Engine Controls - Remove/install/overhaul Mazda Protege BG

INTRODUCTION

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished. See TORQUE SPECIFICATIONS .

On Miata, obtain code number and deactivate anti-theft alarm before disconnecting battery cable.

DISTRIBUTOR IGNITION SYSTEM

Note. Miata, Navajo and RX7 are equipped with distributorless ignition system.

Refer to appropriate illustration when removing, overhauling or installing distributor. (Scheme 1)- (Scheme 8).

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Miata

Disconnect sensor connector. Remove hold-down bolt. Remove sensor. To install, reverse removal procedure. See TORQUE SPECIFICATIONS . Adjust ignition timing. See the appropriate ADJUSTMENTS article in the ENGINE PERFORMANCE section.

Removal (RX7)

Align Yellow timing mark on pulley with indicator. Disconnect sensor connector. Remove hold-down bolt. Remove sensor.

Installation (RX7)

Align mark on sensor drive gear with mark on sensor housing. Ensure Yellow timing mark on pulley is aligned with indicator. Install sensor and lock bolt. See TORQUE SPECIFICATIONS . Adjust ignition timing. See appropriate ADJUSTMENTS article in the ENGINE PERFORMANCE section.

Removal & Installation

Disconnect negative battery cable. Disconnect crankshaft (variable reluctance) sensor connector. (Scheme 9) Remove crankshaft sensor mounting screws and crankshaft sensor. To install, reverse removal procedure.

Scheme 9

FUEL SYSTEM PRESSURE RELEASE

Navajo

1. Disconnect negative battery cable. Remove snow/ice shield. Remove air intake tube between air cleaner and throttle body. Remove fuel filler cap to release fuel tank pressure. Connect Fuel Pressure Gauge (49UN01010) to relief valve (Schrader valve) on fuel supply manifold, near fuel pressure regulator. (Scheme 27)
2. As an alternate method, disconnect inertia switch connector, behind instrument panel, under radio. Start and operate engine until it stalls.

Except Navajo

1. Start engine. On B2200 PFI, B2600i, Miata, MX-6 & 626, disconnect circuit opening relay. See «CIRCUIT OPENING RELAY LOCATION»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. On MPV 3.0L, disconnect airflow sensor connector.
2. On all other models, disconnect fuel pump connector near fuel tank (on MPV 2.6L, Protege and 323, fuel pump connector is accessible from under rear seat cushion; on RX7 and 929, connector is on right side of trunk).
3. On all models, allow engine to run until it stalls. Turn ignition off. Reconnect electrical connector. CIRCUIT OPENING RELAY LOCATION Application Location B2200 PFI & B2600i Behind Left Kick Panel Miata To Left Of Steering Column MX-6 & 626 Near Fuse Block, On Relay Panel

FUEL LINE CONNECTORS (NAVAJO)

Note. Although push-connect fittings and spring lock couplers are similar in function, different procedures and tools are used to disconnect and connect these connectors. To identify type of connector (Scheme 10)and (Scheme 11).

Push-Connect Fitting (Disconnecting)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Remove locking (safety) clip (if equipped).
2. Position Push-Connect Fitting Releaser (49UN01053 for 5/16" line; 49UN01054 for 3/8" line) over fuel line. (Scheme 10) Slide releaser into fitting. Pull fuel lines apart.

Push-Connect Fitting (Connecting)

Press fuel lines together until a click is heard. Attempt to pull lines apart to ensure coupler is fully engaged. Install locking clip (if equipped).

Scheme 10

Spring Lock Coupler (Disconnecting)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Remove locking (safety) clip (if equipped). Place Spring Lock Coupler Releaser (49UN01051 for 3/8" line; 49UN01052 for 1/2" line) over fuel line coupler. (Scheme 11)
2. Push spring lock coupler releaser to release female fitting from garter spring. Pull spring lock coupler apart. Remove releaser.

Scheme 11

1. Check for damaged garter spring. If garter spring is damaged, remove with small hooked wire and replace. Wipe end of lines with clean cloth. Place new "O" rings onto tube. Lubricate ends of lines with clean refrigerant oil.
2. Push fitting together with a slight twisting motion. Ensure garter spring is over flared end of female fitting. Attempt to pull lines apart to ensure coupler is fully engaged. Install locking clip (if equipped).

