Mazda Protege 5. Manual - part 240

SYMPTOM TROUBLESHOOTING 

05–03–19

05–03

NO.23 TRANSAXLE OVERHEATS

A3U050301030W27

Diagnostic procedure

Note

•

If malfunction remains, inspect related Service Bulletins and perform repair or diagnosis.

•

If vehicle is repaired, troubleshooting is completed.

•

If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

End Of Sie

NO.24 ENGINE STALLS WHEN SHIFTED TO D, 2, 1 RANGES, OR IN R POSITION

A3U050301030W28

Diagnostic procedure

Note

•

If malfunction remains, inspect related Service Bulletins and perform repair or diagnosis.

•

If vehicle is repaired, troubleshooting is completed.

•

If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

End Of Sie

NO.25 ENGINE STALLS WHEN DRIVING AT SLOW SPEED OR STOPPING

A3U050301030W29

23

Transaxle overheats

DESCRIPTION

•

Burnt smell is emitted from transaxle.

•

Smoke is emitted from transaxle.

POSSIBLE 

CAUSE

•

The malfunction is restricted to hindrance of coolant at the oil cooler. In addition, overheating of the 
transaxle may be caused by a malfunction of the TFT sensor.
a. Burned (TCC)

•

Control valve body malfunction

•

Accelerator cable misadjustment

b. Oil cooler malfunction (Foreign material mixed in with ATF)
c. TFT sensor malfunction
d. Excessive amount of ATF
e. Torque converter malfunction

STEP

INSPECTION

ACTION

1

•

Inspect for bend, damage, corrosion or kinks 
of oil cooler pipes.

•

Are oil cooler pipes okay?

Yes

Go to next step.

No

Replace any defective parts.

2

•

Remove torque converter.

•

Inspect torque converter.
(See ATX Workshop Manual.)

•

Is torque converter okay?

Yes

Repeat basic inspection and repair or replace any defective 
parts according to inspection result.
(See 05–03–6 AUTOMATIC TRANSAXLE BASIC 
INSPECTION.)

No

Replace torque converter.

24

Engine stalls when shifted to D, 2, 1 ranges, or in R position

DESCRIPTION

•

Engine stalls when shifting from N or P position to D, 2, 1 ranges or R position at idle.

POSSIBLE 

CAUSE

•

The malfunction is on the engine control side (i.e. IAC system). Otherwise, the malfunction is in the 
input/turbine speed sensor (engine sometimes starts) or TCC circuit (engine always stalls).

STEP

INSPECTION

ACTION

1

•

Go to symptom troubleshooting No.4 
“Engine stalls”.
(See 01–03A–7 SYMPTOM DIAGNOSTIC 
INDEX [ZM].)
(See 01–03B–7 SYMPTOM DIAGNOSTIC 
INDEX [FS].)

•

Is engine control system okay?

Yes

Repeat basic inspection and repair or replace any defective 
parts according to inspection result.
(See 05–03–6 AUTOMATIC TRANSAXLE BASIC 
INSPECTION.)

No

Repair or replace any defective parts according to 
inspection results.

25

Engine stalls when driving at slow speed or stopping

DESCRIPTION

•

Engine stalls when brake pedal is depressed while driving at low speed or stopping.

POSSIBLE 

CAUSE

•

The malfunction is on the engine control side (e.g. Fuel injection control and IAC system).

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SYMPTOM TROUBLESHOOTING 

05–03–20

Diagnostic procedure

Note

•

If malfunction remains, inspect related Service Bulletins and perform repair or diagnosis.

•

If vehicle is repaired, troubleshooting is completed.

•

If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

End Of Sie

NO.26 O/D OFF INDICATOR LIGHT DOES NOT ILLUMINATE WHEN O/D OFF SWITCH IS TURNED TO ON

A3U050301030W30

End Of Sie

NO.27 O/D OFF INDICATOR LIGHT ILLUMINATES WHEN O/D OFF SWITCH IS NOT TURNED TO ON

A3U050301030W31

End Of Sie

STEP

INSPECTION

ACTION

1

•

Go to symptom troubleshooting No.9 “Low 
idle/stalls during deceleration”.
(See 01–03A–7 SYMPTOM DIAGNOSTIC 
INDEX [ZM].)
(See 01–03B–7 SYMPTOM DIAGNOSTIC 
INDEX [FS].)

•

Is engine control system okay?

Yes

Go to next step.

No

Repair or replace any defective parts according to 
inspection results.

2

•

Go to symptom troubleshooting No.4 
“Engine Stalls”.
(See 01–03A–7 SYMPTOM DIAGNOSTIC 
INDEX [ZM].)
(See 01–03B–7 SYMPTOM DIAGNOSTIC 
INDEX [FS].)

•

Is engine control system okay?

Yes

Repeat basic inspection and repair or replace any defective 
parts according to inspection result.
(See 05–03–6 AUTOMATIC TRANSAXLE BASIC 
INSPECTION.)

No

Repair or replace any defective parts according to 
inspection results.

26

O/D OFF indicator light does not illuminate when O/D OFF switch is turned to ON

DESCRIPTION

•

O/D OFF indicator light in instrument cluster does not illuminate when O/D OFF switch is turned on and 
ignition switch at on.

