Mazda Protege 1997 1.8L DOHC 2, Protege 1997 1.8L DOHC Workshop Manual

mazda :: Mazda Protege ES L4-1839cc 1.8L
DOHC (1997)

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection

Power Door Lock Control Module: Testing and Inspection
DOOR LOCK TIMER UNIT INSPECTION

1. Remove the right front side trim.2. Measure the voltage at the door lock timer unit terminals by using a voltmeter.3. Disconnect the door lock timer unit connector before checking for continuity at terminal N.

4. If not as specified, inspect the parts listed under "Inspection area" and the related wiring harness.5. If the parts and wiring harnesses are OK but the system still does not work properly, replace the door lock timer unit.

Terminal Voltage List (Reference)

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 7

Power Door Lock Control Module: Service and Repair

1. Disconnect the negative battery cable.2. Remove the right front side trim.3. Remove in the order indicated in the table.4. Install in the reverse order of removal indicated in the table.5. Install the right front side trim.6. Connect the negative battery cable

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Testing and Inspection

Sunroof / Moonroof Relay: Testing and Inspection

1. Remove the sunroof relay.

2. Apply battery positive voltage and check for continuity between the sunroof relay terminals by using an ohmmeter.3. If not as specified, replace the sunroof relay.

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Testing and Inspection > Page 11

Sunroof / Moonroof Relay: Service and Repair

1. Remove the headliner.2. Disconnect the sunroof relay connector and remove the sunroof relay.3. Remove the sunroof relay.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Electrical Specifications

ABS Main Relay: Electrical Specifications
RESISTANCE SPECIFICATIONS

Fail-Safe Relay ........................................................................................................................................................................................... 60-100 OHMSMotor Relay .................................................................................................................................................................................................. 50-90 OHMS

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Electrical Specifications > Page 17

ABS Main Relay: Mechanical Specifications
TIGHTENING SPECIFICATIONS

Bolt ..................................................................................................................................................................................... 7.9-10.7 Nm (70-95 inch lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Page 18

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Testing and Inspection > Fail-Safe Relay

ABS Main Relay: Testing and InspectionFail-Safe Relay

1. Measure the resistance between terminals A and B of the fail-safe relay connector.
^

Resistance .60-100 Ohms

2. Check for continuity between the relay terminals.

3. If not as specified, replace the fail-safe relay.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Testing and Inspection > Fail-Safe Relay > Page 21

ABS Main Relay: Testing and InspectionFail-Safe Relay Inspection With Harness

1. Turn the ignition switch to OFF and disconnect the ABS control module connector.2. Turn the ignition switch to ON.3. Connect terminal 2J of the control module connector to a ground.4. Check the following points:
>

Fail-safe relay does not click when 2J terminal grounded. ^

Check fail-safe relay

^ Check Harness between fail-safe relay and ABS control module.

>

Warning light illuminates after grounded 2J terminal.^

Check fail-safe relay.

>

1D terminal of ABS control module connector does not indicate 12V.^

Check fail-safe Relay

^ Check harness between fail-safe relay and ABS hydraulic unit.

5. If not as specified, inspect the wiring harness and the fail-safe relay.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Testing and Inspection > Fail-Safe Relay > Page 22

ABS Main Relay: Testing and InspectionMotor Relay

1. Measure the resistance between terminals A and B of the ABS relay connector.
^

Resistance .50-90 Ohms

2. Check for continuity between the relay terminals.

3. If not as specified, replace the ABS motor relay.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Testing and Inspection > Fail-Safe Relay > Page 23

ABS Main Relay: Testing and InspectionMotor Relay With Harness

1. Inspect the fail-safe relay.2. Turn the ignition switch to OFF and disconnect the ABS control module connector.3. Turn the ignition switch to ON.4. Connect terminal 2J to a ground.5. Connect terminal 2H to a ground.6. Check the following points:
>

ABS motor relay does not click when terminals grounded.^

Check harness between motor relay and ABS control module.

^ Check motor relay.

>

Motor does not operate.^

Check motor relay.
^ Check harness between ABS motor relay and motor.
^ Check fuse.

