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1991 Mazda Protege CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Mazda REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1991 Mazda Protege car and truck
repair procedures including Mazda engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Mazda Protege automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1991 Mazda Protege AUTOMOBILES
Air Bag System Precautions -> Mazda -> Disarming -> 1990-93 -> 1994-96 -> 1997-2001 -> 2002-04
Vehicle: 1991 Mazda Protege 4WD 1.8 L4 GAS
NOTE: For B2300, B3000 And B4000, Refer To "Ranger" In "Ford Motor Co."
NOTE: For Tribute, Refer To "Escape" In "Ford Motor Co."
1990-93
- On 929 models, refer to "1994-96."
- On models equipped with audio anti-theft, obtain audio unit anti-theft code number from vehicle owner.
- On all models, disconnect battery ground cable.
- On Miata models, disconnect orange and blue air bag clockspring connectors, Fig. .
- On 626, MX-6 and RX-7 models, remove lower lefthand sound insulator from instrument panel, then disconnect clockspring orange and blue connectors, Figs...
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BRAKE SERVICE PROCEDURES FOR 1991 Mazda Protege AUTOMOBILES
HYDRAULIC BRAKES -> COMPONENT SERVICE -> All Models Except Navajo -> MASTER CYLINDER OVERHAUL -> Navajo -> WHEEL CYLINDER OVERHAUL
Vehicle: 1991 Mazda Protege GT 1.8 L4 GAS
MASTER CYLINDER OVERHAUL
All Models Except Navajo
- Remove brake fluid from reservoir after removal of master cylinder.
- Refer to Figs. and for master cylinder disassembly.
- Visually inspect all parts and repair or replace any faulty parts.
- Reverse procedure to install.
Navajo
- Clean outside of master cylinder and drain fluid after removal.
- Remove snap ring by depressing rear piston, Fig.
- Remove primary piston from master cylinder, then remove secondary piston by directing compr...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Mazda Protege AUTOMOBILES
Mazda -> Fuel Filter Replacement -> 1990-00 Protege, 323 & MX-3 -> Fuel System Pressure Relief -> Removal & Installation
Vehicle: 1991 Mazda Protege 4WD 1.8 L4 GAS
Fuel System Pressure Relief
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
The anti-theft function is available as an option for the audio system. Before removing the battery ground cable or disconnecting the audio system power source, obtain the code number to reset the system when repairs are complete.
After the ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Mazda Protege AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1991 Mazda Protege DX 1.8 L4 GAS
- Raise and support vehicle, then remove wheel and tires.
- Remove splash shield, then transaxle drain plug.
- Raise staked portion of driveshaft locknut using suitable tool.
- Apply brakes, then loosen and remove locknut.
- Remove stabilizer, then tie rod ends using tool No. 490118850C or equivalent.
- Remove lower ball joint attaching bolt.
- Remove driveshaft clinch bolt and nut, pry down on lower arm to disconnect ball joint.On vehicles equipped with autom...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Mazda Protege AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Mazda Protege 4WD 1.8 L4 GAS
- Disconnect battery ground cable.
- Disconnect wire and connector from alternator.
- Remove drive belt.
- Remove alternator mounting bolts and nut.
- Remove alternator from vehicle.
- Reverse proc...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Mazda Protege AUTOMOBILES
Mazda -> Air Bag Warning Lamp ->
Vehicle: 1991 Mazda Protege LX 1.8 L4 GAS
This lamp should light for a approximately 6-8 seconds when the ignition is turned On as a bulb check. If the Air B...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Mazda Protege AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 1991 Mazda Protege LX 1.8 L4 GAS
Inlet
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at heater core.
- Remove hose from heater core.
- Reposition hose clamp at heater pipe.
- Remove hose from heater pipe.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at heater co...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Mazda Protege AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Mazda Protege 4WD 1.8 L4 GAS
- Loosen alternator pivot bolt.
- Loosen adjuster lock bolt.
- Loosen alternator adjustment bolt and relieve belt tension.
- Remove driv...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Mazda Protege AUTOMOBILES
Component location diagrams for most 1991 Mazda Protege cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Locations Diagram for 1991 Mazda Protege GT 1.8 L4 GASComponents on diagram: |
 Automatic Transaxle Electrical Component Locations Diagram for 1991 Mazda Protege 4WD 1.8 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1991 Mazda Protege AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Mazda Protege cars and light trucks sold in the U.S.
 1991 Mazda Protege GT 1.8 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Mazda Protege AUTOMOBILES
OEM TSB listings for most 1991 Mazda Protege cars and light trucks sold in the U.S. from 1985+.
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Document: SERVICE BUMPER SPECIFICATION CHANGE Vehicle: 1991 Mazda Protege GT 1.8 L4 GAS Auto Systems: |
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Document: SERVICE BUMPER SPECIFICATION CHANGE Vehicle: 1991 Mazda Protege GT 1.8 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Mazda Protege AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Mazda Protege cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 Mazda Protege cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 Mazda Protege cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 Mazda Protege cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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