MAZDA PROTEGE 1992 Workshop Manual

1992
Mazda
CONTENTS
Protege
Workshop
Manual
FOREWORD
This workshop manual is intended for use
by service technicians of Authorized Mazda
Dealers to help them service Mazda vehicles.
For proper repair and maintenance, a
thorough familiarization with this manual is im-
portant, and it should always be kept in a han-
dy place for quick and easy reference.
All the contents of this manual, including
drawings and specifications, are the latest avail-
able at the time of printing. As modifications
affecting repair or maintenance occur, relevant
information supplementary to this volume will
be made available at Mazda dealers. This
manual should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of this
manual without obligation or advance notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by any
means, electronic or mechanical-including
photocopying and recording and the use of
any kind of information storage and retrieval
system-without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN)
shown on the following page.
Title
General Information Section
Pre-Delivery Inspection and
Scheduled Maintenance Services
SOHC
Engine
DOHC
Lubrication System
Cooling System
Fuel and Emission Control System
Engine Electrical System
Clutch
FSM-R
Manual Transaxle
GSM-R
Automatic Transaxle
Front and Rear Axles
Steering System
Braking System
Wheels and Tires
Suspension
Body
--
Body Electrical System
Heater and Air Conditioner Systems
Technical Data
Special Tools
Parts Index
Wiring DNvam
I Part No. 5209-10-91 F)
9999~95-019(3-92)
o 1991 Mazda Motor Corporation
PRINTED IN USA, JUL. ‘91
1270-l O-91 G
(9999-95-0178-92)

VEHICLE IDENTIFICATION NUMBERS (VIN)
PROTEGli
JMl BG223 * NO 400001-
JM1 86224
* NO 400001-
JMl 86225 *NO 400001-
JMl BG226 * NO 400001-
3-DOOR HATCHBACK
JMl BG231 *NO 400001-
JMl 86232 *NO 400001-
JMl BG233 * NO 400001-

GENERAL INFORMATION
IMPORTANT INFORMATION ..................... GI- 2
BASIC ASSUMPTIONS ............................ GI- 2
SAFETY RISK ........................................ GI- 2
POSSIBLE LOSS OF WARRANTY ............. GI- 2
WARNING ON LUBRICANTS
AND GREASES .................................... GI- 2
HOW TO USE THIS MANUAL.. .................. GI- 3
PREPARATION ...................................... GI- 3
REPAIR PROCEDURE ............................. GI- 3
SYMBOLS ............................................. GI- 4
NOTES, CAUTIONS, AND WARNINGS.. ..... GI- 4
FUNDAMENTAL PROCEDURES.. ............... GI- 4
PROTECTION OF THE VEHICLE .............. GI- 4
A WORD
ABOUT SAFETY ....................... GI- 5
PREPARATION OF TOOLS
AND MEASURING EQUIPMENT.. ........... GI- 5
SPECIAL TOOLS .................................... GI- 5
REMOVAL OF PARTS ............................. GI- 5
DISASSEMBLY ...................................... GI- 5
REASSEMBLY ....................................... GI- 6
ADJUSTMENTS ..................................... GI- 7
RUBBER
PARTS AND TUBING ................
GI- 7
JACK AND SAFETY STAND POSITIONS.. .. GI- 6
VEHICLE LIFT (P-SUPPORT TYPE)
POSITIONS ............................................ GI- 6
TOWING .................................................. GI- 9
IDENTIFICATION NUMBER LOCATIONS ..... 61-10
UNITS ..................................................... GI-10
ABBREVIATIONS ..................................... GI-10
CAUTION ................................................ GI-1 1
INSTALLATION OF MOBILE
TWO-WAY RADIO SYSTEM .................... GI-11
REMOVAL OF IGNITION KEY ON
AUTOMATIC TRANSAXLE MODEL.. ........
GI-1 1
ELECTRICAL TROUBLESHOOTING TOOLS GI-12
CAUTION WITH ELECTRICAL PARTS ........
GI-13
03UGIX-001

IMPORTANT INFORMATION
IMPORTANT INFORMATION
BASIC ASSUMPTIONS
This workshop manual assumes that you have certain special tools that are necessary for the safe and effi-
cient performance of service operations on Mazda vehicles and that you know how to use them properly.
It also assumes that you are familiar with automobile systems and basic service and repair procedures. You
should not attempt to use this manual unless these assumptions are correct and you understand the conse-
quences described below.
SAFETY RISK
This manual contains certain notes, warnings, and other precautionary information that you should carefully
read and follow to reduce the risk of personal injury to yourself or others and the risk of improper service
that may damage the vehicle or render it unsafe. If there is no such information in regard to any specific
service method, this does not mean there is no possibility that personal safety or vehicle safety will be
jeopardized by the use of incorrect methods or tools.
POSSIBLE LOSS OF WARRANTY
The manufacturer’s warranty on Mazda vehicles and engines can be voided if improper service or repairs
are performed by persons other than those at an Authorized Mazda Dealer.
WARNING ON LUBRICANTS AND GREASES
Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated
during service (e.g., engine sump oils) are more irritating and more likely to cause serious effects, including
skin cancer, in the event of gross and prolonged skin contact.
Wash skin thoroughly after work involving oil.
Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not
use gasoline, paraffin, or other solvents to remove oil from the skin.
Lubricants and greases may be slightly irritating to the eyes.
Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particu-
lar care should be taken with used oils and greases containing lead. Do not allow work clothing to be con-
taminated with oil. Dry clean or launder such clothing at regular intervals.
9MUGIX-002
GI-2