POSSIBLE 

CAUSE

•

O/D OFF switch, O/D OFF indicator light or related wiring harness malfunction

27

O/D OFF indicator light illuminates when O/D OFF switch is not turned to ON

DESCRIPTION

•

O/D OFF indicator light in instrument cluster illuminates even though O/D OFF switch is turned off and 
ignition switch at on.

POSSIBLE 

CAUSE

•

O/D OFF switch or related wiring harness malfunction

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CLUTCH 

05–10–1

05–10

05–10

CLUTCH

CLUTCH COMPONENT 

LOCATION INDEX  . . . . . . . . . . . . . . . .  05–10–2

GENERAL PROCEDURES . . . . . . . . . . .  05–10–3

Clutch Pipe Removal/Installation Note. 05–10–3

CLUTCH FLUID INSPECTION . . . . . . . .  05–10–3
CLUTCH FLUID 

REPLACEMENT/AIR BLEEDING . . . . .  05–10–3

CLUTCH PEDAL INSPECTION  . . . . . . .  05–10–3

Clutch Pedal Height Inspection  . . . . . .  05–10–3
Clutch Pedal Free Play Inspection . . . .  05–10–4

CLUTCH PEDAL ADJUSTMENT . . . . . .  05–10–4

Clutch Pedal Height Adjustment  . . . . .  05–10–4
Clutch Pedal Free Play Adjustment . . .  05–10–4
Clutch Pedal Disengagement Stroke . .  05–10–4

CLUTCH PEDAL 

REMOVAL/INSTALLATION . . . . . . . . .  05–10–5

CLUTCH MASTER CYLINDER 

REMOVAL/INSTALLATION . . . . . . . . .  05–10–6

CLUTCH MASTER CYLINDER 

DISASSEMBLY/ASSEMBLY  . . . . . . . .  05–10–7

Snap Ring Disassembly Note  . . . . . . .  05–10–7

Snap Ring Assembly Note  . . . . . . . . . . 05–10–8

CLUTCH RELEASE CYLINDER 

REMOVAL/INSTALLATION . . . . . . . . . . 05–10–8

CLUTCH RELEASE CYLINDER 

DISASSEMBLY/ASSEMBLY . . . . . . . . . 05–10–10

CLUTCH UNIT 

REMOVAL/INSTALLATION . . . . . . . . . . 05–10–11

Clutch Cover Removal Note . . . . . . . . . 05–10–12
Pilot Bearing Removal Note  . . . . . . . . . 05–10–12
Flywheel Removal Note  . . . . . . . . . . . . 05–10–12
Flywheel Installation Note . . . . . . . . . . . 05–10–12
Pilot Bearing Installation Note . . . . . . . . 05–10–13
Clutch Disc Installation Note . . . . . . . . . 05–10–13
Clutch Cover Installation Note. . . . . . . . 05–10–13

CLUTCH COVER INSPECTION. . . . . . . . 05–10–13
CLUTCH DISC INSPECTION . . . . . . . . . . 05–10–14
CLUTCH RELEASE COLLAR 

INSPECTION  . . . . . . . . . . . . . . . . . . . . . 05–10–15

PILOT BEARING INSPECTION . . . . . . . . 05–10–15
FLYWHEEL INSPECTION . . . . . . . . . . . . 05–10–15

End of Toc

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CLUTCH 

05–10–2

CLUTCH COMPONENT LOCATION INDEX

A3U051016003W01

.

End Of Sie

Z3U510W01

1

Clutch fluid
(See 05–10–3 CLUTCH FLUID INSPECTION)
(See 05–10–3 CLUTCH FLUID REPLACEMENT/
AIR BLEEDING)

2

Clutch pedal
(See 05–10–3 CLUTCH PEDAL INSPECTION)
(See 05–10–4 CLUTCH PEDAL ADJUSTMENT)
(See 05–10–5 CLUTCH PEDAL REMOVAL/
INSTALLATION)

3

Clutch master cylinder
(See 05–10–6 CLUTCH MASTER CYLINDER 
REMOVAL/INSTALLATION)
(See 05–10–7 CLUTCH MASTER CYLINDER 
DISASSEMBLY/ASSEMBLY)

4

Clutch release cylinder
(See 05–10–8 CLUTCH RELEASE CYLINDER 
REMOVAL/INSTALLATION)
(See 05–10–10 CLUTCH RELEASE CYLINDER 
DISASSEMBLY/ASSEMBLY)

5

Clutch unit
(See 05–10–11 CLUTCH UNIT REMOVAL/
INSTALLATION)

6

Clutch cover
(See 05–10–13 CLUTCH COVER INSPECTION)

7

Clutch disc
(See 05–10–14 CLUTCH DISC INSPECTION)

8

Clutch release collar
(See 05–10–15 CLUTCH RELEASE COLLAR 
INSPECTION)

9

Pilot bearing
(See 05–10–15 PILOT BEARING INSPECTION)

10

Flywheel
(See 05–10–15 FLYWHEEL INSPECTION)

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