ECU MAZDA PROTEGE 1992 Workshop Manual

R REAR SUSPENSION (STRUT)
Assembly
41-50)
N.m (m-kg, f&lb)
03UORX-041
!J ‘6
1. Shock absorber
2. Lower spring seat
3. Coil spring
4. Bound stopper
5. Stopper seat
03UORX.047
R-24
6. Mounting block
7. Retainer
8. Nut and washer
9. Cap
1. Secure the shock absorber in a vise.
Caution
l Use protective plates in the jaws of the vise.
2. Install the lower spring seat.
3. Install the coil spring, fitting the end of the coil into the step
of the lower seat.
4. Compress the coil spring with the SST.
5. Install the bound stopper and the stopper seat.

REAR SUSPENSION ~STRUT~
T LbWER BRACKET
LOWER BRACKET
23UQRX-02
6. Install the mounting block, aligning the studs of the mount-
ing block and the lower bracket of the shock absorber as
shown in the figure.
7. Install the retainer.
8. Loosely tighten the piston nut.
9. Carefully loosen and remove the
SST.
Caution
l Verify that the coil spring is correctly seated In the
mounting block and lower spring seat.
IO. Secure the mounting block in a vise.
11. Install the retainer and washer.
12. Tighten the mounting block nut to the specified torque.
Tightening torque:
55-66 Narn (5.6-6.9 m-kg, 41-50 ft-lb)
13. Install the cap over the nut.
R-25

MOLDING, PROTECTOR, GARNISH S
ADHESIVE
-------
03UOSX-06
--.-
03UOSX-OE
ADHESIVE
Installation Note
Roof molding
1. Remove the adhesive remaining on the body.
Note
l Remove as much adhesive as possible without
damaging the painted surface.
l If the adhesive is difficult to remove, soften it with
a hot air blower.
2. Remove any grease or dirt from the molding and molding
adhesion surface of the body.
3. Apply primer to the molding as shown.
4. Apply the adhesive (polyurethane) to the molding as shown.
Caution
l Do not apply too much adhesive because it will ooze
out when installed.
5. Peel away the molding adhesive tape protector.
6. Install the’front molding clip to the body stud.
7. Align the molding on the body and attach it securely.
8. Install the rear molding clip to the body stud.
I
03UOSX-065
S-47

S MOLDING, PROTECTOR, GARNISH
I 03UOSX-06
PRIMER 9
I
I 03uosx-070
BONDING AGENT
DOUBLE-SIDED ADHESIVE TAPE
03uosx-071
Installation Note
Protector
1. Use a knife to remove the adhesive remaining on the body
and protector.
Note
l Remove as much adhesive as possible without
damaging the painted surface.
l If the adhesive is difficult to remove, soften it with
a hot air blower.
2. Remove any grease or dirt from the protector and body
adhesion surface.
3. Apply primer to the protector as shown.
4. Attach double-sided adhesive tape to the protector (when
reused).
5. Apply adhesive (polyurethane) to the protector as shown.
6. Mark the installation position on the body with masking tape.
7. Align the protector on the body and attach it securely.
Note
l Adhesion conditions deteriorate if air temperature
is below 20°C (66OF); heating of the body is recom-
mended.
I 03UOSX-072
s-50

OUTSIDE MIRROR S
Rearview mirror
1. Knob cover
2. Knob
3. Inner garnish
4. Outside mirror
Inspection (Remote control) . page S-56
Disassembly . . .., ,.,...... ,., ,. . . . . . . page S-57
Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . page S-57
5. Front door trim, Door screen Power outside mirror switch
7. Meter hood
Removal / installation . . . . . . . . . . . . . . . . . . page S-94
8. Power outside mirror switch
Inspection .,,....,..,...,..........., . . . . . . . . page S-55
23UOSX-044
Removal / Installation . . . . . . . . . . pages S-l 0, 11
6. Power outside mirror harness
. .
23UOSX-04
Disassembly of Door Mirror
1. Warm the frame and the mirror glass with a hot air blower.
2. Insert a scraper between the mirror glass and the frame.
Pry the mirror loose.
3. Remove the remaining adhesive.
Assembly of Outside Mirror
1. Warm the frame with a hot air blower.
2. Install the glass in the frame. Gently press it in to secure it.
s-57

WINDSHIELD
mm (in)
03uosx-09
________
03uosx 09
(PROTEGt) 4
(HATCHBACK) ;
F I
I
B
Installation Note
Windshield
1. Cut away the old sealant with a razor knife so that 1 to 2mm
(0.04 to 0.08 in) of sealant remains around the circumfer-
ence of the frame. If all the sealant has come off in any one
place, apply primer after degreasing, and allow it approx.
30 minutes to dry. Then put on new sealant to create a
2mm (0.08 in) layer. _,
2. Carefully clean an area 5 cm (1.97 in) wide around the cir-
cumference of the glass and the bond on the body.
3. Bond a new dam along the circumference of the glass 7mm
(0.28 in) from the edge.
Caution
l Bond the dam securely and allow it to dry.
4. Apply primer with a brush to the bonding area of the glass
and the body, and allow it to dry for approx. 30 minutes.
Caution
l Keep the area free of dirt and grease. Do not touch
the surface. If primer gets on the hands, remove it
immediately.
5. Apply primer to the upper windshield molding as shown.
Caution
l Keep the area free of dirt and grease. Do not touch
the surface.
0:1IJosx 096
6. Install the spacers onto the body as shown
Caution
. Damaged spacers must be replaced.
o3uosx~o97
S-60