FUEL SYSTEM PRIMING

Without starting engine, turn ignition on and off 5-10 times.

Scheme 12

1. On B2200 PFI, B2600i, MPV, MX-6, RX7, 626 and 929, connect jumper wire between terminals of Yellow 2-pin connector. See «FUEL PUMP TEST CONNECTOR LOCATION»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul) table.
2. On Miata, Protege and 323, connect jumper wire between GRN and F/P terminals of diagnostic connector. (Scheme 12) On all models, turn ignition on for about 10 seconds, then turn ignition off. Disconnect jumper wire. FUEL PUMP TEST CONNECTOR LOCATION Application Location B2200 PFI & B2600i In Right Rear Corner Of Engine Compartment MPV & 929 In Left Front Corner Of Engine Compartment MX-6 & 626 Near Left Strut Tower RX7 In Right Front Corner Of Engine Compartment

CARBURETOR (B2200)

Disconnect negative battery cable. Remove air cleaner. Disconnect accelerator cable, cruise control cable (if equipped), all necessary vacuum hoses, fuel hoses and electrical connectors. Remove carburetor mounting nuts. Remove carburetor. To install, reverse removal procedure.

Disassembly (Air Horn & Choke Assembly)

1. DO NOT remove choke valve and shaft from air horn. Disconnect vacuum hose from choke opener (pull-off) diaphragm. Remove accelerator pump connecting rod, spring and lever. (Scheme 17) Disconnect air vent solenoid valve wire from connector.
2. Disconnect choke rod. Remove air horn retaining bolts. Remove air horn and choke assembly from main body. Remove air vent solenoid valve, spring and gasket from air horn.

Disassembly (Needle Valve & Float)

Remove float, pin and gasket. (Scheme 16)and (Scheme 17). Remove needle valve assembly. Remove sight glass assembly from main body.

Disassembly (Air Bleeds & Jets)

1. Remove secondary slow jet, secondary slow bleed, secondary main bleed and secondary main jet from main body. (Scheme 13)and (Scheme 17). Remove primary main bleed, slow jet and plug, primary slow bleed and primary main jet from main body.
2. Remove richer air bleed, primary slow bleed, coasting richer air bleed and coasting richer jet from air horn. (Scheme 14)and (Scheme 17).

Disassembly (Main Body)

1. DO NOT remove venturis from main body. Remove coasting richer solenoid valve and "O" ring. (Scheme 17) Remove idle switch and spring. Remove slow fuel-cut solenoid valve, needle valve, spring and gasket. Remove dashpot (M/T).
2. Remove accelerator pump plunger and spring assembly. Remove retaining clip, strainer and inlet check ball. Remove outlet check ball plug, outlet check ball and spring.
3. Disconnect throttle link, vacuum diaphragm connecting rod and throttle return spring. Remove throttle body-to-main body retaining bolts (one bolt is located inside throttle body). Separate throttle body from main body.

Disassembly (Throttle Body)

DO NOT remove throttle valve and shaft from throttle body. Remove vacuum (secondary) diaphragm assembly. Remove diaphragm cover screws. Remove cover, spring and diaphragm. Using small punch and hammer, remove spring pin located in front of mixture adjusting screw. Remove mixture adjusting screw.

Scheme 13

Scheme 14

Note. DO NOT immerse diaphragms, electrical components or synthetic parts in carburetor cleaner.

Scheme 15

1. Thoroughly clean parts in carburetor cleaner. Using compressed air, dry all components and blow out all passages. DO NOT use wire or pointed metal objects for cleaning. Inspect air horn, main body and throttle body for cracks.
2. Inspect choke shaft and throttle shaft for wear. Check all jets and air bleeds for open passages. Inspect needle and seat for wear. Inspect float and accelerator pump cup for damage. Replace all damaged components.
3. Inspect vacuum diaphragm for damage. Inspect idle mixture screw for wear or burrs. Apply battery voltage to solenoids to ensure solenoids operate (indicated by valve stem movement).
4. Check electric choke heater by connecting an ohmmeter to wire connector and heater ground. If there is no continuity, replace electric choke heater.
5. To check air/fuel (A/F) solenoid valve, apply battery voltage across solenoid using solenoid connector. (Scheme 15) From bottom of air horn, blow air through valve in direction indicated in illustration. If air does not flow through valve with solenoid energized, replace air horn assembly (air/fuel solenoid and air horn are replaced as an assembly).

