key MAZDA PROTEGE 1992 Owner's Manual

J2 TRANSAXLE
I
23UOJ2-OC
W-W i
W-U
(REVERSE)
I 03UOJ2-054
(FOUR PLACES)!
23UOJ2-00
r
1
03UOJ2-O!
52-m
7
1 57
Bearing inner race (primary shaft end)
1. install the new bearing inner race with the SST.
3rd gear, synchronizer ring (3rd) and clutch hub
assembly (3rd/4th)
Note
l The size of the lst, 2nd, 3rd, and 4th synchronizer
rings are the same. Be careful when installing them.
The 2nd ring has the larger cut-out as shown in the
illustration.
l Align the synchronizer ring groove and clutch hous-
ing hub key when installing.
1, Install the 3rd gear, synchronizer ring (3rd), and clutch hub
assembly (3rd/4th) with the
SST.
Synchronizer ring (4th), 4th gear and bearing inner race
1. Install the synchronizer ring (4th), 4th gear, and bearing in-
ner race with the
SST.
2. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05-0.20mm (0.002-0.008 in)
Maximum : 0.25mm (0.010 in)

TRANSAXLE J2
13UOJ2-006
I 03UOJ2-06f
23UOJ2.011
3. Measure the clearance between the 4th gear and bearing
inner race.
Clearance: 0.165-0.365mm (0.0065-0.0144 in)
Maximum : 0.415mm (0.0163 in)
4. If not as specified, reassemble the primary shaft assembly.
Bearing inner race (secondary shaft end)
1. Install the new bearing inner race with the SST.
1st gear, synchronizer ring (1st) and clutch hub
assembly (1 st/2nd)
Note
l Align the synchronizer ring, groove and clutch hous-
ing hub key when installing.
1. Assemble the 1 st gear, synchronizer ring (1 St), and clutch
hub assembly (lst/2nd), as shown in the figure.
2. Press the clutch hub assembly (1 st/2nd) on with the
SST.
Synchronizer ring (2nd), 2nd gear and secondary 3rd
gear
1. Install the synchronizer ring (2nd) and 2nd gear.
2. Install the secondary 3rd gear with the
SST.
23UOJ2-011
J2-29

N MANUAL STEERING
1 I
13UONX-033
Steering lock assembly (ATX)
Verify that the cable connector does not move when the key
is in the LOCK position and that it moves freely with the key
in other positions.
Assembly note
Steering lock assembly
Install the steering lock assembly on the jacket. Install new
steering lock mounting bolts, and tighten them until the heads
break off.
I 13UONX-034
N-12

DASHBOARD S
1, Rear ashtray (Without passive IO. Combination switch 18. Glove box lid
shoulder belt) Removal / Installation 19. Lower panel (R.H.)
2. Rear console ,..,,.,......,,.,.,....... Section T 20. Front ashtray
3. Front console 11. Center upper hole cover 21. Lower panel (Center)
4. Control box center cover 12. Upper garnish
22. Glove box cover
(With small front console) 13. Side panel 23. Dash board
5. Side walls 14. Hood release knob Removal Note . . page S-95
6. Undercover 15. Lower panel (L.H.) Installation Note page S-96
7. Steering column 16. Meter hood 24. Pipe frame (Lower)
Removal / Installation 17. Instrument cluster 25. Pipe frame (Upper)
. . . . . . . . ...*. . . . . ..n..... Section N Removal I Installation
1 suosx-017
8. Key cylinder set ring
9. Column cover
JOINT BOX
. . . . . . . . . . . . . . . . . . . . . . . . . . Section T
Removal Note
Dashboard
1, Remove the control wires of the heater unit and blower unit.
2. Disconnect the necessary harness connectors.
s-95

INDEX T
INTERIOR LAMPS
23UOTX-OC
1. Spot lamp (in overhead console)
Removal / Inspection /
Installation ,,,,,.,,,.,..,.,................. page T-52
2. Interior and spot lamp (Without sunroof)
Removal / Inspection I
Installation .,,........,.....,.,............. page T-53
3. Interior lamp (Without sunroof)
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-52
4. Interior lamp (With sunroof)
Removal I Inspection I
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-53 5. IG key illumination
Troubleshooting .,.,..........,........... page T-50
6. Cargo compartment lamp
Removal I Inspection I
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-54
7. Trunk compartment lamp
Removal I Inspection I
Installation ..,.,...,...........*............ page T-54
8. Door switch
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-51
9. Courtesy lamp
Removal I Inspection I
Installation . . ,.., . . . ., ,, . . ,...... . . . . . . . . . . . page T-54
T-5

