for engine oil condition and ambient
temperature.
Check oil pressure.
If lower than specification, check for
cause. Oil pressure; 294-392 kPa
(3.0-4.0 kg/cm’, 43-57 psi)-3000 rpm
(Refer to page 82-60)
Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.
If more than Omm (0 in), replace HLA.
Check oil level.
Drain or add oil as necessary.
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
2311082-01
B2-7

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

OUTLINE
Component Function Remark
Engine control unit (ECU) Controls operation of the following:
(Cont’d)
1. A/C (Cut-off) 1. A/C relay
2. Fail-safe function 2. Self-Diagnosis Checker and MIL
3. Fuel injection system 3. Injector
4. idle speed control 4. Idle speed control (ISC) valve
5. Ignition timing control system 5. Igniter
6. Monitor function 6. Monitor lamp (Self-Diagnosis Checker)
7. Pressure regulator control system 7. Solenoid valve
(Pressure regulator control) (BP)
8. Purge control system 8. Purge control solenoid valve
9. VICS 9. Solenoid valve (WCS) (DOHC) Fuel filter
Filters particles from fuel Fuel pump
Provides fuel to injectors l Operates while engine running l Installed in fuel tank Igniter
Receives spark signal from ECU and gener-
ates high voltage in ignition coil Ignition switch
Engine cranking signal sent to ECU (START position)
Inhibitor switch (ATX)
Detects in-gear condition; sends signal to Switch ON in N or P range
ECU Injector
Intake air thermosensor
Idle speed control (ISC)
valve
Main relay
(FUEL INJ relay)
MIL (Malfunction
indicator lamp)
Neutral switch (MTX)
Oxygen sensor
PCV valve
P/S pressure switch
Pressure regulator
Resonance chamber
Resonance duct
Separator
Stoplight switch
Solenoid valve
(Purge control)
Shutter valve actuator
(DOHC)
Throttle body
Throttle sensor
Injects fuel into intake port l Controlled by signals from ECU
l High-ohmic injector
Detects intake air temperature; sends signal Installed on dynamic chamber
to ECU
Controls bypass air amount Controlled by duty signal from ECU
Supplies electric current to injectors, ECU,
etc.
Lamp flashes to indicate malfunction code
number of input and output devices
Detects in-gear condition; sends signal to
ECU
Detects oxygen concentration; sends signal
to ECU
Controls blowby gas introduced into engine
Detects P/S operation; sends signal to ECU
Adjusts fuel pressure supplied to injectors
Reduces intake air noise
Reduces intake air noise
Prevents fuel from flowing into charcoal
canister
Detects braking operation (deceleration),
sends signal to ECU
Controls evaporative fumes from canister to
intake manifold
Closes/opens shutter valve to improve
torque characteristics
Controls intake air quantity
l Detects throttle valve fully closed/fully
opened condition (MTX) TEN terminal grounded
Switch ON in neutral
Zirconia ceramic and platinum coating
P/S: ON when steering wheel turned right or
left
Controlled by duty signal from ECU
For Variable inertia charging system (VICS*)
Integrated throttle sensor, dashpot, and ISC
valve
l Detects throttle valve opening angle
(A-W
l Sends signals to ECU
F-l 7

F TROUBLESHOOTING GUIDE
RELATIONSHIP CHART
OUTPUT DEVICE
INPUT DEVICE
DIAGNOSIS CONNECTOR
[TEN TERMINAL) 0 0 0 0
IGNITION SWITCH (START POSITION) 0 0 0 0 0 0
E/L SIGNALg4 0
0
P/S PRESSURE SWITCH 0 0
B/C SWITCH 0 0 0
INHIBITOR SWITCH (ATX) 0 0 0 0 0 0 0
NEUTRALANDCLUTCH
SWITCHES (MTX) 0 0 0 0 0 0 0
STOPLIGHT SWITCH 0
0
&TMOSPHERIC PRESSURE SENSOR
[IN ECU) o 0 0 0 0
rHROTTLE SENSOR 0 0 0 0 0 0 0
INTAKE AIR THERMOSENSOR 0 0 0 0 0
MRFLOW METER 0 0 0 0 0
3XYGEN SENSOR 0 0 0 0
JVATERTHERMOSENSOR 0 0 0 0 0 0 0
G-SIGNAL*’ 0 0
3ISTRIBUTOR
Ne-SIGNAL 0 0 0 0 0 0 0 0
-- ,.-, ,--., ,.*
+z
*3 &HC
MIL: Malfunction Indicator Lamp
r.9u”rn-” I
*’ E/L SIGNAL: Blower fan control switch second position or higher, cooling fan operating, headlights ON, or rear win-
dow defroster switch ON
F-24

