service MAZDA PROTEGE 1992 Repair Manual

M REAR AXLE
DISC BRAKE TYPE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Remove the brake caliper assembly.
3. Position a dial indicator against the wheel hub. Push and
pull the wheel hub by hand in the axial direction and meas-
ure the wheel bearing play.
4. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
-I 5 Maximum wheel bearing play: 0.05mm (0.002 in)
Removal / Inspection / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation. check the rear wheel alianment (Refer to Section R.)
45-61
(4.6-6.2, 33-45)
-118
-12.0,
-87)
REPLACE
16-23
(1.6-2.3, 12-17)
N-m (m-kg, ft-lb]
311 InMY-nif4
1. Wheel and tire
2. Hub cap
3. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-15
4. Brake caliper assembly
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~ Section P
5. Disc plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P 6. Hub bearing assembly
Inspect for cracks and damage
Disassembly I Assembly . . . . . . . . . . . . page M-l 5
7. Dust cover
8. Rear spindle
Inspect for cracks and damage
M-14

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

S REAR WINDOW GLASS
03uosx-11
WOTEGk GLASS
SPACER
-lATCHBACk
GLASS
SPACER
mm (in
03uosx-11
6. 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.
7. 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
Temperature Surface hardening Time required until car
time can be put into service
5T (41 OF) Approx. 1.5 hrs 12 hrs
2o”c (6WF) Approx. 1 hr 4 hrs
35% (95OF) Approx. 10 min 2 hrs
8. Use a scraper to smooth away any sealant that oozes out.
Add more sealant to any points of poor contact.
9. Check for water leaks. If a leak is found, wipe the water off
well and add
sealant (BOO1 77 739) where needed.
S-66

AIR CONDITIONER U
REFRIGERANT SYSTEM
Safety Precaution
1. R-12 liquid refrigerant is highly volatile. A drop of it on the
skin could result in localized frostbite. When handling the
refrigerant, be sure to wear gloves.
2. If the refrigerant splashes into the eyes, wash them with clean
water immediately. Always wear goggles or glasses to pro-
tect the eyes.
9MUOUX-125 3. The R-12 container is a highly pressurized vessel.
Never subject it to high heat, and be sure that the temper-
ature where it is stored is below 52OC
(125.6OF).
4. A halide leak detector is often used to check the system
for refrigerant leakage. R-l 2, upon coming into contact with
the flame, produces phosgene, a toxic gas. Always provide
adequate ventilation.
o3uoux-11 4
9MUOUX-12
Refrigerant System Service Basics
Refrigerant container service valve
1. Turn the handle fully counterclockwise before connecting
the valve to the refrigerant container.
2. Turn the outlet valve counterclockwise until it reaches its
highest position.
3. Turn the outlet valve fully clockwise by hand. Connect the
center hose to the valve fitting.
4. Turn the handle clockwise to puncture the sealed can.
5. Turn the handle fully counterclockwise to fill the center hose.
Do not open the high- or low-pressure manual valves.
6. Loosen the hose nut connected to the center fitting of the
manifold gauge. Allow air to escape. Then retighten the nut.
13uoux-012
u-31

CHARGING HOSE
CLOSED
CLOSED
23UOUX-061
CHARGING HOSE
CHARGING VALVE CLOSED 0
23UOUX.061
3. Connect high-and low-pressure side charging hoses and
stop valves to the refrigerant system service valves.
23UOUX-062
FREON (REFRIGERANT RECOVERY
ND RECYCLING
CONTAINER
VALVE
Manifold gauge set/Stop valve installation
Caution
l Connect all charging hoses via stop valves to avoid
venting the refrigerant remaining in the hoses into
the atomosphere. _A
l Do not disconnect the stop valve from the charg-
ing hose when there is refrigerant remaining in the
hose.
1. Turn the knob counterclockwise to close the stop valve.
2. Install the stop valve to the end of the charging hose of the
manifold gauge set.
Caution
l Verify that high-and low-pressure side valves of the
manifold gauge set are fully closed before connect-
ing the charging hose and stop valve to the refriger-
ant system service valve.
23UOUX-063 Evacuation/Airtiahtness test
1. Connect the manifold gauge set and stop valves to the
refrigerant system service valves.
2. Connect the center hose of the manifold gauge set to the
vacuum pump inlet.
3. Prepare as follows according to the charging method.
Charging from service container.
Connect the charging hose and service container valve to the
manifold gauge set air purge valve.
I
23UOUX-06
U-32
4
Refrigerant recovery operation.
Remove the refrigerant from the refrigerant system by using
a freon (refrigerant) recovery and recycling system.
Caution
. Never vent the refrigerant into the atomosphere.
l When using a freon recovery and recycling system,
follow the operation instructions provided by the
equipment manufacturer.
_-,