Reassembly

1. To reassemble, reverse disassembly procedure using new gaskets. DO NOT install spring pin in front of mixture screw until idle mixture has been adjusted with engine running. Before installing air horn on main body, adjust float level and float drop; install a new "O" ring on air/fuel solenoid valve and coat "O" ring with gasoline.
2. After reassembly and before installing carburetor, adjust choke pull-off diaphragm, fast idle cam (throttle opening angle), fast idle cam (choke opening angle), choke unloader, secondary throttle valve and accelerator cable.
3. After installing carburetor, adjust curb (hot) idle speed, fast (cold) idle speed and idle mixture. See appropriate ADJUSTMENTS article in the ENGINE PERFORMANCE section.

Adjusting Float Level

With air horn upside down and gasket removed, allow float to hang by its own weight. (Scheme 16) Measure distance between top of float and air horn gasket surface. If distance is not.42-.46" (10.7-11.7 mm) for vehicles with A/T, or.46-.50" (11.7-12.7 mm) for vehicles with M/T, bend float seat as necessary.

Scheme 16

Adjusting Float Drop

With air horn upright and gasket removed, allow float to hang by its own weight. (Scheme 18) Measure distance between bottom of float and air horn gasket surface. If distance is not 1.81-1.85" (46.0-47.0 mm), bend float stop as necessary.

Scheme 17

Scheme 18

Adjusting Choke Pull-Off Diaphragm

Apply about 16 in. Hg vacuum to choke pull-off diaphragm. Lightly push choke plate toward closed position. Measure clearance between top of choke plate and air horn. (Scheme 19) If clearance is not.067-.085" (1.70-2.16 mm), bend choke tang until clearance is within specification.

Scheme 19

Adjusting Fast Idle Cam - Throttle Opening Angle

Set fast idle cam on second highest step. Measure clearance between primary throttle valve and throttle bore. (Scheme 20) If clearance is not.033-.041" (.84-1.04 mm), rotate fast idle adjusting screw as necessary.

Scheme 20

Adjusting Fast Idle Cam - Choke Opening Angle

Set fast idle cam on second highest step. Measure clearance between top of choke plate and air horn. (Scheme 21) If clearance is not.024-.045 (.60-1.14), bend starting arm. If large adjustment is required, bend choke rod.

Scheme 21

Adjusting Choke Unloader

Fully open primary throttle valve. Measure clearance between top of choke plate and air horn. (Scheme 22) If clearance is not.110-.143" (2.80-3.62 mm), bend tab as necessary.

Scheme 22

Adjusting Secondary Throttle Valve

Secondary throttle valve should start to open when primary throttle valve opens 50-54 degrees and should be fully open when primary throttle valve is fully open. Measure clearance between primary throttle valve and throttle bore when secondary throttle valve starts to open. (Scheme 23) If clearance is not.289-.325" (7.35-8.25 mm), bend tab as necessary.

Scheme 23

Adjusting Accelerator Cable

Check accelerator cable deflection (free play) at carburetor. If deflection is not .039-.118" (1.0-3.0 mm), turn cable adjusting nuts as necessary. Fully depress accelerator pedal. If primary throttle valve does not fully open, turn accelerator stop bolt (above accelerator pedal) as necessary to obtain full valve opening.

FUEL PUMP

B2200 Carbureted W/ Electric Pump, B2200 PFI & B2600I

Release fuel system pressure (except B2200 Carbureted). See FUEL SYSTEM PRESSURE RELEASE . Remove fuel tank. Remove sending unit and pump assembly from tank. Remove fuel pump from assembly. To install, reverse removal procedure.