HOW TO USE THIS MANUAL GI
HOW TO USE THIS MANUAL
PREPARATION
PREPARATION points out the needed Special Service Tool (SST) for the service operation that it pro- m
ceeds. Gather all necessary
SST before beginning work.
Example:
49 0118 850C
removal of be-rod
9MUGIX-033
REPAIR PROCEDURE
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the
parts fit together, and visual parts inspections. If a damaged or worn part is found, repair or replace it
as necessary.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration.
3. Pages related to service procedures are shown under the illustration. Refer to this information when ser-
vicing the related part.
Example:
SHOWS
NEEDED SST

SHOWS
APPLICATION
#T OF OIL,
SHOWS
RELATED
PAGE FOR
SERVICE ----

3. Bearing cup 1. Bolt
2. Lock Dlate
4. Adjusting screw
5. Bearing outer race
6. Locknut
7. Washer
8. Companion flange 16. Bearing Inner race
@ Removal. ,,,..,,,..
lnstallatlon page
page M--5 M-Z
i 7. Spacer
18. Drive pinion
Removal, .,,, ,.,, .,......... page M--i
Inspect spllnes and teeth for wear or damagl
Adjustment of height page M-2
Adurstp- w
SHOWS TIGHTENING
TORQUE
SPECIFICATION ‘2
SHOWS TIGHTENING
rORQlJE UNIT
SHOWS VISUAL
INSPECTION
INFORMATION
* 1: The numbering (ex.a) shows service procedure.
*2: Units shown in N.m (m-kg, ft-lb) unless otherwise specified.
9MUGIX-034
GI-3

HOW TO USE THIS MANUAL/FUNDAMENTAL PROCEDURES
SYMBOLS
There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such
materials during service.
Symbol Meaning Kind
Apply oil New engine oil or gear oil as appropriate
aI i . Apply brake fluid Only brake fluid
Apply automatic transaxle fluid Only ATF
Apply grease Appropriate grease
amal Apply sealant Appropriate sealant
0 Apply petroleum jelly Appropriate petroleum jelly
23UGIX-001
Note
l When special oil or grease is needed, this is shown in the illustration.
NOTES, CAUTIONS, AND WARNINGS
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each
one is there for a specific purpose.
NOTES give you added information that will help you to complete a
particular procedure.
CAUTIONS are given to prevent you from making an error that could damage the
vehicle. WARNINGS
remind you to be especially careful in those areas where carelessness can cause per-
sonal injury.
The following list contains some general WARNINGS you should follow when you work on
a vehicle.
9MUGIX-036
SMUGIX-037
a-4 FUNDAMENTAL PROCEDURES
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas be-
fore starting work.

FUNDAMENTALPROCEDURES GI
SMUGIX-0: B
47UOGX-00 5 ‘3
16
A WORD ABOUT SAFETY
The following precautions must be followed when jacking up
the vehicle.
1. Block the wheels.
2. Use only the specified jacking positions.
3. Support the vehicle with safety stands.
Start the engine only after making certain the engine compart-
ment is clear of tools and people.
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT
Be sure that all necessary tools and measuring equipment are
available before starting any work.
SPECIAL TOOLS
Use special tools when they are required.
REMOVAL OF PARTS
While correcting a problem, try also to determine its cause.
Begin work only after first learning which parts and subassem-
blies must be removed and disassembled for replacement or
repair.
DISASSEMBLY
If the disassembly procedure is complex, requiring many parts
to be disassembled, all parts should be disassembled in a way
that will not affect their performance or external appearance
and identified so that reassembly can be performed easily and
efficiently.
GI-5

GI FUNDAMENTAL PROCEDURES
9MUGIX-04t 3
9MUGIX-041
9MUGIX.004
I
Depending on location:
1. Inspection of parts
When removed, each part should be carefully inspected for
malfunctioning, deformation, damage, and other problems.
2. Arrangement of parts
All disassembled parts should be carefully arranged for re-
assembly.
Be sure to separate or otherwise identify the parts to be
replaced from those that will be reused.
3. Cleaning parts for reuse
All parts to be reused should be carefully and thoroughly
cleaned in the appropriate method.
REASSEMBLY
Standard values, such as torques and certain adjustments,
must be strictly observed in the reassembly of all parts.
Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE
in Section TD for tightening torques not mentioned in the main
text.
If removed, these parts should be replaced with new ones:
1. Oil seals 2. Gaskets
3. O-rings 4. Lock washers
5. Cotter pins 6. Nylon nuts
1. Sealant should be applied or new gaskets used.
2. Oil should be applied to the moving components of parts.
3. Specified oil or grease should be applied at the prescribed
locations (such as oil seals) before reassembly.
I
23lJGIX.004
GI-6

FUNDAMENTALPROCEDURES GI
I
67UOGX-00
ADJUSTMENTS
Use suitable gauges and/or testers when making adjustments.
EN
RUBBER PARTS AND TUBING
Prevent gasoline or oil from getting on rubber parts or tubing.
--.
GI-7

GI JACK AND SAFETY STAND POSITIONS/VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS
JACK AND SAFETY STAND POSITIONS
FRONT END
Jack position:
At the front crossmember
1 03UGIX-007
REAR END
Jack position:
At the center of the rear crossmember
Safety stand positions:
On both sides of the body frame
Safety stand positions:
On both sides of the body frame
VEHICLE LIFT (29SUPPORT TYPE) POSITIONS
FRONT END FRONT END
Frame Frame
Side sills Side sills
REAR END
Frame
Side sills
1
03UGIX-010
SMUGIX-01
- .’