TROUBLESHOOTING GUIDE
DIAGNOSTIC INDEX
No. TROUBLESHOOTING ITEM DESCRIPTION
1 Will not crank or cranks slowly Refer to Engine Electrical System PAGE
G- 4
Engine cranks at normal speed but shows no sign of 1 F-30
Engine cranks at normal speed but shows only par-
I
tial combustion and will not continue to run
Engine starts normally when cold, but will not start af-
After warm-up
5 Cranks normally but
Always
hard to start Engine cranks at normal speed but requires exces-
sive cranking time before starting F-36
F-38
I----
F-40 Same condition as No.5 when engine cold
Restarts normally after warm-up
Same cond;ion as No.5 after running and hot
soaked
Starts normally when cold
8
H
Rough idle
9 (Low idle speed)/
Engine stalls at idle Enaine stalls or vibrates excessivelv at idle
Engine stalls or vibrates excessively at idle during
warm-up 1 F-42
F-44
Engine runs normally at idle during warm-up but
vibrates excessively or stalls after warm-up
Engine stalls or vibrates excessively at idle when
A/C, P/S, or E/L ON F-46
F-46
starting (acceleration from idle)
l---- Engine stalls or vibrates excessively only just after
Idle speed excessive after warm-up 1 F-50 F-49 12 Rough idle/Engine stalls just after starting
13 High idle speed after warm-up
1 14 1 Idle moves up and down/Idle hunting Engine speeds up and down periodically at idle
1 F-52
I l5 I Engine stalls on deceleration
Engine unexpectedly stops running while decelerat-
ing or after deceleration F-54
Engine intermittently stops running
Flat spot occurs just after accelerator depressed or
mild jerkrng occurs during acceleration
Unexpected change in engine speed which is usually
repetitive F-56
F-57
F-59 16 Engine stalls suddenly (Intermittent)
17 Hesitates/Stumbles on acceleration
1 18 1 Surges while cruising
19
I I
Lack of power Performance poor under load when throttle valve F-61
wide open
Maximum speed reduced
Performance poor-while accelerating
-I- F-65 20 Poor acceleration
21 Runs rough on deceleration/Backfire Engine runs rough while decelerating and abnormal
combustion occurs in exhaust system F-69
Abnormal combustion accompanied by audible
“pinging” noise
Gasoline odor in cabin 22 Knocking
23 Fuel odor
24 Exhaust sulfur smell
26 High oil consumption Exhaust gas smells abnormal
Oil consumption excessive
Fuel economy unsatisfactory 1 26 1 Poor fuel economy 1 F-75
Self-Diagnosis Checker does not indicate malfunction
23UOFX~O’
F-27

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

F TROUBLESHOOTING GUIDE
7 CRANKS NORMALLY BUT HARD TO START - AFTER WARM-UP
*Engine cranks at normal speed but requires excessive cranking time before starting after running and hot
DESCRIP- soaked
TION *Battery in normal condition
*Engine starts normally when cold
*Engine runs normally at idle [If idle condition not OK, refer to “Rough idle” (Nos. 8-12)] [TROUBLESHOOTING HINTS]
3 Air/Fuel mixture too rich
@ Vapor lock l Fuel injection control malfunction
*Fuel pressure not held in fuel line after engine stopped l Injector fuel leakage
*High RVP (winter) fuel used in warm weather
l Pressure regulator control system malfunction [BP] w page F-150
Specification: Battery voltage
(Ignition switch ON)
W: SELF TEST c3 If OK, replace ECU w page F-149 * If not OK, check wiring between CT- page F-134
Fuel line pressure: More than 147 kPa
(1.5 kg/cm*, 21 psi) for 5 min. w page F-130
+ If OK, replace pressure regulator CT- page F-130
c3 If not OK, check fuel pump hold w page F-125
If fuel pump is OK, check injectors
for fuel leakage (3 page F-132
F-40

TROUBLESHOOTING GUIDE
iTEP INSPECTION ACTION
5 Warm-up engine to normal operating tempera-
Yes Change fuel to another brand
ture and stop it
Connect diagnosis connector terminals F/P and
GND with jumper wire for 3 minutes with ignition
switch ON, then check if engine starts easily
DIAGNOSIS CONNECTOR No
Go to next step
G
F/P 6
Try known good ECU and check if condition
Yes Replace ECU w page F-149 improves w page F-149 No
Change fuel to another brand
23UOFX-02:
F-41