Removal (Miata, Protege & 323)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) .
2. On Miata, remove rear package trim (behind seat). On Protege and 323, remove rear seat.
3. On all models, remove fuel tank access cover. Disconnect fuel hoses and electrical connector. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Installation (Miata, Protege & 323)

Install fuel pump to assembly using new cap, "O" ring and spacer between fuel pump and outlet pipe (coat components with oil or gasoline before installing). (Scheme 24) After installing pump to assembly, blow through outlet pipe (at top of assembly) toward pump to confirm "O" ring seal. To install remaining components, reverse removal procedure.

Removal (MPV)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove rear seat.
2. Remove fuel tank access cover. Disconnect fuel hoses and electrical connector. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Installation (MPV)

1. Replace fuel hose between pump and outlet pipe ( DO NOT apply excessive force when installing onto pump nipple). Install hose clamps so each clamp is located.10" (3 mm) from end of hose and hose clamp tabs are positioned around circumference of hose as specified in illustration. (Scheme 25)
2. Install pump with terminals positioned in relation to assembly frame as specified in illustration. To install remaining components, reverse removal procedure.

Removal (MX-6, RX7, 626 & 929)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) .
2. On MX-6 and 626, remove rear seat. On RX7, lift floor mat in rear compartment. On 929, lift rear floor mat in trunk.
3. On all models, remove fuel tank access cover. Disconnect fuel hoses and electrical connector. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Installation (MX-6, RX7, 626 & 929)

To install, reverse removal procedure.

Removal (Navajo)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove fuel tank. Using Fuel Tank Lock Ring Wrench (T86T-9275-A), turn lock ring counterclockwise. Remove lock ring. Remove fuel sending unit and pump assembly from tank.

Installation (Navajo)

Clean seal area on tank and assembly flange. Lightly coat new "O" ring with molybdenum grease. Install seal in groove. Carefully install assembly into fuel tank, ensuring filter is not damaged and seal remains in groove. Install lock ring, and tighten to 40-45 ft. lbs. (54-61 N.m). Install fuel tank.

Scheme 24

Scheme 25

FUEL PRESSURE REGULATOR

1. Disconnect battery ground cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect vacuum hose from regulator. Disconnect fuel line coupling at regulator. See «FUEL LINE CONNECTORS (NAVAJO)»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connectors-navajo) .
2. Remove regulator mounting bolts. Remove regulator, "O" ring and washer. To install, reverse removal procedure using new washer and "O" ring. Lubricate new "O" ring with light oil. DO NOT use silicone grease.

RX7

Fuel pressure regulator is part of secondary fuel rail. See FUEL RAILS & INJECTORS.

Except Navajo & RX7

1. Disconnect battery ground cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . On MX-6 and 626, remove dynamic chamber. On all models, disconnect vacuum and fuel hose(s) from regulator. Remove regulator mounting bolts. Remove regulator, gasket and "O" ring (if equipped).
2. To install, reverse removal procedure. Install new gasket and "O" ring (if equipped). On MX-6 and 626, install dynamic chamber with new gasket, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) .

FUEL RAILS & INJECTORS

B2200 PFI, B2600I & MPV 2.6L

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove throttle body. See «THROTTLE BODY»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__throttle-body) .
2. Remove support brackets and injector harness bracket from dynamic chamber. Disconnect vacuum hoses, PCV hose, intake air thermosensor connector and ground wire from dynamic chamber. Remove dynamic chamber.
3. Disconnect vacuum hose and fuel hoses from fuel rail. Disconnect injector electrical connectors. Pull fuel rail with injectors and pressure regulator upward to remove. Remove insulators, injectors and "O" rings from fuel rail.
4. To install, reverse removal procedure. Apply coat of engine oil to new "O" rings and install on injectors. Install new insulators. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) . Install dynamic chamber with new gasket.

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Remove air valve and PCV valve from intake manifold. Disconnect vacuum and fuel hoses from fuel rail. Disconnect injector electrical connectors. Remove insulators, injectors and "O" rings from fuel rail.
2. To install, reverse removal procedure. Apply coat of engine oil to new "O" rings, and install rings on injectors. Install new insulators. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) .