U
r
I
23UOUX-061
23UOUX-067
23UOUX-061 3
Caution
l Connect the charging hose to the air purge valve
via its tap pin side.
l Do not disconnect the charging hose or the serv-
ice container valve until the charging operation is
completed.
l Do not open the service container valve when not
used.
Charging from freon recovery and recycling system.
Connect the charging hose and stop valve to the manifold
gauge set air purge valve.
23UOUX-065
Caution
l Connect the charging hose to the air purge valve
via its tap pin side.
l Do not disconnect the charging hose or stop valve
until the charging operation is completed.
l Do not open the stop valve when not used.
4. Start the vacuum pump and open the high-and low-pressure
side valves of the manifold gauge set.
5. Start the pump and let it operate for 15 minutes.
6. Check high- and low-pressure side gauge readings. When
both of them are at 750 mmHg or more, close the manifold
gauge set valves.
7. Stop the vacuum pump and wait for about 5 minutes.
8. Verity that the low-pressure side gauge reading does not
change.
9. If the reading changes, retighten the piping connections and
repeat the evacuation operation.
10. If not changed, check for leaks (see below) and charge the
system.
u-33

ENGINE sro~i32 U
Leak test
1. Carry out the system evacuation and airtightness test as
described above.
2. Prepare as follows according to charging method.
Charging from service container.
Connect the refrigerant service container to the service con-
tainer valve (which is connected to the manifold gauge set air
purge valve) and open the service container.
Charging from freon recovery and recycling system.
Connect the charging valve of the system to the stop valve
(which is connected to the manifold gauge air purge valve).
23UOUX-06
23UOUX-070
I 23UOUX-072
I
80 x 0
23UOUX-07
u-34
3
3. Open the high-pressure side valve of the manifold gauge
set. Charge the system until the low-pressuer side gauge
indicates 98.1 kPa. (1 kg/cm*, 14.22 psi).
4. Close the high pressure side valve.
5. Check for leaks at the system piping joints by using a gas
leak tester.
6. If leaks are found, check the O-rings and tightening torques
at the joints. Replace or retighten as necessary.
7. If no leaks are found, fully charge the system.
Caution
l Carry out the leak test in an well-ventilated but still
air area because it is affected by moving air.
23UOUX-071
Initial charging from service container
1. Carry out the system evacuation, airtightness test, and leak
test.
2. Open the high-pressure side valve of the manifold gauge
set and charge the system as specified.
Charging amount: Approx. 400 g (14.12 oz)
3. Close the high pressure side valve.
4. Start the engine and actuate the A/C compressor.
Caution
l Do not turn the service container upside down while
charging when the engine is running.
l Do not open the high-pressure side valve while the
engine is running.
5. Open the low-pressure side valve of the manifold gauge set
and charge the system to specification.
Specified total refrigerant amount: 800 g (28.24 oz) -.

U
L
ENGINE STARTED
*-ENGINE STARTED
23UOUX.071
6. Close the low-pressure side valve.
7. Stop the engine.
8. Close the stop valves and the service container valve.
Caution
l Do not disconnect the stop valves or the service
container valve from the charging hoses when there
is refrigerant remaining in the hoses.
Refilling
Caution
l Do not overcharge the system.
l Note the sight glass during refilling the refrigerant.
Stop charging when no bubbles are observed in the
glass.
(Refer to page U-40).
l Care must be taken when the ambient temperature
is low. The bubbles may not be present even if the
refrigerant amount is insufficient.
1. Connect the manifold gauge set to the refrigerant system
charging valve.
(Refer to page U-32).
2. Start the engine.
3. Open the low-pressure side valve of the manifold gauge set
and charge the system as necessary.
4. Note the sight glass, and when no bubbles can be seen,
close the low-pressure side valve.
5. Stop the engine.
6. Close the stop valve and service container valve. Discon-
nect the stop valves quickly.
u-35