Allowing the motor to operate for more than two seconds will damage the motor.CAUTION:

7. If not as specified, inspect the wiring harness and the ABS motor relay.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Testing and Inspection > Page 24

ABS Main Relay: Service and Repair

(1) Connector(2) Bolt(3) Fail-safe Relay(4) ABS Motor Relay

The ABS relay contains the fail-safe relay and the motor relay. Remove the left side headlight.NOTE:

1. Remove in the order indicated in the table.2. Install in the reverse order of removal indicated in the table.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 28

Electronic Brake Control Module: Testing and Inspection

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 29

Protege ES L4-1839cc 1.8L DOHC (1997)

(Part 1 Of 2)

(Part 2 Of 2)

*1

Solenoid valve and ABS motor are ON only when ABS is functioning. Voltage when solenoid and motor are ON can be measured by followingsystem Inspection. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - AntilockBrakes/Testing and Inspection

*2

Check following terminals in AC range: 2M-2N (right front, 2O-2P (left front), 2R-2Q (left rear), 2S-2T (right rear). In DC range, voltage will beapprox. 0.5-1.0 V (with Ignition switch ON).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 30

Electronic Brake Control Module: Service and Repair

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal indicated in the table.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams

Radiator Cooling Fan Motor Relay: Diagrams

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 35

Radiator Cooling Fan Motor Relay: Testing and Inspection

1. Remove the cooling fan relay.2. Apply battery positive voltage and check continuity between terminals of the cooling fan relay by using an ohmmeter.

3. If not as specified, replace the cooling fan relay.

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Testing and Inspection

Cruise Control Module: Testing and Inspection

1. Remove the passenger's side front scuff plate.2. Remove the passenger's side front side trim.3. Remove the door lock timer unit.4. Remove the cruise control module without disconnecting the connector.5. Measure the voltage at the cruise control module terminals as indicated below.6. Disconnect the cruise control module connector before checking for continuity at terminal N and T.7. If not as specified, inspect the parts listed under "Inspection area" and the related wiring harnesses.8. If the parts and wiring harnesses are okay but the system still does not work properly, replace the cruise control module.

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Testing and Inspection > Page 40

Protege ES L4-1839cc 1.8L DOHC (1997)

Terminal voltage list (reference)

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Testing and Inspection > Page 41

Cruise Control Module: Service and Repair

1. Disconnect the negative battery cable.2. Remove the passenger's side front scuff plate.3. Remove the passenger's side front side trim.4. Remove the door lock timer unit.5. Remove in the order indicated in the table.6. Install in the reverse order of removal.7. Install the door lock timer unit.8. Install the passenger's side front side trim.9. Install the passenger's side front scuff plate.

10. Connect the negative battery cable.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection

Blower Motor Relay: Testing and Inspection

1. Remove the relay.2. Check for continuity between the relay terminals by using an ohmmeter.

3. If not as specified, replace the relay.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 49

Compressor Clutch Relay: Testing and Inspection

1. Remove the relay.2. Check for continuity between the relay terminals by using an ohmmeter.

3. If not as specified, replace the relay.

> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Testing and Inspection

Condenser Fan Motor Relay: Testing and Inspection

Condenser Fan Relay Inspection

1. Verify that engine is cold and the A/C switch and fan switch are OFF.2. Start the engine and let it idle.3. Verify that the condenser fan is not operating.4. If the condenser fan is operating, check the short circuit in wiring between condenser fan relay and PCM.5. Turn the A/C switch and fan switch on.6. Verify that the condenser fan is operating.7. Turn the A/C switch and fan switch off.8. If the condenser fan does not operate, do as follows

Special Service Tool New Generation Star Tester Connected to Data Link Connector 2

a. Connect the Special Service Tools New Generation Star tester to the data link connector 2. (NGS)

b. Select the SIMULATION TEST function on the NGS display.c. Turn the condenser fan relay from OFF to ON by using the "A/C RLY" (MTX) or "FANN" (ATX) and check for the condenser fan operation.d. If the condenser fan operates check the PCM terminal voltage - A/C signal.e. If the condenser fan does not operate, do as follows.

I.

Turn the condenser fan relay from OFF to ON by using the simulation function. Operate the condenser fan relay and check it the operationsound of the relay is heard.
II. If the operation sound is heard, check the following.

- Wiring harness and connectors (Condenser fan relay - Condenser fan motor).

- Condenser fan motor.

III. If the operation sound is not heard, check the following.

- Condenser fan relay.

- Open circuit in wiring harness and connectors (Battery - Condenser fan relay - PCM).

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest: > T0900598 > May > 98 > Brake Warning Light - ON

Constantly

Speedometer Module: Customer InterestBrake Warning Light - ON Constantly

Bulletin No. 005/98
Issued 05/06/98
Revised

CategoryT (09)

Applicable Model/s1997 - 98 Protege

SubjectBRAKE WARNING LIGHT ON CONSTANTLY

APPLICABLE MODEL(S)/VINS1997-98 Protege with VINs lower than JM1 BC14** W0 204584
DESCRIPTION

Brake warning light in the combination meter is ON constantly. This is caused by surge current damaging a transistor which controls the brake warninglight illumination in the speedometer assembly. The speedometer assembly has been modified to protect this transistor.
Customers complaining of this subject should have the vehicle inspected and if necessary, use the following repair procedure.
REPAIR PROCEDURE

1. Verify customer concern.

2. Replace the speedometer assembly per the Workshop Manual.

3. Verify repair.

PART(S) INFORMATION
Interchangeability Note:
"A" means an old part can be replaced with a new part, however, a new part cannot be replaced with an old part.
WARRANTY INFORMATION

Note

^

This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warrantyterm information.