Scheme 26

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Remove air intake tube. (Scheme 26) Remove throttle body. See «THROTTLE BODY»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__throttle-body).
2. Remove intake air pipe, extension manifolds and dynamic chamber. Disconnect fuel hoses from fuel rail. Disconnect injector electrical connectors. Remove fuel rail and injectors as an assembly. Remove insulators, injectors and "O" rings from fuel rail.
3. To install, reverse removal procedure. Apply coat of engine oil to new "O" rings and install on injectors. Install new insulators. Tighten fuel rail mounting nuts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications). Install new extension manifold and intake air pipe gaskets. (Scheme 26): View of Upper Intake Manifold Components & Fuel Rail (MPV 3.0L Shown; 929 SOHC Similar)

MX-6 & 626

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove dynamic chamber. Disconnect fuel return pipe from intake manifold. Disconnect injector electrical connectors. Remove fuel rail, injectors, pressure regulator and pulsation damper as an assembly.
2. Remove insulators, injectors and "O" rings from fuel rail. To install, reverse removal procedure. Apply coat of engine oil to new "O" rings, and install rings on injectors. Install new insulators. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) .

1. Thoroughly clean engine. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Disconnect negative battery cable. Remove upper intake manifold and throttle body (as an assembly). (Scheme 27)
2. Disconnect fuel supply line from fuel supply manifold. See «FUEL LINE CONNECTORS (NAVAJO)»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connectors-navajo). Disconnect fuel return line from fuel pressure regulator. Remove fuel supply manifold. Disconnect injector electrical connectors. Remove injectors from fuel supply manifold.

Scheme 27

1. If injectors were removed, lubricate new injector "O" rings with light oil. DO NOT use silicone grease. Carefully install injectors into fuel supply manifolds. Carefully install fuel supply manifolds into lower manifold using new manifold gasket.
2. Clean and oil fuel supply manifold bolt threads. Install fuel supply manifold. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) . To complete installation, reverse removal procedure.

Protege & 323

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect injector electrical connectors. Remove injector harness from fuel rail. Remove fuel rail mounting bolts. Remove fuel rail, injectors and pressure regulator as an assembly.
2. Remove insulators, injectors and "O" rings from fuel rail. To install, reverse removal procedure. Apply coat of engine oil to new "O" rings, and install rings on injectors. Install new insulators. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) .

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Remove throttle body and dynamic chamber as an assembly. See «THROTTLE BODY»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__throttle-body). (Scheme 28)& (Scheme 29).
2. Disconnect vacuum and fuel hoses from secondary fuel rail. Disconnect injector electrical connectors. Remove secondary fuel rail and injectors as an assembly. Remove insulators, injectors and "O" rings from fuel rail. Remove air bleed socket. (Scheme 30)
3. On non-turbo, remove extension manifold. On all vehicles, disconnect fuel hoses from primary fuel rail. Disconnect primary injector electrical connectors. Remove primary fuel rail and injectors as an assembly. Remove insulators, injectors and "O" rings from fuel rail. Remove air bleed socket and mixing plate. (Scheme 31)

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. Apply coat of engine oil to new "O" rings. Install "O" rings on primary injectors and air bleed sockets. (Scheme 31) Install mixing plates, ensuring tab on plate is indexed with notch in housing.
2. Install primary injectors onto fuel rail, ensuring electrical connectors are positioned as illustrated. (Scheme 31) Install primary fuel rail and injector assembly. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications).
3. On non-turbo models, install extension manifold using new gasket. On all vehicles, apply coat of engine oil to new "O" rings. Install "O" rings on secondary injectors and air bleed sockets. (Scheme 30) Install secondary air bleed sockets.
4. Install secondary injectors onto fuel rail, ensuring injector electrical connectors are positioned as illustrated. (Scheme 30) Install secondary fuel rail and injector assembly. To install remaining components, reverse removal procedure using new dynamic chamber gasket.

929

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove dynamic chamber cover. Remove dynamic chamber and throttle body as an assembly. Disconnect injector electrical connectors. Disconnect vacuum and fuel hoses. Remove fuel rail, injectors and pressure regulator as an assembly.
2. Remove insulators, injectors and "O" rings from fuel rail. To install, reverse removal procedure. Apply coat of engine oil to new "O" rings, and install rings on injectors. Install new insulators. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) .

Removal

Disconnect oxygen sensor electrical connector. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). If sensor is difficult to remove, use rust penetrant to avoid damaging threads. Carefully remove sensor.