TECHNICAL DATA
D. LUBRICATION SYSTEM
Item I I bhricatinn mothnd
Engine
B6 SOHC BP SOHC
Force-fed BP DOHC 1
Requlated pressure kPa (kg/Cm”, p
Inner rotor tooth tip to outer rotor Standard
I-‘---- -.----,
clearance mm (in) Maximum 0.20 (0.0078)
Outer rotor to body clearance mm (in) Standard 0.09-0.18 (0.0035-0.0071)
Maximum 0.22 (0.0087)
Side clearance mm (in) Standard 0.03-0.11 (O.pniq n nnn=’
Maximum n4rl ‘-
“” I r-“.““+..I,
I “. I ‘t (U.0055)
I
1
Oil filter
_ Type
Relief pressure differential
Engine oil
I
Capacity
liters (US qt, Imp qt)
Grade
I Viscosity Full-flow, paper element
kPa (kg/cm’, psi) 1 78-l 18 (0.8-I .2, 1 l-l 7) Tntal /An, nnr*inol 3.4 (3.6, 3.0) 1 4.0 (4.2, 3.5)
3.0 (3.2, 2.6) 1 3.6 (3.8, 3.2)
VII 111Lb1 0.17 (0.18, 0.15)
API Service SG Energy Conserving II (ECQ
1
SA!f InW-Xl 1~ Above -25% (-13OF _ .-.. --
I
I
number
1 Below O’C (32OF) SAE 5W-30
1
E. COOLING SYSTEM
Cooling method EnginelTransaxle
MTX ] ATX 1 MTXl
Water-cooled, forced circulation
J B6 SOHC BP SOHC BP DOHC
, ATX 1 MTX ) ATX
LThermostat
Type Opening temperature
Full-open temperature
Full-open lift
Radiator
_ Type
Cap valve opening pressure
Cooling circuit checking pressure Wax, two-stage
“C (OF) Sub: 83.5-86.5 (182--188), Main: 86.5-89.5 (188-193)
OC (OF) 100 (212)
mm (in) Sub: 1.5 (0.06) min., Main: 8.0 (0.31) min.
Corrugated fin
kPa (kg/cm2, psi) 74-103 (0.75-1.05, 11-15)
kPa (kg/cm’, psi) 103 (1.05, 15)
~..
Cooling fan
Type Electric .-
Number of blades 4
_.---- _I___-
Outer diameter mm (in) 320 (12.6)
--_ ~~-
Capacity w-v 80-12 - 160-12 80-l 2 160-12
6.6 Hi : 13.3
6.6 Hi : 13.3
Current A
Low : 8.8 Low : 8.8
_------ ._____
Water thermoswitch
“c (OF) 1
OFF-ON 97 (207)
I--.
Radiator thermoswitch
__-I____-
OFF+ON “C (OF) 1 1105 (221)( - (105 (221)
TD-8

TECHNICAL DATA TD
J2. MANUAL TRANSAXLE (G5M-R)
tern EnginelTransaxle BP DoHc
-__-
G BM-R
hansmission
shift lever position
First
Second
Third
;ear ratio
Fnt rrth Floor shift
3.307
1.833
1.310
1.030
3il Reverse
Viscosity
Capacity All-season
Above -18OC (OOF)
liters (US qt, imp qt) a. IOD
ATF Dexron@II, M2C33-F or SAE 75W-80
API service GL-4 SAE 8OW-90
3.35 (3.55, 2.96)
Clearance
Clearance of
idler gear
Clearance of
clutch sleeve
Clearance of lever and reverse Standard 0.1-0.32 (0.004-0.013)
mm (in) Wear limit 0.5 (0.020)
-
1 st-2nd 0.08-0.228 (0.003-0.009)
Standard 3rd-4th 0.1-0.5 (0.004-0.020)
shift fork and 5th~Rev. 0.15-0.458 (0.059-0.018)
mm (in)
1 st-2nd 0.728 (0.029)
Wear limit 3rd-4th 1.000 (0.039)
5th~Rev.
0.958 (0.03
synchronizer ring and gear Standard
mm (in) Wear limit I
First Standard
Limit
I I I 8) 1.5 (0.059)
0.8 (0.032)
0.05-0.28 (0.002’-0.011)
0.33 (0.013)
Gear thrust clearance
mm (in) Second
Third
Fourth
Fifth Standard
Limit
Standard
Limit
Standard
Limit
nr- --,_-..I
3tariuaru
Limit 0.175-0.455 (0.0069-0.0179)
0.505 (0.0199)
0.05-0.20 (0.002-0.008)
0.25 (0.010)
0.165-0.365 (0.0065-0.0144)
0.415 (0.0163)
al-O.22 (0.0039-0.0087)
0.27 (0.0106)
Bearing preload of primary shaf t gear
N.m (cm-kg, in-lb) 0.1-0.25 (1.0-2.5, 0.87-2.18)
Bearing preload of secondary shaft gear
N.m (cm-kg, in-lb)
Bearing preload adjust shim mm (in)
Drive and differential
Type
Final gear
Reduction ratio
Bearing preload N.m (cm-kg, in-lb)
Bearing
preload adjust
shim (in) mm
Backlash of side gear and pinion gear mm (in) 0.2-0.4 (2.0-4.0, 1.7-3.5)
0.20 (0.008) 0.30 (0.012) 0.40 (0.016) 0.50 (0.020)
0.25 (O.OlO), 0.35 (0.014) 0.45 (0.020) 0.55 (0.022)
0.60 (0.023) 0.65 (0.025) 0.70 (0.028)
Helical
4.105
1.4-2.0 (14-20, 12.2---17)
0.10 (0.004) 0.20 (0.008) 0.25 (0.010) 0.30 (0.012)
0.35 (0.014) 0.40 (0.016) 0.45 (0.018) 0.50 (0.020)
0.55
(0.022) 0.60
(0.024) 0.65 (0.026) 0.70 (0.028)
0.75 (0.030) 0.80 (0.031) 0.85 (0.033) 0.90 (0.035)
0.95 (0.037) 1.00 (0.039), 1.05 (0.041) 1.10 (0.043)
1 ,15 (0.045) 1.20
(0.047)
o-o.1 (O-0.004)
TD-13