Warranty Type A
Symptom Code 62
Damage Code 9Q
Part Number Main Cause Refer To Part(s) Information
Quantity 1
Operation Number T0608XRX
Labor Hours 0.6

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > T0900598 > May >

98 > Brake Warning Light - ON Constantly

Speedometer Module: All Technical Service BulletinsBrake Warning Light - ON Constantly

Bulletin No. 005/98
Issued 05/06/98
Revised

CategoryT (09)

Applicable Model/s1997 - 98 Protege

SubjectBRAKE WARNING LIGHT ON CONSTANTLY

APPLICABLE MODEL(S)/VINS1997-98 Protege with VINs lower than JM1 BC14** W0 204584
DESCRIPTION

Brake warning light in the combination meter is ON constantly. This is caused by surge current damaging a transistor which controls the brake warninglight illumination in the speedometer assembly. The speedometer assembly has been modified to protect this transistor.
Customers complaining of this subject should have the vehicle inspected and if necessary, use the following repair procedure.
REPAIR PROCEDURE

1. Verify customer concern.

2. Replace the speedometer assembly per the Workshop Manual.

3. Verify repair.

PART(S) INFORMATION
Interchangeability Note:
"A" means an old part can be replaced with a new part, however, a new part cannot be replaced with an old part.
WARRANTY INFORMATION

Note

^

This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warrantyterm information.

Warranty Type A
Symptom Code 62
Damage Code 9Q
Part Number Main Cause Refer To Part(s) Information
Quantity 1
Operation Number T0608XRX
Labor Hours 0.6

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > AD00397 > Feb >

97 > Speedometer - Replacement Procedure

Speedometer Module: All Technical Service BulletinsSpeedometer - Replacement Procedure

Bulletin No.: 003/97Issued: 02/25/97Revised
Category

AD

Applicable Model/sAll Models

Subject:SPEEDOMETER REPLACEMENT PROCEDURE
DESCRIPTION
In accordance with Federal regulations, follow the procedures listed below when replacing a speedometer.

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service

Bulletins for Speedometer Module: > AD00397 > Feb > 97 > Speedometer - Replacement Procedure > Page 71

Protege ES L4-1839cc 1.8L DOHC (1997)

NOTE:

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service

Bulletins for Speedometer Module: > AD00397 > Feb > 97 > Speedometer - Replacement Procedure > Page 72

Protege ES L4-1839cc 1.8L DOHC (1997)

1. Mazda vehicles are manufactured with tamper-proof speedometers and the mileage can not be altered or adjusted.2. When a speedometer is replaced, the new speedometer will read zero (0).3. This procedure is extremely important to accurately represent actual vehicle mileage.4. The "Speedometer Replacement Label" referenced below is available through the Mazda Program Center for a limited time. Mazda Motor of

America, Inc. is providing 1 sheet of 20 labels with this bulletin (see Illustration).

REPLACEMENT PROCEDURE

1. Remove and replace the speedometer according to the workshop manual.

2. Complete the following information on the "Speedometer Replacement Label."
^ Mileage before speedometer replacement

^ Date of replacement
^ Dealer code.

3. Attach the label to the driver's side "B" pillar.

4. Complete the "Speedometer Replacement Record" in the Warranty Information Booklet as referenced.

DISCLAIMER

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speedometer Module: > AD00397 > Feb > 97 >

Speedometer - Replacement Procedure

Speedometer Module: All Technical Service BulletinsSpeedometer - Replacement Procedure

Bulletin No.: 003/97Issued: 02/25/97Revised
Category

AD

Applicable Model/sAll Models

Subject:SPEEDOMETER REPLACEMENT PROCEDURE
DESCRIPTION
In accordance with Federal regulations, follow the procedures listed below when replacing a speedometer.

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Other Service Bulletins

for Speedometer Module: > AD00397 > Feb > 97 > Speedometer - Replacement Procedure > Page 78

Protege ES L4-1839cc 1.8L DOHC (1997)

NOTE:

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Other Service Bulletins

for Speedometer Module: > AD00397 > Feb > 97 > Speedometer - Replacement Procedure > Page 79

Protege ES L4-1839cc 1.8L DOHC (1997)

1. Mazda vehicles are manufactured with tamper-proof speedometers and the mileage can not be altered or adjusted.2. When a speedometer is replaced, the new speedometer will read zero (0).3. This procedure is extremely important to accurately represent actual vehicle mileage.4. The "Speedometer Replacement Label" referenced below is available through the Mazda Program Center for a limited time. Mazda Motor of

America, Inc. is providing 1 sheet of 20 labels with this bulletin (see Illustration).