TROUBLESHOOTING GUIDE T
TROUBLESHOOTING GUIDE
System
Exterior lighting system
Interior lamp system
Warning system
Instrument cluster
Rear window defroster
Cruise control system
Audio system Symptom Reference page
Headlights do not operate T-32
Headlights either do not operate or are dim T-33
Low-High beam or passing flasher does not operate T-33
Daytime running lights (DRL) do not operate T-33
Turn signal lights do not operate T-35
Only hazard function does not operate T-36
Only one side of signal operates
T-36
TNS system (side marker, license, tail, illumination light) does not operate T-38
Both stoplights do not operate when brake pedal is depressed T-40
One stoplight does not come on T-40
IG key illumination does not operate
T-51
Key reminder alarm does not sound
Light-off reminder alarm does not sound
Seat belt alarm does not sound
Seat belt timer does not operate
Passive shoulder belt alarm does not sound
IG key illumination timer does not operate T-58
T-59
T-59
T-59
T-59
T-59
Speedometer does not operate or indication is not correct
Tachometer does not operate
Water temperature gauge does not operate
Fuel gauge does not operate
Defroster does not operate
Can’t set or control the speed T-65
T-66
T-67
T-68
T-76
T-84
No sound
Sound is partial
Bad sound quality of radio
Bad sound quality of tape
Noise
Scan or tuning does not stop T-93
T-93
T-94
T-94
T-95
T-95
T-l 1

INTERIOR LAMP SYSTEM T
INTERIOR LAMP SYSTEM
STRUCTURAL VIEW
ZYUU I x-02
1. Spot lamp (in overhead console) 5. IG key illumination
Removal I Inspection / Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-52 6. Cargo compartment lamp
2. Interior and spot lamp (Without sunroof) Removal I Inspection /
Removal / Inspection I Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-53 7. Trunk compartment lamp
3. Interior lamp (Without sunroof) Removal I Inspection /
Removal / Inspection / Installation . ..*......................*...... page T-54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-52 8. Door switch
4. Interior lamp (With sunroof) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-51
Removal I Inspection / 9. Courtesy lamp
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-53 Removal I Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-54
Specifications
Item
Interior and spot lamp
interior lamp
Spot lamp (in overhead console)
Cargo compartment lamp
Trunk compartment lamp
Courtesy lamp Interior
spot Number 1
2
1
2
1
1
2 Specification (W) (Bulb trade number) 10
6
10
8 (67)
5 (168)
5 (168)
5 (168)
23UOTX-028
T-49

T INTERIOR LAMP SYSTEM
TROUBLESHOOTING
IG Key Illumination
Circuit diagram
03UOTX-080
T-50

INTERIOR LAMP SYSTEM T
IG key illumination does not operate
Check room IOA fuse NG
- Short circuit
0 OK
Confirm battery voltage on V Defective harness (Fuse - Joint box), or bulb
0 OK
Confirm continuity on B wire of the joint box (CPU) to
ground Repair harness (Joint box - Body ground)
OK
When any door is opened, confirm that interior lamp
comes on
OK NG
~ Defective harness (Joint box - Door switch), or door
switch
Confirm continuity between N terminal of JB-09 connec- _ NG
-
tor and B terminal of JB-03 connector Repair harness (JB-09 - JB-03)
I OK
Replace CPU
23UOTX-029
Inspection
Door switch (Front sides with passive belt)
Confirm continuity between the R/W wire and the B wire of
the door switch connector (in passive motor connector).
Condition Continuity
Push X
Not push 0
0: Indicates continuity X: No continuity
03UOTX-181 Door switch (Others)
Confirm for continuity between the terminals of the door switch.
Condition Continuity
Push X
Not push 0
0: Indicates continuity X: No continuity
1 I OSJOTX-082
T-51

CENTRAL PROCESSING UNIT (CPU) T
CENTRAL PROCESSING UNIT (CPU)
I I IG KEY ILLUMI.
I
T
1. 30A KEY REMIN-
0
DOOR A.lAR
WARNING LAMP
TNS
REAR WIPER SW
rb
T
RASSIVE CONTROL UNIT -
SYSTEM DIAGRAM
CPU SEAT BELT WARNING LAMP
m
w
REAR WASHER SW
IGl
REAR WASHER
03UOTX-08! 3
T-55