Installation

Apply anti-seize to sensor threads (if reusing old sensor or if new sensor is not coated with anti-seize). Install sensor. See TORQUE SPECIFICATIONS . Reconnect sensor electrical connector and negative battery cable.

THROTTLE BODY

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Drain cooling system. On Turbo models, remove intercooler, oil filler pipe and Accelerated Warm-Up Solenoid (AWS) valve. (Scheme 29)
2. On all models, remove throttle body air intake tube. Disconnect all necessary vacuum and coolant hoses, control cables and electrical connectors from throttle body.
3. Remove throttle body and dynamic chamber as an assembly. Remove throttle body from dynamic chamber. To install, reverse removal procedure using new gaskets. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications).

Except RX7

1. On MPV 3.0L, drain about 2 qts. (1.9 L) of coolant from cooling system. On all models, disconnect negative battery cable. Remove air intake tube.
2. Disconnect accelerator cable, coolant hoses and electrical connectors from throttle body as necessary. On 929, remove by-pass air control valve. On all models, remove throttle body. To install, reverse removal procedure using new throttle body gasket. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) .

Removal (MX-6 & 626)

1. Drain coolant. Remove air hoses and air by-pass valve. Remove heat shields. Disconnect oil hoses from oil pipes. (Scheme 32) Remove coolant hoses, EGR pipe and oxygen sensor.
2. Disconnect exhaust downpipe. Remove bolts securing turbocharger to bracket. Remove turbocharger and exhaust manifold as an assembly. Disassemble turbocharger and exhaust manifold.

Disassembly (MX-6 & 626)

1. Remove exhaust pipe joint. (Scheme 32) Remove coolant pipe (inboard), inlet oil pipe and coolant pipe (outboard). Remove outlet oil pipe. Remove exhaust manifold. For reassembly reference, place turbocharger on a surface plate. (Scheme 33) Mark turbine plate and turbine housing in line with outlet oil pipe.
2. Mark wastegate actuator as illustrated. (Scheme 33) Measure and record distance from surface plate to mark. Remove wastegate actuator, compressor plate and compressor housing. Remove turbine plates and bearing assembly.

Reassembly (MX-6 & 626)

1. To reassemble, reverse disassembly procedure. To prevent heat distortion, install turbine plates as illustrated. (Scheme 34) Install compressor plates with rounded edge toward compressor housing.
2. Remove old sealant from compressor housing (inward of sealing flange) and apply thin bead of new sealant. After reassembly, reach into compressor housing through inlet air opening. Rotate turbine wheel. If excessive load or noise exists, or if wheel touches housing, replace turbocharger.

Installation (MX-6 & 626)

1. Add .85 oz. (25 cc) of clean engine oil to oil inlet passage of turbocharger. Install turbocharger with new gasket between turbocharger and exhaust manifold.
2. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/mazda/protege/bg-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) . To install remaining components, reverse removal procedure. Prime the oil system.

Priming Oil System

Disconnect igniter electrical connector. Crank engine for 20 seconds. Reconnect igniter electrical connector. Start engine and operate at idle for 30 seconds. Turn off engine. Disconnect negative battery cable. Depress and hold brake pedal for at least 5 seconds to clear fault code.

Scheme 32

Scheme 33

Scheme 34

1. Drain coolant. Disconnect air inlet and outlet hoses from turbocharger. Remove airflow meter air hose. Remove air pump. Remove air control valve. Remove split air pipe. Disconnect water hose and water pipe. (Scheme 35)
2. Disconnect oil pipes. Remove insulator covers (heat shields). Disconnect front converter from turbocharger. Remove turbocharger and insulator covers. Remove exhaust manifold and actuator. Remove air by-pass valve.

Disassembly & Reassembly (RX7)

Information is not available. (Scheme 35)for exploded view of turbocharger and exhaust assembly.

To install, reverse removal procedure. Replace all gaskets. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .

Scheme 35

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• CIRCUIT OPENING RELAY LOCATION
• FUEL SYSTEM PRESSURE RELEASE
• FUEL SYSTEM PRIMING
• FUEL LINE CONNECTORS (NAVAJO)
• THROTTLE BODY