REPLACEMENT PROCEDURE

1. Remove and replace the speedometer according to the workshop manual.

2. Complete the following information on the "Speedometer Replacement Label."
^ Mileage before speedometer replacement

^ Date of replacement
^ Dealer code.

3. Attach the label to the driver's side "B" pillar.

4. Complete the "Speedometer Replacement Record" in the Warranty Information Booklet as referenced.

DISCLAIMER

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 84

Daytime Running Lamp Relay: Testing and Inspection

1. Remove the DRL relay.

2. Check for continuity between the DRL relay terminals by using an ohmmeter.3. If not as specified, replace the DRL relay.

> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations

> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 88

Headlamp Relay: Testing and Inspection

1. Remove the headlight relay.

2. Check for continuity between the headlight relay terminals by using an ohmmeter.3. If not as specified, replace the relay.

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Testing and Inspection

Horn Relay: Testing and Inspection

1. Remove the passenger's side front scuff plate.2. Remove the passenger's side front side trim.3. Remove the horn relay.

4. Check for continuity between the horn relay terminals by using an ohmmeter.5. If not as specified, replace the horn relay.

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Testing and Inspection > Page 92

Horn Relay: Service and Repair

1. Disconnect the negative battery cable.2. Remove the passenger's side front scuff plate.3. Remove the passenger's side front side trim.4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Install the passenger's side front side trim.7. Install the passenger's side front scuff plate.8. Connect the negative battery cable.

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations

Connector Locations

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions

Interior Lighting Module: Diagram Information and Instructions

Ground Points

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions

> Page 98

Protege ES L4-1839cc 1.8L DOHC (1997)

Ground Points

^ This shows ground points of the harness.

Routing Diagram

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions

> Page 99

Protege ES L4-1839cc 1.8L DOHC (1997)

Routing Diagram

^ The routing diagram shows where electrical components are on the system circuit diagram by call outline and connector symbols.

Harness Symbols

............................................................................................................................................................................................Description of Harness Symbol

Front Harness .................................................................................................................................................................................................................... (F)Front No.2 Harness ......................................................................................................................................................................................................... (F2)Engine Harness ................................................................................................................................................................................................................. (E)Dash Harness .................................................................................................................................................................................................................... (D)Rear Harness ..................................................................................................................................................................................................................... (R)Rear No.2 Harness .......................................................................................................................................................................................................... (R2)Rear A Harness .............................................................................................................................................................................................................. (RA)Instrument Panel Harness ................................................................................................................................................................................................... (I)Emission Harness .......................................................................................................................................................................................................... (EM)Emission No.2 Harness ................................................................................................................................................................................................ (EM2)Emission No.3 Harness ................................................................................................................................................................................................ (EM3)Door No.1 Harness ...................................................................................................................................................................................................... (DR1)Door No.2 Harness ...................................................................................................................................................................................................... (DR2)Door No.3 Harness ...................................................................................................................................................................................................... (DR3)Door No.4 Harness ...................................................................................................................................................................................................... (DR4)Floor Harness .................................................................................................................................................................................................................. (FR)Interior Light Harness ..................................................................................................................................................................................................... (IN)A/C Harness ................................................................................................................................................................................................................... (AC)

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions

> Page 100

Protege ES L4-1839cc 1.8L DOHC (1997)

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions

> Page 101

Protege ES L4-1839cc 1.8L DOHC (1997)

Symbols (Part 1 Of 2)

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions

> Page 102

Protege ES L4-1839cc 1.8L DOHC (1997)

Symbols (Part 2 Of 2)

Logic Symbols

System Circuit Diagram/Connector Diagram

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions

> Page 103

Protege ES L4-1839cc 1.8L DOHC (1997)

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions

> Page 104

Protege ES L4-1839cc 1.8L DOHC (1997)

System Circuit Diagram/Connector Diagram(Part 1 Of 2)
System Circuit Diagram/Connector Diagram(Part 2 Of 2)

^

OFF

These show the circuits for each system, from the power supply to the ground. The power supply side is on the upper part of the image, the groundside on the lower part. The diagrams describe circuits with the ignition switch .Refer to images for an explanation of the various points in the diagram.

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 105

Spot Lights/Interior Light-Connectors

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 106