WINDSHIELD S
PROTECTOR
I SEALANT
mm (in)
.
03uosx-09
GLASS /
SPACER
mm (in
03uosx-1c
PROTEG6
MOLDING MOLDING
SEALANT SEALANT
CROSS-SECTION
mm (in)
03uosx-1c
7. Align the protector on the body, and attach it securely as
shown.
8. Prepare the nozzle of the sealant gun so that it has a flange
that can run along the edge of the glass and a V from which
the sealant can flow. Once the primer is dry, apply the seal-
ant around the entire circumference of the glass to fill the
gap between the dam and the edge of the glass with a ridge
of sealant
12mm (0.47 in) high.
Keep the bead of sealant smooth and even, reshaping it
where necessary with a spatula.
9. Lift the glass into place. Push it in lightly toward the vehicle
to compress the sealant.
Caution
l Open the windows to prevent the glass from being
pushed out by air pressure if a door is closed.
Hardening time of repair seal
I Temperature Surface hardening Time required until car
time can be put into service
I
5% (41 OF) Approx. 1.5 hrs 12 hrs
2ooc (68OF) Approx. 1 hr
4 hrs
35OC (95OF)
Approx. 10 min 2 hrs
10. Align the upper windshield molding on the body as shown,
and push the molding into place along the top.
Note
l Install the molding before the sealant has hardened.
11. Check for water leaks. If a leak is found, wipe the water off
well and add
sealant (BOO1 77 739) where needed.
S-61

REAR WINDOW GLASS S
9MUOSX-09
Note
l If the glass is not to be reused, a tool like that shown
in the figure may be used.
Insert the blade in the sealant, and pull on the bars.
Installation Note
Rear window glass
1. Cut away the old sealant with a razor knife so that 1 to 2mm
(0.04 to 0.08 in) of sealant remains around the circumfer-
ence of the frame. If all the sealant has come off in any one
place, apply primer after degreasing, and allow it
approx.
30 minutes
to dry. Then put on new sealant to create a
2mm (0.08 in) layer.
2. Carefully clean an area 5
cm (1.97 in) wide around the cir-
cumference of the glass and the bond on the body.
3. Bond a new dam along the circumference of the glass
7mm
(0.28 in) from the edge.
Caution
l Bond the dam securely and allow it to dry.
4. Apply primer with a brush to the bonding area of the glass
and the body, and allow it to dry for
approx. 30 minutes.
Caution
l Keep the area free of dirt and grease. Do not touch
the surface. If primer gets on the hands, remove it
immediately.
5. Install the spacers onto the body.
Caution
l Damaged spacers must be replaced.
S-65

TROUBLESHOOTING GUIDE
Symptom: Condenser fan and magnetic clutch do not operate.
03uoux-023
r
3EAR WIPER 10A OA
L
03uoux-02.
I
1 Step 1 Check fuses
1. Check the following fuses.
Fuse Amperage Location
AD FAN 20A In main fuse box
REAR WIPER 10A In fuse box
2. If the fuse is burned, check for a short-circuit in the wiring
harness before replacing it.
3. If the fuses are OK, go to Step 2.
I
23uoux-011
Step 2 Measure voltage at A/C relay connector
1. Run the engine at idle.
2. Turn the A/C and blower switches ON.
3. Measure the voltage at the following terminal wires of the
A/C relay connector. VEX Battery voltage
,
Wire
0-Q
W) Voltage Action
VB Next check wire (L/Y)
ov Repair wire (L/G)
V0 Next check wire (B/L)
ov
VB
ov
VB
ov Repair wire (L/Y)
Repair wire (B/L)
Next check wire (LIB)
Go to Step 3
Replace A/C relay
Step 3 Measure voltage at A/C switch
Measure the voltage at the following terminal wires of the A/C
switch connectors.
VB: Battery voltage
Step 4 Measure voltage at thermoswitch
Measure the voltage at the terminal wires of the thermoswitch
connector.
VB: Battery voltage
Wire
(G/R)
WB)
Voltage
VB
ov
VB
OV
Action
Repair wire (G/R)
Next check wire (G/B)
Go to Step 5
Check ECU ooeration
1 -. [ Refer to Secti6n F
u-12

HEATER U
HEATER UNIT
Removal / Installation
1. Drain the engine coolant.
2. Remove the dashboard. (Refer to Section S.)
3. Remove as shown in the figure.
4. Install in the reverse order of removal
Note
l When disconnecting the heater hose from the heater core, unlock the hose connector at the
heater core side.
l When installing the heater hose on the heater core, verify that the hose connector is securely
locked.
l Release the clamp, and remove the seal plate together with the heater unit.
1. Seal plate 3. Heater hose
2. Hose connector
4. Heater unit
u-21